C5G Control Unit - Technical Specification

Comau Robotics
Instruction Handbook
Control Unit
Standard Version
Technical Specification
Description and general characteristics of the Control Unit

Guide to the choice of the Control Unit version
General description of the expandability to I/O signals,
communication networks, safety devices
Description and order codes for option
CR00757596_en-00/1010
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 © 2008 by COMAU - Date of publication 10/2010

SUMMARY
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Content of the C5G Control Unit manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Document preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Manual content limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Symbols in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2. INTRODUCTION TO THE CONTROL UNIT: RELIABILITY AND SAFETY . . . . . . . ...21

Reliability and serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Calculation power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Expandability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Compliance with the norms in force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Directives and norms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Statement of incorporation of quasi-machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Manufacturer’s details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Safety devices control procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Safety solutions installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3. VERSIONS AND TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...31

Selecting the Control Unit version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
C5G Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control Unit technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Teach Pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Teach Pendant operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Teach Pendant technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Programming terminal with cable connection (C5G-iTP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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SUMMARY
Programming terminal with wireless connection (C5G-WiTP) . . . . . . . . . . . . . . . . . . . . . . . . 38

Connection cables between C5G and Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4. DETAILS ABOUT THE C5G CONTROL UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..41

Modules installed in the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Arm Controller Electromechanical (ACE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CPU, power supplies and power modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Modules installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
AMS-APC820 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
AMS-PPS8 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
AMS-ASM32 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
AMS-IAM module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Thermal dissipator AMS-FMP14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Safety Distribution Module (SDM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Uninterruptible Power Supply (UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Operator Panel Devices (OPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connector Interface Panel (CIP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Internal ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
General information about the communication networks inside the C5G Control Unit . . . . . . . 83
Ethernet POWERLINK Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Ethernet POWERLINK Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Address on ASM modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Address on Bus Coupler module for the X20 interface modules . . . . . . . . . . . . . . . . . . . . .88
CAN Bus network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Termination resistancec in the CAN Bus net . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Address on the CAN Bus network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Connector pin structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
System variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5. INTERFACING WITH THE C5G CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . ..91

Overview of the C5G Control Unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Robot, positioning devices and auxiliary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
X10 connector (Robot signals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
X60 connector (Robot Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
X10-EXT connector (Extension, Positioning device signals) . . . . . . . . . . . . . . . . . . . . . . . . . 96
X60-EXT connector (Extension, motors and brakes of the positioning device) . . . . . . . . . . . 96
X61..X64 connectors (Signals and power for auxiliary Axes). . . . . . . . . . . . . . . . . . . . . . . . . 97
Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
X30 connector (Safety items) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ETH2 connector on AMS-APC820 (Ethernet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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COM2 connector on AMS-APC820 (RS422 serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
X90 cable gland connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
X31..X32 connectors (Applications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
X93..X94 connector (Master field Bus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
COM2 connector on AMS-APC820 (RS232 serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Programming and User interface on PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Overview for 24 Vdc power supply in the Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
24 Vdc distribution principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Meaning of the 24 Vdc power supplies inside the Control Unit . . . . . . . . . . . . . . . . . . . . . . 110
24 Vdc distribution complete diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
How to use the 24 Vdc in the user’s applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
X106/SDM connector at the user’s disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Selecting the 24 Vdc power supply source (24V I/O and 24V SAFE only) . . . . . . . . . . . . . 113
Selecting the 24 Vdc source (24V I/O and 24V SAFE only) . . . . . . . . . . . . . . . . . . . . . . . . 114
Safety circuits: E-Stop, Auto-Stop (Fence) and General Stop . . . . . . . . . . . . . . . . . . . . . . . . . 115
Digital Inputs / Output on the SDM module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
General principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Position of the connectors on the Safety Distribution Module (SDM) . . . . . . . . . . . . . . . . . 116
I/O electric features and pin structure of the connectors on the Safety Distribution Module
(SDM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Connection diagram for the I/O on the Safety Distribution Module (SDM). . . . . . . . . . . . . . 119
Configuration of the I/O on the Safety Distribution Module (SDM). . . . . . . . . . . . . . . . . . . . 120
Usage restrictions for the I/O on the Safety Distribution Module (SDM) . . . . . . . . . . . . . . . 120
Inputs / Outputs and field Bus on X20 interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
X20 interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Bus Coupler PFG-BCO module on X20 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
General principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Address on Bus Coupler module for the X20 interface modules . . . . . . . . . . . . . . . . . . . .124
Technical features and purchase code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Configuration of the Bus Coupler module in the system . . . . . . . . . . . . . . . . . . . . . . . . . .125
Field Bus Modules on the X20 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Installation rules for the field bus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Technical features and purchase code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Configuration of the field Bus modules in the system. . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Digital and analog I/O module on the X20 interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Rules for the installation of I/O on X20 modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Circuit Diagram for the connction of the I/O on X20 modules . . . . . . . . . . . . . . . . . . . . . .132
Prearranged solutions and technical specifications related to the digital and analog I/O. .135
Powering devices technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Digital input/output technical features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Analog inputs/output technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Configuration of the I/O modules in the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
RS232 and RS422 serial communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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Serial port technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
RS232 serial connection cable to PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Communication via Ethernet network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
ETH2 connection technical features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Summary of connectors and corresponding function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6. OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..155
Option listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Information abut the option installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Options for the C5G Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
C5G-AFK: Auxiliary Fan Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
C5G-AI2 - C5G-AO2, analog I/O options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
C5G-APK1 kit Auxiliary Plate 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
C5G-D12 - C5G-D24, digital I/O options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
C5G-DNM-DNMI: DeviceNet Master Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
C5G-DNM-DNSI: DeviceNet Slave Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
C5G-DNPC: movable connector for Devicenet modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
C5G-EDI: External digital I/O interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
C5G-ETHK: Ethernet kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
C5G-HFK kit fastening hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
C5G-HMK: Hour-meter kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
C5G-HSK5: High Speed Input Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
C5G-OPK: Option Panel kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
C5G-OTK: Axis Over Travel kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
C5G-PFG-BCO: Bus Coupler module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
C5G-PFM-PDPM: Profibus-DP Master Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
C5G-PFM-PDPS: Profibus-DP Slave Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
C5G-PFPC: movable connector for Profibus-DP modules. . . . . . . . . . . . . . . . . . . . . . . . . . 186
C5G-RSK100: 100-mm rising socket kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
C5G-SMK: Signal Machine Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
C5G-TDC400: 400V Tip Dresser Command kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
C5G-TDC400-2: 400V Double Tip Dresser Command kit . . . . . . . . . . . . . . . . . . . . . . . . . . 192
C5G-TDS400: 400V Tip Dresser Supply kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
C5G-UCK: user connector kit, for SDM module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
C5G-USBK: USB kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
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Preface
PREFACE
This chapter deals with the following topics:
– Reference documents
– Content of the C5G Control Unit manuals
– Document preservation
– Manual content limits
– Symbols in the manual.
Reference documents
This document refers to the C5G Control Unit.
The complete set of manuals concerning the C5G control units consists of:
Comau C5G Control Unit – Technical Specification

– Transport and installation
– Maintenance
– Control Unit usage modes
– Schema elettrico
Those manuals are to be supplemented by the following documents:
Comau Robot – Technical Specifications *¹

– Transport and installation *¹
– Maintenance *¹
Programming – PDL2 Programming Language Manual
– VP2 - Visual PDL2
– Motion programming
Applications – According to the required application
type.
*¹ specific for the installed Robot type
The above mentioned manuals shall be preserved in good repair for the entire
Robot System operating life and shall always be available for the staff members
carrying out activities on the Robot System.
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Preface
Content of the C5G Control Unit manuals
Device Manuals Contents

C5G Control – Technical – Description and main features of the Control Unit
Unit Specification – Guide to Control Unit model selection
– General description about the expanding possibilities in
relation to I/O signals, communication networks and safety
devices
– Description and purchase codes for the Control Unit and its
optionals.
– Transport and – Information about the preparing activities and
installation prearrangements required to install the C5G
– Dimensions and weights, transport and lifting methods
– Procedures to adapt the internal components and options for
the powering network
– Procedure to perform the connection to the mains
– Preliminary procedure to set the Control Unit at work
– Maintenance – Help to problem-solving
– Preventive maintenance plan to guarantee the C5G
efficiency over time
– Preventive and special maintenance procedures
– Spare part list
– Wiring diagram
Document preservation
All documents forwarded shall be preserved nearby the Robot System and be at the
disposal of all staff members, who carry out activities on the Robot System. Moreover
the documents shall be preserved in good repair for the entire Robot System operating
life.
Manual content limits

The images in the instruction manuals are aimed at representing the product and may
differ from the items actually installed on the Robot System.
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Symbols in the manual
Find below the symbols highlighting WARNING, CAUTION and NOTES together with
their meaning
This symbol applies to operating procedures, technical information and

precautions that are to be complied with and/or properly performed to prevent
possible injuries.

precautions that are to be complied with and/or properly performed to prevent
possible equipment damages.

precautions that need necessarily to be highlighted.
This symbol concerns the material disposal procedures ruled by the RAEE
Directive.
This symbol reminds the user to avoid polluting the environment and stimulate a
sustainable attitude, i.e. disposing of the materials in the suitable waste collection
sites.
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General Safety Precautions
1. GENERAL SAFETY PRECAUTIONS
It deals with a general specification that apply to the whole Robot System. Due to
ist significance, this document is referred to unreservedly in any system
instruction manual.
This specification deals with the following topics:

– Responsibilities
– Safety Precautions.
1.1 Responsibilities
– The system integrator is responsible for ensuring that the Robot System (Robot
and Control System) are installed and handled in accordance with the Safety
Standards in force in the country where the installation takes place. The application
and use of the protection and safety devices necessary, the issuing of declarations
of conformity and any CE markings of the system are the responsibility of the
Integrator.
– COMAU Robotics & Service shall in no way be held liable for any accidents caused
by incorrect or improper use of the Robot System (Robot and Control System), by
tampering with circuits, components or software, or the use of spare parts that are
not included in the spare parts list.
– The application of these Safety Precautions is the responsibility of the persons

assigned to direct / supervise the activities indicated in the Applicability sectionally
are to make sure that the Authorised Personnel is aware of and scrupulously follow
the precautions contained in this document as well as the Safety Standards in
addition to the Safety Standards in force in the country in which it is installed.
– The non-observance of the Safety Standards could cause injuries to the operators
and damage the Robot System (Robot and Control System).
The installation shall be made by qualified installation Personnel and should

conform to all national and local codes.
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1.2 Safety Precautions

1.2.1 Purpose
These safety precautions are aimed to define the behaviour and rules to be observed
when performing the activities listed in the Applicability section.
1.2.2 Definitions
Robot System (Robot and Control System)
The Robot System is a functional unit consisting of Robot, Control Unit, Programming
terminal and possible options.
Protected Area
The protected area is the zone confined by the safety barriers and to be used for the
installation and operation of the robot
Authorised Personnel
Authorised personnel defines the group of persons who have been trained and assigned
to carry out the activities listed in the Applicability section.
Assigned Personnel
The persons assigned to direct or supervise the activities of the workers referred to in
the paragraph above.
Installation and Putting into Service

The installation is intended as the mechanical, electrical and software integration of the
Robot and Control System in any environment that requires controlled movement of
robot axes, in compliance with the safety requirements of the country where the system
is installed.
Programming Mode
Operating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual handling of robot axes and programming of
work cycles at low speed, programmed cycle testing at low speed and, when allowed,
at the working speed.
Auto / Remote Automatic Mode

Operating mode in which the robot autonomously executes the programmed cycle at the
work speed, with the operators outside the protected area, with the safety barriers
closed and the safety circuit activated, with local (located outside the protected area) or
remote start/stop.
Maintenance and Repairs

Maintenance and repairs are activities that involve periodical checking and / or
replacement (mechanical, electrical, software) of Robot and Control System parts or
components, and trouble shooting, that terminates when the Robot and Control System
has been reset to its original project functional condition.
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Putting Out of Service and Dismantling

Putting out of service defines the activities involved in the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.
Integrator
The integrator is the professional expert responsible for the installation and putting into
service of the Robot and Control System.
Incorrect Use
Incorrect use is when the system is used in a manner other than that specified in the
Technical Documentation.
Range of Action
The robot range of action is the enveloping volume of the area occupied by the robot
and its fixtures during movement in space.
1.2.3 Applicability
These Specifications are to be applied when executing the following activities:
– Installation and Putting into Service;
– Programming Mode;
– Auto / Remote Automatic Mode;
– Robot axes release;
– Maintenance and Repairs;
– Putting Out of Service and Dismantling
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1.2.4 Operating Modes

Installation and Putting into Service
– Putting into service is only possible when the Robot and Control System has been
correctly and completely installed.
– The system installation and putting into service is exclusively the task of the
authorised personnel.
– The system installation and putting into service is only permitted inside a protected
area of an adequate size to house the robot and the fixtures it is outfitted with,
without passing beyond the safety barriers. It is also necessary to check that under
normal robot movement conditions there is no collision with parts inside the
protected area (structural columns, power supply lines, etc.) or with the barriers. If
necessary, limit the robot working areas with mechanical hard stop (see optional
assemblies).
– Any fixed robot control protections are to be located outside the protected area and
in a point where there is a full view of the robot movements.
– The robot installation area is to be as free as possible from materials that could
impede or limit visibility.
– During installation the robot and the Control Unit are to be handled as described in
the product Technical Documentation; if lifting is necessary, check that the
eye-bolts are fixed securely and use only adequate slings and equipment.
– Secure the robot to the support, with all the bolts and pins foreseen, tightened to
the torque indicated in the product Technical Documentation.
– If present, remove the fastening brackets from the axes and check that the fixing
of the robot fixture is secured correctly.
– Check that the robot guards are correctly secured and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– If applicable, connect the robot pneumatic system to the air distribution line paying
attention to set the system to the specified pressure value: a wrong setting of the
pressure system influences correct robot movement.
– Install filters on the pneumatic system to collect any condensation.
– Install the Control Unit outside the protected area: the Control Unit is not to be used
to form part of the fencing.
– Check that the voltage value of the mains is consistent with that indicated on the
plate of the Control Unit.
– Before electrically connecting the Control Unit, check that the circuit breaker on the
mains is locked in open position.
– Connection between the Control Unit and the three-phase supply mains at the
works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned
appropriately for the power installed on the Control Unit. See the product
Technical Documentation.
– The power supply cable is to enter the Control Unit through the specific fairlead and
be properly clamped.
– Connect the earth conductor (PE) then connect the power conductors to the main
switch.
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– Connect the power supply cable, first connecting the earth conductor to the circuit
breaker on the mains line, after checking with a tester that the circuit breaker
terminals are not powered. Connect the cable armouring to the earth.
– Connect the signals and power cables between the Control Unit and the robot.
– Connect the robot to earth or to the Control Unit or to a nearby earth socket.
– Check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors could cause permanent damage to the
Control Unit components.
– The C5G Control Unit manages internally the main safety interlocks (gates,
enabling pushbuttons, etc.). Connect the C5G Control Unit safety interlocks to the
line safety circuits, taking care to connect them as required by the Safety
standards. The safety of the interlock signals coming from the transfer line
(emrgency stop, gates safey devices etc) i.e. the realisation of correct and safe
circuits, is the responsibility of the Robot and Control System integrator.
In the cell/line emergency stop circuit the contacts must be included of the control
unit emergency stop buttons, which are on X30. The push buttons are not
interlocked in the emergency stop circuit of the Control Unit.
– The safety of the system cannot be guaranteed if these interlocks are wrongly
executed, incomplete or missing.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic states; in Programming the power is cut out (power
contactors open) immediately. The procedure for the selection of the controlled
stop time (that can be set on SDM board) is contained in the Installation manual .
– When preparing protection barriers, especially light barriers and access doors,
bear in mind that the robot stop times and distances are according to the stop
category (0 or 1) and the weight of the robot.
Check that the controlled stop time is consistent with the type of Robot connected
to the Control Unit. The stop time is selected using selector switches SW1 and
SW2 on the SDM board.
– Check that the environment and working conditions are within the range specified
in the specific product Technical Documentation.
– The calibration operations are to be carried out with great care, as indicated in the
Technical Documentation of the specific product, and are to be concluded
checking the correct position of the machine.
– To load or update the system software (for example after replacing boards), use
only the original software handed over by COMAU Robotics & Service.
Scrupulously follow the system software uploading procedure described in the
Technical Documentation supplied with the specific product. After uploading,
always make some tests moving the robot at slow speed and remaining outside the
protected area.
– Check that the barriers of the protected area are correctly positioned.
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Programming Mode
– The robot is only to be programmed by the authorised personnel.
– Before starting to program, the operator must check the Robot System (Robot and
Control System) to make sure that there are no potentially hazardous irregular
conditions, and that there is nobody inside the protected area.
– When possible the programming should be controlled from outside the protected
area.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the hand-held programming unit functions
correctly (slow speed, emergency stop, enabling device, etc.).
– During the programming session, only the operator with the hand-held terminal is
allowed inside the Protected Area.
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (Drive On) is always to be controlled from a position
outside the range of the robot, after checking that there is nobody in the area
involved. The Drive On operation is concluded when the relevant machine status
indication is shown.
– When programming, the operator is to keep at a distance from the robot to be able
to avoid any irregular machine movements, and in any case in a position to avoid
the risk of being trapped between the robot and structural parts (columns, barriers,
etc.), or between movable parts of the actual robot.
– When programming, the operator is to avoid remaining in a position where parts of
the robot, pulled by gravity, could execute downward movements, or move
upwards or sideways (when installed on a sloped plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at slow speed has been executed. The
test is to be controlled from a safe distance.
– Special attention is to be paid when programming using the hand-held terminal: in
this situation, although all the hardware and software safety devices are active, the
robot movement depends on the operator.
– During the first running of a new program, the robot may move along a path that is
not the one expected.
– The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the robot position out
of the path that links two steps of the program), could give rise to movements not
envisaged by the operator when testing the program.
– In both cases operate cautiously, always remaining out of the robot’s range of
action and test the cycle at slow speed.
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Auto / Remote Automatic Mode

– The activation of the automatic operation (AUTO and REMOTE states) is only to
be executed with the Robot System (Robot and Control System) integrated inside
an area with safety barriers properly interlocked, as specified by Safety Standards
currently in force in the Country where the installation takes place.
– Before starting the automatic mode the operator is to check the Robot and Control
System and the protected area to make sure there are no potentially hazardous
irregular conditions.
– The operator can only activate automatic operation after having checked:
• that the Robot and Control System is not in maintenance or being repaired;
• the safety barriers are correctly positioned;
• that there is nobody inside the protected area;
• that the Control Unit doors are closed and locked;
• that the safety devices (emergency stop, safety barrier devices) are
functioning;
– Special attention is to be paid when selecting the automatic-remote mode, where
the line PLC can perform automatic operations to switch on motors and start the
program.
Robot axes release

– In the absence of motive power, the robot axes movement is possible by means of
optional release devices and suitable lifting devices. Such devices only enable the
brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enable button) are cut out; also the robot
axes can move upwards or downwards because of the force generated by the
balancing system, or the force of gravity.
Before using the manual release devices, it is strongly recommended to sling the
robot, or hook to an overhead travelling crane.
– Enabling the brake releasing device may cause the axes falling due to gravity as
well as possible impacts due to an incorrect restoration, after applying the brake
releasing module. The procedure for the correct usage of the brake releasing
device (both for the integrated one and module one) is to be found in the
maintenance manuals.
– When the motion is enabled again following the interruption of an unfinished
MOVE, the track recovery typical function may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next automatic cycle
restarting. Avoid moving the Robot to positions that are far away from the ones
provided for the motion restart; alternatively disable the outstanding MOVE
programmes and/or instructions.
Maintenance and Repairs

– When assembled in COMAU Robotics & Service, the robot is supplied with
lubricant that does not contain substances harmful to health, however, in some
cases, repeated and prolonged exposure to the product could cause skin irritation,
or if swallowed, indisposition.
First Aid. Contact with the eyes or the skin: wash the contaminated zones with
abundant water; if the irritation persists, consult a doctor.
If swallowed, do not provoke vomiting or take anything by mouth, see a doctor as
soon as possible.
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– Maintenance, trouble-shooting and repairs are only to be carried out by authorised

personnel.
– When carrying out maintenance and repairs, the specific warning sign is to be
placed on the control panel of the Control Unit, stating that maintenance is in
progress and it is only to be removed after the operation has been completely
finished - even if it should be temporarily suspended.
– Maintenance operations and replacement of components or the Control Unit are to
be carried out with the main switch in open position and locked with a padlock.
– Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages coming from connections to peripheral units or external
power sources (e.g. 24 Vdc inputs/outputs). Cut out external sources when
operating on parts of the system that are involved.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Faulty components are to be replaced with others having the same code, or
equivalent components defined by COMAU Robotics & Service.
After replacement of the SDM module, check on the new module that the setting
of the stop time on selector switches SW1 and SW2 is consistent with the type of
Robot connected to the Control Unit.
– Trouble-shooting and maintenance activities are to be executed, when possible,

outside the protected area.
– Trouble-shooting executed on the control is to be carried out, when possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards are to be observed
when operating with hazardous voltages present.
– Trouble-shooting on the robot is to be carried out with the power supply cut out
(Drive off).
– At the end of the maintenance and trouble-shooting operations, all deactivated
safety devices are to be reset (panels, protection shields, interlocks, etc.).
– Maintenance, repairs and trouble-shooting operations are to be concluded
checking the correct operation of the Robot System (Robot and Control System)
and all the safety devices, executed from outside the protected area.
– When loading the software (for example after replacing electronic boards) the
original software handed over by COMAU Robotics & Service is to be used.
Scrupulously follow the system software loading procedure described in the
specific product Technical Documentation; after loading always run a test cycle to
make sure, remaining outside the protected area
– Disassembly of robot components (motors, balancing cylinders, etc.) may cause
uncontrolled movements of the axes in any direction: before starting a disassembly
procedure, consult the warning plates applied to the robot and the Technical
Documentation supplied.
– It is strictly forbidden to remove the protective covering of the robot springs.
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Putting Out of Service and Dismantling

– Putting out of service and dismantling the Robot and Control System is only to be
carried out by Authorised Personnel.
– Bring the robot to transport position and fit the axis clamping brackets (where
applicable) consulting the plate applied on the robot and the robot Technical
Documentation.
– Before stating to put out of service, the mains voltage to the Control Unit must be
cut out (switch off the circuit breaker on the mains distribution line and lock it in
open position).
– After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the distribution line,
first disconnecting the power conductors, then the earth. Disconnect the power
supply cable from the Control Unit and remove it.
– First disconnect the connection cables between the robot and the Control Unit,
then the earth cable.
– If present, disconnect the robot pneumatic system from the air distribution line.
– Check that the robot is properly balanced and if necessary sling it correctly, then
remove the robot securing bolts from the support.
– Remove the robot and the Control Unit from the work area, applying the rules
indicated in the products Technical Documentation; if lifting is necessary, check the
correct fastening of the eye-bolts and use appropriate slings and equipment only.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU Robotics & Service,
or one of its branches, who will indicate, according to the type of robot and Control
Unit, the operating methods in accordance with safety principles and safeguarding
the environment.
– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.
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1.2.5 Performance
The performances below shall be considered before installing the robot system:
– Stop distances
– Mission time (typ. case).
Stop distances
– With Robot in programming modality (T1), if you press the sttop pushbutton (red
mushroom-shaped one on WiTP) in category 0 (secondo norma EN60204-1), you
will obtain:
Tab. 1.1 - Stop spaces in programming modality (T1)

Expected Stopping Stopping
Mode Case
speed time space
Nominal 120 ms 30 mm
T1 250 mm/s
Limit 500 ms 125 mm
Tab. 1.2 - Safety electronics reaction time in programming

modality (T1)
Expected Stopping
Mode Case
speed time
For the safety inputs of the SDM module (e.g.
stop pushbutton of TP in wired version)
For the stop stop and enabling device inputs 150 ms
from the TP in wireless version, when the
T1 250 mm/s
safety wire trasmission is active.
For the time-out of stop input and enabling
device from TP in wireless version, when the 350 ms
safety wire transmission is lost or interrupted.
– Considering the Robot in automatico modality, under full extension, full load and
maximmum speed conditions, if you press the stop pushbutton (red
mushroom-shaped one on WiTP) in category 1 (according to norm EN60204-1)
you will trigger the Robot complete stop with controlled deleration ramp.
Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 °
motion, that correspond to about 3000 mm movement measured on TCP flange.
Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5
seconds.
Mission time (typ. case)

– We remind you that the safety system efficiency covering is equal to 20 years
(mission time of safety-related parts of control systems (SRP/CS), according to
EN ISO 13849-1).
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Introduction to the control unit: reliability and safety
2. INTRODUCTION TO THE CONTROL

UNIT: RELIABILITY AND SAFETY
The C5G Control Unit is an industrial appliance created for user-friendly, efficient and
multi-purpose management of all SMART5 Comau Robot range.
The C5G Control Unit:

