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FRONT PANEL LAYOUT (C3G-SAU2 Model 1/2/3/4/5/7)

Connectors

Function

Led

Colour

Meaning

J6

Supplies: 110 Vac auxiliary circuits;
24 Vdc brakes circuit, uninterrupted
24 Vdc (the 0 V is shared with the
24 Vdc of the brakes) for releasing
the brakes on board robot.

ENA1
ENA2
ENA3
ENA4
ENA5
ENA6
ENA7
ENA8

green
green
green
green
green
green
green
green

Off: indicates that the corre-
sponding axis is disabled

Flashing: indicates that the
system is initialising (axis
self-recognition)

On: indicates that the corre-
sponding axis is enabled

MAINTENANCE

C3G

Plus

08/0702

7-56

SERVO

AMPLIFIERS

UNIT

SAU2

Summary of Contents for C3G Plus

Page 1: ...C3G Plus OPERATIONS AND MAINTENANCE MANUAL 3UM C3G Plus 08 0702 00757045 GB CELL CONTROLLER REL 1 x e REL 2 x ...

Page 2: ... Any form of reproduction even partial is forbidden without the prior written authorization of COMAU S p A COMAU reserves the right to modify the characteristics of the product described in this manual without prior notice PRINTED IN ITALY 07 2002 Copyright 1999 by COMAU ...

Page 3: ...tituted 01 0498 6 Emergency procedure 1 2 3 Substituted 01 0498 7 Maintenance 14 24 31 37 Added i 3 30 38 40 45 59 67 68 70 Substituted 02 1198 Cover Substituted 02 1198 Back Substituted 02 1198 Summary all Substituted 02 1198 Chapter divider 4 5 Substituted 02 1198 2 Installation 7 9 Substituted 02 1198 3 Operator interface 1 24 30 40 54 55 60 Substituted 02 1198 4 Integration guide 1 3 4 33 Subs...

Page 4: ...tions for system use 19 20 Substituted 06 0400 Cover Substituted 06 0400 Back Substituted 06 0400 Preface ii iii iv v Substituted 06 0400 Chapter divider 3 Substituted 06 0400 3 Operator interface 12 13 2 17 24 26 27 31 37 39 40 41 44 51 52 53 60 Added Substituted 06 0400 4 Integration guide 5 34 35 36 Substituted Added 06 0400 5 Main operations for system use 14 19 20 Substituted 06 0400 7 Mainte...

Page 5: ...8 0702 Summary iv vi Substituted 08 0702 2 Installation 2 20 Substituted 08 0702 3 Operator interface 24 25 35 36 37 59 69 Substituted 08 0702 4 Integration guide 28 Substituted 08 0702 6 Emergency Procedures 1 3 4 Substituted 08 0702 7 Maintenance 1 4 5 10 11 20 21 38 53 56 68 74 Substituted C3G Plus UPDATING LIST 08 0702 C ...

Page 6: ...This page has been intentionally blank UPDATING LIST C3G Plus D 08 0702 ...

Page 7: ...C3G Plus PREFACE 05 1199 i PREFACE C3G Plus VERSIONS SDLP SDMP SDHP C3G Plus VERSIONS DDMP DDHP ...

Page 8: ...ersion 5 2X 5 3X 5 4x 5 5x 5 6x 1 RPT module is not available on robots identified by a release similar higher to that indicated in the following table Manufacture release is printed on robot identification plate Where necessary this manual also gives information about RPT as documentation concerning robots man ufactured in previous releases not specified in table or equipped with RPT module for s...

Page 9: ... electrical voltage Components that are damaged by electrostatic charges Earth connection point or pin TRAINING COURSES COMAU Robotics organises special training courses for robot system operating programming and maintenance personnel Further courses can be organised to cater for any particular requirements and to provide the technical and practical information required for independent operation o...

Page 10: ...ot off line functional check 2 14 Turn_Set operation 2 17 Deactivating the C3G Plus 2 18 Robot system integration 2 18 Functional check of the installed robot system 2 19 CHAPTER 3 OPERATOR INTERFACE Control panel and serial and parallel interfaces 3 1 Programming and emergency terminal C3G PTU4 3 3 C3G PTU4 display 3 9 Provision for activating the emergency terminal 3 11 Emergency terminal active...

Page 11: ...Parallel inputs outputs 4 14 Serial inputs outputs 4 33 Programmes contained in floppy disk 3 1 2 C3G CONFIGURATION TOOL 4 33 CHAPTER 5 MAIN OPERATIONS FOR SYSTEM USE System operating modes 5 1 System statuses 5 1 System status in multimachine multiarm configuration 5 4 Robot movement in programming status 5 5 File management between PC and cell controller 5 10 Use of the Floppy Disk 5 11 Examples...

Page 12: ...C3G Plus versions DDMP DDHP connections 7 14 Diagnostics 7 25 Troubleshooting indications 7 38 Fuses and protections 7 39 Circuit diagrams 7 41 Control Unit 7 43 C3G DBU3 module 7 49 C3G BKM module 7 50 C3G MPI module 7 51 C3G RPT module when installed 7 52 Servo Amplifiers Unit SAU2 7 54 System software loading 7 60 List of spare parts 7 68 SUMMARY C3G Plus vi 08 0702 SUMMARY ...

Page 13: ...RATOR INTERFACE 3 1 INTEGRATION GUIDE 4 1 MAIN OPERATIONS FOR SYSTEM USE 5 1 EMERGENCY PROCEDURES 6 1 MAINTENANCE 7 1 SUMMARY Paragraph Page Responsibility 1 1 Safety regulations 1 1 C3G Plus Operations and Maintenance Manual SAFETY REGULATIONS ...

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Page 15: ...a is the area that is enclosed by protective barriers in which the robot is to be in stalled and operated 2 3 Authorized Personnel Authorised Personnel is the group of persons that have been appropriately trained and delegated to perform the activities listed in point 3 2 4 Foremen Foremen are personnel who direct or supervise the activities assigned to subordinate workers as defined in the previo...

Page 16: ...ing 4 1 1 Commissioning is allowed only when the robot system is incorporated in a manufacturing system or in a research environment that guarantees the use of safety conditions 4 1 2 Installation and commissioning of the system must be performed by authorized personnel only 4 1 3 The system must only be installed and commissioned inside a protected area of a suitable size to house the robot and i...

Page 17: ...e mains in the same way and according to the same sequence of operations as speci fied for connection of the power supply 4 1 18 Connect the earth wire and the signals and power cables between the control unit and the robot 4 1 19 Check that the control unit door s is are locked with the special key 4 1 20 The components of the control unit may be permanently damaged if the connectors are con nect...

Page 18: ... a further three position safety device connected to the control system 4 2 7 During programming the operator must keep far enough away from the robot to be able to avoid any unexpected movements from the robot and in a position to avoid being caught between the robot and parts of the surrounding structure pillars safety barrier etc or between moving parts of the robot 4 2 8 During programming the...

Page 19: ...ode must only be used when special robot system conditions will not allow the use of manual movement during programming 4 4 3 Emergency manual operation must be controlled from outside the protected area since the safety system is downgraded 4 4 4 If it is absolutely necessary to work inside the protected area The robot system integrator must realize an appropriate safety circuit that allows the o...

Page 20: ...ase conductors and then the ground conductor 4 5 6 Disconnect the cables connecting the robot and the control unit then disconnect the earth 4 5 7 Disconnect the robot pneumatic system from the air distribution network if applicable 4 5 8 Make sure that the robot is correctly balanced and if necessary harness it correctly and then dis assemble the robot anchor bolts from the support structure 4 5 ...

Page 21: ... grilles etc 4 6 6 Faulty components must be replaced with others having the same code 4 6 7 Checks for faults on the control unit must whenever possible be performed outside the protected area 4 6 8 If the control unit needs to be powered in order to proceed with the troubleshooting all the precautions required by the safety standards regarding personnel working in the presence of dangerous volta...

Page 22: ...This page has been intentionally blank SAFETY REGULATIONS C3G Plus 1 8 02 1299 SAFETY REGULATIONS ...

