C5G Tech Specs en PDF

Comau Robotics
Instruction Handbook
Control Unit
Standard Version
Technical Specification (Quick Reference)
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
Quick Reference _en-00/0411

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 © 2008-2011 by COMAU - Date of publication 04/2011

Summary
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Content of the C5G Control Unit manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Document preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Manual content limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Symbols in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2. INTRODUCTION TO THE CONTROL UNIT: RELIABILITY AND SAFETY . . . . . . . ...18

Reliability and serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Calculation power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Expandability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Compliance with the norms in force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Directives and norms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Statement of incorporation of partly completed machinery . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Manufacturer’s details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Safety devices control procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Safety solutions installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3. VERSIONS AND TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27

Selecting the Control Unit version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
C5G Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control Unit technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Teach Pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Teach Pendant operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Teach Pendant overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Teach Pendant technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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Summary
Teach Pendant with cable connection (C5G-iTP), selecting mode T1, AUTO and REMOTE 35
Teach Pendant with cable connection (C5G-iTP2), selecting mode T1 and REMOTE . . . . . 36
Teach Pendant with wireless connection (C5G-WiTP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connection cables between C5G and Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4. OVERVIEW OF THE CONNECTIONS TO THE C5G CONTROL UNIT. . . . . . . . . . . ..39

Overview of the C5G Control Unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Robot, positioning devices and auxiliary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
X10 connector (Robot signals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
X60 connector (Robot Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
X10-EXT connector (Extension, Positioning device signals) . . . . . . . . . . . . . . . . . . . . . . . . . 44
X60-EXT connector (Extension, motors and brakes of the positioning device) . . . . . . . . . . . 45
X61..X64 connectors (Signals and power for auxiliary Axes). . . . . . . . . . . . . . . . . . . . . . . . . 46
Line ................................................................... 48
X30 connector (Safety items) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ETH2 connector on AMS-APC820 (Ethernet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
COM2 connector on AMS-APC820 (RS422 serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
X90 cable gland connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
X31..X32 connectors (Applications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
X93..X94 connector (Master Field Bus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
COM2 connector on AMS-APC820 (RS232 serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Programming and user’s interface on PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Summary of connectors and corresponding function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5. OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..61
Information about the options installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Options Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Opzions for the C5G Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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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 use
Circuit Diagram – Circuit Diagram (ver. ACC1 and ACC3)
– Circuit Diagram (ver. ACC5)
– Circuit Diagram (ver. PAL)
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 -10% to 500
Vac +10% with no need of any adapting transformer.
– 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 Teach Pendant featuring cable or wireless connection. The Teach Pendant
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 Teach Pendant,
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 partly completed machinery
– 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 “partly completed machinery” (according to the definition in
the Machinery 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 partly completed machinery on page 24.
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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 partly completed machinery

The group consisting of the C5G Control Unit and the SMART5 series robot is supplied
with statement of incorporation of partly completed machinery, as provided for in
the Annex 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 machinery 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 partly completed machinery 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 Machinery 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 Teach Pendant.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 Teach Pendant 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
• enabling device releasing in programming mode
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• 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 Teach Pendant.
– 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 Teach Pendant.
This mode may be unavailable for some Teach Pendant versions.
– 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 Teach Pendant
– Connection cables between C5G and Robot, depending on the Robot family and
the installation distance.
– Customizing adding optional functions (refer to Chap.5. - Options on page 61).
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

Power *² No. of axes
Matching C5G No. of
Robot family*¹ Total installed / avalable /
Control Unit peak controllable
(SMART5 series) average current max
/ Comau Code (<= 2s) robots
at 400 Vac controllable *4
SMART5 3 kVA / 4,5 A 9 kVA 1 6
C5G-ACC1
SiX
CR17930181 12 kVA*³ / 18,5 A 36 kVA 1 6 / 11
NS
SMART5 8 kVA / 14 A 24 kVA 1 6
NM
NJ < 180 12 kVA*³ / 18,5 A 36 kVA 1
C5G-ACC3
SMART5 CR17930381 6/9
NJ > 175 < 400 12 kVA*³ / 18,5 A 36 kVA 1
NJ 450 - 2.7
SMART5 C5G-ACC3P
12 kVA / 18,5 A 36 kVA 1 4
PAL CR17930681
SMART5
C5G-ACC5
NJ 420 - 3.0 12 kVA / 18,5 A 36 kVA 1 6
CR17930581
NJ 500 - 2.7
*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.
*³
Besides the 8 kVA installed the option C5G-AFK: Auxiliary Fan Kit is required.
*4
Refer to section Additional axes.
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Fig. 3.2 - C5G Control Unit: front and rear view
This picture shows the C5G Control Unit already supplied with iTP Teach Pendant.
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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 -10%