– is powered directly from the factory mains with a voltage from 400 Vac -15% to 500
Vac +10% with no need of any adapting transformer. Optionally it is available the
voltage extended range.
– with a total maximum power of 16 kVA, it can handle robot configured with up to
16 interpolated axes, supplied with brushless synchronous motors and
high-resolution Encoder-type position transducer with EnDat 2.2 interface.
– can be interfaced through the most common communication interfaces (USB,
serial, Ethernet) as well as with the most common field Bus and communication
protocols (CanOpen, DeviceNet, Profibus-DP, EtherNet/IP, etc.). It can become an
Ethernet net node on the plant network to facilitate remote updating and
diagnostics.
– can be programmed through a user-friendly software and controlled using a
chosen programming terminal featuring cable or wireless connection. The
programming terminal is supplied with a TFT 6.4” 4096-colour graphic display,
easy-to-understand user interface, is lightweight and ergonomically structured with
on-board USB interface.
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– It is easily expandable through optional modules, to better adapt to the user’s

applications and make them easier.
This Control Unit shall be matched to a SMART5 series Comau robot only.
The C5G Control Unit has been conceived to guarantee:

– Reliability and serviceability
– Calculation power
– Expandability
– Programming
– Safety
– Control modes.
The results obtained has enabled us to develop a Control Unit suitable to fulfil the
requirements of multiple applications featuring high-level sophisticated performances.
2.1 Reliability and serviceability

The C5G Control Unit has been conceived and developed applying care and precision
principles and using high-quality components, according to the following concepts:
– minimum functional divisions, with specific high-potential modules
– limited interconnections among modules, accomplished mainly through
communication networks
– high MTBF: the system main items have been developed to guarantee a high
MTBF. The control unit internal wiring and interconnections have been carried out
such as not to impact on the main item MTBF.
– reduced MTTR: the Control Unit main items assembly is such as to guarantee a
quick replacement of all control unit internal items.
– sophisticated diagnostics in order to facilitate maintenance, with the possibility
of remote diagnostics as well as SMS and e-mail sending.
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2.2 Calculation power

The C5G Control Unit features state-of-the-art processors to control the trajectory and
the periphery, the application software and the user’s interface, in order to ensure the
highest level of performance of both areas. The processors work through a real time
VxWorks operating system.
The processor controlling the movements carries out the following functions reliably and
accurately:
– Servo-adaptive algorithms, with dynamic pattern calculated in real time based on
the load, position speed (Smart Move) and inertia conditions. The dynamic model
is applied to all 6 axes.
– Acceleration/deceleration modulation for joint-like movements, to optimize the
robot motor performances in terms of speed.
– Linear interpolation featuring fly-path total programmability and constant speed.
– Circular interpolation featuring different orientation evolution possibilities (even 2
angles in relation to the trajectory).
– Possibility to control up to 16 axes:
• Synchronized movements - Sync Move (function provided for)
• Integrated Arms the control arm chains (1 arm carries a second one that
performs the process) (function provided for)
• is open to Cooperative Motion, to control two cooperating arms (1 arm
position the item, 1 arm carries out the process).
– Conveyor tracking, to carry out the process of items moving on conveyor lines or
rotating plates that are not controlled by the robot.
– Weaving, for more sophisticated arc welding processes (Cartesian weaving and
high frequency joints).
– Sensor Tracking, guaranteeing the highest tracking precision and the possibility to
interfacing with different sensor typologies: 3D laser telecameras, arc parameter
sensors, power sensors, others (function provided for).
– Reference systems: base, tool, users, to reuse programmes on different cells.
– Collision detection: it allows to detect collision situation between the robot and the
surrounding environment.
– Load self-determination: a software tool is available that allows to correctly define
the load parameters that will influence the robot movements, to optimize the
performances and protect the components.
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2.3 Expandability
The expandability is based on the usage of standard protocols and connections, usually
available in industrial environments.
The C5G Control Unit is supplied with 6 base axes that can be expanded up to 11 inside
the same cabinet.
Modules are available on the Ethernet POWERLINK network for the interfacing with field
and application control Bus and parallel I/O signals.
The safety circuit basic prearrangement, that can be easily integrated on the line, can
be expanded using modules for the safe control on Safety Bus and axes safe shutting.
Moreover, several options allow to adapt and customize the C5G Control Unit such as
to fulfil the different installation requirements.
2.4 Programming
The programming features:
– on-line and off-line programming facilities through a graphic programming terminal,
Personal computer and dedicated CAD (e.g. RobCad)
– PDL2 easy language combined with the potential to guarantee the robot integration
in the most demanding applications
– possibility to run simultaneously more PDL2 programmes
– possibility to customize application programmes through Java graphics and
language.
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2.5 Safety
– Compliance with the norms in force
– Directives and norms
– Statement of incorporation of quasi-machines
– Manufacturer’s details
– Safety devices control procedures
– Safety solutions installed.
2.5.1 Compliance with the norms in force

The C5G Control Unit consists of a functional area specifically designed to fulfil the
safety requirements provided for by the norms in force:
– Compliance with norm EN ISO 10218-1: the Robot Control Unit to be used with
the Comau robots has been developed to fulfil the norm requirements and facilitate
the controller integration
– Safe stopping circuits: the emergency stop control, that is available also as
connection outside the Control Unit, ensures a safe stop of the corresponding
Comau robot, also under the most demanding conditions that are to be expected
(full load at high speed)
– Safe movement control circuits: the motion is triggered and controlled by the
Control Unit, which ensures the correct motion accomplishing. All trajectories are
constantly checked and monitored and any possible deviation due to external
causes is immediately detected and corrected. If the trajectory is compromised, the
immediate stop will be triggered in good time.
– Safety circuit category: all safety circuits inside on Robot Control Unit standard
models are in compliance with category 3 according to standard EN ISO 13849-1
(PL = d, DCawg = 95%, MTTFd > 100, CCF = 75). Also all internal circuits, external
interconnection circuits and expansion modules, which allow to increase the
number of contacts for the application interfacing, comply with the same category.
– Compliance with the European Directives: Machine Directive,
Electromagnetic Compatibility Directive (EMC), Low Voltage Directive and
Directives pertaning the environmental protection. The Control Unit matched
to a Comau robot is an “quasi-machine” (according to the definition in the Machine
Directive 2006/42/CE, item 2 paragraph g). The terms of compliance with the
directives are described in details in par. 2.5.3 Statement of incorporation of
quasi-machines on page 27.
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2.5.2 Directives and norms

The C5G Control Unit has been designed and manufactured in compliance with the
directives and norms listed in Tab. 2.1.
Tab. 2.1 - Applicable Directives and norms

Directive / Norm Description and applicability
2006/42/CE DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE
COUNCIL of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast) (for the sake of brevity referred to as Machine directive)
COUNCIL of 12 December 2006 on the harmonisation of the laws of Member
States relating to electrical equipment designed for use within certain voltage
limits (for the sake of brevity referred to as Low voltage directive)
COUNCIL of 15 December 2004 on the approximation of the laws of the Member
States relating to electromagnetic compatibility and repealing Directive
89/336/EEC (for the sake of brevity referred to as EMC Directive)
COUNCIL of 27 January 2003 on the restriction of the use of certain hazardous
substances in electrical and electronic equipment (for the sake of brevity referred
to as RoHS Directive) and later amendments (2008/385/EC)
EN ISO 13850 Safety of machinery - Emergency stop - Principles for design
EN ISO 13732-1 Ergonomics of the thermal environment - Methods for the assessment of human
responses to contact with surfaces - Part 1: Hot surfaces
EN ISO 10218-1 Robots for industrial environments - Safety requirements - Part 1: Robot
EN ISO 13849-1 Safety of machinery - Safety related parts of control systems - General principles
for design
EN 60068-2-6 Basic environmental testing procedures - part 2: Vibration (sinusoidal)
EN 60068-2-31 Basic environmental testing procedures - part 2: Drop and topple, primarily for
equipment type specimens
EN 60068-2-64 Environmental testing - Test methods - Test FH: vibration, broad band random
(Digital Control) and guidance
EN 60204-1 Safety of Machinery - Electrical equipment of machines - Part 1: General
requirements
EN 60529 Degrees of protection provided by enclosures (IP code)
EN 61000-6-2 Electromagnetic Compatibility - Generic immunity standard - Part 6-2: Industrial
environment
EN 61000-6-4 Electromagnetic Compatibility - Generic emission standard - Part 6-4: Industrial
environment
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2.5.3 Statement of incorporation of quasi-machines

The group consisting of the C5G Control Unit and the SMART5 series robot is supplied
with statement of incorporation of quasi-machines, as provided for in the Enclosure
II b. of directive 2006/42/EC.
it is forbidden to set the group consisting of the C5G Control Unit and the
SMART5 series Robot at work before the machine in which it is to be installed is
declared to be in compliance with the provisions in directive 2006/42/EC.
The Statement of incorporation of quasi-machines is supplied in original together

with the group consisting of the C5G Control Unit and SMART5 serie Robot.
The C5G Control Unit identification plate is posted on the electric cabinet front side.
Fig. 2.1 - C5G Control Unit Identification Plate (facsimile for

version C5G-ACC3)
2.5.4 Manufacturer’s details

The manufacturer, as defined in the Machine Directive, is:
COMAU S.p.A.
Robotics Business Line
Via Rivalta, 30
10095 Grugliasco (TO) - ITALY
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2.5.5 Safety devices control procedures

To facilitate the safety devices control procedures, the controlling circuits and basic
interlocks, that are necessary to control a cell, have been integrated inside the C5G
Robot Control Unit.
This solution represents a noticeable advantage for the installation, as it will no longer
be necessary to provide for the outside interlocks controlling the safety gates or other
operator protecting devices and it will simply be sufficient to connect to the dedicated
connector located by the cabinet base to make use of all available safety functions.
This flexibility do not damage the reverse situation, i.e. the safety signals controlling by
the external circuits. In that case all C5G Robot Control Unit safety and status signals
are available on the same dedicated connector.
If the number of contacts related to the safety and status signals available in the Control
Unit are not sufficient to control one or more applications, it is possible to use the
available expansion cards to increase the contact number without altering the safety
circuit category.
(In compliance with norm EN 60204-1) the stopping procedure is accomplished
according to category 0 (zero) in Programming (T1) mode and to category 1 in Local
automatic (AUTO) and Remote automatic (REMOTE) mode
2.5.6 Safety solutions installed

The safety circuit and the connections for the external devices allow the compliance in
according to norm EN ISO 13849-1.
Find below the solutions installed to guarantee the operators’ safety:
– Emergency stop push button
The red mushroom-shaped push button triggering the emergency stop is installed
on the programming terminal.The potential-free push button contacts are available
on the interface connector and are not connected to the internal emergency stop
circuit.
– Emergency stop control
The cell emergency contacts (mushroom-shaped push buttons) can be connected
to the internal safety circuit to trigger the robot stopping. In automatic mode, the
robot stopping is accomplished through controlled decelation ramp, in compliance
with category 1, according to norm EN 60204-1.
– Enabling Device pushbutton
The programmig terminal hosts the three-position Enabling Device with hardware
control. By pressing the enabling device power is delivered to the actuating devices
and the robot movements are enabled in programming operating mode. The
enabling device is active in programming mode only and disabled in the other
machine modes.
– Cell access gates control
The contacts of the limit switches installed on the cell access gates can be
connected to the safety circuit to control the robot stopping in automatic mode. In
programming mode, those contacts are cut off to allow the robot motion with open
gates.
– Safe power cut-off
The 24V I/O power supply to the dedicated interface connectors depends on the
following items:
• emergency stop
• safety gate opening in automatic mode
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• enabling device releasing in programming mode

• motor-off command (Drive Off).
2.6 Control modes

The group consisting of the C5G Control Unit and SMART5 series Robot features 3
control modes. The control modes can be selected using the key selector switch
located on the programming Terminal.
– Programming (T1)
Used for low speed motion, to programme the robot operating trajectory.
The operator may remain inside the cell. The robot movements are accomplished
at reduced speed, reaching maximum 250 mm/s by the flange centre. The robot is
directly controlled by the operator. Movements and program running at reduced
speed are allowed.
– Local automatic (AUTO)
Used to run working programmes, in automatic mode with gates closed and at set
speed, that are triggered from the programming terminal.
– Remote automatic (REMOTE)
Used to run programmes, in automatic mode with gates closed and at set speed,
that are triggered from external devices (PLC, others).
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Versions and Technical features
3. VERSIONS AND TECHNICAL FEATURES

– Selecting the Control Unit version:
– C5G Control Unit
– Teach Pendant
– Connection cables between C5G and Robot
3.1 Selecting the Control Unit version

To choose the most suitable C5G Control Unit version it is necessary to take into
account first of all the Robot family and the related required electric power. This manual
does not deal with the selection of the Robot version, please refer to the Robot specific
“Technical Specifications” manuals.
The C5G Control Unit configuration has to be chosen accomplishing the following steps:
– C5G Control Unit, depending on the Robot family it will be matched to
– Teach Pendant, depending on the type of connection required between Control
Unit and Programming terminal
– Connection cables between C5G and Robot, depending on the Robot family and
the installation distance.
– Customizing adding optional functions (refer to Chap.6. - Options on page 155).
Fig. 3.1 - C5G Control Unit: overall view
A: C5G Control Unit
B: Teach Pendant
B -: Connection cables between C5G
and Robot
-: Options
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3.2 C5G Control Unit

Different configurations are available for the C5G Control Unit. The main feature that
distinguishes the configuration is the available electric power and therefore the Robot
family it can be matched to.
The Control Unit includes all modules necessary to control the Robot (powering from the
mains, actuating devices, signal distribution module and safety devices control). The
basic version does not include the Teach Pendant and the optional modules. Also the
Connection cables between C5G and Robot are to be chosen separately.
Tab. 3.1 - C5G: available basic versions

Robot family*¹ Suitable C5G Control Unit
Comau Code Power *²
(SMART5 series)
SiX - NS C5G-ACC1 CR17930180 8 kVA
NM - NJ (up to 450) C5G-ACC3 CR17930380 8 kVA
*¹ As for the information related to the Robot features and available versions, please
refer to the Robot specific “Technical Specifications” manuals
*² The power value does not vary with the powering voltage fluctuations, as the system
works at constant power.
Fig. 3.2 - C5G Control Unit: front and rear view
This picture shows the C5G Control Unit already supplied with iTP Programming
terminal.
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3.2.1 Control Unit technical features

In Tab. 3.2 are listed the technical features of the product basic version.
Tab. 3.2 - General technical feature

C5G-ACC1 C5G-ACC3 C5G-ACC5
Size
1110 x 800 x 510 mm
Height x width x depth (basics version, no options)
43.31 x 31.50 x 20.08 in
– Height with wheel option no difference
– Height with rising socket option 100 mm +100 mm (+3.94 in)
– Height with Application Box option +540 mm (+21.26 in)
Powering details
Powering voltage from 400 Vac -15%

(according to norm EN 60204-1 § 4.3.3, voltage breaking not exceeding to 500 Vac +10%
20 ms) (optional from 400 Vac -15% to 575 Vac +10%)*¹
Frequency
50 at 60 Hz (±2 Hz)
(according to norm EN 60204-1 § 4.3.3)
Main switch breaking power 6 kA at 500 Vac
Installed power 8 kVA 8 kVA 16 kVA
Auxiliary circuit voltage 24 Vdc
Axis controlling capability
Total for the system up to 16 axes
Control Unit without expansion cabinets up to 11 axes
Environmental conditions
Cabinet protection (non including rear space)
IP 54 / NEMA 12
(according to norm EN 60529)
Rear space protection
IP 2x
(according to norm EN 60529)
Room temperature without cooling systems from +5 °C to +45 °C *²

(test conditions according to norm EN 60068-2-14) from +41 °F to 113 °F
Room temperature with cooling systems from +5 °C to +55 °C *²
(test conditions according to norm EN 60068-2-14) to +41 °F a 131 °F
from -25 °C to +55 °C
Storage room temperature
from -13 °F to 131 °F
(according to norm EN 60204-1 § 4.5)
+70 °C / 158 °F fro short periods, less than a hour.
1,5 °C/minute
Maximum thermal gradient
2.7 °F/minute
Relative humidity
from 5% to 95% without condensate
(according to norm EN 60204-1 § 4.4.4, test conditions HD 323.2.3. S2)
Installation area altitude from 0 to 1.000 m / 0 to 3280 ft

(according to norm EN 60204-1 § 4.4.5) above sea level
Cooling
Standard booth Natural convection
Booth with cooling options Conditioner
Actuation Forced air recirculation
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Tab. 3.2 - General technical feature (Continued)

Weight
Control Unit (basic version)
The weight specified may change depending on the configuration, in
125 kg / 275 lb without package
particular when it deals with the version featuring Application Box. Always
refer to the plate posted on the Control Unit
Conditioner (optional) 31 kg / 68 lb
Vibrations and impacts
Frequency 10 - 250 Hz
Sinusoidal vibrations acceleration 0,6 g rms axis Z
(according to norm EN 60068-2-64)
acceleration 0,2 g rms axes X-Y
Colour
Cabinet body, painted items RAL 7024
*¹ It is possible to widen the voltage range with the transformer option and voltage switch
on terminal board.
*² With restrictions (refer to par. 4.13 Internal ventilation system on page 82).
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3.3 Teach Pendant

The Control Unit basic version shall be completed with the Teach Pendant that is
available in models that differ depending on the type of connection required between
Control Unit and Programming terminal.
There are 2 possible solutions:
– Programming terminal with cable connection (C5G-iTP)
– Programming terminal with wireless connection (C5G-WiTP).
The technical differences are to be found in par. 3.3.2 Teach Pendant technical features
on page 36.
Fig. 3.3 - Programming terminal: overall view
3.3.1 Teach Pendant operating principle

The Teach Pendant communicate with the C5G Control Unit through the Ethernet
protocol. The connection starts on the dedicated Ethernet ETH1 port of the
AMS-APC820 module and, depending on the terminal type, ends directly on the
C5G-iTP terminal or connects to the access point on the docking station for the
C5G-WiTP terminal.
Through the color user interface it is possible to easily access all parameters and
perform the Robot movements as well as run the working programmes. Using suitable
application softwares (that can be developed also by the user), the interface can be
customized to fulfil the requirements of specific production environments and
processes.
The Programming terminal functions are complex and are dealt with in details in
the usage manual.
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3.3.2 Teach Pendant technical features
Tab. 3.3 - Teach Pendant: versions available

C5G-iTP C5G-WiTP
Feature
Terminal Terminal
Modal selector switch (Modalty T1, AUTO, Installed on the docking
Installed on terminal
REMOTE) station
lit-up LCD
Display 4096-colour TFT 6.4”
resolution 640 x 480
Sizes 360 x 210 x 80 mm
Weight 1090 g 1470 g
Port USB 1.1 available on terminal 1
Connection typology Cable Wireless
Reachable distance between Control Unit and
up to 30 m guaranteed up to 40 m
Programming terminal
Need to combine the terminal with one only Control
Yes No*²
Unit
Colour Grey Blue
Processor Intel® PXA 270 Intel® PXA 270
Operating system Microsoft® Windows® CE Microsoft® Windows® CE
Internal memory 128 Mbyte 128 Mbyte
TCP-IP TCP-IP
Communication protocol / method
through cable IEEE802.11a
Independent communication channels *¹ (as per
NA 19 EU / 24 USA
standard 802.11 a)
Pairing / Un-Pairing *² -
Connection safety wired
Comau Patented
PL = d, DCawg = 95%,
Safety according to standar EN ISO 13849-1 PL = d
MTTFd > 100, CCF = 75
Usage endurance illimited 5 hours (typical)
Battery charging time NA 2 hours (typical)
*¹ Each independent communication channel can be used to send and receive data from
different Wi-Fi sources at the same time.
*² Implementing the Pairing / Un-Pairing procedure (Comau Patented) it is possible to
use an only one terminal for 2 or more Control Units
NA: Not Applicable
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3.3.3 Programming terminal with cable connection (C5G-iTP)

At the time of purchase it is necessary to choose a Station, including programming
terminal and medium.
The medium can be installed on the door or be delivered separately to allow the
customized installation by the line/cell control station (installation to be carried out by the
user). At the time of purchase the user shall specify if it shall be pre assembled on the
Unit Control door.
Tab. 3.4 - Programming terminals with cable, supplied with

medium: available station versions
Description Cable length Abbreviation Comau Code
Station C5G-iRT10 10 m (33 ft) C5G-iRT10 CR17431980


It includes: C5G-iTP Programming terminal with inside-cabinet cable and connectors, C5G-iBK medium.
When only the programming terminal with cable is needed, it is possible to choose
among the versions listed below.
Tab. 3.5 - Programming terminals with cable (no medium):

available versions
Description Cable length Abbreviation Comau Code
10 m (33 ft) C5G-iTP10 CR17910381
C5G-iTP Terminal with cable 20 m (66 ft) C5G-iTP20 CR17910382
30 m (98 ft) C5G-iTP30 CR17910383

It includes: C5G-iTP Programming terminal with cable.
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3.3.4 Programming terminal with wireless connection

(C5G-WiTP)
At the time of purchase it is necessary to choose a Station, including Programming
terminal and docking station.
Tab. 3.6 - Programming terminals with cable, equipped with

docking station: available station versions
Description Abbreviation Comau Code
Station C5G-xxx
It includes : C5G-WiTP wireless programming terminal, inside-cabinet cables and connectors, medium and
docking station C5G-xxx on cabinet door, antenna
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3.4 Connection cables between C5G and Robot

The connection cables between the C5G Control Unit and the Robot are connected from
one end by the cabinet base to another end by the Robot base, on the corresponding
connector panels respectively.
The cable supply kit includes the service, motor and earth cables. The cables are
fixed-laying-type and can be chosen depending on the installation required length and
the Robot family:
– service cable, X10 connector by cabinet base, X1 by Robot base
– motor cable, X60 connector by cabinet base, X2 by Robot base
– earth cable, supplied with eyelet lug by the ends.
Tab. 3.7 - Cable kit to connect C5G and Robot: available

versions
Comau Code Description
For all Robot versions
Kit consisting of service, motor and earth cables.
CR18945880
Cable length 5 m (16 ft)
CR18945881
CR18945882
CR18945883
CR18945884
CR18945885
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Details about the C5G Control Unit
4. DETAILS ABOUT THE C5G CONTROL

UNIT
– Modules installed in the Control Unit
– Arm Controller Electromechanical (ACE)
– CPU, power supplies and power modules
– AMS-APC820 module
– AMS-PPS8 module
– AMS-ASM32 module
– AMS-IAM module
– Thermal dissipator AMS-FMP14
– Safety Distribution Module (SDM)
– Uninterruptible Power Supply (UPS)
– Operator Panel Devices (OPD)
– Connector Interface Panel (CIP)
– Internal ventilation system
– General information about the communication networks inside the C5G Control
Unit
– Ethernet POWERLINK Network
– CAN Bus network
– Connector pin structure
– System variables.
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4.1 Modules installed in the Control Unit

The C5G Control Unit basic version consists of the following homogeneous groups:
– Arm Controller Electromechanical (ACE), consisting of the electromechanical
modules of the mains powering section
– CPU, power supplies and power modules, consisting of the actuating modules and
control unit
– Safety Distribution Module (SDM), cosmogonist of a module to control the safety
signal and the 24 Vdc distribution
– Uninterruptible Power Supply (UPS), consisting of a module for the 24 Vdc backup
(through battery) to power the modules for the time necessary to the shutdown in
case of missing power.
– Operator Panel Devices (OPD), consisting of the Control Unit front panel where the
main switch control and the options for the robot system maintenance are installed
– Connector Interface Panel (CIP), consisting of the lower front panel where the
connectors for the interfacing with the Robot and the applications are located
– Internal ventilation system, consisting of fans for the air forced circulation inside the
cabinet and on the rear dissipator.
To guarantee an improved versatility and adaptability, the Control Unit basic version can
be supplied with Options and/or complete solutions that allow the application
customization.
Fig. 4.1 shows the position of the modules installed in the Control Unit.
Fig. 4.1 - Position of the modules installed in the Control Unit
A: Arm Controller Electromechanical (ACE)
B: CPU, power supplies and power modules

A E
C: Safety Distribution Module (SDM)
B D: Uninterruptible Power Supply (UPS)
E: Operator Panel Devices (OPD)

C
F: Connector Interface Panel (CIP)
D
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4.2 Arm Controller Electromechanical (ACE)

Function
The Arm Controller Electromechanical (ACE) controls the electric energy distribution
from the mains and removes the possible electrical troubles using the network filter.
Technical features
The Arm Controller Electromechanical (ACE) consists of main switch, filter and terminal
boards.
Structure
Fig. 4.2 - ACE: overall view
A: Handle for main switch
B: Main switch
C: Line EMI filter
D: Power supply input terminal board
A B C D
Tab. 4.1 - ACE: product codes

No. in the Control Unit
Component Comau Code
handle and extension for switch
CR19191127 1
PKZO-XH-MCC
Main switch PKZMO-25 CR19191126 1
Line EMI filter CR10140283 1
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4.3 CPU, power supplies and power modules

Function
The control device, power supply units and power modules feed and control the whole
system, monitor all other modules in the Control Unit and interact with them.
Technical features
The system consists of control unit (AMS-APC820 module), DC bus power supply
(AMS-PPS8 module), 24 Vdc power supply (AMS-ASM32 module) and the power and
axes control modules (AMS-IAM module).
The power of the Robot controlled by the Control Unit influences the no. of axes modules
installed and the related supply currents.
Each installed module can take 1 or 2 slots; the size of each slot is equal to 53,5 mm
(21.00 in).
With the exception of AMS-ASM32 module (that does not require any POWERLINK
connection), the remaining modules exchange information through the Ethernet
POWERLINK Network. Each module has an univocal IP address. The address definition
is described in par. 4.15.1 Ethernet POWERLINK Address on page 84.
Structure
Fig. 4.3 - System: overall view
A: control unit AMS-APC820 module (Acopos