Page 23: ...rface 2 1 Connection to power mains 2 2 C3G Plus robot connections 2 5 Application Box connections 2 6 Connection of safety devices and cutting off commands leading from the transfer 2 7 Activation of C3G Plus 2 12 RPT buffer battery connection when installed 2 13 C3G Plus robot off line functional check 2 14 Turn_Set operation 2 17 Deactivating the C3G Plus 2 18 Robot system integration 2 18 Func...

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Page 25: ... Application Box manual 7 CONNECTION OF SAFETY DEVICES AND CUTTING OFF COMMANDS LEADING FROM THE TRANSFER Robot manual chapter 4 of manual 8 ACTIVATION OF C3G Plus Application manual 9 RPT BACK UP BATTERY CONNECTION WHEN INSTALLED Chapter 7 of manual 10 C3G Plus ROBOT ROBOT OFF LINE FUNCTIONAL CHECK Chapters 3 and 5 of manual 11 TURN_SET OPERATION Chapter 3 of manual 12 DEACTIVATING THE C3G Plus C...

Page 26: ...This page has been left intentionally blank INSTALLATION C3G Plus 2 ii 01 0498 SUMMARY ...

Page 27: ...ices suitable for dialogue between the cell controller and the operator Control panel and serial and parallel interfaces Programming and PTU4 emergency terminal Display PTU4 Provisions for activating the emergency terminal Emergency terminal active keys Connector for additional Enabling Device push button C3G Plus interface on PC Connection cable for COMP PC connectors Connection cable for serial ...

Page 28: ...pstream of the controller must be suited to the power rating of the controller installed Differential current 30 mA version inst power Ir therm Im magn Cable cross section External network fuse SDLP 3 8 kVA 380 500 Vca 7 5 A 140 A 2 5 mm2 13 AWG 16 A SDMP 7 kVA 380 500 Vca 13 5 A 220 A 4 mm2 11 AWG 20 A 7 kVA 220 Vca 23 A 350 A 6 mm2 10 AWG 25 A SDMP 9 kVA 380 500 Vca 16 A 250 A 6 mm2 10 AWG 25 A ...

Page 29: ...nserting it in the special cable clamp at the bottom right of the cabin as il lustrated The length of the cable inside the cabin must be correct to avoid interfering with already existing cables C3G Plus INSTALLATION 08 0702 2 3 INSTALLATION 4 ...

Page 30: ...ype two phases earth wire cross section 2 5 mm2 1 13 5 PG 7 terminals for 2 5 mm2 cable and numbers 368 369 to be inserted on the cable PROCEDURE When making the connection refer to the procedure and the explanatory diagrams given below the controller main circuit breaker must be at OFF Disconnect wires no 370 and 371 from F117 isolate them with cap terminals and place them in the fairlead Connect...

Page 31: ...C3G Plus INSTALLATION 08 0702 2 5 Connection for C3G Plus Versions SDLP SDMP SDHP Connection for C3G Plus Versions DDMP DDHP INSTALLATION 4 ...

Page 32: ...cabin CHECKS BEFORE CONNECTION Check that the cell controller to be connected is the one associated with the robot On the controller cabin there is a label stating the se rial number of the robot with which it is associ ated the robot has a label stating its serial number The two numbers on the labels must correspond Check that the pins of the connectors to be connected are not knocked inwards or ...

Page 33: ...he literature about the C3G MMUX device and the specific cell documentation for connection CHECKS AFTER CONNECTION The ground cable must be connected correctly between the control unit and the robot The harting connectors must be perfectly clamped pull the cable with the hands to check that connec tion is correct The electrical connections of the Application Box if present depend on the type of ap...

Page 34: ...the counterpart of the ser vices connector and refer to the robot use and maintenance manual CHECKS BEFORE CONNECTION Check for the presence of the optional safety stop device relay K107 and of connector X80 presence of sec ond operator in the work area Connect them if present OPERATION The connection of safety devices takes place through connectors X30 X30 2 if double machine and X80 at the botto...

Page 35: ...emergency stop and or opening of the safety gates causes controlled stopping of the robot EN 60204 1 category 1 stop In this way power is cut off opening of the power contactor after 1 second In PROGR programming status the power is cut off immediately EN 60204 1 category 0 stop These times must be taken into account when installing the protective barriers in particular if light curtains are used ...

Page 36: ...t be fitted with a suitable ca ble clamp the cables must be screened and the screening appropriately connected to the ground in order to guarantee electromagnetic compatibility of the system as per directive 89 392 INSTALLATION C3G Plus 2 10 08 0702 INSTALLATION 7 ...

Page 37: ...cal Remote status Enabling device push button on PTU4 in PROGRAMMING status Tool supplied contacts closed DRIVE ON command All above safety devices closed At a DRIVE OFF command following DRIVE ON the tool remains supplied Power contactor redundancy Power contactors K101 and K102 52 53 55 56 The auxiliary contactors of the power contactors are made available Closing of the power contactors and aux...

Page 38: ...COMMANDS LEADING FROM THE TRANSFER For running the controller robot functional standalone check it is necessary to make the bridges illustrated on connector X30 at the bottom left of the cabin PIN X30 SIGNALS DESCRIPTION 7 81 User Input Common Return Internal 0V 24Vcc to external equipment Internal 0V 24 Vdc connection to common user inputs on SIM module 19 20 45 DRIVE OFF HOLD Internal 24Vcc to e...

Page 39: ...ated the system software is activated CHECKS AFTER SWITCHING ON The programming terminal PTU4 must be operational and the display must show the operating system bootstrap test for further information refer to chapter 7 DIAGNOSIS At the end of this test the display should show the following If an application programme spot arc welding has been set up and down loaded in sys tem start up after the bo...

Page 40: ...ve the switch to ON and load the operating system following the procedure given in the Main tenance chapter The PTU4 terminal displays er ror messages Presence of error messages Using the PCINT programme consult the explanation cause remedy on the error message shown Operator inter face chapter This step of the installation procedure must only be carried out if the RPT module Resolver Position Tra...

Page 41: ...nabling Device button in the intermediate position the motors turn on again DRIVE ON led on If the additional Enabling Device button is present connector X80 perform the same test as de scribed for the PTU4 considering that both must be closed for performing DRIVE ON 2 Checking the safety devices Safety buttons and gates a Press the PTU4 Enabling Device button in the intermediate position the robo...

Page 42: ...uxiliary contacts of power contactors K101 and K102 K121 and K122 only for C3G Plus versions DDMP DDHP close Refer to step 7 of the installation proce dure for the pins involved in the test To check that they open release the Enabling Device button 3 Checking manual robot motion Reduce the robot speed to 25 pressing the key of the PTU4 On the PTU4 select JNT movement using the TYP key Press the PT...

Page 43: ...ovement Physically check that the calibration in dexes fixed and mobile index coincide PROBLEMS DURING FUNCTIONAL TESTS Fault Check Suggestions Possible causes 1 Checking Enabling Device button and DRIVE ON Pressing the Enabling Device but ton DRIVE ON is not performed motors off The PTU4 display shows RE MOTE DRIVE OFF Wiring error on connector X30 consult step 7 of the procedure If relay K107 is...

Page 44: ...eck that the robot geometry has no distortions or interferences Replace the damaged robot parts This step of the procedure must be carried out if the word TURN appears in the PTU4 status window TURN may be shown following movement of one or more axes of the robot with the C3G Plus CONTROL UNIT off If TURN is not shown on the PTU4 carry out the next step of the procedure PROCEDURE 1 Set the status ...

Page 45: ...r and robot in the specific application and the creation of software programmes for executing the pro cess The technical information for performing integration is given in specific manuals provided with the robot sys tem Chapter 4 of this manual gives part of this information and in particular that referring to the cell control ler listed below remote safety signals System Inputs Outputs Parallel ...

Page 46: ...s must take place firstly in programming at low speed normal speed in cases in which AUTO MAN on PTU4 is indispensable under the direct control of the operator PTU4 and point to point Checking the working programmes in AUTOMATIC Local or Remote must take place fully complying with the safety specifications for Automatic operation of the robot system given in this manual and with any other rules ap...