(according to norm EN 60204-1 § 4.3.3, voltage breaking not exceeding to 500 Vac +10%
20 ms) (optional from 400 Vac -10% 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 @ 500 Vac
Installed power from 3 to 12 kVA (see Tab. 3.1)
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)

C5G-ACC1 C5G-ACC3 C5G-ACC5
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 84).
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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 Teach Pendant.
Fig. 3.3 - Teach Pendant: 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.
The Programming (T1), Local automatic (AUTO) and Remote automatic (REMOTE)
control mode selection may be performed acting on the slector switch installed on the
Teach Pendant (C5G-iTP) or through the docking station (C5G-WiTP).
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.
More details about the control modes are to be found in the par. 2.6 Control
modes on page 26.
The Teach Pendant functions are complex and are dealt with in details in the
usage manual.
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3.3.2 Teach Pendant overview

There are following possible solutions:
– Teach Pendant with cable connection (C5G-iTP), selecting mode T1, AUTO and
REMOTE
– Teach Pendant with cable connection (C5G-iTP2), selecting mode T1 and
REMOTE
– Teach Pendant with wireless connection (C5G-WiTP).
The technical differences are to be found in par. 3.3.3 Teach Pendant technical features
on page 34.
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3.3.3 Teach Pendant technical features
Tab. 3.3 - Teach Pendant: versions available

C5G-iTP / C5G-iTP2 C5G-WiTP
Feature
Terminal Terminal
Modal selector switch (Mode T1, AUTO *¹, 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 Teach
up to 60 m guaranteed up to 40 m
Pendant
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 *² (as per
NA 19 EU / 24 USA
standard 802.11 a)
Pairing / Un-Pairing *³ -
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 Modality unavailable for model C5G-iTP2

*² Each independent communication channel can be used to send and receive data from
different Wi-Fi sources at the same time.
*³ 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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3.3.4 Teach Pendant with cable connection (C5G-iTP), selecting

mode T1, AUTO and REMOTE
At the time of purchase it is necessary to choose a Station, including Teach Pendant
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.
The Programming (T1), Local automatic (AUTO) and Remote automatic (REMOTE)
control mode selection may beperformed acting on the key selector switch available
on the terminal.
Tab. 3.4 - Teach Pendant with cable, selector switch for 3 modes,
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 Teach Pendant with inside-cabinet cable and connectors, C5G-iBK2 medium.
When only the Teach Pendant with cable is needed, it is possible to choose among the
versions listed below.
Tab. 3.5 - Teach Pendant with cable (no medium): available

versions
10 m (33 ft) C5G-iTP10 CR17910381
C5G-iTP Teach Pendant with cable 20 m (66 ft) C5G-iTP20 CR17910382
30 m (98 ft) C5G-iTP30 CR17910383

It includes: C5G-iTP Teach Pendant with cable.
Moreover it is possible to install an additional extension, to be chosen among the models

specified below.
Tab. 3.6 - Extension cable for Teach Pendant with cable:

available models
C5G-iTP cable extension iTP 10 m 10 m (33 ft) -- CR17241260

It includes: Cable extension with end male and female connectors
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3.3.5 Teach Pendant with cable connection (C5G-iTP2),

selecting mode T1 and REMOTE
At the time of purchase it is necessary to choose a Station, including Teach Pendant
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.
The Programming (T1) and Remote automatico remoto (REMOTE) control mode
selection can be performed acting on the lever selector switch available on the
terminal.
Tab. 3.7 - Teach Pendants with cable, selector switch for 2

modes, supplied with medium: available station
versions

It includes: C5G-iTP2 Teach Pendant with inside-cabinet cables and connectors, medium C5G-iBK2.
When only the Programing terminal with cable is needed, it is possible to choose among
the versions listed below.
Tab. 3.8 - Teach Pendants with cables (no medium): available

models
10 m (33 ft) C5G-iTP210 CR17910581
Terminal C5G-iTP2 con cavo 20 m (66 ft) C5G-iTP220 CR17910582