PC)
B: DC bus power supply AMS-PPS8 module

(Passive Power Supply)
C: 24 Vdc power supply AMS-ASM32 module

(Auxiliary Supply Module)
D: power and axes control modules AMS-IAM

module (Inverter Axis Module)
E: Thermal dissipator AMS-FMP14
F: DC bus and 24 Vdc connector
A B C D E F
The picture shows the typical structure for the C5G-ACC1 Control Unit
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Tab. 4.2 - System: product codes

Component Slot taken Comau Code
AMS-APC 820
1 CR10140783 1
Acopos PC
AMS-PPS 8
2 CR10140383 1
Passive Power Supply
AMS-ASM 32
1 CR10140483 1
Auxiliary Supply Module
AMS-IAM 22+22
2 CR10141583 x 2
Inverter Axis Module
AMS-IAM 11+11
2 CR10141483 1 1
AMS-IAM 5,5+5,5
1 CR10141283 1 x
AMS-IAM 2,8+2,8
1 CR10141183 1 x
AMS-ETI22
- CR10140883 6 6
Encoder trasducer
AMS-FMP 14
- CR10140183 1
Thermal dissipator
C5G-ERR
- CR19191128 1
Recovery resistance
Spare battery for
- 1
AMS-APC 820
AMS-AFU
Spare fan for -- Refer to Chap.8.3 - 2
AMS-APC 820 Spare part list on
AMS-AFU page 57 in the
Spare fan for “Maintenance” manual
AMS-PPS 8 -- 1 each module
AMS-ASM 32
AMS-IAM x
X: Not required
4.3.1 Modules installed

The system consists of the following modules:
– AMS-APC820 module (Acopos PC) (A), calculation unit made up of a dual core
industrial PC module.
– AMS-PPS8 module (Passive Power Supply) (B), feeder / converter to produce the
actuation DC bus.
– AMS-ASM32 module (Auxiliary Supply Module) (C), feeder / converter to produce
the 24 Vdc used to power the auxiliary circuits.
– AMS-IAM module (Inverter Axis Module) (D), complete axis module, made up of
the power section, position control and brake control. The IAM modules no. and
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sizes differ depending on Robot power and/or no. of axes to be controlled. The
position control interface is a AMS-ETI22 card fitted in the AMS-IAM module.
– C5G-ERR (Energy Recovery Resistance), recovery resistance 15 ohm 2 kW)
– Thermal dissipator AMS-FMP14, aluminium plate to fasten the modules and
perform the module thermal dissipation. To the dissipator are connected the bus
connectors that distribue the DC bus and 24 Vdc power supply used by the
modules installed.
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4.4 AMS-APC820 module

The AMS-APC820 module is the calculation unit that controls the trajectory generator,
the HMI interface, the system and application I/O. It is master of the real-time Ethernet
POWERLINK (EPL) protocol and the CANopen serial connection.
The module is an industrial Personal Computer (PC) supplied with dual core processor.
The Ethernet POWERLINK Address do not require customization by the user.
Fig. 4.4 - AMS-APC820: overall view
Battery: CMOS battery
CAN Bus: CAN Bus port for the

communication with the Safety Distribution
Module (SDM)
CARD SLOT: reserved expansion slot
CompactFlash Slot 1: slot for system CF
CompactFlash Slot 2: slot for CF reserved

Leds
COM1: serial portRS232 reserved
COM2: serial port RS232/RS422 for user’s

applications
ETH1 XD2 XD3
ETH1: Ethernet network port for Teach
ETH2 XD4 XD5 Pendant
ETH2: Ethernet network port dor user’s

COM2 COM1 applications
DVI / SDL: monitor port reserved

X3A
XD
LED / Switch: CAN termination on-status
Led / Switch LED and related switch
Compact Flash Slot 1
Compact Flash Slot 2
CAN Bus
Power button: starting push button

AMS-APC820
DVI/SDL
Battery XD: USB port for the connection to compatible
CARD storage pheriferals
Slot
XD2: USB port reserved for option

C5G-USBK: USB kit
Fans
XD3:USB port reserved for option
Top C5G-USBK: USB kit
side
XD4: USB port reserved for expansion
Front
XD5: USB port reserved for expansions
side
X3A: Ethernet POWERLINK port
LEDs: Status LED
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Tab. 4.3 - AMS-APC820: connections and devices

Connector /
Description
component
Buffer battery
Features:
Battery – Type: “Renata” 950 mAh
– Life: 5 years typ. The diagnosis system advises when
about 500-hour endurance are left.
CAN Bus port for the communication with the Safety

Distribution Module (SDM)
CAN resistor
On
Features:
1 – Admissible speed: Max. 500 kbit/s
CAN Bus
4
– Max cable length: 1000 m (3281 ft)
Pins:
CAN Bus
Between the CAN Bus network connector and the close

Ethernet one is installed a dip-switch to turn on the bus
termination resistance and a LED that lights up to advises
that the resistance is on.
Although the dip-switch and the LED are positiond slightly
inwards are easily visible and reachable.
The termination resistance shall always be on.
Expansion slot reserved for options (Ethernet card for field

CARD SLOT
bus (ETH3), second Ethernet card for POWERLINK)
Slot for CompactFlash card including the Operating System

CompactFlash
Slot 2
as well as the system and user’s files.
CompactFlash Features:
Slot 1 – Size: 512 Mbyte
CompactFlash – Formatting: proprietary
Slot 1
– Available user’s space: 290 Mbyte (UD:)
CompactFlash
Reserved
Slot 2
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Tab. 4.3 - AMS-APC820: connections and devices (Continued)

Connector /
Description
component
Serial port RS232 reserved.
DSUB (tray) 9-pin male connector.
Features:
– RS232, modem-capable, not-electrically insulated
– UART 16550-compatible, 16-byte FIFO
– Speed: Max. 115 kbaud *¹
– Max cable length: 15 m (49 ft)
Pins:
COM1
*¹ depends on the cable type and length

Serial port RS232/RS422 for user’s applications. The
RS232 and RS422 ports cannot be used
contemporaneously.
COM2
More details in par. 5.11 RS232 and RS422
serial communication on page 149.
Ethernet 10/100/1000 network port, reserved for the

connection with the Teach Pendant
Features:
ETH1 – Controller: Realtek RTL8111B
– Speed: 10/100/1000 Mbit/s
– Max cable length: 100 m (328 ft), minimum Cat5e
– Cable type: S/STP (Cat5e)
Ethernet 10/100/1000 network port for user’s applications
(e.g. connection with factory Host)
ETH2 Details in par. 5.12 Communication via

Ethernet network on page 151.
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Connector /
Description
component
DVI / SDL Monitor port reserved: DVI / SDL (Smart Display Link)
LED: CAN bus network termination status signalling:

– when on, it means that the termination resistance is on
(correct condition)
– when off, it means that the termination is off (wrong
LED / Switch condition)
Switch: termination resistance on / off:
– ON, termination resistance on (correct condition)
– OFF, termination resistance off (wrong condition)
Reset
button XD
USB port for the connection to compatible storage
XD peripherals.
Max supply current 1 A.
USB port reserved for the option C5G-USBK: USB kit

XD2
Max supply current 500 mA.
USB port reserved for the option C5G-USBK: USB kit
XD3
Max supply current 500 mA.
USB port reserved for future expiations.
XD4
Max supply current 1 A
USB port reserved for future expiations.
XD5
Max supply current 1 A
Common features for USB XD, XD2, XD3, XD4, XD5 ports:
– USB 2.0 (Universal Serial Bus)
– Type-A female connector.
– Admissible speeds: Low speed (1.5 Mbit/s), Full speed
(12 MBit/s) and High speed (480 Mbit/s)
– Connection cable length: 5 m (without HUB)
Ethernet POWERLINK network port for the communication

X3A with the actuation modules (intended for AMS-PPS8
module)
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Connector /
Description
component
Status LED:
– PWR: Power LED:
• [ON] when on it means that the APC820 is
powered
– CF: CompactFlash LED:
• [ON] on when accessing the CF on slot 1
– SDL: Link LED: not used
LEDs
– RUN: Run LED: not used
– CAN: CAN Bus LED:
• [ON] on in fixed modality during the bootstrap
phase
– ACT LNK: Ethernet POWERLINK LED
– SPD LNK: Ethernet ETH1 LED: not used
– SPD LNK: Ethernet ETH2 LED: not used
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4.5 AMS-PPS8 module

The AMS-PPS8 module is a feeder / converter to produce the actuation DC bus.
The Ethernet POWERLINK Address is predefined at “T1=0 e T2=1”.
Fig. 4.5 - AMS-PPS8: overall view
X1: DC Bus ready signal (intended for

AMS-ASM32 module)
X3A:Ethernet POWERLINK port for the

communication among modules (coming from
AMS-APC820 module)
X3B: Ethernet POWERLINK port for the

X1 communication among modules (intended for
X3B the first AMS-IAM module)
Leds
X3A
X5A: input for power from the mains,
three-phase
X5B: Recovery resistance connection
LEDs: Status LED

Top
side
X5B
X5A
AMS-PPS8
Front
side
Bottom
side
Tab. 4.4 - AMS-PPS8: connections and devices

Connector /
Description
component
X1 X1 DC Bus ready signal (intended for AMS-ASM32 module)
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Tab. 4.4 - AMS-PPS8: connections and devices (Continued)

Connector /
Description
component

X3A with the actuation modules (coming from AMS-PPS8
X3A module)
X3B Ethernet POWERLINK network port for the communication

X3B with the actuation modules (intended for the first AMS-IAM
module)
X5A X5A Input for power from the mains, three-phase
X5B X5B Recovery resistance connection
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Tab. 4.4 - AMS-PPS8: connections and devices (Continued)

Connector /
Description
component
Status LEDs:
Supply voltage:
– 24V (green)
• [ON] The 24 Vdc internal system supply voltage
is within the tolerance range
Inverter - power:
– RDY (green)
• [ON] The module is operational and the power
stage can be enabled (operating system present
and booted, no permanent or temporary errors).
– RUN (orange)
LEDs
• [ON] The module power stage is enabled.
– ERR (red)
• [ON] A permanent*¹ or temporary*² error exists on
the module.
Ethernet POWERLINK:
– R/E (green/red): see Tab. 4.5
– L/D1 (green): see Tab. 4.5
Encoder (section not used):
– UP (yellow): not used
– DN (yellow): not used
*¹ Examples of permanent errors:
– Internal error on the device (e.g. IGBT heat sink temperature sensor defective)
*² Examples of temporary errors:
– 24 VDC supply voltage exceeds the tolerance range
– DC bus voltage exceeds the tolerance range
– Internal 15 VDC control voltage exceeds the tolerance range
– Over-temperature on the module (IGBT junction, heat sink)
– Powerlink network disturbance
– Over-temperature on the line filter / regeneration choke (temperature sensor)
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Tab. 4.5 - Ethernet POWERLINK status Leds

Description
Ethernet POWERLINK:
– R/E Read/Error (green/red)
• [OFF] Supply voltage is not applied to the module or initialization of the network interface has failed.
• [ON, Red] The POWERLINK node number of the module is 0.
• [ON, Red/Green blinking] The client is in an error state (drops out of cyclic operation).
• [ON, Green blinking x1] The client recognizes a valid POWERLINK frame on the network.
• [ON, Green blinking x2] Cyclic operation on the network; however the client itself is not yet
participating in cyclic operation.
• [ON, Green blinking x3] Cyclic operation of the client is in preparation.
• [ON, Green] The client is participating in cyclic operation.
• [ON, Green flickering] The client is not participating in cyclic operation and also does not detect any
other stations on the network that are participating in cyclic operation.
– L/D1 Link / Data activity Port 1 (green)
• [ON] There is a physical connection to another station on the network.
• [Blinking] Activity Port 1.
– L/D2 Link / Data activity Port 2 (green)
• See L/D1, for Port 2.
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4.6 AMS-ASM32 module

The AMS-ASM32 module is a feeder / converter to produce the 24 Vdc used to power
the auxiliary circuits.
Fig. 4.6 - AMS-ASM32: overall view
X1 input for DC Bus ready signal coming from

AMS-PPS8 module
X2: 24 Vdc output to power the safety circuit

section of the Safety Distribution Module
(SDM) and input to disable the 24 Vdc output
on the X3 connector, during the shutdown
procedure.
X3: 24 Vdc output to power the distribution

Leds section of the Safety Distribution Module
(SDM) and 24 Vdc input/output to power the
X2
Uninterruptible Power Supply (UPS) and
X1 receive the 24 Vdc power supply back in case
of missing power from the mains.
X3
LEDs: Status LED
Top
side
AMS-ASM32
Front
side
Tab. 4.6 - AMS-ASM32: connections and devices

Connector /
Description
component
1
DC Bus ready signal coming from AMS-PPS8 module,
X1 X1 used to enable the internal DC/DC converter and produce
the 24 Vdc to power the auxiliary circuits.
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Tab. 4.6 - AMS-ASM32: connections and devices (Continued)

Connector /
Description
component
24 Vdc output to power the safety circuit section of the
X2 Safety Distribution Module (SDM) (terminals 1 and 2,
1
+24V2). The output is available also in case of missing
power from the mains thanks to the Uninterruptible Power
X2
Supply (UPS).
Input to disable the 24 Vdc output on the X3 connector,

during the shutdown procedure.
24 Vdc output to power the distribution section of the Safety
Distribution Module (SDM) (terminals 2 and 3, +24V1). The
output is available up until shortly before the end of the
1
shutdown procedure, even in case of missing power from
the mains thanks to Uninterruptible Power Supply (UPS).
X3 X3
24 Vdc input/output to power the Uninterruptible Power
Supply (UPS) and receive the 24 Vdc power supply back in
case of missing power from the mains (terminals 1 and 4,
+24VUPS).
Status LED:
Supply voltage:
– 24V (green, left)
is within the permissible tolerance
– ERR (red, left)
• [ON] The module is not supplied via the DC bus
voltage. The 24 VDC internal system supply
voltage is outside of the permissible tolerance
(overload, over-temperature, short-circuit, etc).
24Vdc out:
– 24V (green, right)
LEDs
• [ON] One of the switchable 24 VDC outputs is
active and the output voltage is within the
permissible tolerance. The 24 VDC internal
system supply voltage is within the permissible
tolerance.
– ERR (red, right)
• [ON] The 24 VDC internal system supply voltage
is outside of the permissible tolerance (overload,
over-temperature, short-circuit, etc). At least one
of the switchable outputs is active and the
electronic fuse has been triggered on one or more
switchable outputs.
*¹ The module is enabled via the input CR_OK, no electrical contact to the backplane
module - check bottom mounting screws.
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4.7 AMS-IAM module

The AMS-IAM modules are axis control cards dedicated to the axes control.
Configured modules are available to control 1 or 2 axes; depending on the power, the
modules take 1 or 2 slots.
The Ethernet POWERLINK Address shall be customized.
Fig. 4.7 - AMS-IAM (double-slot): overall view
ETIx: Encoder AMS-ETI22 interface module
Two axis Single axis X1:axis enabling signal coming from the
Safety Distribution Module (SDM)
X2:digital inputs for options C5G-HSK5: High

Speed Input Kit, C5G-OTK: Axis Over Travel
kit and C5G-SMK: Signal Machine Kit (usage
restrictions apply)
X3A: Ethernet POWERLINK port for the

communication among modules (if it deals
with the first module, it come from AMS-PPS8
module, otherwise it come from the adjoining
AMS-IAM module)
X3B:Ethernet POWERLINK port for the

Top communication among modules (intended for
the next AMS-IAM module)
side
X4A:axis brake control (first axis)
X4B:axis brake control (second axis)

Two axis Single axis
X5A axis motor (first axis)
X5B axis motor (first axis)
X11: encoder connection
AMS-IAM
Bottom
side
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Fig. 4.8 - AMS-IAM (single-slot): overall view
ETIx: Encoder AMS-ETI22 interface module
Two axis Single axis X1:axis enabling signal coming from the
Safety Distribution Module (SDM)
X2:digital input for options C5G-HSK5: High

Speed Input Kit and C5G-OTK: Axis Over
Travel kit (usage restrictions apply)
X3A: Ethernet POWERLINK port for the

communication among modules (if it deals
with the first module, it comes from
AMS-PPS8 module, otherwise it comes from
the adjoining AMS-IAM module)
X3B: Ethernet POWERLINK port for the

communication among modules (intended for
the next AMS-IAM module)
X4A:axis brake control (first axis)

Top
side X4B:axis brake control (second axis, if
installed)
Two axis Single axis
X5A axis motor (first axis)
X5B axis motor (second axis, if installed)
X11: encoder connection
AMS-IAM
Bottom
side
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Tab. 4.7 - AMS-IAM (double and single): connections and

devices
Connector /
Description
component
AMS-ETI22 internal module, for interface for Encoder. each

ETI 1 module controls one only axis.
ETI 1
ETI 2
ETI 2 ETI 1 controls the first axis.
ETI 2 controls the second axis, when installed.
1
Axis/axes enabling signal coming from the Safety
Distribution Module (SDM).
The X1 connector features 6 pins in case of one-axis
module and 12 pins in case of double-axis module.
X1 Do not change the position of the movable

X1 connectors in relation to the module X1
connectors, in particular when the options for
the axes safe cut-off options are available.
The X1 movable connectors exchanging among
modules may imply risks in case one single
ARM is stopped.
Digital inputs for options. A specific option is associated to

X2 each module:
– first module: C5G-HSK5: High Speed Input Kit
– second module: C5G-OTK: Axis Over Travel kit
1
– third module: C5G-SMK: Signal Machine Kit.
IThe second module X2 connector is supplied
with terminal board with jumpers, to close the
circuits of the axes over-stroke limit switches.
X2 Removing the connector without installing the
C5G-OTK option causes a system error for
axes over-stroke exceeding.
The third module X2 connector is supplied
with terminal board with jumpers, to close the
alarm signal circuits by the robot border area.
Removing the connector without installing the
C5G-SMK option causes a system error for
Robot air and flange alarms.
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Tab. 4.7 - AMS-IAM (double and single): connections and devices

(Continued)
Connector /
Description
component

with the actuation modules (if it deals with the first module,
X3A
X3A
it comes from AMS-PPS8 module, otherwise it comes from
the adjoining AMS-IAM module)
X3B Ethernet POWERLINK network port for the communication

X3B with the actuation modules (intended or the next AMS-IAM
module)
X4A
X4A Axis brake control (first axis)
X4A
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(Continued)
Connector /
Description
component
X4B
X4B Axis brake control (second axis, if installed)
X4B
X5A
X5A Axis motor (first axis)
X5A
X5B
X5B Axis motor (second axis, if installed)
X5B
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(Continued)
Connector /
Description
component
X11 (1)
Connection for Encoder.
X11 (2)
X11 X11 (1) is connected to the first axis.
If installed, X11 (2) is connected to the second axis.
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(Continued)
Connector /
Description
component
Status Leds:
Supply voltage:
– 24V (green)
is within the tolerance range
Inverter first axis:
– RDY (green, left)
• [ON] The module is operational and the power
stage can be enabled (operating system present
and booted, no permanent or temporary errors).
• [Blinking] No signal on or both enable inputs;
otherwise there is no permanent or temporary
error present on the module.
– RUN (orange, left)
• [ON] The module power stage is enabled.
– ERR (red, left)
• [ON] A permanent *¹ or temporary *² error exists
on the module.
Ethernet POWERLINK:
– R/E (green/red): see Tab. 4.5
Leds
Encoder SLOT 1:
– UP (orange, left): Encoder direction of rotation +
• The encoder position of the connected encoder
changed in the positive direction. The faster the
encoder position changes, the brighter the LED is
lit.
– DN (orange, left): Encoder direction of rotation -
• The encoder position of the connected encoder
changed in the negative direction. The faster the
encoder position changes, the brighter the LED is
lit.
Status leds (only for double axis module):

Inverter second axis:
– RDY (green, left) see “Inverter first axis”
– RUN (orange, left) see “Inverter first axis”
– ERR (red, left) see “Inverter first axis”
Encoder SLOT 2:
– UP (orange, right): see Encoder SLOT 1
– DN (orange, right): see Encoder SLOT 1
*¹ Examples of permanent errors:
– Low level on an enable input
– Internal error on the device (e.g. IGBT heat sink temperature sensor defective)
– Motor feedback not connected or defective
– Motor temperature sensor not connected or defective
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*² Examples of temporary errors:

– 24 VDC supply voltage exceeds the tolerance range
– DC bus voltage exceeds the tolerance range
– Internal 15 VDC control voltage exceeds the tolerance range
– Over-temperature on the module (IGBT junction, heat sink)
– Powerlink network disturbance
– Over-temperature on the line filter / regeneration choke (temperature sensor)
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4.8 Thermal dissipator AMS-FMP14

The thermal dissipator is an aluminium plate used also as support base where all
actuation modules and the Safety Distribution Module (SDM) are fastened.
The module power thermal dissipation is accomplished on this plate, that is cooled at
the back through the Internal ventilation system fans.
The dissipator can host modules up to a maximum of 14 slots. Each slot size is equal to
53,5 mm (21.00 in).
Fig. 4.9 - AMS-FMP14: overall view
A:rack / dissipator
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4.9 Safety Distribution Module (SDM)

Function
The Safety Distribution Module (SDM) is the one controlling the safety signals and the
24 Vdc distribution (auxiliary and user 24 Vdc power supply).
Technical features
The SDM module is mechanically fastened on the ACC rack and therefore takes a slot
space. Tne module 24 Vdc power supply and all signals are connected through
connectors; the bus on the rack is not used.
This module is supplied with inside logics with double processor to control the safety
signals and the communication with the APC module via CAN Bus. The safety signal
controlling is compliant to standard EN13849-1 (see par. 2.5.1).
Inside the module are 2 separate interconnected cards: one for the 24 V distribution and
the other to control the safety logics.
Structure
Fig. 4.10 - SDM: overall view
X3/SDM: CAN Bus from APC

X4/SDM: CAN Bus to other CAN modules
X10/SDM: Safety signal expansion.
X100/SDM: Power supply input for FIA5 card
X101/SDM: Power supply input for ESM5
card
X102/SDM: 24 V output for X30 (line signal
SW1
connector)
X103
A
X103/A/B/C: 24 Vdc output reserved for
SW2
X103
internet options
X104/SDM: Status input and inhibition output
ML1 AL1 B
ML2 AL2
X103
of UPS module
WLK
ML3 C
EN1
PSF
EN2
PEC
X106
X106/SDM *¹: V Safe output and 24 V I/O
SL1
DRO
SL2
PBA output
X107/SDM: Output for hour-meter (optional)
PSA PIO
EPR
X108/SDM: Enabling signals for basic axes

RESET X124
(AMS-IAM 1, AMS-IAM 2, AMS-IAM 3)
X109/SDM: Enabling singles for additional
X100
axes (AMS-IAM 4 and following ones)
X310
X110/SDM: Signals and power supply for /fro
X101 Programming terminal with cable (Wired)
X119
X126
X112/SDM: Selector switch signal and E-stop
X107 from OPD panel
X119/SDM: 24 V output for the cooling fans
inside the cabinet
X112
X311
X108
X122/SDM: Safety signals for X30 connector
X104 X122 (line signal connector)
X124/X126/X128/SDM: Signals for
X128
X302
X109
X312
applications
X302/SDM: Signal and power supply for/from
Programming terminal without cable
X3
(Wireless).
SDM JP200
X102 X310/X311/X312/SDM *¹: digital I/O available

X4 X10 for the user
JP200: 24 Vdc selection and 0V reference to
earth
X110
SW1/SW2: rotating selector switch for the

emergency circuit stop timing
LEDs: Status LED
Reset: Reset push button (reserved)
Top Bottom Front *¹ it requires the option C5G-UCK: user
side side side connector kit, for SDM module
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Tab. 4.8 - SDM: product codes

Component Comau Codes
Safety Distribution Module
CR17430080 1
C5G-SDM
Tab. 4.9 - SDM: connections and devices

Connector /
Description
component
CAN Bus coming from AMS-APC820 module
Pins:
Pin Signal
1 CAN H (CAN High)
2 CAN L (CAN Low)
X3/SDM 3 CAN ^ (CAN Ground)
4 Not connected
5 Not connected
6 Not connected
7 Not connected
8 Not connected
Direct CAN Bus to other CAN modules.
A CAN line cap is fitted, if no other modules are available.
The cap consists of a connector featuring a 120-ohm
resistance connected between pin 1 and 2.
Pins:
Pin Signal
1 CAN H (CAN High)
X4/SDM
2 CAN L (CAN Low)
3 CAN ^ (CAN Ground)
4 Not connected
5 Not connected
6 Not connected
7 Not connected
8 Not connected
CAN Bus
Rj45 Pins
120 ohm
1% ¼ W 1 = CAN H
2 = CAN L
Cap for CAN network 3 = GND
120 ohm
1% ¼ W
or Comau cod. 17201560
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Tab. 4.9 - SDM: connections and devices (Continued)

Connector /
Description
component
The SDM module does not supply the repeated contacts
for any of the safety signal. To obtain the repetition it is
necessary to install the optional modules C5G-ERM1:
X10
mod.1 expansion of the SDM module safety functions
and/or C5G-ERM2: mod.2 expansion of the SDM module
safety functions.
ERM-1: It delivers the repetition of the signal:
X10/SDM – E-Stop from line
– Drive ON
– Status selector switch in programming position
ERM-2: It delivers the repetition of the signal:
– A-Stop from line
– PT Enabling device
– Status selector switch in automatic position
Power supply input for 24 Vdc coming from AMS-ASM32

module for the card inside the SDM module controlling the
distribution of the 24 Vdc power supply
X100/SDM
Features:
– Voltage: 24 Vdc
– Corresponding signal: +24V1, 0V(24V1)
Power supply input for 24 Vdc coming from AMS-ASM32

module for the card inside the SDM module controlling the
safety circuits. It includes also the signal to cut off the 24
Vdc on X100 during the shutdown phase.
X101/SDM The UPS module guarantees the 24 Vdc on those
terminals in case of missing power.
Features:
– Voltage: 24 Vdc
– Corresponding signal: +24V2, 0V(24V2)
24 Vdc power supply input/output for X30 connector
(Safety items)
Features:
– Voltage: 24 Vdc
X102/SDM
– Max current: 1 A (V24 INTP), 8 A (V24 Ext), 4A
(V24 Ext FieldBus)
– Corresponding signals: V24 INTP, V24 Ext,
V24 Ext FieldBus
Direct and protected 24 Vdc power supply output for
internal devices that do not require the cut-off with E-Stop.
Those connectors are reserved for the option power
supplies.
X103/A/SDM The movable connector is supplied together with the
X103/B/SDM option.
X103/C/SDM
Features:
– Voltage: 24 Vdc
– Max total current between connector: 5 A
– Corresponding signal: +24 Vint
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Connector /
Description
component
Status input and inhibition output of UPS module.