Page 47: ...g the emergency terminal 3 11 Emergency terminal active keys 3 11 Emergency control C3G EMC2 3 12 Connector for enabling device additional button 3 14 C3G Plus interface on Personal Computer 3 15 Connection cable for COMP PC connectors 3 15 Cable for connecting serial port connectors COM0 and COM1 3 15 Parallel port PAR connection cable 3 15 PCINT programme 3 15 C3G Plus video on PC 3 18 System co...

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Page 49: ...es auto matically through the programming terminal in the automatic remote po sition it is possible to run programmes through commands leading from remote devices a line PLC or local control boards for example 3 Mushroom head emergency stop button Used to stop the machine immediately If pressed power to the motors is cut off and the brakes are applied It is of the forced opening type with mechani ...

Page 50: ... the two serial ports only COM0 can be utilized to load system soft ware 6 X113 connector 37 pin connector female for connecting the test device 7 PAR connector Parallel port for system software fast downloading 8 230 Vac socket 230 Vac 6 A service socket Schuko type Only for Rel 1 x 9 Housing for Floppy Disk unit Panel that is removed to install a Floppy Disk unit Two SDB3 modules are provided fo...

Page 51: ...e without requiring particular set tings and it has 16 line display 40 backlit columns 19 LEDs keypad display contrast and brightness adjustment through keys The following figures show the front top and bottom views of the PTU4 C3G Plus OPERATOR INTERFACE 07 1200 3 3 c3g ptu4 F2 F1 F4 F3 F6 F5 F8 F7 U1 U2 U3 U4 ALARM STEP DISB A2 EZ A1 PREV TOP DRIVE OFF ON HOLD START 1 SCRN ENTER BACK T2 RUN T1 R...

Page 52: ...ON key powers the drives for all the arms The LED indicates that the function is active The DRIVE OFF key cuts off the power to the drives for all arms The LED indicates that the function is active The START key runs all programmes in the ready status and activates movement during step by step checking of a programme or immediate ex ecution of a programme until it is released The green LED indicat...

Page 53: ...r up and down and to the right and left of the display If pressed in reply to a prompt the up arrow key calls the last ten answers entered from keyboard in reverse se quence The SCRN key toggles between the system and user screens When the editor is active it switches between system user and editor screens The ENTER key confirms entry of a command or data input Numeric Edit Keys The 7 CUT key ente...

Page 54: ...or further information refer to the PDL2 Programming Language manual If it is pressed together with the SHIFT key it selects speed at 100 SHIFT and or 25 SHIFT and These are rocker type keys The TYP key selects the reference system as follows Jnt joints mode The keys are associated with each axis of the arm selected the auxiliary axes if any follow those of the arm typi cally and keys Pressing one...

Page 55: ...e used to adjust display brightness and contrast The Step Disb key is used in EZ and system editor environment to switch from the current step mode to Disabled and vice versa For example if the step mode in EZ environment is Statement this mode is disabled pressing the Step Disb key Pressing Step Disb again the Statement mode is re en abled The function of the EZ key differs depending on the statu...

Page 56: ... operating speed Jogging of the axes immediate execution and step by step checking of a programme at reduced speed Some terminals do not have this selector In this case the programming terminal operates as if manual mode is always selected and when the drives are on Dr ON the enabling button must be held down to jog the robot Three position enabling button ENABLING DEVICE This is a safety switch t...

Page 57: ...L REMOTE AUTO T it has the following meanings means that no holdable programme is being run RUN means that at least one holdable programme is being run With the selector in the PROGR position it has the following meanings means that no movement is in progress JOG means that a jog movement is in progress FORW means that a FORWARD movement is in progress BACK means that a BACKWARD movement is in pro...

Page 58: ...movement according to the Cartesian tern x y z referring to the robot base Tol movement according to the Cartesian tern x y z referring to the robot tool Usr movement according to the Cartesian tern x y z set by the user Uwr transfer according to the Cartesian tern x y z set by the user and changing geometry according to the robot wrist axes Twr transfer according to the Cartesian tern x y z of th...

Page 59: ...bin for further information see chapter 6 of this manual EMERGENCY TERMINAL ACTIVE KEYS Only for Rel 1 x Substantially the emergency terminal active keys have the function described for the programming terminal The axis movement keys only work in JOINT mode The table below shows the active keys of the terminal SYMBOL DESCRIPTION Enabling button Mushroom head emergency stop button DRIVE ON and DRIV...

Page 60: ...P cut off of 110 V a c supply to the electronics rack The non disconnection of this connector during the emergency terminal function could cause the system malfunctioning Connect the cable X110 EMC2 to X110 SDB3 on the card C3G EMC2 Connect the cable X111 EMC2 running out from the box C3G EMC2 to the connector X111 SDB3 Connect the cable X7 EMC2 running out from the box C3G EMC2 to the connector X...

Page 61: ...SAMPLE CONNECTION OF C3G EMC2 C3G Plus OPERATOR INTERFACE 07 1200 3 13 EMERGENCY CONTROL C3G EMC2 ...

Page 62: ...esent on request for connecting an additional three position safety switch Enabling Device with the same functions as the one on the PTU4 programming terminal The connector is at the bottom left cabin front view below connectors X10 and X30 OPERATOR INTERFACE C3G Plus 3 14 00 1097 CONNECTOR X80 1 2 4 3 ...

Page 63: ...E Maximum cable length 15 m Use a standard PC PC cable PARALLEL PORT PAR CONNECTION CABLE Connector 25 pin SUB D MALE Maximum cable length 1 5 m Use a standard PC PC cable PCINT PROGRAMME The PCINT programme is contained on a floppy disk supplied with the C3G Plus The language in which the programme is written is specified on the floppy disk SET UP The PC on which it is decided to install the prog...

Page 64: ...r working on the PTU4 as follows Type the commands UCMC You will be asked on which C3G Plus port to install Type COMP and confirm with ENTER The C3G Plus screen is displayed on the PC As the normal PC keyboard does not have all the neces sary function keys some keys of the C3G Plus keyboard have been re mapped to give them new func tions on the video emulation protocol Consulting the help provided...

Page 65: ...re the file has to be addressed E G Drive Directory c save The name of the file created is MESSAGE TXT We recommend to open this file from an MS DOS session in fact should it be opened with Word under Windows the special characters held in the text of the error messages could be not be correctly displayed DOWNLOADING SYSTEM SOFTWARE Through the Download System Software option it is possible to dow...

Page 66: ... and 3 3 will then be requested in sequence Insert the disks and confirm with ENTER At the end of downloading entry of the time and date will be requested Enter the time date and confirm with ENTER At the end of downloading the PTU4 displays the system menu If the PC is connected on the COMP serial port of the C3G Plus e g COM1 of the PC with COMP the system video is also automatically displayed o...

Page 67: ...us of the selectors HOLD means that the HOLD button is pressed thus execution of the holdable programmes and the movement of all arms are stopped ALARM means that the system is under alarm indicates the movement percentage speed and it may vary 1 to 100 Arm The First Field may have the following values 1 1 2 2 Number of arm selected 1 2 Synchronised movements for more Arms 3 2 1 4 2 1 1a C3G MMux ...

Page 68: ...P indicates that the programming terminal is placed in the special housing on the cabin indicates that the programming terminal is not placed in the special housing on the cabin The above information is shown on the first line of the status window the second line shows the error and system information messages SCROLLING WINDOW this window displays the messages that the system sends to the operator...

Page 69: ...available commands have an upper case first letter On the PC screen an available command will be highlighted in bold in addition to having an upper case first letter Press the function keys F1 F8 on the PC or programming terminal keyboard to execute the corre sponding command For example pressing F2 executes the DISPLAY command from the main menu Press the key corresponding to the first letter of ...

Page 70: ...ible files The response to a parameter prompt must be typed before pressing the ENTER key The left and right arrow keys can be used to move the cursor on the response line The delete DEL key will delete the character immediately before the cursor while the left and right arrow keys pressed together with the SHIFT key move the cursor to the beginning and end of the response respectively Character m...

Page 71: ...ar key Otherwise press any key and a new page will be displayed Selecting the NOPAGE option the information continues to scroll without waiting for a key to be pressed 4 option The 4 option is used to format displays so that the information contained in them does not exceed 40 col umns in width This is useful when View commands are issued from PDL2 via the SYS CALL internal rou tine in which displ...