30 m (98 ft) C5G-iTP230 CR17910583
It includes: C5G-iTP Teach Pendant with cableo.
Moreover it is possible to install an additional extension, to be chosen among the models

specified below.
Tab. 3.9 - Extension cable for Teach Pendant with cable:

available models

It includes: Cable extension with end male and female connectors
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3.3.6 Teach Pendant with wireless connection (C5G-WiTP)

At the time of purchase it is necessary to choose a C5G-WiWS Station, including Teach
Pendant and docking station.
The key selector switch is located on the docking station and it si possible to select
the Programming control (T1) mode, Local automatic (AUTO) and Remote automatic
(REMOTE).
Tab. 3.10 - Teach Pendant without cable (wireless), equipped with

docking station: available station versions
Description Abbreviation Comau Code
Station C5G-WiWS C5G-WiWS CR17432280

It includes : C5G-WiTP wireless Teach Pendant, inside-cabinet cables and connectors, medium and docking
station C5G-WiDK5 on cabinet door, antenna
When components are to be purchased separately (e.g. Teach Pendant) the user may
choose among the ones listed in the table below.
Tab. 3.11 - Single components: available versions

Description Abbreviation Comau Code
Wireless C5G-WiTP Teach Pendant C5G-WiTP CR17911380

C5G-WiDK5 Docking station for C5G-WiTP Teach
C5G-WiDK5 CR17432180
Pendant
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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. 3.12 - 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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Overview of the connections to the C5G Control Unit
4. OVERVIEW OF THE CONNECTIONS TO

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’s interface on PC connections
To help the user to identify the functions of the main connectors:
– Summary of connectors and corresponding function.
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4.1 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’s interface on PC (D). It allows to program, control and
diagnose the robot system through the Teach Pendant and related software
supplied with it.
Ethernet A - Robot, positioning

devices and auxiliary
Safety axes
B - Line
B C - Application
from (Line)
D X30 D - Programming and
(Programming) user’s interface on
PC
from
X93
....
A
(Robots)
C from
(Applications) X10
X60
....
Field Bus
The picture shows the main connections between the Control Unit and the peripherals
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4.2 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.
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4.2.1 X10 connector (Robot signals)

The X10 is a multipole 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 par. 9.3 Digital Inputs / Outputs, by the Robot
border area on page 157.
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. 13.2.1 on page 248). As for the
pin structure and the connections by the Robot border area, refer to the Robot specific
manuals.
Fig. 4.1 - X10 connector: structure
A: Connector Interface Panel (CIP)
X10 X10: Signal connector for the Robot
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4.2.2 X60 connector (Robot Power)

The X60 is a multipole 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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4.2.3 X10-EXT connector (Extension, Positioning device

signals)
The X10-EXT is a multipole 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. 4.2.5 X61..X64 connectors (Signals and power for auxiliary Axes) on
page 46).
Fig. 4.3 - 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. 4.2.4 on page 45)
X61:Additional auxiliary axis installed

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

positioning device)
The X60-EXT is a multipole 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).
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. 4.2.5 X61..X64 connectors (Signals and power for auxiliary Axes) on
page 46).
Fig. 4.4 - 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. 4.2.3 on
page 44)
X61: Additional auxiliary axis installed

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

Axes)
The X61, X62, X63 or X64 are multipole 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. 4.1 - Axis-connector match

Auxiliary axis Matching connector
Axis 7
X61
(usually saddle)
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. 4.5 - 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. 4.6 - 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
Pin
No
Pin
Axis 7 Axis 8 Axis 9 Axis 10
Fig. 4.7 - 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. 4.2.4 on page 45)
X10E: X10-EXT connector (Extension,

Positioning device signals) (see par. 4.2.3 on
A page 44)
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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4.3 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: principles (see par. 9.4.5 on page 167)).
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. 4.3.2 on page 50))
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. 4.3.3 on page 50)).
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,
communication
use the way provided by the I X90 cable gland connector.
cables output)
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4.3.1 X30 connector (Safety items)