The SDM module reads the Ready (UPS ready), Buffering
X104/SDM (UPS in only-battery mode), Replace Battery (battery to be
replaced) status. Moreover, an output allows to turn off the
UPS by sending the inhibition signal.
24 V Safe protected power supply output and 24 V I/O

output to power the cards and devices that require the
cut-off with E-Stop.
X106/SDM More details in par. 5.7 How to use the 24 Vdc
in the user’s applications on page 113.
Output to connect the hour-meter (C5G-HMK: Hour-meter

X107/SDM
kit optional).
X108/SDM Enabling signals for AMS-IAM module 1, 2 and 3.
Enabling signals for additional AMS-IAM module (AMS-IAM

X109/SDM
4 and following ones)
X110
Signals and power supply fro /from Programming terminal

1
X110/SDM
with cable (Wired).
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Connector /
Description
component
Input for signals from the mode selector switch (Auto-L,

X112/SDM
Auto-R, Local, T1), E-Stop.
24 V output and PWM signal to power and control the

X119/SDM
cooling fans inside the cabinet
X122/SDM Safety signals for X30 connector (Safety items)
X124/SDM Outputs for power supply for the applications

X128
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Connector /
Description
component
Signals and power supply for the Docking Station of the

X302/SDM
Programming terminal without cable (Wireless).
4 digital outputs available for the user’s applications.
X310/SDM More details in par. 5.9 Digital Inputs / Output

on the SDM module on page 116.
4 digital inputs available for the user’s applications.

on the SDM module on page 116.
4 digital inputs available for the user’s applications.
1
X312 on the SDM module on page 116.
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Connector /
Description
component
Movable connector:
– to select the 24 Vdc powering source for +24 Vdc I/O e
+24 Vdc SAFE
– to connect the 0 V with the equipotential circuit (PE).
Features:
– Voltage: 24 Vdc
– Connection between 0 V (GND of the 24 Vdc) and
equipotential circuit.
The earth connector connected to terminal 5
shall be removed only for the time necessary
to detect possible faults: the permanent
removal of the connector neutralizes the
solution of faults towards earth (EN 60204-1
JP200/SDM
§ 9.4.3.1).
Pins:
Pin Signal
1 +24Vdc INT (from AMS-ASM32)
2 To internal 24 Vdc
3 +24Vdc EXT (from X30/pin 15 & 22)
4 Not connected
5 GND
6 Not connected
Usage modalities in par. 5.7 How to use the
24 Vdc in the user’s applications on
page 113.
Rotating selector switches to set the stopping circuit
stopping timing.
The settings shall be consistent with the
Robot type.
SW1/SW2
Usage modalities in par. 6.5 Safety stop:
checking the stop circuit timer on page 45 of
the “Transport and installation” manual.
RESET Reset push button (reserved to Comau technicians)
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Connector /
Description
component
Status Leds
LEDs:
– AL1: Auxiliary CPU LED 1.
• Active only when the Programming terminal with
wireless connection (C5G-WiTP) is available, on
in fixed modality when it is possible to perform
the terminal pairing or unpairing procedure.
– AL2: Auxiliary CPU LED 2.
• Off when all safety signals (E-Stop, General
Status leds LEDs
Stop, Gates) are closed and no faults are
occurring
• Flashing when one or ore safety signals (E-Stop,
Drive leds
General Stop, Gates) are open
• On in fixed modality in case of fault
– Note: the LEDs ML2 and AL2 are the result of
24 Power
concurrent processing performed by CPUs inside the
leds
SDM and therefore light up almost always under the
same conditions.
– DRO: Drive OFF – On in fixed modality in DRIVE-OFF, it signals the availability of 24 Vdc
power supply intended for the brake releasing device by the Robot border
area
– ML1: Master CPU LED 1 – Usually flashing: it signals the correct communication between the SDM
CAN Bus node and the AMS-APC820 module.
– On in fixed modality or off, in case of faulty CAN Bus communication.
– ML2: Master CPU LED 2 – Off when all safety signals (E-Stop, General Stop, Gates) are closed and
no faults are occurring
– Flashing when one or ore safety signals (E-Stop, General Stop, Gates)
are open
– On in fixed modality in case of fault.
– Nota: the LEDs ML2 and AL2 are the result of concurrent processing
performed by CPUs inside the SDM and therefore light up almost always
under the same conditions.
– ML3: Master CPU LED 3 – Flashing when an error is occurring on the configuration connections of
the SDM.
– WLK: Wireless Link – With Programming terminal with cable connection (C5G-iTP): off
– WithProgramming terminal with wireless connection (C5G-WiTP):
• On in fixed modality when the pairing has been accomplished
properly and the wireless communication among SDM, docking
station and terminal is working fine
• Off when no terminal is matched to the Control Unit
• Flashing when one of the pairing / unpairing procedures are in
progress (flashing time equal to the time needed for the procedure)
or in case the communication with the matched terminal goes missing
(constant flashing).
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Connector /
Description
component
Drive Leds
– EN1: Enable 1: – On in fixed modality in DRIVE-ON, it signals that the actuation enabling
is available.
– Off in DRIVE-OFF.
– EN2: Enable 2: – It is usually always On in fixed modality, in DRIVE-ON and DRIVE-OFF.
it signals than the actuation enabling is available, used both to enable the
in DRIVE-ON and apply the dynamic braking in DRIVE-OFF.
– Off in case of fault on the actuation controlling branches.
24 Vdc Power Leds
– EPR: Electronics Power – Usually Off
out of Range – On in fixed modality in case of fault, then the powering on the X101
connector is not within the admissible limits (admissible values between
18 Vdc and 36 Vdc); or the internal circuits are overloaded; or one or more
output mosfets is overloaded
– Note: the circuits controlled by the mosfets are EnT1, EnT2 and the safety
output expansions.
– PEC: Power Enable – On in fixed modality when the internal relay controlling the powering of
Circuit all output mosfets is closed.
– Off in case of short-circuit of the output mosfets, that is detected during the
self-test that the card performs periodically.
– Note: the circuits controlled by the mosfets are EnT1, EnT2 and the safety
output expansions.
– PIO: Power I/O *¹ – On in fixed modality when the 24V I/O power supply is available.
– P5A: Power 5A *¹ – On in fixed modality when the 24V INT power supply is available down
the 5 A protection.
– P8A: Power 8A *¹ – On in fixed modality when the 24V power supply is available down the 8
A protection. This 24 Vdc powers the 24V SAFE and 24V I/O.
– PSF: Power Safe *¹ – On in fixed modality when the 24V SAFE power supply is available
(active in DRIVE-ON only)
– SL1: Supply Led 1 *¹ – On in fixed modality when the 24V power supply is available on the X100
input connector.
– SL2: Supply Led 2 *¹ – On in fixed modality when the 24V power supply is available down the
JP200 connector, used to select the internal/external power supply.
*¹ Refer to the picture below for a better understanding.
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Connector /
Description
component
*¹ Reference representation
of the connection of the SDM MODULE
diagnostics LEDs dedicated to X30
24V INTP
X102
1A
the status of the 24 Vdc in the

1
8
24V EXT.
Safety Distribution Module

29
FIELD BUS
24V EXT.
(SDM).
15
22
0V
INT./EXT.
2
16
23
30
JP200
X126
24V EXT. 8A DRIVE ON
24V SAFE
1
24V INT. 7
SL2 P8A PSF 0V

2
24V I/O
3
X100
5A 9
24V
ASM PIO 24V EXT. FIELD BUS
4
AUX. 10
SUPPLY SL1 P5A
MODULE 0V
X128
5A 24V SAFE
1
1A 5A 0V
2
24V I/O
3
DRIVE OFF
9
24V EXT. FIELD BUS

24V DRIVE OFF
4
24V ROBOT
10
24V FANS
24V INT.
0V
0V
0V
0V
X119 X110
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4.10 Uninterruptible Power Supply (UPS)

Function
The Uninterruptible Power Supply (UPS) is the module that guarantees the endurance
needed during the system shutdown procedures when the power supply is missing.
Technical features
The UPS works at 24 Vdc and thanks to an internal battery delivers the 24 Vdc to the
Control Unit for the time needed for the system shutdown.
For the system diagnostics, System variables are available.
Structure
Fig. 4.11 - UPS: overall view
A: 24 Vdc input/output terminal board

(connected to the ASM module).
B:Status signal terminal board (connected to

the SDM module).
C:Status LED.
D: Diagnostics LED
E: Connection control LED.
F: adjusting device for the power supply

buffering limit time.
It shall be set at 30
seconds.
Tab. 4.10 - UPS: product codes

Uninterruptible Power Supply
CR10140583 1
C5G-UPS
Battery Refer to Chap.8.3 - 1
Spare part list on
Fuse page 57 in the 1
“Maintenance” manual
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Tab. 4.11 - UPS: connections and devices

Connector /
Description
component
Usually on in fixed modality, it flashed to signal a given
operating status:
– Ready *¹: on in fixed modality (normal status) to signal
Green status that the battery is charged, no error are occurring on
LED (C) the connection, the input power supply is sufficient
– Charging *¹: slow flashing to signal that the battery is
charging, endurance less than85%
– Buffering *¹: rapid flashing to signal that the battery is
delivering power to maintain the output 24V
Usually off, it flashes during the Control Unit shutdown
phase.
Moreover, during the operating phase lights up to signal
that a fault is occurring:
– Overload *¹: 24V output disabled due to the overload
protracting or high temperature
Yellow diagnosis – Replace batty *¹: battery replacement necessary, to
LED (D) be performed asap
– Buffer-time expired *¹: output disabled because the
power supply buffering set time has been exceeded.
This signalling stays on for 15 minutes
– Inhibit active *¹: it signals that the power supply
buffering function has been disabled due to the
inhibition signal enabling (inhibit)
*¹ Find the LEDs status details in the picture below.
Red connection Usually off, it lights on to signal an error occurring on the

control LED(E) connections, battery, battery fuse or installation (e.g. input
voltage too low)
Rotating selector switch to adjust the power supply

Buffering limit buffering limit time.
time adjusting The selector switch shall be set at 30
device seconds.
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4.11 Operator Panel Devices (OPD)

Function
The Operator Panel Device (OPD) is the Control Unit from panel. It is supplied empty
with prepunched shapings to install the maintenance options.
Technical features
The Operator Panel Device can be equipped with options to facilitate the robot system
maintenance: USB connector, Ethernet network connector, hour-meter and PC power
supply plug.
Structure
Fig. 4.12 - OPD: overall view
A: (optional) USB connector
B: second USB connector or Ethernet

network connector (both optionals)
C: (optional) hour-meter
A B C
Tab. 4.12 - OPD: (optional) product codes

(Optional) USB connector
CR17130780 1 or 2
C5G-USBK: USB kit
(Optional) Ethernet network
connector CR17130880 1
C5G-ETHK: Ethernet kit
(Optional) Hour-meter
CR17132480 1
C5G-HMK: Hour-meter kit
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4.12 Connector Interface Panel (CIP)

Function
The Connector Interface Panel (CIP) is the Control Unit lower pane, where all interface
connector are installed.
Tehnical features
The panel features the connectors for the connection with the Robot, the programming
terminal (wired version only) and the interfacing with the line.
Moreover, other 3 blind panels are available for optional extensions as well as holes with
caps to install connectors matched to options for the interfacing with the external
environment.
Structure
Fig. 4.13 - CIP: overall view with the main connectors
A: X60 connector (motors and brakes)
B: X124 connector (wired programming

terminal)
C: X10 connector (position and signal

transducers)
D: X30 connector (line interfacing)
E: Screw to connect earth wire intended for

A B C D the Robot
F: dinkings to install panels for optional

extensions (see details below under Preferred
installation positions for optional connector)
G: X90 cable gland connector (cableway at

the user’s disposal)
H: dikings to install X93..X94 connector

(Master field Bus)
E F1 F2 F3 H G
Preferred installation positions for optional connector

The connectors on CIP panel are to be installed preferably as described below:
– F1 panel to install X10-EXT connector (Extension, Positioning device signals) and
X60-EXT connector (Extension, motors and brakes of the positioning device) or
X61..X64 connectors (Signals and power for auxiliary Axes)
– F2 panel to install X61..X64 connectors (Signals and power for auxiliary Axes) or
4 M25 cable gland connectors (4 M25 dinkings available)
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– F3 panel to install X31..X32 connectors (Applications)

– H: dinkings to install X93..X94 connector (Master field Bus).
Standard prearrangements
The CIP panel is supplied with several dinkings to install one or more connectors,as
described below:
– 4 x M25 connectors / cable glands M25, available on F2 panel
– 2 x connectors to install X93..X94 connector (Master field Bus).
Optional extensions
The CIP panel can be extended with optional panels supplied with dinkings to suit the
main requirements, as described below:
– C5G-APK1 kit Auxiliary Plate 1: panel for 2 72-pole connectors and 1 42-pole
connector
– C5G-APK2 kit Auxiliary Plate 2: panel for 3 42-pole connectors
– C5G-APK3 kit Auxiliary Plate 3: panel for 1 72-pole connector, 1 42-pole connector
and 4 holes for M25 connectors / cable glands.
For further details about the connectors and their function, please refer to par. 5.1
Overview of the C5G Control Unit connections on page 92 and following sections.
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4.13 Internal ventilation system

Function
The internal ventilation system ensures the necessary air exchange when the
installation environment temperature does not exceed 40 °C, with peaks up to 45 °C.
If the installation environment temperature is constant or exceeds 45 °C it will be
necessary to install the cooling option.
Technical features
The fans are 24-Vdc-powered and the rotation speed is automatically controlled by the
system using a PWM signal. All fans are connected in parallel on the X119/SDM
connector of the Safety Distribution Module (SDM).
For the fan diagnostics, System variables are available.
Structure
The cooling system is replaced by 1 internal fan for the air circulation and by 2 or more
fans (maximum 4) located on the cabinet back, that perform the forced air exchange on
the dissipator AMS-FMP14, that is located by the CPU, power supplies and power
modules module base. Depending on the axis module no. it may be necessary to install
the option C5G-AFK: Auxiliary Fan Kit.
Fig. 4.14 - Cooling system: overall view
A: air circulation internal fan (E110)
B: rear fans for forced air exchange on

dissipator (E111...E114, view without cover
panel)
B
A
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4.14 General information about the

communication networks inside the C5G
Control Unit
The module inside the Control Unit communicate with one another through the following
protocols and connections:
– Ethernet POWERLINK Network
– CAN Bus network.
Fig. 4.15 - Reference diagram related to the Ethernet POWERLINK

e CAN Bus networks
Ethernet POWERLINK CAN Bus
APC 820
PPS8 ASM32 IAM x X20 interface SDM
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4.15 Ethernet POWERLINK Network

The Ethernet POWERLINK (EPL) network is use to connect all modules of the CPU,
power supplies and power modules (see par. 4.3 on page 44) and the X20 interface
modules (see par. 5.10.1 on page 121) to one another.
The Ethernet POWERLINK network is based on a proprietary protocol connected
through the physical layer of an Ethernet network. Although it shares the logics and
physical layers with a standard system, it cannot be used for the transport and
connection with the traditional Ethernet network.
Each module connected on the Ethernet POWERLINK network shall feature an univocal
address (par. 4.15.1 Ethernet POWERLINK Address on page 84).
To connect the Control Unit with a traditional Ethernet system use the ETH2 connector
on AMS-APC820 (Ethernet) (see par. 5.3.2 on page 102).
Fig. 4.16 - Reference diagram related to the Ethernet POWERLINK

network
Ethernet POWERLINK
APC 820
PPS8 ASM32 IAM x X20 interface
4.15.1 Ethernet POWERLINK Address

All modules connected to the Ethernet POWERLINK network are identified by a univocal
address.
– Address on ASM modules
– Address on Bus Coupler module for the X20 interface modules.
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4.15.1.1 Address on ASM modules

The address of the ASM modules on the Ethernet POWERLINK network is configures
through the 2 rotating selector switches T1 and T2 (Fig. 4.17), according to the
instructions in Tab. 4.13.
Inside the same Control Unit, the address of a module on the Ethernet POWERLINK
network shall be univocal.
The rotating selector switch T2 represents a homogeneous group of more modules
while the rotating selector switch T1 the progressive no. within the group.
For the sake of simplicity and immediacy, in the most simple configurations the no.
represented by T2 is allocated directly to the ARM. To identify the address given to some
of the possible configurations, please refer to Tab. 4.14 - Allocation of the Ethernet
POWERLINK network addresses to the ASM modules for typical configurations on
page 86.
Fig. 4.17 - Rotating selector switches T1 and T2 for Ethernet

POWERLINK address
Tab. 4.13 - Rules to allocate the Ethernet POWERLINK network

addresses to the CPU, power supplies and power
modules modules
Rotating
selector switch
Module setting Notes about the addresses configuration
(address)
T1 T2
Module connected to the Ethernet POWERLINK
AMS-APC820 module - - network with no need for the user to customize the
address
AMS-PPS8 module 0 1 The address is pre-defined and shall not be modified
Module not connected to the Ethernet POWERLINK
AMS-ASM32 module - -
network.
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Tab. 4.13 - Rules to allocate the Ethernet POWERLINK network

addresses to the CPU, power supplies and power
modules modules
Rotating
selector switch
Module setting Notes about the addresses configuration
(address)
T1 T2
See examples in Tab. 4.14 - Allocation of the
AMS-IAM module >= 1 >= 1 Ethernet POWERLINK network addresses to the
ASM modules for typical configurations on page 86.
Tab. 4.14 - Allocation of the Ethernet POWERLINK network

addresses to the ASM modules for typical
configurations
Rotating
selector switch
Axis Module setting Arm
(address)
T1 T2
Control Unit and fitting: C5G-ACC1 with one Robot
- AMS-PPS8 module 0 1 -
1 and 2 AMS-IAM module 11+11 1 1

3 and 4 AMS-IAM module 11+11 2 1 1

Control Unit and fitting: C5G-ACC3 with one Robot

Control Unit and fitting: C5G-ACC3 with 2 NM or NJ Robots
1 and 2 (Robot 1) AMS-IAM module 22+22 1 1
3 and 4 (Robot 1) AMS-IAM module 22+22 2 1 1
5 and 6 (Robot 1) AMS-IAM module 11+11 3 1
1 and 2 (Robot 2) AMS-IAM module xx+xx 1 2
3 and 4 (Robot 2) AMS-IAM module xx+xx 2 2 2
5 and 6 (Robot 2) AMS-IAM module xx+xx 3 2
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configurations (Continued)
Rotating
selector switch
(address)
T1 T2
Control Unit and fitting: C5G-ACC3 with NM or NJ Robot and saddle (Ax7) and
electric welding gripper (Ax8)

1
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configurations (Continued)
Rotating
selector switch
(address)
T1 T2
Control Unit and fitting: C5G-ACC3 with PTDV or PTDO
main axis (Ax7), rotation axis A (Ax8) and rotation axis B (Ax9)

2 (Ax7) / 3
(Ax8)
9 AMS-IAM module 11 5 3 4
4.15.1.2 Address on Bus Coupler module for the X20 interface modules
The X20 interface modules communicate with the Ethernet POWERLINK network
through a Bus Coupler PFG-BCO module on X20 interface. The module address on the
Ethernet POWERLINK network is configured through 2 rotating sector switches, X1 and
X16.
The address of a module on the Ethernet POWERLINK network shall be univocally
inside the same Control Unit.
For further details and usage modalities related to the Bus Coupler module refer
to par. 5.10.3 Bus Coupler PFG-BCO module on X20 interface on page 122
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4.16 CAN Bus network

The CAN Bus network is used to connect the AMS-APC820 module (see par. 4.4 on
page 47) and the Safety Distribution Module (SDM) (see par. 4.9 on page 67) to one
another.
The CAN Bus network is based on the free protocol connected through the physical
layer of a CAN Bus network. Although it shares standard protocols on logics and
physical layers with a standard system, it cannot be used for the connections with
commercial CAN Bus modules.
The address of a module on the CAN Bus network shall be univocal inside the same
Control Unit (par. 4.16.2 Address on the CAN Bus network on page 89).
Fig. 4.18 - CAN Bus network reference diagram
CAN Bus
To next
CAN Bus
device
APC 820
SDM
4.16.1 Termination resistancec in the CAN Bus net

The termination resistance of the CAN Bus net node ends shall always be on. In the
basic Control Unit the termination resistance is installed in the CAN second connector
of the Safety Distribution Module (SDM) (see par. 4.9 on page 67) .
If the net needs to be extended by adding new modules, remove the resistance and
install it on the last CAN module of the chain.
The pin arrangement of the connector and the termination resistance are to be
found in the Tab. 4.9 - SDM: connections and devices on page 68.
4.16.2 Address on the CAN Bus network

All modules connected to the CAN Bus network are identified through an univocal
address. As the system features only customized COMAU modules, the latter are
supplied already configured and the user does not need to customize them.
As option, modules available in specific applications supplied by Comau

Robotics can be connected to the CAN Bus network. For further information,
please refer to the corresponding application manual.
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4.17 Connector pin structure

To facilitate the consultation, the connectors available for the user are also represented
and described in this chapter and in Chap. Interfacing with the C5G Control Unit on
page 91:
– Tab. 4.3 - AMS-APC820: connections and devices on page 48
– Tab. 4.4 - AMS-PPS8: connections and devices on page 52
– Tab. 4.6 - AMS-ASM32: connections and devices on page 56
– Tab. 4.7 - AMS-IAM (double and single): connections and devices on page 60
– Tab. 4.9 - SDM: connections and devices on page 68
– Tab. 4.11 - UPS: connections and devices on page 78.
The pin structure of all connectors and the related electric connection among
modules are also documented in the Control Unit Schema elettrico.
4.18 System variables

For the sake of convenience, the list of system variables in Tab. 4.15 summarizes the
diagnostics available only for the main hardware modules installed in the Control Unit.
The system variable complete list is to be found in the usage manual.
Tab. 4.15 - System variables: concise list for the basic modules
Module Available diagnostics System variable
UPS status monitor:
– Ready $SDI[117]
Uninterruptible Power Supply
– Active $SDI[118]
(UPS)
– Replace battery $SDI[119]
– Disable input $SDO[5] *¹
$SDO[9]
$SDO[10]
Internal ventilation system Speed set on the fans coded at 16 levels, 4 bits
$SDO[11]
$SDO[12]
*¹ reading only
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Interfacing with the C5G Control Unit
5. INTERFACING WITH THE C5G

CONTROL UNIT
– Overview of the C5G Control Unit connections
– Summary of the Robot, positioning devices and auxiliary axes connections
– Summary of the Line connections
– Summary of the Application connections
– Summary of the Programming and User interface on PC connections
Moreover, detailed descriptions and connection methods are listed for the following
items:
– Overview for 24 Vdc power supply in the Control Unit
– How to use the 24 Vdc in the user’s applications
– Safety circuits: E-Stop, Auto-Stop (Fence) and General Stop
– Digital Inputs / Output on the SDM module
– Inputs / Outputs and field Bus on X20 interface
– RS232 and RS422 serial communication
– Communication via Ethernet network.
To help the user to identify the functions of the main connectors:
– Summary of connectors and corresponding function.
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5.1 Overview of the C5G Control Unit

connections
The C5G Control Unit connects and interface with:
– Robot, positioning devices and auxiliary axes (A). Those connections allow to
control the Robot and the auxiliary axes.
– Line (B). Through this connection, the Control Unit connects with the production
plant where the robot system is integrated.
– Application (C). It allows to control the application connected with the Robot and
the related equipment or other items required by the integrator.
– Programming and User interface on PC (D). It allows to program, control and
diagnose the robot system through the Programming terminal and related software
supplied with it.
A - Robot, positioning
devices and auxiliary
axes
B - Line
B C - Application
D
D - Programming and
User interface on PC
A
C
The picture shows the main connections between the Control Unit and the peripherals
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5.2 Robot, positioning devices and auxiliary

axes
The connection with the Robot, positioning devices and auxiliary axes is accomplished
through suitable connectors installed on the Connector Interface Panel (CIP) by the
C5G Control Unit base.
The typical configurations feature the following solutions:
Involved
C5G peripheral Description
connector
the main Robot is connected through the Connection cables between
X10
Robot C5G and Robot with the X10 connector (Robot signals) and the X60
X60
connector (Robot Power)
the positioning device (e.g. series SMART5 PTDV, PTDORB, other
ones) is connected through the Connection cables between C5G and
X10-EXT Robot (uses the same Robot cables exploiting only the necessary wires,
Positioning device
X60-EXT depending on the no. of available axes) with the X10-EXT connector
(Extension, Positioning device signals) and the X60-EXT connector
(Extension, motors and brakes of the positioning device)
the single auxiliary axes (e.g. saddle on axis 7, electric gripper for spot
X61
welding on axis 8, other ones) are connected through the Connection
X62
Auxiliary axes cables between C5G and Robot, each one with only one connector that
X63
includes both the power and the control signal, with the X61..X64
X64
connectors (Signals and power for auxiliary Axes)
The X10, X60, X10-EXT, X60-EXT, X61..X63 connector pin structure is available in
the wiring diagram of the C5G Control Unit.
5.2.1 X10 connector (Robot signals)