Page 72: ...on file in the Flash Eprom SAU2 RPT optional the C3G SYS file and the ASCII calibration file User uses the pre learned user calibration position CAL_USER instead of the system position CAL_SYS Syntax CAC arm_num axis_num CAC L arm_num CAC U arm_num axis_num Reten_Mem displays the commands for downloading from and saving in the Flash Eprom retentive memory in SAU2 or RPT module optional This makes ...

Page 73: ...tion Use this option only if the robot is still currently calibrated the controller has not been powered off since the RPT data was lost This option is disabled is the RPT device is not present User uses the pre learned user calibration position Syntax CAT arm_num axes_num CAT C arm_num axes_num CAT U arm_num axes_num View_cal displays the calibration constants Options 4 Syntax CAV arm_num Cntrler...

Page 74: ...ent system situation The PDL2 holdable no holdable programmes are deacti vated and erased from the execution memory The PLC programme starts again automatically RUN from cycle start Syntax CCRW Startup sets the name of the startup programme which is run at each system restart This programme can be holdable or non holdable but a holdable programme will not begin running until the START but ton is p...

Page 75: ... file C3G SYS is loaded The system must be in the PROG status and the drives off for this command to be executed This command cannot be used if the system is in automatic status drive power is on or system memory or programme pro tection is on A warm restart WARM is required to make the values operational As options the LOAD command supports all of the single categories that can be loaded separate...

Page 76: ...motor currents of the axes in amperes Syntax DAC arm_num Data displays arm interpolator data Syntax DAD arm_num Following displays following errors of the axes in bit units Syntax DAF arm_num Joint displays the current position target of each axis in degrees Syntax DAJ arm_num Position displays the current Cartesian position target as an x y z location Eular angle and configura tion string the val...

Page 77: ...PLAY command Syntax DCT Vars closes all variable windows Syntax DCV Fieldbus Master Slave Arm Close Fieldbus Input Output Rll Vars The FIELDBUS command contains a menu of commands in order to display the status of the Fieldbus Mas ter and Slave cards In particular the following information can be displayed for each card NOCNFG indicates that the card is not configured RUNNING indicates that the co...

Page 78: ...ed to each individual bit Use the LH and RH arrow keys to move the cursor along the bits use the UP and DOWN arrow keys to change module Different notations are used for indicating if the RIO board if present is communicating correctly with the PLC On the screen display line the flashing message COM RUNNING or COM STOPPED is shown on the programming terminal a flashing up arrow indicates correct c...

Page 79: ...ts relating to outputs use the left right arrow keys to change module use the up and down arrow keys Pressing the SELECT key on a highlighted output it is possible to obtain a help that describes the meaning of the bit Syntax DOS Program The PROGRAM command displays information about active PDL2 programmes It is possible to specify a particular programme name It is also possible to add an asterisk...

Page 80: ...me as second parameter of the EXECUTE command The option for the EXE CUTE command is available in the second parameter Options Context causes association of all references to predefined variables with the programme specified If this option is not used default values will be used for the predefined variables and assignments to them will be ineffectual An error occurs if this option is used and the ...

Page 81: ...d creates duplicate copies of files The original files are not affected At the FROM prompt specify the source file at TO specify the destination file Use of the asterisk is allowed for file names and extensions It is advisable to use the FILER UTILITY BACKUP and FILER UTILITY RESTORE commands instead of FILER COPY when copying all the files of the default backup device for example FD to the defaul...

Page 82: ...on ports using the UTILITY COMMUNICN MOUNT command issued beforehand In the case of a Filer Print command specifying a VAR file and a destination file LSV a back up file is cre ated with BKL for that LSV file If no destination device is specified the VAR file is printed on the screen If a COD file contains checksum errors or other damaged data and it is not possible to recover a backup copy of the...

Page 83: ... only device that can be specified is RD If no file extension is specified the extension will be PDL If the COD file already exists the extension is changed to BKC before creating the new COD file If warnings or errors are detected during translation they are displayed in the scroll window and logged in a file called TRANS ERR Both system and memory protection must be off for use of this command O...

Page 84: ... Where necessary the Kermit protocol is installed automatically If no file is specified all the files are copied Syntax FUB file_name Compress recovers files from a compressed archive file and allows them to be viewed Extract View Attribute Backup Compress FD_format Install Restore Search Verify Extract extracts files from a compressed archive file Both system and memory protection must be off to ...

Page 85: ...G SYS present on the backup device is copied and given the new name C3G OLD Option Configure loads the old configuration file C3G OLD and saves it as C3G SYS It is wise to follow this command with Restart Cold to make the data file operational Syntax FUR file_name Search allows the user to find a string in a file on the RAM DISK A file specification and a string must be given The file specificatio...

Page 86: ...aded in the memory To use this command the controller must not be in a FATAL status and the system memory and programme protection must be off The DEBUG command cannot be used when the FILER EDIT PROGRAM EDIT or MEMORY TEACH commands are active or while the EZ environment is active Syntax MD programme_name Erase All Program Variable Debug Erase Load Rll Save Teach View The ERASE command displays a...

Page 87: ...COD file To be able to use this command the controller must not be in a FATAL status and both system and memory protection must be off Options As allows programmes to be loaded with a different data file specified as a parameter The asterisk cannot be used with this option Convert converts various kinds of mismatches between the data file and the programme Depend automatically loads the code and v...

Page 88: ...E command saves programme data or code from memory to a file on the default device The programme name is specified as parameter A wildcard can be used for the programme name The file created will have the same name as the programme and a VAR or COD extension If a data file by the same name already exists it will be renamed to have a BKV or BKC extension If the data were loaded with the AS option a...

Page 89: ...been modified in memory but not saved on the RAM disk Issuing this command from the CRT keyboard or from SYS_CALL this symbol is dis played next to the code and variable sizes If the command is issued from the programming terminal the Full option must also be issued The symbols used are the following S indicates that the program code or the variables have been saved indicates that the program code...

Page 90: ...able type reference counter number of loaded programmes referencing the variable status private exported local to routine value If a programme or variable name is not specified as a parameter information for all loaded variables is dis played The asterisk can be used for the programme or variable name Options Nopage Full displays the names of the variables in full Syntax MVV programme_name variabl...

Page 91: ... on The controller must not be in a FATAL status The following options can be used to activate the programme with a different step mode than the default mode Refer to PROGRAM TEST STEP command for the meaning of each step Options Cycle Disable Fly Move Routine Statement Syntax PA programme_name Deactiv The DEACTIV command deactivates programmes that are in running ready paused or unpaused states D...

Page 92: ...s shown asking whether two or more programmes should stay active on the same arm If a holdable programme is still active and the DETACH attribute is not specified a message is displayed say ing that the arm is already ATTACHed If the programme is already active a prompt will ask if deactivation is required If the programme is already loaded and the COD file is newer than the loaded version a warni...

Page 93: ...s deactivated This command can be used when system memory or programme protection is active or when the controller is in the FATAL status Syntax PRD Go loads the specified PLC programme into the PLC memory and starts execution It is a combination of the MEMORY RLL LOAD and PROGRAM RLL ACTIVATE commands This command cannot be used when system memory or programme protection is active or when the con...

Page 94: ...mme Bypass allows the programmer to bypass the current statement when debugging the programme This command is helpful when the programme is suspended for example waiting for a determinate condition to occur BYPASS cannot be used when memory system or programme protection is on or when the controller is in the FATAL status Syntax PSB programme_name Pause sets the specified programme from a running ...

Page 95: ...ely A programme name and a line number parameter are required the line number must correspond to an executable code The break occurs at the specified line number before the statement is executed If a line number is not specified an error message is displayed Options Label allows a label to be specified instead of a line number Routine allows a routine name to be specified instead of a line number ...

Page 96: ...abled the following information for each active programme programme name CPU time used percentage of CPU time used If an EXECUTE command has been issued while PROFILE is enabled performance calculations related to its execution are also displayed The performance calculations listed next to the programme named Free represent the CPU time not used by the programmes or by the EXECUTE function Options...