The X30 is a multipole 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. 7.1 Safety
circuits: particulars about the E-Stop, Auto-Stop (Fence) and General Stop
signals on page 126.
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4.3.2 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. 4.9 - 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
Chap. Ethernet network communication on page 221.
4.3.3 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. 4.10 - 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. 10.3 RS232 serial
connection cable to PC on page 219.
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4.3.4 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. 9.4.5 Field Bus Modules
on the X20 interface: principles on page 167.
The connections with Ethernet network are described in par. 4.3.2 ETH2
connector on AMS-APC820 (Ethernet) on page 50.
The connection with serial protocols are described in par. 4.3.3 COM2 connector
on AMS-APC820 (RS422 serial) on page 50.
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4.4 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. 9.2 Internal Digital Inputs / Output,
applications
X312/SDM on the SDM module on page 151
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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4.4.1 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. 4.12 - 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. 9.4.9.4 Overview of
prearranged solutions related to the digital and analog I/O on page 197 (solutions
with connection on connector and terminal board)
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4.4.2 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. 4.13 - 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. 9.4.5 Field Bus Modules on
the X20 interface: principles on page 167.
The usage, connector pin structure and connection cables examples are to be
found in the manuals of the corresponding application.
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4.4.3 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. 4.14 - 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. 10.3 RS232 serial
connection cable to PC on page 219.
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4.5 Programming and user’s interface on PC

Programming and motion can be performed by means of theTeach Pendant (see par.
3.3 on page 32).
Program WinC5G offers a convenient interface to the Control Unit, to facilitate the
diagnostic, setting and other activities. WinC5G runs on Personal Computer (PC)
supporting Microsoft© Windows© operating system.
A - Teach Pendant
B - Personal
Computer
A B
The usage modalities for the Teach Pendant and program WinC5G are described
in details in the Usage Manual of the Control Unit or in chapter “Program WinC5G
– Interface to the C5G on Personal Computer”.
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Die typical connections feature the solutions below.
USB
ETH
ETH2
XD2:
XD3:
ETH
XD:
Peripheral device
Involved
connectors
C5G
Ethernet net connection for automation applications with Host systems.
Available as standard on Modulo AMS-APC820 (see par. 4.4 on
ETH2
page 49) or Ethernet connector C5G-ETHK: Kit Ethernet (see par. 11.4
PC via Ethernet on page 220) as optional.
Optional Ethernet net connection for programming.
ETH
Available with the option C5G-U2E: Adattatore USB to Ethernet (see
additional
par. 11.5 on page 221).
Connection for USB storage media (e.g. C5G-FDU: Flash Disk USB
(see par. 14.2 on page 256).
USB
Available as standard:
USB storage
XD: – XD: on Modulo AMS-APC820 (see par. 4.4 on page 49)
media
XD2: – XD2: on Operator Panel Devices (OPD).
XD3: Available with options:
– XD3: on Operator Panel Devices (OPD) with option C5G-USBK: Kit
USB.
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4.6 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. 4.2 - Summary of connectors

Connector /
Typical function Description
Position
Analysis,
The communication with the systems (e.g. measurement systems, other
COM2 / measurement
ones) can be controlled 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 serial)
on AMS-APC820 (RS422 serial) (see par. 4.3.3 on page 50)).
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. 4.3.2 on page 50))
The main Robot is connected through the Connection cables between
X10/CIP Robot
C5G and Robot con I X10 connector (Robot signals)
The positioning device (e.g. series SMART5 PTDV, PTDORB, other
X10-EXT/CIP 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/CIP 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/CIP
X32/CIP 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/CIP Robot
C5G and Robot with the X60 connector (Robot Power)
The positioning device (e.g. series SMART5 PTDV, PTDORB, other
X60-EXT/CIP 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/CIP The single auxiliary axis (e.g. saddle on axis 7, electric gripper for spot
welding, other ones) are connected through the Connection cables
X62/CIP
Auxiliary axes between C5G and Robot, each one with an only one connector that
X63/CIP
includes both the power and the control signals, with the X61..X64
X64/CIP connectors (Signals and power for auxiliary Axes)
Multiple cable The cables can be connected inside the Control Unit through the X90
X90/CIP
input/output cable gland connector with no interruption
HS-RC-C5E-SPT_05.fm
00/0211 59
Tab. 4.2 - Summary of connectors (Continued)