The X10 is a multipolar connector that collects all Robot position control signals
(Encoders with EnDat 2.2 interface), for configurations featuring up to 6 axes.
The X10 is installed on the Connector Interface Panel (CIP) and connects to the X1
connector by the Robot base through the Connection cables between C5G and Robot.
Some I/O signal that can be used freely by the user are available on the Safety
Distribution Module (SDM) and through suitable options can be made available by the
Robot border area (on corresponding connectors on axis 3 or Robot wrist, depending on
the version). For further details refer to the Robot specific manuals.
The High Speed Input (HSI) signals are available on the CPU, power supplies and
power modules and are at disposal by the Robot border area only after the installation
of the option C5G-HSK5: High Speed Input Kit (see par. 6.3.15 on page 175). As for the
pin structure and the connections by the Robot border area, refer to the Robot specific
manuals.
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Fig. 5.1 - X10 connector: structure
A: Connector Interface Panel (CIP)
X10 X10: Signal connector for the Robot
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5.2.2 X60 connector (Robot Power)

The X60 is a multipolar connector that collects all power signals of the Robot axes
(motor) and brakes, for configurations featuring up to 6 axes.
The X60 is installed on the Connector Interface Panel (CIP) and connects to the X2
connector by the Robot base through the Connection cables between C5G and Robot.
X60 X60: Power connector for the Robot
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5.2.3 X10-EXT connector (Extension, Positioning device

signals)
The X10-EXT is a multipolar connector that collects all positioning device position
control signals (Encoders with EnDat 2.2 interface), with the possibility to connect 5
additional axes in the most extended configuration. This connector and the
corresponding connection cable are available only if optional auxiliary axes are installed
in the configuration for the positioning device and is matched to the X60-EXT connector
(Extension, motors and brakes of the positioning device).
The X10-EXT is installed on a plate fastened on the Connector Interface Panel (CIP)
and connects to the X1 connector by the positioning device base through the
Connection cables between C5G and Robot.
In case of need, the plate features an area for the installation of an additional auxiliary
axis (refer to par. 5.2.5 X61..X64 connectors (Signals and power for auxiliary Axes) on
page 97).
Fig. 5.3 - X10-EXT connector: structure
A: Area intended for the installation of the

plate with the auxiliary axes connectors
X60E X10E
X10E: Control signal connector (Encoders)
X60E: X60-EXT connector (Extension, motors

and brakes of the positioning device) (see
par. 5.2.4 on page 96)
X61:Additional auxiliary axis installed

A
X61
5.2.4 X60-EXT connector (Extension, motors and brakes of the

positioning device)
The X60-EXT is a multipolar connector that collects all power signals of the axes of the
positioning device (motors) and brakes, with the possibility to connect additional 5 axes
in the most extended configuration. This connector and the corresponding connection
cable are available only if optional auxiliary axes are installed in the configuration for the
positioning device and is matched to the X10-EXT connector (Extension, Positioning
device signals).
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The X60-EXT connector is installed on the Connector Interface Panel (CIP) and
connects to the X2 connector by the positioning device base through the Connection
cables between C5G and Robot.
In case of need, the plate features an area for the installation of an additional auxiliary
axis (refer to par. 5.2.5 X61..X64 connectors (Signals and power for auxiliary Axes) on
page 97).
Fig. 5.4 - X60-EXT connector: structure

plate with the auxiliary axes connectors
X60E X10E
X60E: Motor and brake connector
X10E: X10-EXT connector (Extension,

Positioning device signals) (see par. 5.2.3 on
page 96)
X61: Additional auxiliary axis installed

A
X61
5.2.5 X61..X64 connectors (Signals and power for auxiliary

Axes)
The X61, X62, X63 or X64 are multipolar connectors that collect the power, brake and
the position control signals (Encoders with EnDat 2.2 interface) of the auxiliary axes.
Those connectors and the corresponding cable are available only if optional auxiliary
axes are installed.
Each auxiliary axis is matched to a specific connector and the latter is polarized such as
to prevent connection errors; the axes and matching connectors are listed in the table
below:
Tab. 5.1 - Axis-connector match

Auxiliary axis Matching connector
Axis 7
X61
(usually saddle)
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Tab. 5.1 - Axis-connector match

Auxiliary axis Matching connector
Axis 8
X62
(usually electric gripper)
Axis 9 X63
Axis 10 X64
The X61, X62, X63 or X64 connectors are installed on one or more plates fastened on
the Connector Interface Panel (CIP) and connect to the connector on the motor
switching case through the corresponding cables. Each plate can take up to 3
connectors.
Fin below some typical match examples:
– X61..X63 connector in a solution featuring up to 3 axes: structure
– X61 connector in a solution featuring 1 axis matched to X60-EXT and X10-EXT
already available: structure
Fig. 5.5 - X61..X63 connector in a solution featuring up to 3 axes:

structure

plate hosting the auxiliary axes connectors
X61 X62
X61:First auxiliary axis installed
X62: Second auxiliary axis installed
X63:Third auxiliary axis installed
Note: the picture shows an example featuring

3 connectors with consecutive abbreviation.
A
X63
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Fig. 5.6 - Polarization of connectors X61..X64
A: Area inteded for the installation of the plate

hosting the auxiliary axes connectors
A X61 X62
X61..X64: connector possible configurations
X63
X61 X62 X63 X64
Axis 7 Axis 8 Axis 9 Axis 10
Fig. 5.7 - X61 connector in a solution featuring 1 axis matched to

X60-EXT and X10-EXT already available: structure

plate hosting the auxiliary axes connectors
X60E X10E
X61: First auxiliary axis installed
X60E: X60-EXT connector (Extension, motors

and brakes of the positioning device) (see
par. 5.2.4 on page 96)
X10E: X10-EXT connector (Extension,

Positioning device signals) (see par. 5.2.3 on
A page 96)
X61
The cables, connector polarization, the connections between X61..X64 and the
motors are dealt with in details in the instruction manuals of the auxiliary axes.
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5.3 Line
The connection with the line is accomplished through special connectors installed on the
Connector Interface Panel (CIP) by the C5G Control Unit base.
The typical configurations include the solutions described below.
ETH2
COM2
X30
X90 X20 modules
Peripheral
Involved
connected to the Description
connector
C5G
the safety signals (e.g. emergency stop, cell access door limit switch,
Safety item X30
other ones) are available on the X30 connector (Safety items)
the communication with the Host systems (e.g. line PLC) can be
Host system -- controlled through field Bus (see Field Bus Modules on the X20 interface
(see par. 5.10.4 on page 126)).
Host system for the communication with the Host systems (e.g. line PLC, factory
ETH2 / production control PC, analysis devices, other ones) can be controlled
monitoring
APC820 through Ethernet connections (see ETH2 connector on AMS-APC820
(Ethernet) (Ethernet) (see par. 5.3.2 on page 102))
the communication with the Host systems (e.g. line PLC, factory
Host system for production control PC, analysis devices, other ones) can be controlled
COM2 /
monitoring through the RS422 serial connection (see COM2 connector on
APC820
(Serial) AMS-APC820 (RS422 serial) (see par. 5.3.3 on page 102)).
Also the RS232 serial connection is available.
Other connections
The cables that do not features a specific optional connector by the
(e.g. net or serial
X90 cabinet base and exit the Control Unit to reach the device on the line,
communcation
use the way provided by the I X90 cable gland connector.
cables output)
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5.3.1 X30 connector (Safety items)

The X30 is a multipolar connector that collects all safety signals to and from the C5G
Control Unit. It is installed on the Connector Interface Panel (CIP).
To interface with the Control Unit, a movable connector equipped with cap and pins for
crimping connection is supplied as standard.
The safety signal are connected internally with the Safety Distribution Module (SDM)
and using special options it is possible to increase the no. and type of available signals.
The auxiliary signals will be available on other connectors (being defines).
X30 X30: X30 connector
More details about the safety signals connection are to be found in par. 5.8 Safety
circuits: E-Stop, Auto-Stop (Fence) and General Stop on page 115.
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5.3.2 ETH2 connector on AMS-APC820 (Ethernet)

The ETH2 is a RJ45 connector that allows to connect the Ethernet network to a host
system. It is available on AMS-APC820 module.
Fig. 5.9 - ETH2 connector: structure
A: ETH2 connector on AMS-APC820
A
ETH1 XD2 XD3
ETH2 XD4 XD5
COM2 COM1
X3A
Further details about the connection with the Ethernet network are available in
par. 5.12 Communication via Ethernet network on page 151.
5.3.3 COM2 connector on AMS-APC820 (RS422 serial)

The COM2 is a tray-type 9-pin connector that allows the RS422 serial connection. It is
available on AMS-APC820 module.
On the same connector also the RS232 serial connection is available (refer to COM2
connector on AMS-APC820 (RS232 serial)).
Fig. 5.10 - COM2 connector: structure
A: COM2 connector on AMS-APC820
A
ETH1 XD2 XD3
ETH2 XD4 XD5
COM2 COM1
X3A
Further details about the serial connection are available in par. 5.11 RS232 and
RS422 serial communication on page 149.
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5.3.4 X90 cable gland connector

The X90 is a multiple-way cable gland that represents the crossing point of the cables
of the Field Bus and/or Ethernet network/ serial connection or other cables that connect
directly on the internal connectors located on the specific modules. It is installed on the
Connector Interface Panel (CIP). The X90 connector is supplied as standard with the
Control Unit.
A movable connector with cap and rubber cable glands is supplied to allow the cable
passage while preserving the IP 54 protection category of the Control Unit.
X90 X90: X90 connector
Further details about the Field Bus are available in par. 5.10.4 Field Bus Modules
on the X20 interface on page 126.
The connections with Ethernet network are described in par. 5.3.2 ETH2
connector on AMS-APC820 (Ethernet) on page 102.
The connection with serial protocols are described in par. 5.3.3 COM2 connector
on AMS-APC820 (RS422 serial) on page 102.
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5.4 Application
Under application we understand a set consisting of one or more tool or machine parts
connected to the Robot and/or used in the production process associated to the Robot,
typically integrated to obtain a homogeneous solution.
The typical configurations include the solutions described below.
COM2
X31..X32 X93..X94 X90
X310/SDM
X311/SDM
X312/SDM
X20 modules
Peripheral
Involved
connector
C5G
I/O and safety

X31 the I/O, safety and powering signals directly available on the optional
signal, on
X32 X31..X32 connectors (Applications)
connectors
X310/SDM the I/O signals are available as standard on the Safety Distribution
digital I/O for small
X311/SDM Module (SDM) and described in par. 5.9 Digital Inputs / Output on the
applications
X312/SDM SDM module on page 116
remote I/O the communication with the systems (e.g. measurement devices,
X93
(C5G with remote I/O, other ones) can be controlled through Field Bus protocols
X94
master role) with X93..X94 connector (Master field Bus) with X20 interface modules
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Peripheral
Involved
connector
C5G
Analysis, the communication with the systems (e.g. measurement systems, other
measurement COM2 / ones) can be controlled through the serial RS232 on COM2 connector
systems APC820 on AMS-APC820 (RS232 serial).
(serial) The serial connection RS422 is also available.
Other connections
The cables that do not features a specific optional connector by the
(e.g. net or serial
X90 cabinet base and exit the Control Unit to reach the device on the line,
communication
use the way provided by the I X90 cable gland connector.
cables output)
Other connections The powering cables can exit from the box base through the cable
(e.g. output for glands (that are not part of the supply volume), which are to be fastened
--
electrode dresser to the 25,5 mm dinking holes (M25 cable glands) located on the central
powering cables) panel.
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5.4.1 X31..X32 connectors (Applications)

The X31..X32 is a multipolar connector that collects one or more solutions with digital
I/O, power supplies and safety signals. It is installed on the Connector Interface Panel
(CIP).
To interface with the Control Unit, a movable connector equipped with cap and pins for
crimping connection is supplied as standard.
The I/O signals are internally connected with the Ethernet POWERLINK bus and using
special options it is possible to increase the no. and type of available signals.
Fig. 5.12 - X31..X32 connector: structure

plate with the application connectors
X31 X32
X31: First application installed
X32: Second application installed
The options for the signal expansion are described in par. 5.10.5.4 Prearranged
solutions and technical specifications related to the digital and analog I/O on
page 135 (solutions with connection on connector and terminal board)
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5.4.2 X93..X94 connector (Master field Bus)

The connector for the Master field Bus allows to connect the field Bus between the
master module inside the Control Unit and the slave modules available on the tooling
and/or Robot border area.
The connector, matched to its specific cable, is a solution called Multibus, i.e. both the
field bus signal (Device Net or Profibus-DP) and the 24 Vdc power supply for the remote
slave modules are trasmitted through the same multipolar cable.
The connector is installed by the Control Unit base on the Connector Interface Panel
(CIP).
The X93 connector is matched to the first Master field Bus module while the X94 to the
second master module, if available.
Fig. 5.13 - X93..X94 connector: structure
X93: Multibus connector for the first Master

field Bus module
X93
X94: Multibus for the second Master field Bus
module
A
X94
Further details on the Field Bus are available in par. 5.10.4 Field Bus Modules on
the X20 interface on page 126.
The usage, connector pin structure and connection cables examples are to be
found in the manuals of the corresponding application.
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5.4.3 COM2 connector on AMS-APC820 (RS232 serial)

The COM2 is a tray-type 9-pin connector that allow the RS232 serial connection. It is
available on AMS-APC820 module.
Also the RS422 serial connection is available (see COM2 connector on AMS-APC820
(RS422 serial)).
Fig. 5.14 - COM2 connector: structure
A: COM2 connector on AMS-APC820
A
ETH1 XD2 XD3
ETH2 XD4 XD5
COM2 COM1
X3A
Further details about the serial connection are available in par. 5.11 RS232 and
RS422 serial communication on page 149.
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5.5 Programming and User interface on PC

The programming and movement can be accessed through the Teach Pendant (see
par. 3.3 on page 35).
The WinC5G program supplies a convenient interface to the Control Unit, to facilitate
the diagnosis, setting and other operating procedures. WinC5G can be operated in
Personal Computers (PCs) runnning Microsoft© Windows©.
A - Progrmaming
terminal
B - Personal
Computer
A B
The Programming terminale and WinC5G program usage modalities are

described in detaisl in the “Control Unit use” under chapter “WinC5G Program –
Interface to C5G on Personal Computer”
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5.6 Overview for 24 Vdc power supply in the

Control Unit
– 24 Vdc distribution principles
– Meaning of the 24 Vdc power supplies inside the Control Unit
– 24 Vdc distribution complete diagram.
5.6.1 24 Vdc distribution principles

The 24 Vdc voltage in the Control Unit is produced by the AMS-ASM32 module.
For some power supply (V24 I/O and V24 SAFE) it is possible to select the source
between the AMS-ASM32 module and an external powering device (details in par. 5.7
How to use the 24 Vdc in the user’s applications on page 113).
The 24 Vdc distribution is accomplished by the Safety Distribution Module (SDM), that
includes also the protection items against the overloading and short-circuit on the 24
Vdc branches. The shortcircuit and overload protection is performed through
self-restoring fuses.
The 0V signals of the 24 Vdc internal powering supplies (0V I/O, 0V SAFE, ...) and the
0V signal of the powering supply coming from outside (optional) are connected together
and also to the GND.
5.6.2 Meaning of the 24 Vdc power supplies inside the Control

Unit
Tab. 5.2 - Abbreviations and usage of the 24 Vdc power supplies

Abbreviat
Definition Connector
ion
Source: the power supply comes from the AMS-ASM32 module. X30 connector (Safety items)
(see par. 5.3.1 on page 101)
Usage: to power components inside the Control Unit, at the user’s
24V INTP
disposal.
Protection*¹: 1 A
Source: the power supply comes from the AMS-ASM32 module. Not at the user’s disposal.
Usage: to power components inside the Control Unit.

24V INT
Protection*¹: 5 A, shared with 24V INTP, 24V ROB and 24V
DROFF
Source: the power supply comes from the AMS-ASM32 module. X10 connector (Robot signals)
(see par. 5.2.1 on page 93)
Usage: power supply always available on board of Robot, for
24V ROB
user’s minor automation routines.
Protection*¹: 1 A
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Tab. 5.2 - Abbreviations and usage of the 24 Vdc power supplies

Abbreviat
Definition Connector
ion
Source: the power supply comes from the AMS-ASM32 module. Not at the user’s disposal.
Usage: power supply available in Drive OFF only, by the Robot

24V
border area, serves the purpose of release the robot axis brake
DROFF
with brake-release module installed on board of Robot.
Protection*¹: 5 A, shared with 24V INT, 24V INTP and 24V ROB.
Source: the power supply comes from the AMS-ASM32 module. – X106/SDM. For the
Through the selection on the JP200/SDM connector it is possible connection the
to switch to the external source coming from the X30 connector C5G-UCK: user
connector kit, for SDM
24V I/O Usage: to power cards and devices requiring the power supply to module (see par. 6.3.27
be always available. It’s used for user’s applications. on page 195) is required.
Protection*¹: 24V I/O = 8 A, shared with 24V SAFE
– X124/SDM, X126/SDM,
X128/SDM.
Source: the power supply comes from the AMS-ASM32 module. – X106/SDM. For the
Through the selection on the JP200/SDM connector it is possible connection the
to switch to the external source coming from the X30 C5G-UCK: user
connector kit, for SDM
Usage: to power cards and devices requiring the power supply to module (see par. 6.3.27
be turned off with E-Stop, Drive-Off and other emergency stop
on page 195) is required.
commands. It’s used for user’s applications.
24V SAFE
– X124/SDM, X126/SDM,
Protection*¹: 24V SAFE = 8 A, shared with 24V I/O
X128/SDM.
– X30 connector (Safety

items) (see par. 5.3.1 on
page 101)
Source: the power supply comes directly from X30 connector – X124/SDM, X126/SDM,
(Safety items) (see par. 5.3.1 on page 101). X128/SDM.
24V EXT
Usage: to power cards and devices requiring the 24 V power
FIELD
supply when Control Unit is off (deactivate).
BUS
Protection: protection isn’t present. Must to be installed a
protection fuse on source for limit to max 4 A.
*¹ self-restoring fuses installed inside the Safety Distribution Module (SDM).
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5.6.3 24 Vdc distribution complete diagram
SDM MODULE
X30 X102 X103
1A
24V INTP 24V INT. 1 A
1
2
8
24V EXT. 1 B
29
FIELD BUS 2
24V EXT. 1 C
15
0V 2
22
0V
INT./EXT.
2
9
X106
24V I/O 1
16
2
23
0V 3
30
24V SAFE 4
X122
X124
24V SAFE
1
0V
2
24V I/O
3
JP200 24V EXT. FIELD BUS

4
10
X126
24V EXT. 8A DRIVE ON
24V SAFE
1
24V INT. 7
SL2 P8A PSF 0V

2
24V I/O
3
X100
5A 9
24V
ASM PIO 24V EXT. FIELD BUS
4
AUX. 10
SUPPLY SL1 P5A
MODULE 0V
X128
5A 24V SAFE
1
1A 5A 0V
2
24V I/O
3
DRIVE OFF
9
24V EXT. FIELD BUS

24V DRIVE OFF
4
24V ROBOT
10
24V FANS
24V INT.
0V
0V
0V
0V
X119 X110
X2 X1
78 79 43 42
INT./EXT. FANS
A B
12 36 10d 11d
X10 X60 X124

24V ROBOT SUPPLY
iTP
24 Vdc Power supply

distribution
ROBOT BRAKES RELEASER
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5.7 How to use the 24 Vdc in the user’s

applications
– X106/SDM connector at the user’s disposal
– Selecting the 24 Vdc power supply source (24V I/O and 24V SAFE only)
– Selecting the 24 Vdc source (24V I/O and 24V SAFE only).
5.7.1 X106/SDM connector at the user’s disposal

Te user can obtain 24 Vdc internal power supply through the X106/SDM connector.
Tab. 5.3 - X106/SDM: pinout and 24Vdc power supply technical

data
Features:
– Voltage: 24 Vdc
– Max current: 8 A, shared between (V24 I/O) and (V24
SAFE)
– Corresponding signals: V24 I/O, GND-V0, V24 SAFE
The movable connector shall be purchased separately
together with the option C5G-UCK: user connector kit, for
SDM module.
X106/SDM
Pins:
Pin Signal
1 +24 Vdc I/O
2 0 Vdc I/O *1
3 0 Vdc SAFE *1
4 +24 Vdc SAFE
* connected together internally. Moreover, connected to the common 0V
GND-V0
5.7.2 Selecting the 24 Vdc power supply source (24V I/O and
24V SAFE only)
The following 24 Vdc power supply sources are at the disposal of the user:
– 24V I/O, always available. This source can be used to power the devices and I/O
requiring power supply always ON.
– 24V SAFE, available in Drive ON only. This power supply can be used to power
the outputs that shall be de-energized following a Drive OFF, E-Stop and other
emergency stop commands.
Those power supply sources are available on the X106/SDM connector (at the user’s
disposal) as well as on the X124/SDM, X126/SDM, X128/SDM ones (intended for the
power supply travel towards to the options) located on the Safety Distribution Module
(SDM).
The 24 Vdc source that delivers power to 24V I/O and 24V SAFE can be selected
through the JP200/SDM connector, to get:
– internal powering, produced internally by the AMS-ASM32 module
– external powering, coming from an external powering device.
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To better understand the 24 Vdc distribution pattern, refer to par. 5.6.3 24 Vdc
distribution complete diagram on page 112.
5.7.3 Selecting the 24 Vdc source (24V I/O and 24V SAFE only)
To select the powering source, take the following items into account:
– the internal powering source does not require devices and the selection on the
JP200/SDM connector is already correct (default position A in Fig. 5.15).
– the external powering source requires an external powering device, (which is not
supplied with the Control Unit), that shall be connected through the X30 connector
(Safety items) (see par. 5.3.1 on page 101). After, the selection is required on the
JP200/SDM connector (position B in Fig. 5.15).
Fig. 5.15 - Powering source selection reference diagram
24V
24V SDM MODULE
EXT. X30 X102
1A
24V INTP
SUPPLY 0V
1
8
24V EXT.
29
FIELD BUS
24V 24V EXT.
24V 15
22
EXT.
SUPPLY 0V
0V INT./EXT.
2
16
23
30
X122
JP200 JP200
24V EXT. 24V EXT. 8A DRIVE ON
24V INT. 24V INT.
SL2 P8A PSF

B A
X100
5A
24V
ASM PIO
AUX.
SUPPLY SL1 P5A
MODULE 0V
5A
1A 5A
To practical carry out the 24 Vdc source section jumper, refer to par. 7.3 Selecting
the 24 Vdc power supply source on page 61 of the “Transportation and
installation” manual.
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5.8 Safety circuits: E-Stop, Auto-Stop (Fence)

and General Stop
The input/output signals for the stop circuits are available on the X30 connector (Safety
items) (see par. 5.3.1 on page 101) posto alla base dell’Unità di Controllo.
3 series of signals are available, for which specific functions are listed in Tab. 5.4.
Tab. 5.4 - Safety input signals and corresponding function

Input signal Function
The E-Stop input shall be used for the following connections:
– stop push button located on the Programming terminal
– emergency stop triggering device of the cell/line where the Robot system will be
installed.
E-Stop
This signal is always active and triggers a type of stop (norm EN60204-1) that depends
on the selected operating mode:
– according to category 1 in automatic mode
– according to category 0 in programming mode.
The Auto-Stop (Fence) input shall be used to connect the safety limit switches
controlling the “close-status” of the access doors of the cell/line where the Robot system
will be installed.
Auto-Stop
This signal is active in automatic operating mode only and triggers a stop according to
(Fence)
category 1 (norm EN60204-1). By selecting the Programming mode, the C5G will be
controlled by the Enabling Device (on programming terminal) and the Auto-Stop input will
be disabled.
The General Stop input can be used to trigger a safety stop that for functional purposes
shall not correspond to an emergency stop (E-Stop), which h is typically used for bigger
geographic areas and requires specific diagnostic warnings.
This input can be used to stop the robot system safely when operators are approaching
the robot range of action (e.g. access to the loading/unloading area or other activity). If
General Stop
the input is not used, the signals shall be closed using a jumper.
This signal is always active (it is physically identical to the E-Stop input) and triggers a
type of stop (norm EN60204-1) that depends on the selected operating mode:
– according to category 1 in automatic mode
– according to category 0 in programming mode.
Due to the importance of the connection carrying out at the time of installation,
this topic is dealt with only in the “Transport and installation” manual in par. 6.6
E-Stop circuits: inputs and control procedure for stop circuits and
mushroom-shaped push button on programming terminal on page 48.
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5.9 Digital Inputs / Output on the SDM module

– General principles
– Position of the connectors on the Safety Distribution Module (SDM)
– I/O electric features and pin structure of the connectors on the Safety Distribution
Module (SDM)
– Connection diagram for the I/O on the Safety Distribution Module (SDM)
– Configuration of the I/O on the Safety Distribution Module (SDM)
– Usage restrictions for the I/O on the Safety Distribution Module (SDM).
5.9.1 General principles