Page 97: ... the step as one statement at a time except that routines are executed as a single statement Syntax PTSR programme_name Statement defines the step as a single statement Syntax PTSS programme_name View displays the step associated with a programme The asterisk may be used to specify the programme name If not all the steps related to all programmes will be displayed Syntax PTSV programme_name View T...

Page 98: ...till now current programme state running held suspended reason for suspension current line number being executed and the programme to which it belongs activation time break points set step mode number of condition handlers defined and the list of them those enabled locally or globally are marked with an asterisk number of errors on which ERR_TRAP_ON has been applied list of predefined variables li...

Page 99: ...num Enable enables the DRIVE ON function of an arm This command can only be issued when the system is in the PROGRAMMING state the drive power is off and memory protection is off For systems with multiple arms an arm number parameter is required An asterisk may be used to indi cate all arms Sintassi SAE arm_num Gen_ovr sets GEN_OVR to the value specified as a parameter This command can be used whi...

Page 100: ...m_num Unsimul turns off arm simulation All holdable programmes will be deactivated This command requires an arm parameter and must be issued with drives off Syntax SAU arm_num Cntrler Key_lock Protect View Win_clear Arm Cntrler Input Output Total_unf Update_io View_io The CNTRLER command displays a menu of commands to set controller characteristics Key_lock prevents unauthorised use of the keyboar...

Page 101: ...ramming terminal is connected but not on the cabinet the FORCE and UNFORCE commands are disabled from the keyboard of the Screen keyboard unit Each INPUT command displays a submenu to select the type of input as follows AIN DIN GIN Force Unforce View Force simulates the inputs The physical input is bypassed and the forced value is used The operator can choose from the submenu to force analogue AIN...

Page 102: ... cabinet the FORCE and UNFORCE commands are disabled from the keyboard of the Screen keyboard unit Each OUTPUT command displays a submenu to select the type of output as follows AOUT DOUT GOUT Force Unforce View Force simulates outputs The forced value is used by the programme and allocated to the physical out put Any allocation to forced outputs will in no way affect the physical outputs or execu...

Page 103: ...m Cntrler Input Output Total_unf Update_io View_io The UPDATE_IO command controls the user I O refresh feature Disable separates the internal I O image from the physical image The input internal values and the out put physical values remain unchanged until an ENABLE command is issued A confirmation is required To use this command system and programme protection must be off the controller must not ...

Page 104: ...s not specified the default one will be used Crt_emu Ddcmp Kermit Tisoft 3964 R Dismount Mount Port_char Set_def View Crt_emu activates the video emulation protocol Before entering this command make sure that the video emulation programme is running on the PC and that the serial line cable is connected to the speci fied port Use the UTILITY COMMUNICN DISMOUNT command to exit the video emulation en...

Page 105: ...w listing the current characteristics The left and right arrow keys can be used to select the different characteristics The ENTER key or the right and left arrow keys will move to the next characteristic while the up and down arrow keys can be used to select different values for the characteristic selected When the desired values for the characteristics are set press the PREV TOP key To use this c...

Page 106: ...vel 4 Level 5 Character keys Function keys Configure Arm Calibrate Learn Nosave User Reten_Mem Load Loadfile Nofile Save Nofile C CA CAC CAR CARL CARS F1 F1 F1 F1 F1 F1 F1 F1 F2 F1 F1 F2 F1 F1 F1 F2 F2 Turn_set Current USer View_cal 4 CAT CAV F1 F1 F3 F1 F1 F4 Cntrler Password Restart Bootmon Cold Reboot Warm CC CCP CCR CCRB CCRC CCRR CCRW F1 F2 F1 F2 F1 F1 F2 F2 F1 F2 F2 F1 F1 F2 F2 F2 F1 F2 F2 F...

Page 107: ...nt Full List Overwrite Nopage Range Rename Confirm Overwrite Translate Back Confirm List Variables Utility F FC FD FE FP FR FT FU F4 F4 F1 F4 F2 F4 F3 F4 F4 F4 F5 F4 F6 F4 F7 Attribute Hidden Reset Readonly Reset System Reset FUA FUAH FUAR FUAS F4 F7 F1 F4 F7 F1 F1 F4 F7 F1 F2 F4 F7 F1 F3 Backup Compress Extract View FUB FUC FUCE FUCV F4 F7 F2 F4 F7 F3 F4 F7 F3 F1 F4 F7 F3 F2 FD_format High Low FU...

Page 108: ..._scan View PA PD PE PG PR PRA PRC PRD PRG PRR PRS PRV F6 F1 F6 F2 F6 F3 F6 F4 F6 F5 F6 F5 F1 F6 F5 F2 F6 F5 F3 F6 F5 F4 F6 F5 F5 F6 F5 F6 F6 F5 F7 State Bypass Pause Confirm Unpause PS PSB PSP PSU F6 F6 F6 F6 F1 F6 F6 F2 F6 F6 F3 Test Break Insert Label Routine Purge View Nopage PT PTB PTBI PTBP PTBV F6 F7 F6 F7 F1 F6 F7 F1 F1 F6 F7 F1 F2 F6 F7 F1 F3 Profile Disable Enable Reset View 4 PTP PTPD PT...

Page 109: ... SIF SIFA SIFD SIFG F7 F3 F7 F3 F1 F7 F3 F1 F1 F7 F3 F1 F2 F7 F3 F1 F3 Unforce AIN DIN GIN SIU SIUA SIUD SIUG F7 F3 F2 F7 F3 F2 F1 F7 F3 F2 F2 F7 F3 F2 F3 View AIN DIN GIN SIV SIVA SIVD SIVG F7 F3 F3 F7 F3 F3 F1 F7 F3 F3 F2 F7 F3 F3 F3 Output Force AOUT DOUT GOUT SO SOF SOFA SOFD SOFG F7 F4 F7 F4 F1 F7 F4 F1 F1 F7 F4 F1 F2 F7 F4 F1 F3 Unforce AOUT DOUT GOUT SOU SOUA SOUD SOUG F7 F4 F2 F7 F4 F2 F1 ...

Page 110: ... Applicatn Communicn Dismount Mount Crt_emu Ddcmp Maint Kermit Speed Tisoft U UA UC UCD UCM UCMC UCMD UCMK UCMT F8 F8 F1 F8 F2 F8 F2 F1 F8 F2 F2 F8 F2 F2 F1 F8 F2 F2 F2 F8 F2 F2 F3 F8 F2 F2 F4 UCP UCS UCV F8 F2 F3 F8 F2 F4 F8 F2 F5 OPERATOR INTERFACE C3G Plus 3 62 03 0499 COMMAND SUMMARY LIST ...

Page 111: ...CA F2 F2 F1 Arm SA F7 F1 Attribute FUA F4 F7 F1 Backup FUB F4 F7 F2 Bit DVB F2 F8 F1 Bootmon CCRB F1 F2 F2 F1 Break PTB F6 F7 F1 Bypass PSB F6 F6 F1 Calibrate CAC F1 F1 F1 Clear SCPC F7 F2 F2 F1 Clear_plc PRC F6 F5 F2 Close DC F2 F2 Cntrler CC F1 F2 Cntrler SC F7 F2 Cold CCRC F1 F2 F2 F2 Communicn UC F8 F2 Compress FUC F4 F7 F3 Configure C F1 Copy FC F4 F1 Crt_emu UCMC F8 F2 F2 F1 Currents DAC F2 ...

Page 112: ...5 F2 DOUT SOFD F7 F4 F1 F2 DOUT SOUD F7 F4 F2 F2 DOUT SOVD F7 F4 F3 F2 Edit FE F4 F3 Edit PE F6 F3 Enable PTPE F6 F7 F2 F2 Enable SAE F7 F1 F2 Enable SUE F7 F6 F2 Erase ME F5 F2 Execute E F3 Extract FUCE F4 F7 F3 F1 FD_format FUF F4 F7 F4 Fieldbus DF F2 F3 Filer F F4 Fly PTSF F6 F7 F3 F3 Following DAF F2 F1 F3 Force SIF F7 F3 F1 Force SOF F7 F4 F1 Gen_ovr SAG F7 F1 F3 GIN DIG F2 F4 F3 GIN SIFG F7 ...