Connector /
Typical function Description
Position
Remote I/O The communication with the systems (e.g. measurement systems,
X93/CIP
(C5G with master remote I/O, other ones) can be controlled through Field Bus protocols
X94/CIP
role) with X93..X94 connector (Master Field Bus)
24 Vdc power
The 24Vdc powering is available according to the modalities specified in
X106/SDM supply for user’s
par. 6.2 How to use the 24 Vdc in the user’s applications on page 120
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. 9.2 Internal Digital Inputs / Output,
applications
X312/SDM on the SDM module on page 151
Connection for USB storage systems (e.g. C5G-FDU: Flash Disk USB
(see par. 14.2 on page 256).
XD:
XD2: Available as standard:
XD3: USB – XD: on Modulo AMS-APC820 (see par. 4.4 on page 49)
/ APC820 or – XD2: on Operator Panel Devices (OPD).
OPD Available with options:
– XD3: on Operator Panel Devices (OPD) with option C5G-USBK: Kit
USB.
HS-RC-C5E-SPT_05.fm
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Options
5. OPTIONS
– Information about the options installation
– Options Circuit diagram
– Opzions for the C5G Control Unit
5.1 Information about the options installation

The options purchased together with the C5G Control Unit are supplied already
installed.
If the options are purchased later, the installation instruction are to be found in the single
option installation manual.
The option listed here can be installed and used solely for the C5G Contrl Unit.
5.2 Options Circuit diagram

The options circuit diagrams (available only for those ones where electric connections
are to be performed) are to be found in the Control Unit complete circuit diagram.
Due to the complexity of some options, some circuit diagrams may be supplied in a
separate document.
All circuit diagrams are available in the CD-ROM supplied together with the C5G
Control Unit. Refere also to par. Reference documents a pag. 5.
HS-RC-C5E-SPT_04.fm
00/0411 61
Options
5.3 Opzions for the C5G Control Unit

The C5G basic model can be integrated with additional options to better suit the
installation requirements. If not otherwise specified, such options can be choosen
among the available ones. Possible limits related to incompatibility or maximum
installable no. are clearly specified.
To facilitate the search, the options below are grouped according to the topic and
application field, while the details are to be found in the corresponsing chapters.
Available optioni
Field Bus
DeviceNet
– Bus Coupler PFG-BCO module on X20 interface
– C5G-DNM-DNMI: DeviceNet Master Interface
– C5G-DNM-DNSI: DeviceNet Slave Interface
– C5G-DNPC: movable connector for Devicenet modules
– C5G-DMI: Multibus cable interface for Devicenet module
Profibus-DP
– C5G-PFM-PDPM: Profibus-DP Master Interface
– C5G-PFM-PDPS: Profibus-DP Slave Interface
– C5G-PFPC: movable connector for Profibus-DP modules
– C5G-PMI: Multibus cable interface for Profibus-DP module
Profinet
– C5G-PNC: Profinet I/O Controller interface
– C5G-PND: Profinet I/O Device interface
Profinet (protocol solution only)
– Profinet I/O Device (software protocol)
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 (12 I / 12 O or 24 I / 24 O)
– C5G-AI2 - C5G-AO2, Analog I/O options (2 I or 2 O)
on multipole connector
– C5G-EDI: Digital I/O external interface (24 I / 12 O)
Safety
– C5G-PSB: PILZ safety Bus
Communication
– C5G-ETHK: Ethernet kit
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Options
Available optioni
Installation customization
Structural items
– C5G-AEB: Empty Box for application
– 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-ACO / C5G-ACBO: Conditioner
– C5G-AFK: Auxiliary Fan Kit
– C5G-ETHK: Ethernet kit
– C5G-HMK: Hour-meter kit
– C5G-MCK: Powering connector kit
– C5G-USBK: USB kit
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
Fittings
– C5G-FDU: Flash Disk USB
Software
– The software options are listed in the Control Unit Usage Modalities manual.
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COMAU Robotics services
Repair: repairs.robotics@comau.com
Training: training.robotics@comau.com
Spare parts: spares.robotics@comau.com
Technical service: service.robotics@comau.com
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Comau Robotics

Technical Specification (Quick Reference)

Description and general characteristics of the Control Unit

Quick Reference _en-00/0411

Copyright © 2008-2011 by COMAU - Date of publication 04/2011

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8

2. INTRODUCTION TO THE CONTROL UNIT: RELIABILITY AND SAFETY . . . . . . . ...18

3. VERSIONS AND TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27

4. OVERVIEW OF THE CONNECTIONS TO THE C5G CONTROL UNIT. . . . . . . . . . . ..39

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 partly completed machinery

The Statement of incorporation of partly completed machinery is supplied in

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

• motor-off command (Drive Off).

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

Fig. 3.2 - C5G Control Unit: front and rear view

3.2.1 Control Unit technical features

Tab. 3.2 - General technical feature