The Control Unit is supplied as standard with digital 8 inputs and 4 outputs (I/O), that
are at disposal for the user’s applications. The I/O are available on the Safety
Distribution Module (SDM) and can be used only on condition that the C5G-UCK:
user connector kit, for SDM module (see par. 6.3.27 on page 195) option is purchased.
The digital I/O on the Safety Distribution Module (SDM) are used also on some C5G
options. If such options are installed, the no. of I/O at the user’s disposal may be less
compared to the one specified (refer to par. 5.9.6 Usage restrictions for the I/O on the
Safety Distribution Module (SDM) on page 120).
5.9.2 Position of the connectors on the Safety Distribution

Module (SDM)
Fig. 5.16 - I/O at the user’s disposal: connectors
X310/SDM: 4 24 Vdc outputs*¹
X311/SDM: 4 24 Vdc inputs*¹
X312/SDM: 4 24 Vdc inputs*¹

OUT
X310 *¹ optional movable connectors C5G-UCK:
user connector kit, for SDM module (see par.
6.3.27 on page 195)
X126
X311 IN
X128
X312 IN
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5.9.3 I/O electric features and pin structure of the connectors on

the Safety Distribution Module (SDM)
Tab. 5.5 - I/O at the user’s disposal: features and pin structure
Connector on
Function Safety Distribution Module Features
(SDM)
4 digital X310/SDM Features:
24 Vdc Outputs – Voltage *¹: typical 24 Vdc (from 18 to 35 Vdc max)
– Max current per output: 0,5 A (self-protected)
– Output type: PNP (source), optoinsulated
– I/O scanning/updating time: 10 ms
The movable connector shall be purchased separately with
the option C5G-UCK: user connector kit, for SDM module.
Pins:
Pin Signal
1 Output common Supply *1
2 Output common Supply *1
3 Output 4
4 Output 3
5 Output 2
6 Output 1
7 GND Output
8 GND Output
*¹ supplied externally, at expense of the user
24 Vdc Inputs – Voltage: 24 Vdc (from 18 to 35 Vdc max)
(“1 logic” > 18 Vdc, “0 logic” < 4 Vdc)
– Typical current: 8 mA
– Input type: PNP (sink), optoinsulated
Pins:
Pin Signal
1 Input 1
2 Input 2
3 Input 3
4 Input 4
5 GND Input * 1
6 GND Input * 1
*¹ connected to the GND of the X312/SDM connector.
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Tab. 5.5 - I/O at the user’s disposal: features and pin structure
Connector on
Function Safety Distribution Module Features
(SDM)
24 Vdc Inputs – Voltage: 24 Vdc (from 18 to 35 Vdc max)
– Min current: 8 mA
1
X312 – I/O scanning / updating time: 10 ms
Pins:
Pin Signal
1 Input 5
2 Input 6
3 Input 7
4 Input 8
5 GND Input * 1
6 GND Input * 1
*¹ connected to the GND of the X311/SDM connector
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5.9.4 Connection diagram for the I/O on the Safety Distribution

Module (SDM)
Fig. 5.17 - I/O on SDM: connection diagram
C5G SDM
Output
Input
Input
Refer to the item Digital I/O on SDM module (see par. 7.4 on page 63) of the
“Transport and installation” manual.
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5.9.5 Configuration of the I/O on the Safety Distribution Module

(SDM)
The digital I/O on the Safety Distribution Module (SDM) can be used in the software only
after being suitably configured.
The I/O configuration shall be carried out using specific programmes supplied together
with the Control Unit (IO_MAP / IO_CNFG).
The usage instructions for the IO_MAP and IO_CNFG routines are to be found in
the “Control Unit Usage” manual, chapter “Programmes for the I/O
configuration”.
5.9.6 Usage restrictions for the I/O on the Safety Distribution

Module (SDM)
The digital I/O on the Safety Distribution Module (SDM) are used also on some C5G
options. If such options are installed, the no. of I/O at the user’s disposal may be less,
i.e. according to the table below:
Tab. 5.6 - Reduction of the no. of I/O if options are available

I/O taken by the I/O at the user’s
Option installed
option disposal
Inp 1..2 and 4 on X311
C5G-DMI Inp 3 on X311 Inp 1..4 on X312
Out 1..4 on X310
Inp 1..2 and 4 on X311
C5G-PMI Inp 3 on X311 Inp 1..4 on X312
Out 1..4 on X310
Inp 1..4 on X311
C5G-SMK: Signal Machine Kit Inp 1..4 on X312
Out 1..4 on X310
Inp 3..4 su X311
Inp 1..2 su X311
C5G-TDC400: 400V Tip Dresser Command kit Inp 1..4 su X312
Out 1 su X310
Out 2..4 su X310
Inp 3..4 on X311
Inp 1..2 on X311
C5G-TDC400-2: 400V Double Tip Dresser Command kit Inp 1..4 on X312
Out 1..2 on X310
Out 3..4 on X310
Inp 2..4 on X311
C5G-TDS400: 400V Tip Dresser Supply kit Inp 1 on X311 Inp 1..4 on X312
Out 1..4 on X310
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5.10 Inputs / Outputs and field Bus on X20

interface
The Control Unit may be expanded using optional modules for digital, analog I/O, and
field Bus by means of the solution consisting of the X20 interface modules (see par.
5.10.1 on page 121).
5.10.1 X20 interface modules

– Bus Coupler PFG-BCO module on X20 interface
– Field Bus Modules on the X20 interface
– Digital and analog I/O module on the X20 interface.

The flexibility of the optional modules for digital, analog I/O and field Bus on the X20
interface allows the coexistence of I/O and field Bus on the same small rack.
The (optional X20 interface module system is based on the following components:
– Bus Coupler PFG-BCO module on X20 interface, item essential for the
interconnection between the internal Ethernet POWERLINK network and the
expansion modules (I/O and/or field Bus).
Each Bus Coupler module is configured with an univocal address on the Ethernet
POWERLINK network. It is possible to install up to 2 Bus Coupler modules.
– Field Bus Modules on the X20 interface, optional item to connect Master and/or
Slave to remote modules in Profibus-DP e DeviceNet protocol.
– Digital and analog I/O module on the X20 interface, optional item to connect
digital or analog I/O.
Ethernet POWERLINK
Bus Coupler
DC/DC
Profibus-DP DeviceNet
Inp Out
APC 820 IAM x
PPS8 ASM32
Bus Coupler
DC/DC
Profibus-DP DeviceNet
Inp Out
The X20 system installation requires the software configuration. To carry out this
task, refer to the “Control Unit Usage” instruction manual.
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5.10.3 Bus Coupler PFG-BCO module on X20 interface

– Connection diagram
– Address on Bus Coupler module for the X20 interface modules
– Technical features and purchase code
– Configuration of the Bus Coupler module in the system.
5.10.3.1 General principles

The Bus Coupler PFG-BCO module is the essential node and shall always be available
to allow the interconnection between the Ethernet POWERLINK network inside the
Control Unit and the Field Bus Modules on the X20 interface and Digital and analog I/O
module on the X20 interface.
The Bus Coupler module is supplied as single unit and consists of:
– omega-guide fastening base (A), with 2 free slots for the Field Bus Modules on the
X20 interface
– one interface for the connection with the Ethernet POWERLINK net (B)
– a DC/DC (C) powering device, identification abbreviation *¹ X20 PS 9400
– prearrangement to add Digital and analog I/O module on the X20 interface.
Fig. 5.18 - Bus Coupler PFG-BCO module
A: Base and bus of the X20 interface module

system, with 2 free slots for field Bus modules
B:Interface for the connection with the
POWERLINK network
C: DC/DC 24 Vdc powering device,
DC identification abbreviation*¹ X20 PS 9400
/
DC
Interface
Slot Slot
2 1
A B C
*¹ Identification abbreviation posted on the component front side
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5.10.3.2 Connection diagram

Each module is connected as additional node on the Ethernet POWERLINK network
(see Fig. 5.19) and configured with an univocal address (see par. 5.10.3.3 Address on
Bus Coupler module for the X20 interface modules on page 124).
The connection between the modules and the network is accomplished using 1,5-m (4.9
ft) Ethernet POWERLINK cables (supplied separately).
It is possible to install up to 2 Bus Coupler modules. With each Bus Coupler module it is
possible to couple:
– uo to 2 Field Bus Modules on the X20 interface (see par. 5.10.4 on page 126),
installed directly on the 2 available slots
– a solution with Digital and analog I/O module on the X20 interface, installed on the
Bus Coupler module right side.
Fig. 5.19 - General connection principles for the Bus Coupler

PFG-BCO module
From last Ethernet POWERLINK internal module
Ethernet POWERLINK Cable Ethernet POWERLINK Cable
Bus Coupler Bus Coupler

#1 #2
&H81 &H82
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5.10.3.3 Address on Bus Coupler module for the X20 interface modules
The module address on the Ethernet POWERLINK network is configured through 2
rotating sector switches, X1 and X16 (Fig. 5.20), according to the instructions in
Tab. 5.7.
The address of a module on the Ethernet POWERLINK network shall be univocally
inside the same Control Unit.
Fig. 5.20 - X1 and X16 selector switches for Bus Coupler module
for X20 interface modules
Tab. 5.7 - Ethernet POWERLINK network address configurations

on the X20 interface module Bus Coupler module
Selector switch
setting
Bus Coupler module function (address) Notes about the address configuration
X16 X1
First module installed 8 1 Address of the first module installed.

Second module installed 8 2 Address of the second module installed.
Further details about the adresses and the setting modalities are to be found in
the par. 4.15 Ethernet POWERLINK Network on page 84.
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5.10.3.4 Technical features and purchase code
Tab. 5.8 - C5G-PFG-BCO: technical features

Item Description
Comau Code – CR10146383
Electrical features – Power supply: 24 Vdc (-15% to +20%)
– Available slots: 2 (for field bus modules only)
Installation position – Inside the C5G, on omega guide.
Usage restrictions – Only two options are allowed
Ethernet POWERLINK 1,5 m (4.9 ft) – CR17231863
cable, Comau Code
The module is described also in the option list in par. 6.3.18 C5G-PFG-BCO: Bus
Coupler module on page 182.
5.10.3.5 Configuration of the Bus Coupler module in the system

The Bus Coupler module can be used in the system only after being suitably configured.
The Bus Coupler module configuration shall be carried out using the special IO_CNFG
(configuration of the module in the system) routine supoplied together with the Control
Unit. After carrying out the configuration, the system shall be restarted acting on the
Restart Cold control.
The usage instructions for the IO_CNFG routine are to be found in the “Control
Unit Usage” manual, chapter “Programmes for the I/O configuration”.
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5.10.4 Field Bus Modules on the X20 interface

– Installation rules for the field bus modules
– Technical features and purchase code.
– Configuration of the field Bus modules in the system

The field bus module is available in the master and slave version, according to choice
between the Profibus-DP and Device Net protocols.
The field bus modules are to be installed on the slot 1 and 2 of the Bus Coupler
PFG-BCO module on X20 interface (see par. 5.10.3 on page 122) only.
It is possible to contemporaneously install field bus and I/O modules.
Before being used , the field bus modules require the later Configuration of the field Bus
modules in the system (see par. 5.10.4.4 on page 130).
Fig. 5.21 - Field bus modules
A: Bus Coupler PFG-BCO module on X20

interface (empty)
B: Device Net Module (example of master
installation on slot 1)
C: Profibus-DP module (example of slave
DC installation on slot 2)
/
DC
Interface
Slot Slot
2 1
A B C
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5.10.4.2 Installation rules for the field bus modules

The installation rules for the field bus modules, (that apply to all versions) are:
– installation allowed on the Bus Coupler PFG-BCO module on X20 interface only
– installation of up to 3 (max no.) field bus modules in the same C5G Control Unit,
using 2 Bus Coupler modules
– the master module:
• takes always first available slot (1, then 2), but slot 1 is for slave module (when
present)
• it is possible to install an only one master module on the same Bus Coupler
PFG-BCO module on X20 interface
• if two master modaules are required, it will be necessary to install a second
Bus Coupler PFG-BCO module on X20 interface, creating a network whose
connection pattern is shown Fig. 5.19
– the slave module:
• the first slave module takes always slot 1 (slot on the right)
• the second slave module tkes always slot 2 (slot on the left)
• it is possible to isntall up to 2 (max no.) slave modules on the same Bus
Coupler PFG-BCO module on X20 interface
• if two slave modules are required and a master module is already installed, it
is necessary to install a second Bus Coupler PFG-BCO module on X20
interface, creating a network whose connection pattern is shown in Fig. 5.19
Fig. 5.22 - Example of field bus module structure
The picture shows the structures

Slot 2 1 possible with an only one Bus
Coupler PFG-BCO module on X20
M interface.

interface (empty)
M: Master module
S, S1, S2: Slave module
S Note: master and slave module, according to

choice between the available protocols
M
S
A
S
S
2
1
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The picture shows the structures

Slot 2 1 2 1 possible with two Bus Coupler
PFG-BCO module on X20 interface.
M M A: Bus Coupler PFG-BCO module on X20
S
1 2 interface (empty)
M1, M2: Master module
S, S1, S2: Slave module
Nota: master and slave module, according to

choice between the available protocols
M S
S
1 2
1
M M
1 2
A
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5.10.4.3 Technical features and purchase code
Tab. 5.9 - Device Net: technical features

Item Description
Device Net Master module
Identification abbreviation *¹ – X20 IF1051-1
Electrical features – it requires the optional connector C5G-DNPC: movable connector
for Devicenet modules (see par. 6.3.10 on page 169)
Mechanical features –
Installation position – Inside the C5G, on the Bus Coupler PFG-BCO module on X20
interface.
– Refer to Fig. 5.22 - Example of field bus module structure on
page 127
Usage restrictions – Up to 2 modules installed (with two Bus Coupler modules)
Device Net Slave module
Electrical features – it requires the optional connector C5G-DNPC: movable connector
for Devicenet modules (see par. 6.3.10 on page 169)
interface.
page 127
Usage restictrions – Up to 2 modules installed
*¹ identification abbreviation posted on the component front side
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Tab. 5.10 - Profibus-DP: technical features

Item Description
Profibus-DP Master
Electrical features – It requires the optional connector C5G-PFPC: movable connector
for Profibus-DP modules (see par. 6.3.21 on page 186)
interface.
page 127
Usage restictrions – Up to 2 modules installed (with two Bus Coupler modules)
Profibus-DP Slave
Electrical features – It requires the optional connector C5G-PFPC: movable connector
for Profibus-DP modules (see par. 6.3.21 on page 186)
interface.
page 127
Usage restictrions – Up to 2 modules installed
Those modules are also described in the option list:

– par. 6.3.8 C5G-DNM-DNMI: DeviceNet Master Interface on page 167
– par. 6.3.9 C5G-DNM-DNSI: DeviceNet Slave Interface on page 168
– par. 6.3.20 C5G-PFM-PDPS: Profibus-DP Slave Interface on page 185
– par. 6.3.19 C5G-PFM-PDPM: Profibus-DP Master Interface on page 184.
5.10.4.4 Configuration of the field Bus modules in the system

The field Bus modules can be used in the system only after being suitably configured .
The field Bus modules configuration shallbe accomplished using the special routines
IO_CNFG (configuration of the module in the system) and IO_MAP (signal mapping)
supplied together with the Control Unit. Following the configuration it may be necessary
to restart the system acting on the Restart Cold control.
The usage instructions for the IO_CNFG and IO_MAP routines are to be found in
configuration”.
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5.10.5 Digital and analog I/O module on the X20 interface

– Rules for the installation of I/O on X20 modules
– Circuit Diagram for the connction of the I/O on X20 modules
– Prearranged solutions and technical specifications related to the digital and analog
I/O
– Powering devices technical features
– Digital input/output technical features
– Analog inputs/output technical features
– Configuration of the I/O modules in the system.

The I/O modules are available in predefined solutions (see Tab. 5.11), that includes
already grouped digital and analog I/O cards as well as the corresponding 24 Vdc
pwering devices.
The predefined solutions are to be instaled on the right side of the Bus Coupler
PFG-BCO module on X20 interface (see par. 5.10.3 on page 122) only, for a maximum
expansion of 10 adjoining modules. If more that 10 modules are required, it is
necessary to use a second Bus Coupler module.
It is possible to install contemporaneously one or more I/O and field bus modules
predefined solutions.
Before being used, the field bus modules require the later Configuration of the I/O
modules in the system (see par. 5.10.5.8 on page 148).
Fig. 5.23 - I/O modules on X20 (configuration example)

interface (empty)
B: DC/DC powering device module or input
DC DC Inp Inp Out DC Out
card or output card (usually consisting of
/ / / terminal board, card and fastening base)
DC DC DC C: DC/DC powering device first module to
Interface
separate I/O from Bus Coupler module
(identification abbreviation*¹ X20 PS 2100)
D: module for inputs powered through the first
powering device module (e.g. digital ones,
identification abbreviation*¹ X20 DI9371)
E: module for outputs powered through the
first powering device module (e.g. digital
ones, identification abbreviation*¹
X20 DO6322)
F: DC/DC powering device second module to
separate the independent powering of the
A CD EF G next outputs (identification abbrevition*¹
X20 PS 2100)
G: module for outputs powered through the
secondo powering device module (e.g. digital
ones, identification abbreviation*¹
A B X20 DO6322)
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5.10.5.2 Rules for the installation of I/O on X20 modules

The installation rules for the I/O modules, (that apply to all versions) are the following:
– installation nest to a Bus Coupler PFG-BCO module on X20 interface. The Bus
Coupler module shall always be available.
– independent 24 Vdc power supply to separate the I/O from the Bus Coupler module
and related Field Bus Modules on the X20 interface. To serve this purpose, in each
configuration the first module is always a DC/DC powering device (identification
abbreviation *¹ X20 PS 2100)
– installation of a second additional DC/DC powering device (identification
abbreviation *¹ X20 PS 2100) per each output card group requiring independent
powering (e.g. to separate the 24 Vdc delivered to the outputs disabled by the
safety circuits from the ones that are always powered)
– the powering delivered to the powering device module requires a delayed 10 A
external protection (same protection for the second powering device as well).
5.10.5.3 Circuit Diagram for the connction of the I/O on X20 modules
The following diagrams are available:
– Digital I/O on X20 modules: connection diagram
– Analog I/O on X20 modules: connection diagram.
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Fig. 5.24 - Digital I/O on X20 modules: connection diagram
C5G
Power supply *1
Input module
Input module
2
Output module *
Power supply *3
4
Output module *
*¹ Primo alimentatore DC / DC: fornisce il 24 Vdc a tutti i moduli di ingresso e i moduli di uscita *²
*² Modulo/i di uscita alimentatore con il 24 Vdc comune agli ingressi
*³ Secondo alimentatore DC / DC: fornisce il 24 Vdc indipendente per i moduli di uscita *4.
L’alimentazione indipendente è tipicamente tagliata in condizioni di emergenza
*4 Modulo/i di uscita alimentato/i con 24 Vdc indipendente, fornito dal secondo alimentatore *³
24 Vdc Power supply must to be protected with fuses.
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Fig. 5.25 - Analog I/O on X20 modules: connection diagram
C5G
Power supply *1
Input module
t
I
1
Power supply *
*2
U
Output module
*¹ DC / DC Power supply: source 24 Vdc to input or output module

*² GNC Power supply of 0V ANALOG is connected with GND analog signal
24 Vdc Power supply must to be protected with fuses (max 1A).
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5.10.5.4 Prearranged solutions and technical specifications related to the

digital and analog I/O
The I/O modules shall be purchased selecting one of the predefined solutions lited in
Tab. 5.11:
– C5G-D12: 12 inputs and 12 outputs, wiring on I/O modules terminal board
– C5G-D24: 24 inputs and 24 outputs, wiring on I/O modules terminal board
– C5G-EDI: 24 inputs and 24 outputs, wiring on 42-pin multipolar connector
– C5G-AI2: 2 analog inputs, wiring on I/O modules terminal board
– C5G-AO2: 2 analog outputs, wiring on I/O modules terminal board
The single I/O modules are described in:
– Tab. 5.12 - X20 PS2100PS2100: technical features on page 141
– Tab. 5.13 - X20 DI9371, digital inputs: technical features on page 142
– Tab. 5.14 - X20 DI 9322, digital outputs: technical features on page 143
– Tab. 5.15 - X20 AI2622, analog inputs: technical features on page 144
– Tab. 5.16 - X20 AO2622, analog outputs: technical features on page 146.
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Tab. 5.11 - Predefined solutions for I/O modules

Item Description
C5G-D12 12 Inp / 12 Out, digital, connection on module terminal block

Comau Code C5G-D12 – CR17130580
Structure – 1 powering device for the input modules and first output module
(1 x “X20 PS2100”)
– 12 inputs 24 Vdc (1 x “X20 DI9371”)
– 6 outputs 24 Vdc - 0,5 A, powering shared with the inputs (1 x “X20
DI 9322”)
– 1 powering device for output independent powering (1 x “X20
PS2100”)
– 6 outputs 24 Vdc - 0,5 A, independent powering (1 x “X20 DI 9322”)

– First powering device:
• X20 PS2100PS2100: technical features
• Power supply: 24 Vdc (-15% to +20%), typical current*¹ 3 A
– Second powering device:
• Power: 24 Vdc (-15% to +20%), typical current*¹ 3 A
– 24 Vdc digital inputs: Tab. 5.13 - X20 DI9371, digital inputs:
technical features on page 142
– 24 Vdc - 0,5 A digital outputs: Tab. 5.14 - X20 DI 9322, digital
outputs: technical features on page 143)
*¹ it depends on the load applied to the digital outputs. A protection is required on the 24
Vdc power supply to be delivered using a delayed 10A fuse.
Connection type – on module terminal block
Dimension – 5 modules size
Installation requirements – A C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on
page 182) shall already be installed and related free space for the
new modules (refer to par. 5.10.5.2 Rules for the installation of I/O
on X20 modules on page 132).
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Tab. 5.11 - Predefined solutions for I/O modules (Continued)

Item Description
C5G-D24 24 Inp / 24 Out, digital, connection on module terminal block

Structure – 1 powering device for the in put modules and the first 2 output
modules (1 x “X20 PS2100”)
– 24 inputs 24 Vdc (2 x “X20 DI9371”)
DI 9322”)
– 1 powering device for output independen powering (1 x “X20
PS2100”)
– 12 outputs 24 Vdc - 0,5 A, independent powering (2 x “X20 DI
9322”)
Electrical features – Power supply: 24 Vdc (-15% a +20%)

• Pwer supply: 24 Vdc (-15% to +20%), typical current*¹ 6 A
• Power supply: 24 Vdc (-15% a +20%), typical current*¹ 6 A
Instlalation requirements – A C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on
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Item Description
C5G-EDI 24 Inp / 12 Out, digital, connection on 42-pole connector

Comau Code C5G-EDI – CR17130380
Structure – 1 powering device for the input modules and first output module
(1 x “X20 PS2100”)
– 24 inputs 24 Vdc (2 x “X20 DI9371”)
DI 9322”)
– 1 powering device for output independent powering (1 x “X20
PS2100”)
– 6 outputs 24 Vdc - 0,5 A, independent powering (1 x “X20 DI 9322”)

• Power supply: 24 Vdc (-15% to +20%), typical current*¹ 3 A
• Power: 24 Vdc (-15% to +20%), typical current*¹ 3 A
Connection type – On 42-pole multipolar connector
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Item Description
C5G-AI2 2 Inp, analog, connection on module terminal block

Comau Code C5G-AI2 – CR17130582
Structure – 1 powering device module to separate the power supplies from the
analog channels (1 x “X20 PS2100”)
– 1 module with 2 analog inputs (1 x “X20 AI2622”)

– Power supply device:
• Power supply: 24 Vdc (-15% to +20%), typical current*¹ 50 mA
– analog inputs: Tab. 5.15 - X20 AI2622, analog inputs: technical
features on page 144
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Item Description
C5G-AO2 2 Out, analog, connection on module terminal block

Comau Code C5G-AO2 – CR17130583
Structure – 1 powering device module to separate the power supplies from the
analog channels (1 x “X20 PS2100”)
– 1 module with 2 analog outputs (1 x “X20 AO2622”)

– Power supply device:
• Power supply: 24 Vdc (-15% to +20%), typical current*¹ 50 mA
– analog outputs: Tab. 5.16 - X20 AO2622, analog outputs: technical
features on page 146
Applies to all solutions
Usage restrictions – The optional device can be installed only if joined to a Bus Coupler
PFG-BCO module on X20 interface (see par. 5.10.3 on page 122)
or to another option already installed.
– The optional devices can be installed side by side up to a maximum
of 10 adjacent modules. Over 10 modules, a second Bus Coupler
module is required.
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5.10.5.5 Powering devices technical features
Tab. 5.12 - X20 PS2100PS2100: technical features

Item Description
Identification abbreviation *¹ – X20 PS2100
Electrical features – Input for power supply for I/O modules connected down:
• 24 Vdc (-15% a +20%)
• Current: 10 A max
• Not protected: it requires an external delayed 10 A protection
– used to optically insulate the power supply to I/O modules from 24
Vdc voltages in the Control Unit .
Pinout
– +24 VI/O, power supply input, terminal 24
– +24 VI/O, power supply input, terminal 25
– GND, power supply input, terminal 26
Status LED
– r (green):
• [OFF]: module off
• [Single flash]: reset mode
• [Flashing]: Preoperational mode
• [ON]: Run mode
– e (red):
• [OFF]: module off or everything all right
• [Duble flash]: input/output powering or X2X bus powering not
sufficient.
– e + r:
• [Red in fixed modality, Green single flash]: incorrect
firmware
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5.10.5.6 Digital input/output technical features