Page 113: ... F2 F1 Load CARL F1 F1 F2 F1 Low FUFL F4 F7 F4 F2 Load CL F1 F4 Load ML F5 F3 Load MRL F5 F4 F1 Master DFM F2 F3 F1 Memory M F5 Memory SCPM F7 F2 F2 F2 Mount UCM F8 F2 F2 Move PTSM F6 F7 F3 F4 Nostroke SAN F7 F1 F4 Output DCO F2 F2 F3 Output DO F2 F5 Output SO F7 F4 Password CCP F1 F2 F1 Pause PSP F6 F6 F2 Port_char UCP F8 F2 F3 Position DAP F2 F1 F5 Print FP F4 F4 Profile PTP F6 F7 F2 Program DCP...

Page 114: ...tine PTSR F6 F7 F3 F5 Reten_Mem CAR F1 F1 F2 Save CARS F1 F1 F2 F2 Save CS F1 F5 Save MRS F5 F4 F2 Save MS F5 F5 Search FUS F4 F7 F5 Select DCS F2 F2 F6 Set S F7 Set_def UCS F8 F2 F4 Sing_scan PRS F6 F5 F6 Simulate SAS F7 F1 F5 Slave DFS F2 F3 F2 Startup CCS F1 F2 F3 State PS F6 F6 Statement PTSS F6 F7 F3 F6 Status DAS F2 F1 F7 Step PTS F6 F7 F3 System DIS F2 F4 F4 System DOS F2 F5 F4 System FUAS ...

Page 115: ...y FU F4 F7 Utility U F8 Variable MEV F5 F2 F3 Variable MVV F5 F7 F3 Vars DCV F2 F2 F8 Vars DV F2 F8 View CCV F1 F2 F5 View FUCV F4 F7 F3 F2 View FV F4 F8 View MV F5 F7 View PRV F6 F5 F7 View PTBV F6 F7 F1 F3 View PTPV F6 F7 F2 F4 View PTSV F6 F7 F3 F7 View PV F6 F8 View SCV F7 F2 F3 View SIV F7 F3 F3 View SOV F7 F4 F3 View SUV F7 F6 F3 View UCV F8 F2 F5 View_cal CAV F1 F1 F4 View_io SV F7 F7 Warm ...

Page 116: ...27 variable set by COMAU SYSTEMS is 10 seconds setting this variable to 0 the function is deactivated The Stand by function is automatically deactivated at the first system request to resume motion START RE SUME The Stand by function can be displayed only with the Display Arm Status DAS command which shows the state of the Arm drives as STB instead of ON or OFF When the Stand by function is active...

Page 117: ... if the lever is re leased the brake stops receiving power again and the axis is locked 3 Socket for connection to a power source 4 Harting connector ROBOT SMART X1 1 Selector used to select the axis whose brake is to be released If the Harting connector is connected to connector X2 it is possible to release the brakes of axes 1 4 5 and 6 if it is connected to connector X3 it is possible to releas...

Page 118: ...ripping ITEM DESCRIPTION 1 Main switch with tripping coil 2 Blinker 3 Microswitch for blinker 4 Microswitch for tripping coil 5 Keylock selector switch with return spring on the control board OPERATOR INTERFACE C3G Plus 3 70 05 1199 C3G Plus KIT IVECO ...

Page 119: ...of three red blinking lamps of the discharge type The blinker connected as above mentioned signals the mesh connection of three or two phases by lighting up the corresponding lamp The mesh connection of one phase only is not signalled all the lamps are off The blinker is installed together with a limit switch S110 with three normally closed N C contacts which makes the blinker turn on when the cab...

Page 120: ...This page has been left intentionally blank OPERATOR INTERFACE C3G Plus 3 72 05 1199 C3G Plus KIT IVECO ...

Page 121: ...m external logic machine line 4 6 Output signals towards external logic machine line 4 7 24 Vdc power supplies 4 8 Procedures for command activation with the controller in automatic remote status 4 8 Examples of use of system signals dedicated to transfer interface 4 11 Parallel inputs outputs 4 14 Serial inputs outputs 4 33 Programmes contained in Floppy Disk 3 1 2 C3G CONFIGURATION TOOL 4 33 INT...

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Page 123: ...s INTEGRATION GUIDE 02 1198 4 1 SAFETY SIGNALS If the C3G CSM Controlled Stop Module is installed on the controller in AUTO LOCAL and AUTO REMOTE states an emergency stop and or opening of the safety gates causes con trolled stopping of the robot EN 60204 1 category 1 stop In this way power is cut off opening of the power contactor after 1 second In PROGR programming status the power is cut off im...

Page 124: ...be fitted with a suitable ca ble clamp the cables must be screened and the screening appropriately connected to the ground in order to guarantee electromagnetic compatibility of the system as per directive 89 392 INTEGRATION GUIDE C3G Plus 4 2 01 0498 SAFETY SIGNALS ...

Page 125: ... Logic Used to connect the supply to the equipment through safety relays 66 68 SAFETY RELAY LOGIC CH2 INPUT SAFETY RELAY LOGIC CH2 OUTPUT 48 50 INTERNAL 24 Vdc OUTPUT x INTERNAL 24 Vdc INPUT x Power connection to the safety circuits Bridge x 24 Vdc bridge y 0 V 24 Vdc 49 51 INTERNAL 0 V 24 Vdc OUTPUT y INTERNAL 0 V 24 Vdc INPUT y If the C3G CSM Controlled Stop Module is installed on the controller...

Page 126: ...NGE INP ROBOT ALARM OUT ROBOT ALARM INP Emergency signals towards the robot that must be used for connection of the safety flange and or other devices PIN X92 SMART S2 S3 S4 SIGNALS 1 3 SAFETY FLANGE OUT SAFETY FLANGE INP SYSTEM INPUTS OUTPUTS The C3G Plus cell controller is pre engineered for connection with control devices of the machine line through a specific interface The diagrams and summary...

Page 127: ...C3G Plus INTEGRATION GUIDE 06 0400 4 5 SYSTEM I O ...

Page 128: ...the motor shutdown cy cle normally active is active at low logic level 2 START LED A3 SIM SDIN 11 When the system is in Remote status this is a request to enable the work cycle normally deactivated is activated at high logic level 20 HOLD LED A4 SIM SDIN 12 When the system is in Remote status this is a request to disable the work cycle normally active is active at low logic level 3 21 4 22 U1 LED ...

Page 129: ...M SDOUT 4 When open indicates that an alarm has occurred and has been detected by the control unit no alarm true alarm false 12 TEACH EN DIS LED C8 SIM SDOUT 12 When closed indicates that the system is in Programming status through selection on front panel and has enabled the relevant safety devices reduced speed servo alarm threshold restriction 13 AUTO MAN PTU SDOUT 17 When closed indicates that...

Page 130: ...l unit 1 On the controller the main power switch must be in the ON position the status selector must be in the Remote position relays K16 SIM LOCAL REMOTE pin 11 on X30 and K17 SIM ALARM pin 29 on X30 are closed In the case of an error all the output relay contacts of the SIM module remain open 2 On the remote control panel if the timeout counter has not expired if the status of relay K10 of the S...

Page 131: ...active true HOLD pin 20 on X30 active true the START signal pin 26 on X30 is activated which causes activation of the holdable programmes in stalled For the programme installation procedures refer to the Programming manuals HOLD PROCEDURE This procedure is activated if the machine is in the START status active cycle 1 On the remote panel it activates the HOLD command low logic level pin 20 on X30 ...

Page 132: ...ndicat ing that the system is once again under the control of the remote PLC DRIVE OFF PROCEDURE This procedure is activated if the robot is in Drive ON status 1 On the remote panel the DRIVE OFF command is activated a timer is initialised 2 The controller stops the robot in controlled mode deactivates the START HOLD output pin 26 on X30 switches off power to the motors deactivates the DRIVE ON OF...