– X20 DI9371, digital inputs: technical features
– X20 DI 9322, digital outputs: technical features
Tab. 5.13 - X20 DI9371, digital inputs: technical features

Item Description
Identification abbreviation * – X20 DI9371
Electrical features – Input: 24 Vdc (-15% to +20%)
– Typical current: 3,75 mA @ 24Vdc
– I/O scannning/updating time: 2 ms
Pinout
– DI 1: digital input 1, terminal 11
– DI 2, digital input 2, terminal 21
Staus LED
– r (green):
• [ON]: Run mode
– e (red):
– e + r:
firmware
– 1..12 (green):
• [ON]: status of the associated input
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Tab. 5.14 - X20 DO6322, digital outputs: technical features

Item Description
Comau Code – X20 DO6322
Electrical features – Output: 24 Vdc (-15% to +20%)
– Max current per output: 0,5 A (self-protected)
– Voltage drop 0,3 V @ 0,5 A
– Output type: PNP (sink), optoinsulated
Pinout
– DO 1: digital output 1, terminal 11
– DO 2, digital output 2, terminal 21
– GND, common 0V, terminal 14
Notes:
– the GND are connected together.
– The 24 Vdc supplied by the outputs is taken from the powering
device connected immediately up the module.
Staus LED
– r (green):
• [ON]: Run mode
– e (red):
• [Single flash]: error on input / output channel.
– e + r:
firmware
– 1..12 (amber):
• [ON]: status of the associated output
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5.10.5.7 Analog inputs/output technical features

– X20 AI2622, analog inputs: technical features
– X20 AO2622, analog outputs: technical features
Tab. 5.15 - X20 AI2622, analog inputs: technical features

Item Description
Identification abbreviation * – X20 AI2622
Electrical features – Up to 2 inputs with selection in voltage or current
– Voltage input:
• Range: +10 Vdc to -10 Vdc (default)
• Impedance: 20 M ohm
• Resolution: ±12 bit
– Current input: *²
• 0-20 mA / 4-20 mA
• Resolution: 12 bit
Pinout
– AI + 1 I, analog input 1 - current signal, terminal 11
– AI + 1 U, analog input 1 - voltage signal, terminal 12
– AI - 1 U/I, GND, input common 1, terminal 13
– AI + 2 I, analog input 2 - current signal, terminal 21
– AI + 2 U, analog input 2 - voltage signal, terminal 22
– AI - 2 U/I, GND, input common 2, terminal 23
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Tab. 5.15 - X20 AI2622, analog inputs: technical features

Item Description
Status LED
– r (green):
• [ON]: Run mode
– e (red):
• [OFF]: modue off or everything all right
• [ON]: Error or reset state
– e + r:
firmware
– 1 - 2 (green):
• [OFF]: connection open or sensor disconnected
• [Flashing]: signal input beyond minimum or maximum limit
• [ON]: converter on and value ok.
*² Check implementation referring to “Control Unit Usage” manual
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Tab. 5.16 - X20 AO2622, analog outputs: technical features

Item Description
Identification abbreviation * – X20 AO2622
Electrical features – Up to 2 outputs with selection in voltage or current
– Voltage output:
• Range: +10 Vdc to -10 Vdc (default)
• Output current: < 10 mA
• Impedance: > 1k ohm
• Resolution: 12 bit
– Current output: *²
• 0-20 mA
• Impedance: 600 ohm
– Protection against short-circuit: 40 mA
– Resolution: 12 bit
– I/O scannning/updating time: 2 ms
Pinout
– AO + 1 I, analog output 1 - current signal, terminal 11
– AO + 1 U, analog output 1 - voltage signal, terminal 12
– AO - 1 U/I, GND, output common 1, terminal 13
– AO + 2 I, analog output 2 - current signal, terminal 21
– AO + 2 U, analog output 2 - voltage signal, terminal 22
– AO - 2 U/I, GND, output common 2, terminal 23
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Tab. 5.16 - X20 AO2622, analog outputs: technical features

Item Description
Status LED
– r (green):
• [Single flashing]: reset mode
• [ON]: Run mode
– e (red):
• [ON]: Error or reset state
– e + r:
firmware
– 1 -2 (amber):
• [OFF]: value equal to 0 (zero)
• [ON]: value other than 0 (zero).
*² Check implementation referring to “Control Unit Usage” manual
Those modules are also described in the option list:

– par. 6.3.2 C5G-AI2 - C5G-AO2, analog I/O options on page 158
– par. 6.3.7 C5G-D12 - C5G-D24, digital I/O options on page 164
– par. 6.3.11 C5G-EDI: External digital I/O interface on page 170.
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5.10.5.8 Configuration of the I/O modules in the system

The I/O modules can be used in the system only after being suitably configured .
The I/O modules configuration shall be accomplished using the special routines
IO_CNFG (configuration of the module in the system) and IO_MAP (signal mapping)
supplied together with Control Unit. Following the configuration it may be necessary to
restart the system acting on the Restart Cold control.
The usage instructions for the IO_CNFG and IO_MAP routines are to be found in
configuration”.
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5.11 RS232 and RS422 serial communication

– Serial port technical features
– RS232 serial connection cable to PC.

The Control Unit is supplied as standard with a serial communication port that
supports the non-contemporaneous connection of the type RS232C and RS422.
The communication port is available on the COM2 connector located on the
AMS-APC820 module; the serial cable to the application can exit the C5G Control Unit
through the X90 cable gland connector.
5.11.2 Serial port technical features
Tab. 5.17 - COM2 technical features

RS232/RS422 serial port for user’s applications.
The RS232C and RS422 ports canno be used
contemporaneously.
DSUB (tray-type) 9-pin male connector.
Features:
– RS232C / RS422, non modem-capable, electrically
insulated
– UART 16550-compatible, 16-byte FIFO
– Speed: Max. 115 kbaud *¹
– Cable max length:
RS232: 15 m (49 ft)
RS422: 1200 m (3937 ft)
Pins:
COM2
n.c.: disconnected in the specified configuration

*¹ it depends on the cable type and length
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5.11.3 RS232 serial connection cable to PC

Fig. 5.26 - Typical RS232 serial cable to connect COM2 on
AMS-APC820 to Personal Computer
Features:
AMS-APC820
AMS-APC820 PersonalComputer
Personal Computer – RS232C
side
side side
side – Crossed cable
– 2 DSUB
(tray-type)
99 99 9-pin female
movable
connectors by
the ends.
11 11 – No control
(female)
(female) (female)
(female) signal.
Pin2:2:RX
Pin RX Pin3:3:RX
Pin RX
Pin3:3:TX
Pin TX Pin2:2:TX
Pin TX
Pin5:5:GND
Pin GND Pin5:5:GND
Pin GND
Shield
Shield
This topic is dealt with also in the manual “Transport and instalation ” in par. 7.6
RS232 / RS422 serial communication on page 67.
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5.12 Communication via Ethernet network

– ETH2 connection technical features.

The ETH2 is a RJ45 connector, which allows to connect the Ethernet network to a host
system. The connection is available on the AMS-APC820 module; the network cable to
the application can exit the C5G Control Unit through the X90 cable gland connector.
The ETH2 port is used also by the option C5G-ETHK: Ethernet kit (see par. 6.3.12
on page 172) and therefore may not be available.
In that case an Ethernet industrial switch may be interposed to obtain the signal
both for the C5G-ETHK option and the connection to a Host system.
5.12.2 ETH2 connection technical features
Tab. 5.18 - Technica features

Ethernet 10/100/1000 netwotk port for user’s applications
(e.g. connection to factory Host)
Features:
– Controller: Intel 82574
– Speed: 10/100/1000 Mbit/s
– Cable max length: 100 m (328 ft), minimum Cat5e
ETH2
– Tipo di cavo: S/STP (Cat5e)
Predefined TCP/IP configuration:
– Address IP: 192.168.29.2
– Subnet mask: 255.255.255.0
– Factory host search address for download / FTP
functions: 192.168.29.1
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5.13 Summary of connectors and corresponding

function
To facilitate the identification of the functions of the main Control Unit connectors, find
below the list in alphabetical order and the corresponding paragraph.
Tab. 5.19 - Summary of connectros

Connector Typical function Description
Analysis,
The communication with the systems (e.g. measurement systems, oher
COM2 / measurement
ones) can be contorlled through the RS232 serial connection on COM2
APC820 systems
connector on AMS-APC820 (RS232 serial).
(via RS232 serial )
The communication with the Host systems (e.g. line PLC, factory
Host systems for
COM2 / production controlling PC, analysis devices, other ones) can be
monitoring
APC820 controlled through the RS422 serial connection (see COM2 connector
(via RS422 seria )
on AMS-APC820 (RS422 serial) (see par. 5.3.3 on page 102)).
The communication with the Host systems (e.g. line PLC, factory
Host systems for
ETH2 / production controlling PC, analysis devices, other ones) can be
monitoring
APC820 controlled through Ethernet connections (see ETH2 connector on
(via Ethernet)
AMS-APC820 (Ethernet) (see par. 5.3.2 on page 102))
The main Robot is connected through the Connection cables between
X10 Robot
C5G and Robot con il X10 connector (Robot signals)
The positioning device (e.g. series SMART5 PTDV, PTDORB, other
X10-EXT Positioning device Robot (it uses the same Robot cables, exploiting only the necessary
wires depending on the no. of axes available) with the X10-EXT
connector (Extension, Positioning device signals)
The safety signals (e.g. emergency stop, cell access door limit switches,
X30 Safety items
other ones) are available on the X30 connector (Safety items)
wired I/O, on The I/O, safety and power supply signals are directly available on the
connector optional X31..X32 connectors (Applications)
X31
X32 wired I/O, on
The I/O signals are directly available on the optional X31..X32
module and terminal
connectors (Applications)
board
The main Robot is connected through the Connection cables between
X60 Robot
C5G and Robot with the X60 connector (Robot Power)
The positioning device (e.g. series SMART5 PTDV, PTDORB, other
X60-EXT Positioning device Robot (it uses the same Robot cables, exploiting only the necessary
wires depending on the no. of axes available) with the X60-EXT
connector (Extension, motors and brakes of the positioning device)
X61 The single auxiliary axis (e.g. saddle on axis 7, electric gripper for spot
welding, other ones) are connected through the Connection cables
X62
Auxiliary axes between C5G and Robot, each one with an only one connector that
X63
includes both the power and the control signals, with the X61..X64
X64 connectors (Signals and power for auxiliary Axes)
Multiple cable The cables can be connected inside the Control Unit through the X90
X90
input/output cable gland connector with no interruption
Remote I/O The communication with the systems (e.g. measurement systems,
X93
(C5G with master remote I/O, other ones) can be controlled through Field Bus protocols
X94
role) with X93..X94 connector (Master field Bus)
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Tab. 5.19 - Summary of connectros (Continued)

Connector Typical function Description
24 Vdc power
The 24Vdc powering is available according to the modalities specified in
X106/SDM supply for user’s
par. 5.7 How to use the 24 Vdc in the user’s applications on page 113
applications
24Vdc power
X124/SDM
supply and Dedicated connectors. They are used with the Control Unit options to
X126/SDM
emergency stop deliver 24Vdc powering and enable the emergency stop control.
X128/SDM signal
X310/SDM The I/O signals are available as standard on the Safety Distribution
digital I/O for minor
X311/SDM Module (SDM) and decribed in par. 5.9 Digital Inputs / Output on the
applications
X312/SDM SDM module on page 116
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Options
6. OPTIONS
– Option listing
– Information abut the option installation
– Options for the C5G Control Unit
For the sake of immediacy, the “C5G Robot Control Unit” will be referred to simply as
C5G.
6.1 Option listing

The basic version may be supplemented with additional options to better suit the
installation requirements. If not otherwise specified, the available options can be
selected and combined as required. Possible restrictions related to the mutual
incompatibility or the maximum no. of admissible options are clearly specified.
To facilitate the search, the options are listed below according to function and
application field, while in the whole chapter are listed according to their abbreviation
alphabetical order.
Function list and corresponding options:
– Field Bus
DeviceNet
• C5G-PFG-BCO: Bus Coupler module
• C5G-DNM-DNMI: DeviceNet Master Interface
• C5G-DNM-DNSI: DeviceNet Slave Interface
• C5G-DNPC: movable connector for Devicenet modules
Profibus-DP
• C5G-PFM-PDPM: Profibus-DP Master Interface
• C5G-PFM-PDPS: Profibus-DP Slave Interface
• C5G-PFPC: movable connector for Profibus-DP modules
– I/O modules
optional movable connectors
• C5G-UCK: user connector kit, for SDM module
on X20 interface
• C5G-D12 - C5G-D24, digital I/O options
• C5G-AI2 - C5G-AO2, analog I/O options
on multipolar connector
• C5G-EDI: External digital I/O interface
– Special applications
• C5G-HSK5: High Speed Input Kit
• C5G-OTK: Axis Over Travel kit
• C5G-SMK: Signal Machine Kit
• C5G-TDC400: 400V Tip Dresser Command kit
• C5G-TDC400-2: 400V Double Tip Dresser Command kit
• C5G-TDS400: 400V Tip Dresser Supply kit
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Options
– Structural items
• C5G-APK1 kit Auxiliary Plate 1
• C5G-HFK kit fastening hangers
• C5G-OPK: Option Panel kit
• C5G-RSK100: 100-mm rising socket kit
– Services
• C5G-AFK: Auxiliary Fan Kit
• C5G-ETHK: Ethernet kit
• C5G-HMK: Hour-meter kit
• C5G-USBK: USB kit
6.2 Information abut the option installation

The options purchased together with the C5G Control Unit are supplied already
installed.
If the options are purchased later, the installation instructions are to be found in the
option installation manual.
The options listed here shall be installed and used solely with the C5G Control
Unit.
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Options
6.3 Options for the C5G Control Unit

6.3.1 C5G-AFK: Auxiliary Fan Kit
Function
With the C5G-AFK (Auxiliary Fan Kit) option an additional fan will be available to
increase the forced air on the CPU, power supplies and power modules dissipator, when
auxiliary axes are added.
Technical features and structure

The auxiliary fan is connected in parallel to the ones already installed in the Control Unit
(for more details, refer to par. 4.13 Internal ventilation system on page 82).
The no. of fans installed depends on the no. of available axis modules: a fan shall be
available for each 3 slot taken on the ACC. Even when the 3-slot group is not complete
and only 2 slots are taken an additional fan is required.
Fig. 6.1 - C5G-AFK: overall view
A: Fan installation area.

The picture shows the 3 fans available in the
Control Unit C5G-ACC3 (view with no cover
panel)
B B: C5G-AFK (the yellow fan serves the

purpose of highlighting the option installed)
Tab. 6.1 - C5G-AFK: technical features

Item Description
Electrical features – 24 Vdc fan with speed control through PWM signal
Size and weight – Not relevant; do not influence the considerations about the size and
weight for the Control Unit basic version
Installation position – On the rear panel only
Usage restrictions – Possible to install:
Available on the basic
on Control Unit Admissible options
version
C5G-ACC1 2 2
C5G-ACC3 3 1
C5G-ACC5 being defined being defined
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Options
6.3.2 C5G-AI2 - C5G-AO2, analog I/O options

Function
The C5G-AI2 (Analog Input 2) and C5G-AO2 (Analog Output 2) options makes
available digital inputs and outputs for the user’s applications.

The I/O are on X20 modules and shall be configured and used according to the
instructions specified in Rules for the installation of I/O on X20 modules (see par.
5.10.5.2 on page 132).
To facilitate the installation, default units are available (see Tab. 6.2), consisting of
fastening base, powering devices, cards and terminal boards.
Minimum requirements
The C5G-AI2 (Analog Input 2) and C5G-AO2 (Analog Output 2) options may be installed
only if the following items are already in place:
– C5G-OPK: Option Panel kit
– C5G-PFG-BCO: Bus Coupler module supplied with Ethernet (1,5 m long) cable
and 24 Vdc powering cable.
Tab. 6.2 - I/O analog modules solutions

Item Description
C5G-AI2
Comau Code C5G-AI2 – CR17130582
Structure – 1 powering device for input module
– 2 analog inputs*¹ (choise from -10 a +10 Vdc, 0-20 mA and 4-20
mA)
Electrical features – Refer to Prearranged solutions and technical specifications related
to the digital and analog I/O (see par. 5.10.5.4 on page 135).
C5G-AO2
Comau Code C5G-AO2 – CR17130583
Structure – 1 powering device for output module
– 2 analog outputs *¹ (choise from -10 a +10 Vdc and 0-20 mA)
Electrical features – Vedi Prearranged solutions and technical specifications related to
the digital and analog I/O (see par. 5.10.5.4 on page 135).
Installation position (valid for – Inside the C5G, on omega guide.

C5G-AI2 and C5G-AO2)
Usage restrictions (valid for – The optional device can be installed only if joined to a
C5G-AI2 and C5G-AO2 C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on page 182)
to another option already installed.
module is required.
*¹ they require one module. The size of one module is 12.5 mm.
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Options
Fig. 6.2 - C5G-AI2: overall view
A: Power supply module, X20 PS2100 *¹

B: 2 analog inputs, X20 AI 2622 *¹
A B
Fig. 6.3 - C5G-AO2: overall view

B: 2 analog outputs, X20 AO 2622 *¹
A B
Usage modalities
For further details and the usage modalities, refer to par. 5.10.5 Digital and analog
I/O module on the X20 interface on page 131.
See also C5G-D12 - C5G-D24, digital I/O options (see par. 6.3.7 on page 164).
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Options
6.3.3 C5G-APK1 kit Auxiliary Plate 1

Function
The C5G-APK1 (Auxiliary Panel Kit 1) option makes available an auxiliary plate to
fasten the following items on the CIP panel by the box base:
– 2 x dinkings for 72-pin connectors, (Harting size 16)
– 1 x dinking for 42-pin connector, (Harting size 10).

The plate is supplied with 6 fastening screws and shall be installed by removing one of
the dinking already available on the CIP panel. It shall be earthed through the supplied
yellow/green wire.
Fig. 6.4 - C5G-APK1: overall view
A: C5G-APK1
Tab. 6.3 - C5G-APK1: technical features

Item Description
Comau code – CR17431480
Mechanical features – Metallic plate
Size and weight – 300 x 147 mm, 500 g
Installation position – On CIP panel by box base
Usage restrictions – Depending on the requirements, but in compliance with the
instructions in par. 4.12 Connector Interface Panel (CIP) on
page 80, item Preferred installation positions for optional connector.
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Options

Function
fasten the following items on the CIP panel by the box base :
– 3 x dinkings for 42-pin connectors, (Harting size 10).

yellow/green wire.
A: C5G-APK2

Item Description
Installation position – On CIP panel by box base
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Options

Function
– 1 x dinking for 108-pin connector, (Harting size 24)
– 1 x dinking for 42-pin connector, (Harting size 10).
– 4 x dinkings for M25 connector / cable gland.

yellow/green wire.
A: C5G-APK3

Item Description
Installation position – Sul pannello CIP a base armadio
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Options

Function
– 2 x dinkings for 42-pin connector, (Harting size 10).
– 1 x fastening hole for wall intallation cap, (Harting size 16).

yellow/green wire.
A: C5G-APK4

Item Description
Mechanical features – Piastra metallica
Installation position – Sul pannello CIP a base armadio
Usage restrictions – Depending on th requirements, but in compliance with the
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Options
6.3.7 C5G-D12 - C5G-D24, digital I/O options

Function
The C5G-D12 (Digital 12Input/Output) and C5G-D24 (Digital 24Input/Output) options
makes available digital inputs and outputs for the user’s applications.

The I/O are on X20 modules and shall be configured and usee according to the
5.10.5.2 on page 132).
To facilitate the installation, default units are available (see Tab. 6.27), consisting of
fastening base, powering devices, cards and terminal boards.
The C5G-D12 (Digital 12Input/Output) and C5G-D24 (Digital 24Input/Output) options
may be installed only if the following items are already in place:
– C5G-PFG-BCO: Bus Coupler module supplied with Ethernet (1,5 m long) cable
and 24 Vdc pwering cable.
Tab. 6.7 - I/O digital modules solutions

Item Description
C5G-D12
Structure – 1 powering device for input modules and first output module
– 12 inputs *¹ 24 Vdc
– 6 outputs *¹ 24 Vdc - 0,5 A, share the power supply with the inputs
– 1 powering device for output independent powering
– 6 outputs *¹ 24 Vdc - 0,5 A, independent powering
to the digital and analog I/O (see par. 5.10.5.4 on page 135)
C5G-D24
Structure – 1 powering device for input modules and first 2 output modules
– 24 inputs *²24 Vdc
– 12 outputs *² 24 Vdc - 0,5 A, share the power supply with the inputs
– 1 powering device for output independent powering
– 12 outputs *² 24 Vdc - 0,5 A, independent powering
Installation position (valid for – Inside the C5G, on omega guide.

C5G-D12 and C5G-D24)
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Options
Tab. 6.7 - I/O digital modules solutions (Continued)

Item Description
Usage restrictions (valid for – The optional device can be installed only if joined to a
C5G-D12 and C5G-D24) C5G-PFG-BCO: Bus Coupler module (see par. 6.3.18 on page 182)
to another option already installed.
module is required.
*¹ they require one module. The size of one module is 12.5 mm.
*² they require two modules. The size of one module is 12.5 mm.
Fig. 6.8 - C5G-D12: overall view

B: 12 inputs module, X20 DI9371 *¹
C: 6 ouptus module, X20 DO6322*¹
A B CA C
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Options
Fig. 6.9 - C5G-D24: overall view

B: 12 inputs module, X20 DI9371 *¹
C: 6 ouptus module, X20 DO6322*¹
A B B C C A C C
Usage modalities
For further details and the usage modalities, refer to par. 5.10.5 Digital and analog
I/O module on the X20 interface on page 131.
Se also C5G-AI2 - C5G-AO2, analog I/O options (see par. 6.3.2 on page 158)
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Options
6.3.8 C5G-DNM-DNMI: DeviceNet Master Interface

Function
The C5G-DNM-DNMI (DeviceNet Module - DeviceNet Master Interface) option makes
available a DeviceNet Master interface module inside the Control Unit.

This module shall be installed on the C5G-PFG-BCO: Bus Coupler module (see par.
6.3.18 on page 182). The corresponding connector is the C5G-DNPC: movable
connector for Devicenet modules (see par. 6.3.10 on page 169), supplied as optional
item.
Fig. 6.10 - C5G-DNM-DNMI: overall view
A: C5G-DNM-DNMI
Tab. 6.8 - C5G-DNM-DNMI: technical features

Item Description
Electrical features –
Installation position – on C5G-PFG-BCO: Bus Coupler module
Usage restrictions – Up to 2 modules (for restrictions and position refer to par. 5.10.4.2
Installation rules for the field bus modules on page 127)
Usage modalities
For further details and the usage modalities, refer to par. 5.10.4 Field Bus Modules
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Options
6.3.9 C5G-DNM-DNSI: DeviceNet Slave Interface

Function
The C5G-DNM-DNSI (DeviceNet Module - DeviceNet Slave Interface) option makes
available a DeviceNet Slave interface module inside the Control Unit.

The module shall be installed on the C5G-PFG-BCO: Bus Coupler module (see par.
6.3.18 on page 182).The corresponding connector is the C5G-DNPC: movable
connector for Devicenet modules (see par. 6.3.10 on page 169), supplied as optional
item.
Fig. 6.11 - C5G-DNM-DNSI: overall view
A: C5G-DNM-DNSI
Tab. 6.9 - C5G-DNM-DNSI: technical features

Item Description
Installation position – Inside the C5G, on the C5G-PFG-BCO: Bus Coupler module
Usage modalities
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Options
6.3.10 C5G-DNPC: movable connector for Devicenet modules

Function
The C5G-DNPC (DeviceNet Plug Connector) option makes available the suitable
connector to connect the DeviceNet network cable on the C5G-DNM-DNMI: DeviceNet
Master Interface or C5G-DNM-DNSI: DeviceNet Slave Interface module.
Fig. 6.12 - C5G-DNPC: overall view
A: C5G-DNPC
Tab. 6.10 - C5G-DNPC: technical features

Item Description
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6.3.11 C5G-EDI: External digital I/O interface

Funciona
The C5G-EDI (External Digital Iinterface) option makes available 24 digital inputs e 12
digital outputs for the user’s applications, that can be accessed on a 42-pin connector
(Harting size 10) installed by the box base on CIP panel.

This option inclides the I/O X20 interface modules, the internal cable, the 42-pin
connector to be installed by the CIP panel base and the movable cap with male pins.
The I/O are on X20 modules and shall be configured and used according to the
5.10.5.2 on page 132).
The C5G-EDI option may be installed only if the following items are already in place:
– C5G-PFG-BCO: Bus Coupler module with Ethernet (1,5 m long) cable and 24 Vdc
powering cable, maximum 4 modules allowed on right side
– APK plate by box base (the user may choose among C5G-APK1 kit Auxiliary Plate
1, C5G-APK2 kit Auxiliary Plate 2, C5G-APK3 kit Auxiliary Plate 3, C5G-APK4 kit
Auxiliary Plate 4).
Fig. 6.13 - C5G-EDI: overall view
A: Powering module, X20 PS2100 *¹

B: 12-spot input module, X20 DI9371 *¹
C: 6-spot output module, X20 DO6322*¹
A B B C A C
Tab. 6.11 - C5G-EDI: technical features

Item Description
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Tab. 6.11 - C5G-EDI: technical features (Continued)

Item Description
Components – 1 power supply for the input modules and the first output one
– 24 inputs *² 24 Vdc
– 6 outputs *¹ 24 Vdc - 0,5 A, common powering for the inputs
– 1 power supply for output independent powering
– 6 outputs *¹ 24 Vdc - 0,5 A, independent power supply
Electric features – Refer to Prearranged solutions and technical specifications related
Size – 6 modules overall dimensione
Installation position – On the C5G-OPK inside panel with connector on CIP panel by box
base
Usage restrictions – Depanding on the requirements, but in compliance with:
• the instructions in Rules for the installation of I/O on X20
modules (see par. 5.10.5.2 on page 132)
• the no. of free spaces for 42-pin connectors, according to the
page 80, item Preferred installation positions for optional
connector.
*¹ take one module. The module size is equal to 12,5 mm.
*² take two modules. The module size is equal to 12,5 mm.
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6.3.12 C5G-ETHK: Ethernet kit

Scope
The C5G-ETHK (ETHernet Kit) option makes available a Ethernet network connector
on the Operator Panel Devices (OPD) remoting the ETH2 port pf the AMS-APC820
module, allowing the connection with a Personal Computer for maintenance
programming and diagnostics purposes (non-continuous usage).
To obtain an Ethernet connection for continuous usage (e.g. connection to factory Host),
we recommend to carry out a direct connection to the Ethernet ETH2 connector and to
have the net cable exiting from the Connector Interface Panel (CIP) (see par. 4.12 on
page 80).
Fig. 6.14 - C5G-ETHK: overall view
A: C5G-ETHK
ETH
A
Tab. 6.12 - C5G-ETHK: technical features

Item Description
Electrical features – Ethernet RJ45 port, 10/100/1000 Mbit/s
– Protection category IP65 (with cap in closed position)
– Remote connection for Ethernet port, obtained from ETH2
connector on the AMS-APC820 module
Installation position – On the Operator Panel Devices (OPD) only, right position A (see
Fig. 6.14).
Usage restrictions – Only 1 option allowed
– It is not possible to install the option if 2 C5G-USBK: USB kit options
are installed
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6.3.13 C5G-HFK kit fastening hangers

Function
The C5G-HFK (Hangers Fixing Kit) option makes available a set of two hangers fasten
the Control Unit to the floor.

The kit consists of a set of two hangers. To carry out the fastneing to the floor, suitable
blocks are required, which are not part of the supply volume.
Fig. 6.15 - C5G-HFK: overall view
A: C5G-HFK
Front view
Side view
Tab. 6.13 - C5G-HFK: technical features

Item Description
Mecchanical features – Fastening hangers out of sheet painted in RAL 7024
Dimensioni e peso
Top view
1,2 kg
605 mm
730 mm
ø 15 mm
Distance between hole centres : 730 x 605 mm (28.74 x 23.82 in)

Hole diameter: 15 mm (0.59 in)
Installation position – Through the box supporting feet
Usage restrictions – It is not possible to install the C5G-HFK option together with the
C5G-WHK: wheel kit (see par. 6.3.50 on page 213) one.
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6.3.14 C5G-HMK: Hour-meter kit

Function
The C5G-HMK (Hour Meter Kit) makes available a hour-meter recording the Robot
working hours on the Operator Panel Devices (OPD) panel.

The hour-meter is connected to the X107/SDM connector on the SDM module. The
output is enabled in Drive On only and therefore the hour-meter records the Robot
operating hours only.
Fig. 6.16 - C5G-HMK: overall view
A: C5G-HMK
Tab. 6.14 - C5G-HMK: technical features

Item Description
Electrical features – Hour-meter, capacity up to 99999,99 hours, cannot be zeroed
– 24 Vdc coming from X107/SDM connector on SDM module
– Protection category IP54
Installation position – On the Operator Panel Devices (OPD) panel only
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6.3.15 C5G-HSK5: High Speed Input Kit

Function
The C5G-HSK5 (High Speed Kit) option makes available two high-speed inputs for
applications, commonly used to acquire a given technological item (e.g. welding line
check).

Inside the C5G 2 inputs are available, one of which is shared with the Robot border area.
The HSI3 is the shared input and cannot be used contemporaneously on the Robot
border area and inside the C5G. The fast input signals converge on the first module
AMS-IAM module.
The connection at the disposal of the user is available on X136 (by HSI1) and X137 (by
HSI3) screw-in connectors (supplied together with the option). The connection by the
Robot border area is available on dedicated connectors, depending on the Robot
version (the signal travels from the X10 connector (Robot signals) by the C5G base to
the X1 connector by the Robot base).
This module is to be installed on the omega guide inside the C5G, carrying out the
suitable connections between the X138 and the X2 connector of the first AMS-IAM
module as well as the X10 connector (Robot signals).
Fig. 6.17 - C5G-HSK5: overall view
A: C5G-HSK5
X136: signal for HSI1, including 24 Vdc power

supply
X137: signal for HSI3, including 24 Vdc power

supply
X138: sorting towards the first AMS-IAM

module and X10 connector (Robot signals)
Tab. 6.15 - C5G-HSK5: technical features

Item Description
Electrical features – 2 high-speed inputs (HSI1 and HSI3)
– shared HSI3, that can be accessed on the module or Robot border
area (contemporaneous usage not allowed)
– Voltage: 24 Vdc (from 15 to 30 Vdc max)
– Connection with clean contact and/or digital signal
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Tab. 6.15 - C5G-HSK5: technical features (Continued)

Item Description
Usage modalities
For the usage modalities, refer to par. 7.5 HSI (High Speed Inputs) on page 65 in
the “Transport and installation” manual
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6.3.16 C5G-OPK: Option Panel kit

Function
The C5G-OPK (Option Plate Kit) roption makes available an area to insall electric
components on the omega guide.
A C5G-OPK plate is supplied as standard with the Control Unit basic version .

This option allows to install electric components on the omega guide, on two 220-mm
(8.66 in) guide segments.
Fig. 6.18 - C5G-OPK: overall view
A: C5G-OPK
Tab. 6.16 - C5G-OPK: technical features

Item Description
Mechanical features – It can take an overall weight below 15 kg, equally divided between
the 2 guides
Size and weight
275 mm
1 kg
220 mm
Overall dimensions: 220 x 275 mm (8.66 x 10.83 in)
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Tab. 6.16 - C5G-OPK: technical features (Continued)

Item Description
Installation position – on the box inside protrusion, in 3 prearranged positions, in
compliance with the instructions in in Tab. 6.17 - Example of
installation for the C5G-OPK plate on page 179
Usage restrictions – maximum 3 plates
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General rules applying to the components installation on the C5G-OPK plate

The majority of options available on the C5G Control Unit require some installation
space on the C5G-OPK plate. Based on logistics and functional analyses, we identified
the suitable installation position, that a re recommended in Tab. 6.17.
Tab. 6.17 - Example of installation for the C5G-OPK plate

Items available Recommended position
Left: A
ABC A
230 / 400 V power
electromechanical items
A B
B
Centre: B ABC
Extension position for:
Field bus
I/O modules
Safety signal extension
B C
C
Right: C ABC
Main position for:
Field bus
I/O modules
Safety signal extension
B C
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6.3.17 C5G-OTK: Axis Over Travel kit

Function
The C5G-OTK (Over Travel Kit) option makes available the axis over-travel limit switch
connection.

2 inputs are available to identify the “axis +” and “axis -” over-travel positions. The option
features terminal boards to connect up to 5 limit switches, connected in series to one
another. The system software identifies only one “axis +” and only one “axis -”
over-travel signal. The over-stroke signals converge on the second module AMS-IAM
module.
The connection at the disposal of the user is available on screw-in connectors (supplied
with the option), installed inside the C5G on the omega guide close to the X10 connector
(Robot signals), carrying out the suitable connections between the X10 connector and
the X2 one of the second AMS-IAM module.
Tab. 6.18 - C5G-OTK: technical features

Item Description
Electrical features – Voltage: 24 Vdc (from 15 to 30 Vdc max)
– Connection with not energized contact
Installation position – On the Connector Interface Panel (CIP), nearby the X10 connector.
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Connection diagram
Fig. 6.19 - C5G-OTK: connection diagram
C5G
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6.3.18 C5G-PFG-BCO: Bus Coupler module

Function
The C5G-PFG-BCO (Bus COupler) module makes possible the interfacing between the
Ethernet POWERLINK Network (see par. 4.15 on page 84) and the X20 interface
modules (see par. 5.10.1 on page 121), both field Bus and I/O modules.

This module consists of a mega-guide fastening base, an interface for the connection
with the Ethernet POWERLINK network and a DC/DC powering device (identified as *¹
X20 PS 9400). The modules features 2 free slots to install field Bus modules on the X20
interface.
The Bus Coupler option may be installed only if the following optional items are already
in place:
– Ethernet POWERLINK 1,5 m long cable (CR17231863)
– 24 Vdc powering cable (CR17240260).
Fig. 6.20 - C5G-PFG: overall view
A: C5G-PFG-BCO
Tab. 6.19 - C5G-PFG-BCO: main technical features

Item Description
– Available slots: 2, only for the following field bus modules:
• C5G-DNM-DNMI: DeviceNet Master Interface
• C5G-DNM-DNSI: DeviceNet Slave Interface
• C5G-PFM-PDPM: Profibus-DP Master Interface
• C5G-PFM-PDPS: Profibus-DP Slave Interface
Ethernet POWERLINK Cable – CR17231863 (ACC ETH POWERLINK 1,5 m)
1,5 m (4.9 ft)
Comau Code
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Tab. 6.19 - C5G-PFG-BCO: main technical features

Item Description
24 Vdc Power supply cable – CR17240260 (PFG supply cable)
Comau Code
Usage modalities
For further details and the usage modalities, refer to par. 5.10.3 Bus Coupler
PFG-BCO module on X20 interface on page 122.
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6.3.19 C5G-PFM-PDPM: Profibus-DP Master Interface

Function
The C5G-PFM-PDPM (ProFibus Module - Profibus-DP Master) option makes available
a Profibus-DP Master interface module inside the Control Unit.

The module is to be installed on the C5G-PFG-BCO: Bus Coupler module (see par.
6.3.18 on page 182). The corresponding connector is the C5G-PFPC: movable
connector for Profibus-DP modules (see par. 6.3.21 on page 186), supplied as optional
item.
Fig. 6.21 - C5G-PFM-PDPM: overall view
A: C5G-PFM-PDPM
Tab. 6.20 - C5G-PFM-PDPM: technical features

Item Description
Usage modalities
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6.3.20 C5G-PFM-PDPS: Profibus-DP Slave Interface

Function
The C5G-PFM-PDPS (ProFibus Module - Profibus-DP Slave) option makes available a
Profibus-DP Slave interface module inside the Control Unit.

This module is to be installed on the C5G-PFG-BCO: Bus Coupler module (see par.
6.3.18 on page 182). The corresponding connector is the C5G-PFPC: movable
connector for Profibus-DP modules (see par. 6.3.21 on page 186), supplied as optional
item.
Fig. 6.22 - C5G-PFM-PDPS: overall view
A: C5G-PFM-PDPS
Tab. 6.21 - C5G-PFM-PFMI: technical features

Item Description
Usage modalities
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6.3.21 C5G-PFPC: movable connector for Profibus-DP modules

Function
The C5G-PFPC (ProFibus Plug Connector) option makes available the connector
suitable to connect the Profibus network cable on the C5G-PFM-PDPM: Profibus-DP
Master Interface or C5G-PFM-PDPS: Profibus-DP Slave Interface module.
Fig. 6.23 - C5G-PFPC: overall view
A: C5G-PFPC
Tab. 6.22 - C5G-PFPC: technical features

Item Description
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6.3.22 C5G-RSK100: 100-mm rising socket kit

Function
The option C5G-RSK100 (Rising Socket Kit 100) makes available an additional
100-mm base to support and lift the cabinet.

The rising socket supports and lifts the cabinet from the floor by additional 100 mm
compared to the standard solution. Moreover serves as a three-side cover (front and
sides) preventing the dirt from reaching the area under cabinet. It is supplied with a
support that allows to keep the cables, that are connected by the cabinet base, 20-30
mm above the floor.
Fig. 6.24 - C5G-RSK100: overall view
A: C5G-RSK100
Tab. 6.23 - C5G-RSK100: technical features

Item Description
Codice Comau – CR17330880
Mechanical features – It increases the cabinet base height by 100-mm compared to the
standard version
Size and weight – The same cabinet base size. Height is equal to 100 mm (3.94 in)
– 12 kg (26.45 lb)
Installation position – Only by the base cabinet, positioned between the sockets/feet of the
standard version.
– It is compatible with the weight increase and barycentre change
caused by the Application Box installation
– Check the installation restrictions with the option C5G-WHK: wheel
kit (see par. 6.3.50 on page 213).
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6.3.23 C5G-SMK: Signal Machine Kit

Function
The C5G-SMK (Signal Machine Kit) option makes available two 24 Vdc alarm inputs,
4 24Vdc inputs and 4 24Vdc outputs by the Robot border area, to be used for minor
applications by the user.

The two 24 Vdc alarm inputs are “Robot Allarm” (flange alarm) e Air Input (air fault). The
signals are of the type normally closed (NC). If they are not used they shall be jumpered.
The 4 24 Vdc inputs and 4 24 Vdc outputs are taken directly from the Safety Distribution
Module (SDM), from the X311 and X310 connector respectively.
The 10 I/O signal obtained that way travel from the X10 connector (Robot signals) by
the box base to the Robot base (connector X1), from which they set out again to be
available on specific connectors installed nearby the Robot axis 3.
The kit is to be installed inside the C5G performing the appropriate connections among
the X2 connector of the third AMS-IAM module, the X311 and X310 connectors of the
Safety Distribution Module (SDM) and the X10 connector (Robot signals).
The Robot already features the connections between the X1 connector by Robot base
and the wrist (or axis 3, depending on the version). The Robot is not supplied with
movable connector, that shall be purchased separately.
Tab. 6.24 - Signal travelling path from C5G to Robot

C5G Robot Border Area
Involved By robot
Signal By box base SiX / NS NM NJ *¹
modules base
Robot Alarm X2/IAM3 X92
Air input X2/IAM3 X91

X10/CIP X1 X92 X70
4 Input X311/SDM X91/X92
4 Output X310/SDM X91
*¹ not available for series NJ4
The pin structure and recommended connection diagram are to be found in the
Robot manual “Technical specification”.
The description, pin structure and purchase code of the movable connector to be
used for the connections by the robot border area are to be found in the Robot
manual “Technical specification”.
Tab. 6.25 - C5G-SMK: technical features

Item Description
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Tab. 6.25 - C5G-SMK: technical features (Continued)

Item Description
Alarm signal electric features (Robot – 2 inputs
Allarm, Air Input) – Voltage: 24 Vdc (from 15 to 30 Vdc max)
– Connection with clear contact and/or digital signal
– Note: as it deals with inputs for faults, they shall be connected as
normally closed (NC). If not in use they are to be jumpered; if they
are left open the associated alarm activates.
Input / Output signals electric – 4 inputs / 4 outputs
features – Voltage: 24 Vdc
– Further details in par. 5.9.3 I/O electric features and pin structure of
the connectors on the Safety Distribution Module (SDM) on
page 117
Installation position – By Robot border area
Usage restrictions – Only one option allowed.
– This option cannot be installed together with the options
C5G-TDC400: 400V Tip Dresser Command kit (see par. 6.3.24 on
page 191), C5G-TDC400-2: 400V Double Tip Dresser Command kit
(see par. 6.3.25 on page 192) o C5G-TDS400: 400V Tip Dresser
Supply kit (see par. 6.3.26 on page 193).
– A movable connector is required for the connection by the robot
border area (refer to Robot manual “Technical specifications”).
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Usage modalities
The alarm signals (Robot Allarm, Air Input) are already configured int eh system. If not
in use they are to be jumpered; if they are left open the associated alarm activates.
The 4 input signals and the 4 output ones of the SDM module shall be onfigured (refer
to par. 5.9.5 Configuration of the I/O on the Safety Distribution Module (SDM) on
page 120).
The I/O taken by the option and the ones still available for the user are specified in
par. 5.9.6 Usage restrictions for the I/O on the Safety Distribution Module (SDM) on
page 120. Also, refer to the option wiring diagram.
Usage modalities in the Robot manual “Transport and installation”.
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6.3.24 C5G-TDC400: 400V Tip Dresser Command kit

Function
The C5G-TDC400 (Tip Dresser Command 400) option makes available a control
system for an electrode dresser for spot welding applications, that is powered at the
mains voltage.

Thi kit uses two digital inputs and one digital output of the Safety Distribution Module
(SDM), to monitor the overload cutout and electromagnetic switch status and to control
the electromagnetic switch respectively.
The kit consists of:
– an overload cutout and an electromagnetic switch installed on a C5G-OPK: Option
Panel kit
– connection cables to take power down the main switch only and connection with
SDM module
– a M25 cable gland to allow the cables intended for the motor to cross the CIP panel.
The C5G-TDC400 powering is taken down the Control Unit main switch. The motor
connection is carried out directly on the electromagnetic switch output terminals.
The motor powering cutoff is carried out through the power electromagnetic
switch, following the opening of the Control Unit safety circuits (emergency,
gates).
The control circuit category is comparable to category b (according to norm EN
ISO 13849-1), which can be improved by suitably managing the electromagnetic
switch feedback signal.
The integrator shall guarantee the appropriate integration and the assessment of
the control circuit reliability degree.
Fig. 6.25 - C5G-TDC400: overall view
A: C5G-TDC400
Usage modalities
The C5G-TDC400 option shall be supplemented by means of a suitable controlling
software.
The inputs and outputs associated to the option shall be suitably configured.
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Set the current value in the overload cutout such as to guarantee the compliance
with the current taken by the motor.
Further details about the configuration of the I/O on SDM module are to be found
in par. 5.9.5 Configuration of the I/O on the Safety Distribution Module (SDM) on
page 120.
The usage modalities and the wiring diagram are to be found in the manuals
about:
– the Spot welding application Low frequency, or
– the Spot welding application Medium frequency.
6.3.25 C5G-TDC400-2: 400V Double Tip Dresser Command kit

Function
The C5G-TDC400-2 (Tip Dresser Command 400-2) option makes available a control
system for two electrode dressers for spot welding applications, that is powered at the
mains voltage.

The kit uses two digital inputs and two digital outputs of the Safety Distribution Module
(SDM), to monitor the overload cutouts and electromagnetic switches status and to
control the electromagnetic switches respectively.
The kit consists:
– two overload cutouts and two electromagnetic switch installed on a C5G-OPK:
Option Panel kit
SDM module
– two M25 cable glands to allow the cables intended for the motor to cross the CIP
panel.due passacavi .
The C5G-TDC400-2 powering is taken down the Control Unit main switch. The motors
connection is carried out directly on the output terminals of the corresponding
electromagnetic switch.
The motors powering cutoff is carried out through the power electromagnetic
switches, following the opening of the Control Unit safety circuits (emergency,
gates).
The control circuit category is comparable to category b (according to norm EN
ISO 13849-1), which can be improved by suitably managing the electromagnetic
switches feedback signal.
The integrator shall guarantee the appropriate integration and the assessment of
the control circuit reliability degree.
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Fig. 6.26 - C5G-TDC400-2: overall view
A: C5G-TDC400-2
Usage modalities
The C5G-TDC400 option shall be supplemented by means of a suitable controlling
software.
The inputs and outputs associated to the option shall be suitably configured.
with the current taken by the motors and run the PDL2 programme to guarantee
the protection efficiency (e.g. preventing the output contemporaneous
activation).
page 120.
about:
– the Spot welding application Medium frequency.
6.3.26 C5G-TDS400: 400V Tip Dresser Supply kit

Function
The C5G-TDS400 (Tip Dresser Supply 400) option makes available the power supply
at mains voltage for an electrode dresser for spot welding applications.

The kit uses one digital input of the Safety Distribution Module (SDM) to monitor the
overload cutout status.
The kit consists of:
– an overload cutout installed on a C5G-OPK: Option Panel kit
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SDM module
– a M25 cable gland to allow the cables intended for the motor to cross the CIP panel
.
The C5G-TDS400 powering is taken down the Control Unit main switch. The motor
connection is carried out directly on the overload cutout output terminals.
The devices connected done the C5G-TDS400 option are powered even by open
safety circuits (emergency, gates). Alternatively, use the C5G-TDC400: 400V Tip
Dresser Command kit (see par. 6.3.24 on page 191) or the C5G-TDC400-2: 400V
Double Tip Dresser Command kit (see par. 6.3.25 on page 192) that allow the load
cutoff also in case of emergency stop.
Fig. 6.27 - C5G-TDS400: overall view
A: C5G-TDS400
Modalità d’uso
The C5G-TDS400 option shall be supplemented by means of a suitable controlling
software.
The input associated to the option shall be suitably configured.
page 120. Consultare inoltre lo schema elettrico dell’opzione.
with the current taken by the motor.
page 120.
about:
– the Spot welding application Medium frequency .
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6.3.27 C5G-UCK: user connector kit, for SDM module

Function
The C5G-UCK (User Connector Kit) makes available 3 movable connectors allowing the
wiring of the Digital Inputs / Output on the SDM module (see par. 5.9 on page 116).
Fig. 6.28 - C5G-UCK: overall view
A: C5G-UCK
Tab. 6.26 - C5G-UCK: technical features

Item Description
Electrical features – plug connectors X106/SDM, X310/SDM, X311/SDM and
X312/SDM for wires up to 1,5 mm², including identification labels
Installation position – On SDM module only
Usage modalities
For further details and the usage modalities, refer to par. 5.9 Digital Inputs /
Output on the SDM module on page 116.
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6.3.28 C5G-USBK: USB kit

Function
The C5G-USBK (USB Kit) option makes available a USB type-A connector on the
Operator Panel Devices (OPD) panel, allowing a convenient connection to compatible
storage peripherals.
Fig. 6.29 - C5G-USBK: overall view
A: C5G-USBK (typical position)
USB B: C5G-USBK (position for second option

installed)
A B
Tab. 6.27 - C5G-USBK: technical features

Item Description
Electrical features – USB port type A
– Protection category IP65 (with cap in closed position)
– Remote connection of the USB port/s, directly connected to the
AMS-APC820 module USB ports (see Tab. 6.28)
Installation position – On the Operator Panel Devices (OPD) panel only
Usage restrictions – Only 2 options allowed contemporaneously
– If the C5G-ETHK: Ethernet kit option is installed, only one option is
allowed.
Tab. 6.28 - C5G-USBK: installation position and USB port taken

Installed options Position (Fig. 6.29) Port on AMS-APC820 module
C5G-USBK
A XD2:
(only one option installed)
C5G-USBK + C5G-USBK
A and B XD2: and XD3:
(two options installed)
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COMAU Robotics services
Repair: repairs.robotics@comau.com
Training: training.robotics@comau.com
Spare parts: spares.robotics@comau.com
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C5G Control Unit - Technical Specification

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C5G Control Unit - Technical Specification

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Comau Robotics

Description and general characteristics of the Control Unit

Copyright © 2008 by COMAU - Date of publication 10/2010

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11

2. INTRODUCTION TO THE CONTROL UNIT: RELIABILITY AND SAFETY . . . . . . . ...21

3. VERSIONS AND TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...31

Programming terminal with wireless connection (C5G-WiTP) . . . . . . . . . . . . . . . . . . . . . . . . 38

4. DETAILS ABOUT THE C5G CONTROL UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..41

5. INTERFACING WITH THE C5G CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . ..91

Comau C5G Control Unit – Technical Specification

Those manuals are to be supplemented by the following documents:

Comau Robot – Technical Specifications *¹

Content of the C5G Control Unit manuals

Device Manuals Contents

Manual content limits

This symbol applies to operating procedures, technical information and

This symbol applies to operating procedures, technical information and

This symbol applies to operating procedures, technical information and

1. GENERAL SAFETY PRECAUTIONS

This specification deals with the following topics:

– The application of these Safety Precautions is the responsibility of the persons

The installation shall be made by qualified installation Personnel and should

1.2 Safety Precautions

Installation and Putting into Service

Auto / Remote Automatic Mode

Maintenance and Repairs

Putting Out of Service and Dismantling

1.2.4 Operating Modes

Auto / Remote Automatic Mode

Robot axes release

Maintenance and Repairs

– Maintenance, trouble-shooting and repairs are only to be carried out by authorised

– Trouble-shooting and maintenance activities are to be executed, when possible,

Putting Out of Service and Dismantling

Tab. 1.1 - Stop spaces in programming modality (T1)

Tab. 1.2 - Safety electronics reaction time in programming

Mission time (typ. case)

2. INTRODUCTION TO THE CONTROL

The C5G Control Unit:

– It is easily expandable through optional modules, to better adapt to the user’s

The C5G Control Unit has been conceived to guarantee:

2.1 Reliability and serviceability

2.2 Calculation power

2.5.1 Compliance with the norms in force

2.5.2 Directives and norms

Tab. 2.1 - Applicable Directives and norms

2.5.3 Statement of incorporation of quasi-machines

The Statement of incorporation of quasi-machines is supplied in original together

Fig. 2.1 - C5G Control Unit Identification Plate (facsimile for

2.5.4 Manufacturer’s details

2.5.5 Safety devices control procedures

2.5.6 Safety solutions installed

• enabling device releasing in programming mode

2.6 Control modes

3. VERSIONS AND TECHNICAL FEATURES

3.1 Selecting the Control Unit version

Fig. 3.1 - C5G Control Unit: overall view

A: C5G Control Unit

3.2 C5G Control Unit

Tab. 3.1 - C5G: available basic versions

SiX - NS C5G-ACC1 CR17930180 8 kVA

NM - NJ (up to 450) C5G-ACC3 CR17930380 8 kVA

works at constant power.