Page 133: ...0 2 DRIVE ON INPUT DRIVE OFF INPUT START INPUT X30 20 HOLD INPUT 1 PROGR CODE INPUT 1 PROGR STROBE INPUT 1 PROGR START INPUT X30 B DRIVE ON OFF OUTPUT X30 26 START HOLD OUTPUT X30 11 LOCAL REMO TE OUTPUT X30 29 ALARM OUTPUT X30 53 DRIVE ON OUTPUT PO WER CONTACTOR 1 REC PROG CODE INPUT 5 5 1 PROGR REC OUTPUT ACKNOW LEDG E 1 END OF PROGRAM PROGRAM RUNNING SYSTEM STA RT U P HW TEST O K D RIVE ON C OM...

Page 134: ...IVE ON OFF OUTPUT X30 26 START HOLD OUTPUT X30 11 LOCAL REMOTE OUTPUT X30 29 ALARM OUTPUT X30 12 TEACH EN DIS OUTPUT X30 X30 2 52 53 55 56 DRIVE ON OUTPUT POWER CONTACTOR 1 2 X30 54 250 m sec M AX 3 4 LOCAL HOLD PUSHBUTTON ON THE OPERATOR PANEL 4 H O LD C OM M AN D H O LD STATU S H O LD C O M M R EL R E STAR T C O M M STAR T STAT US LOC AL H OLD C O M M H OLD STAT U S LOC AL H OLD R EST OR E R E S...

Page 135: ...RT INPUT X30 20 HOLD INPUT X30 8 DRIVE ON OFF OUTPUT X30 26 START HOLD OUTPUT X30 11 LOCAL REMOTE OUTPUT X30 29 ALARM OUTPUT X30 12 TEACH EN DIS OUTPUT X30 X30 2 52 53 55 56 DRIVE ON OUTPUT POWER CONTACTOR 1 2 X30 54 250 msec M AX 3 6 H O LD C OM M AN D H O LD STATU S 250 m sec M AX REMOTE HOLD 7 7 X30 13 AUTO MAN ON T P OUT LOC AL STATU S R EM OTE D R IVE OF F H O LD STATU S POW ER C O N TAC TO R...

Page 136: ...e C3G Plus double cabin versions DDMP DDHP two IOM modules are present at the same time The IOM module of Slot 4 will be dedicated to MACHINE 1 and available ex ternally on connector X30 the IOM module of Slot 6 will be dedicated to MACHINE 2 and available externally on connector X30 2 The IOM module which handles 16 inputs and 16 outputs at 24 Vdc of which 16 inputs and 15 outputs avail able to t...

Page 137: ...th an external power supply jumpers JP 200 and JP 201 on the SDB3 module for IOM slot 4 and or SDB3 2 for IOM slot 6 must be set as shown in the following figures The I O s may be powered in sets of eight These groups may be powered with a 24 Vdc power supply inside or outside the control unit Usually the entire module 8 8 outputs and 8 8 inputs is powered using one or the other type of power supp...

Page 138: ... SUPPLY OUTSIDE the C3G Plus 24 Vdc SUPPLY INSIDE the C3G Plus OUT 1 to 8 24 Vcc EXTERNAL X30 1 2 3 JP 200 1 2 3 JP 201 107 108 24 Vdc SUPPLY OUTSIDE THE C3G Plus OUT 1 to 8 24 Vdc SUPPLY INSIDE the C3G Plus 24 Vdc SUPPLY INSIDE the C3G Plus OUT 9 to 16 24 Vdc SUPPLY OUTSIDE THE C3G Plus OUT 9 to 16 ...

Page 139: ...IN 42 74 R E INP 11 DIN 11 DIN 43 75 S F INP 12 DIN 12 DIN 44 76 G INP 13 DIN 13 DIN 45 77 D INP 14 DIN 14 DIN 46 78 P INP 15 DIN 15 DIN 47 79 T INP 16 DIN 16 DIN 48 80 L H OUT 1 DOUT 17 DOUT 49 99 M c OUT 2 DOUT 18 DOUT 50 100 N J OUT 3 DOUT 19 DOUT 51 101 P Y OUT 4 DOUT 20 DOUT 52 102 Z OUT 5 DOUT 21 DOUT 53 103 F OUT 6 DOUT 22 DOUT 54 104 a OUT 7 DOUT 23 DOUT 55 105 b OUT 8 DOUT 24 DOUT 56 106 ...

Page 140: ...HIGH SPEED INPUT L USER AVAILABLE WIRE 6 M USER AVAILABLE WIRE 24 N USER AVAILABLE WIRE 7 P USER AVAILABLE WIRE 20 R USER AVAILABLE WIRE 3 S USER AVAILABLE WIRE 4 Connectors X91 and X92 for SMART S2 S3 S4 INTEGRATION GUIDE C3G Plus 4 18 01 0498 CONNECTOR X92 PIN SIGNAL 1 SAFETY FLANGE 3 SAFETY FLANGE 2 INTERNAL 0 VDC parallel i o basic c3g iom CONNECTOR X90 PIN SIGNAL A 24 Vcc interno B 0 Vcc inte...

Page 141: ... DIN 11 F DIN 12 G DIN 13 H DOUT 17 J DOUT 18 K DOUT 19 L SAFETY FLANGE M1 OUT M 24 Vdc N NOT CONNECTED P DOUT 27 R DOUT 28 S DOUT 29 T SAFETY FLANGE M1 INP U DIN 2 V DIN 3 W DIN 4 X DIN 5 Y DOUT 20 Z GROUND a SHIELD b KSR 1 c KSR 2 CONNECTOR X201 PIN SIGNAL A 24 Vdc B 0V 24Vdc C DIN 6 D DIN 14 E AVAILABLE F DOUT 22 G DOUT 23 H DOUT 24 J DOUT 21 K DIN 1 L DOUT 25 M DOUT 26 N DIN 7 P DIN 15 R AVAIL...

Page 142: ...ADDITIONAL I O MODULES The additional I O modules inserted in the Control Unit CU rack have a front connector usually identified as J3 which is connected by a harness and a 64 PIN HARTING connector located on the front panel of the con troller in the provisions reserved for additional connectors identified as X31 for the first module X32 for the second and so on in rising order INTEGRATION GUIDE C...

Page 143: ...Additional I O modules C3G Plus INTEGRATION GUIDE 01 0498 4 21 parallel i o additional modules ...

Page 144: ...hat for installations in Italy the conductors must comply with CEI 20 22 standards second part if the COMAU cable is not used conductors with equivalent electrical characteristics and com plying with UL 758 VW1 standards must be used Failure to comply with the above instructions results in non compliance with the UL approval standard of the module to which the cable is connected The maximum permis...

Page 145: ...Number of common returns 24 Vdc 2 Fuses one for each common return 5 A 250 V Normal Blow Type of output transistor Operating voltage 4 5 to 36 Vdc Maximum output current with all channels active 0 5 A ta 25 C 0 4 A ta 45 C SIGNAL ALLOCATION SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE IOM MOD SYSTEM CONFIG AC OUTPUT 1...

Page 146: ...EXAMPLE OF USE OF THE IOMs MODULE IN HANDLING A MULTI MACHINE SYSTEM INTEGRATION GUIDE C3G Plus 4 24 01 0498 PARALLEL I O C3G IOMS ...

Page 147: ... LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE INPUT 1 A1 A1 A1 INPUT 17 C1 C1 C1 INPUT 2 A2 A2 A2 INPUT 18 C2 C2 C2 INPUT 3 A3 A3 A3 INPUT 19 C3 C3 C3 INPUT 4 A4 A4 A4 INPUT 20 C4 C4 C4 INPUT 5 A5 A5 A5 INPUT 21 C5 C5 C5 INPUT 6 A6 A6 A6 INPUT 22 C6 C6 C6 INPUT 7 A7 A7 A7 INPUT 23 C7 C7 C7 INPUT 8 A8 A8 A8 INPUT 24 C8 C8 C8 INPU...

Page 148: ...arity inversion Through diode SIGNAL ALLOCATION SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE INPUT 1 A1 A1 A1 INPUT 17 C1 C1 C1 INPUT 2 A2 A2 A2 INPUT 18 C2 C2 C2 INPUT 3 A3 A3 A3 INPUT 19 C3 C3 C3 INPUT 4 A4 A4 A4 INPUT 20 C4 C4 C4 INPUT 5 A5 A5 A5 INPUT 21 C5 C5 C5 INPUT 6 A6 A6 A6 INPUT 22 C6 C6 C6 INPUT 7 A7 A7 A7...

Page 149: ...gainst transients Through diode SIGNAL ALLOCATION SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE OUTPUT 1 A1 A1 A1 OUTPUT 17 C1 C1 C1 OUTPUT 2 A2 A2 A2 OUTPUT 18 C2 C2 C2 OUTPUT 3 A3 A3 A3 OUTPUT 19 C3 C3 C3 OUTPUT 4 A4 A4 A4 OUTPUT 20 C4 C4 C4 OUTPUT 5 A5 A5 A5 OUTPUT 21 C5 C5 C5 OUTPUT 6 A6 A6 A6 OUTPUT 22 C6 C6 C6 OU...

Page 150: ...on from transistors by diode SIGNAL ALLOCATION SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE OUTPUT 1 A1 A1 A1 OUTPUT 17 C1 C1 C1 OUTPUT 2 A2 A2 A2 OUTPUT 18 C2 C2 C2 OUTPUT 3 A3 A3 A3 OUTPUT 19 C3 C3 C3 OUTPUT 4 A4 A4 A4 OUTPUT 20 C4 C4 C4 OUTPUT 5 A5 A5 A5 OUTPUT 21 C5 C5 C5 OUTPUT 6 A6 A6 A6 OUTPUT 22 C6 C6 C6 OUTPU...

Page 151: ...d 6 0 mA at 60 C Maximum voltage drop with 0 5 A load 1 8 Vac Maximum output current CHANNELS ACTIVE CURRENT CURRENT SIMULTANEOUSLY ta 25 C ta 45 C 16 1 A 0 4 A Supply frequency 47 to 63 Hz SIGNAL ALLOCATION SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE OUTPUT 1 A1 A1 A1 OUTPUT 9 C1 C1 C1 OUTPUT 2 A2 A2 A2 OUTPUT 10 C2...

Page 152: ...il 24 Vdc 10 Maximum contact resistance With 0 5 to 2 A current With 10 to 500 mA current Maximum output current CHANNELS ACTIVE RESISTIVE INDUCTIVE SIMULTANEOUSLY LOAD LOAD CURRENT CURRENT ta 45 C ta 45 C AC DC AC DC 8 2A 1A 0 85A 16 1 5A SIGNAL ALLOCATION SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE OUTPUT 1 A1 A1 A...

Page 153: ...S DIGITAL OUTPUTS ANALOGUE OUTPUTS Number of inputs 8 Number of common earths 1 Input voltages for channel activation 14 0 to 36 0 Vdc Input voltage for channel deactivation 0 0 to 5 0 Vdc Input current with channel activated 2 0 to 15 mA Maximum input current with channel not activated 0 5 mA Protection against polarity inversion Through diode Number of outputs 8 Number of common outputs 1 Fuse o...

Page 154: ...ly as the load or separately if high precision of the signal on the load device is required 1 Common power supply This type of connection requires the use of a single power supply connected both to the load device and to the optoisolated section of the analogue outputs 0 V must be connected to earth on the terminal of the power supply INTEGRATION GUIDE C3G Plus 4 32 00 1097 PARALLEL I O C3G ADM ...

Page 155: ...ry to provide an intersection at right angles Do not lay the cable on surfaces subject to vibration Do not bend the cable with bending radii that are too small SIGNAL ALLOCATION SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE SIGNAL RED LED CONN J3 PIN MOD FRONT CONN X3X PIN CABINET BASE INPUT 1 A1 A1 A1 OUTPUT 1 C1 C1 C1 INPUT 2 A2 A2 A2 OUTPUT 2 C2 C2 C2 INPUT 3 A3 A3 A3 OUTPUT 3 ...

Page 156: ...t 3 FTPCNFG CPK FTP_INST COD FTP_INST DOC This programme enables file transfer protocol FTP configuration 4 IBSM COD IBSM1 COD IBSM DOC This programme makes it possible to configure and diagnose the IBS M board INTERBUS S MASTER 5 RICNFG CPK RI_INST COD RI_INST DOC This programme makes it possible to enter certain parameters concerning the serial management protocols of remote I O s IBS L2 RIO and...

Page 157: ...d sent to execution by PROGRAM GO after loading the program HELPIO2 COD to the memory by MEMORY LOAD 15 COMAFEAF GSD Makes it possible to configure the DP SLAVE Profibus on PLC 16 COMAO4A1 GSD Enables configuration of card PF DP by means of the PLC 17 C3G_EDN EDS It permits to configure DeviceNet from PLC C3G Plus INTEGRATION GUIDE 06 0400 4 35 SERIAL I O AND PDL2 TOOLS ...

Page 158: ...This page has been intentionally blank INTEGRATION GUIDE C3G Plus 4 36 06 0400 SERIAL I O AND PDL2 TOOLS ...

Page 159: ...odes 5 1 System statuses 5 1 System status in multimachine multiarm configuration 5 4 Robot movement in programming status 5 5 File management between PC and cell controller 5 10 Use of the Floppy Disk unit 5 11 Examples of the use of digital I O s and analogue outputs 5 12 Calibration 5 13 Kinematic compensation algorithm 5 19 MAIN OPERATIONS FOR SYSTEM USE C3G Plus Operations and Maintenance Man...

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Page 161: ... button on the programming terminal If the status selector is at pro gramming the enable button should also be kept pressed to power the drives To turn the drives off and activate the brakes for all the robots connected to the controller simply release the enable button SYSTEM STATUSES The status the system is in mainly depends on the status selector on the control panel the optional AUTO MAN sele...

Page 162: ...OLD status has been caused by pressing the DRIVE OFF button on the programming terminal it will be necessary to press the DRIVE OFF and HOLD buttons again to exit the HOLD status and the DRIVE ON button to re enable the drives AUTO status For the system to be in the AUTO status the status selector on the control panel must be in the automatic lo cal or automatic remote position In the AUTO status ...

Page 163: ...ll request this button to be pressed switching of the AUTO MAN on the programming terminal or of the status selector on the control panel It will then be necessary to press the HOLD button to return to the AUTO status All the conditions that cause HOLD from AUTO such as pressing the HOLD or DRIVE OFF buttons also remain valid PROG status The PROG status is obtained when the status selector is set ...

Page 164: ... the axes which form the three ARMS are enabled motors on Management with the IOMs module inserted in the CONTROL UNIT rack when the DRIVE ON key on the PTU4 is pressed it is possible to activate both machines or from the remote panel managed by the IOMs module MACHINE 1 MOTOR ON MACHINE 1 or MACHINE 2 MOTOR ON MACHINE 2 Then depending on the case both power contactors are closed which supply the ...

Page 165: ...troller has three system variables BASE TOOL and UFRAME which make it possible to de scribe the main co ordinate transformations Before proceeding with the explanation of these transforma tions definition of some reference terns is necessary World tern Reference tern of the workshop with respect to which the machines are positioned Base tern Tern that indicates the robot base User tern Tern that i...

Page 166: ...z reference tern or TCP tern The first three keys allow linear movements in the direction of the three tool reference system axes defined by TOOL variable the next three keys allow rotation of the tool around the same axes keep ing the position of the TCP tool work point unchanged Usr linear movement mode according to the user x y z reference tern for example the tern that de scribes the piece bei...

Page 167: ...on the status line arm 1 if 1 2 and arm 2 if 1 2 It is possible to change the direction of the arrow pressing the ARM key in DRIVE ON status it has this function only if the arms were both in DRIVE ON For manual movement of integrated arms a particular case of the multi arm system see the special chapter in the C3G Programming guide manual MANUAL MOVEMENT IN WRIST_JNT MODE In movement of certain t...

Page 168: ...programme but it is also possible to allocate them di rectly in the instruction line of the EXECUTE command Two ways of allocating the destination point which are particularly useful for set up and maintenance are described below A Cartesian destination point can be allocated through the built in POS which allows the three co ordinates x y and z in which to take the TCP the three tool direction an...

Page 169: ...t of the TCP all the arm axes can move MOVE ARM 2 JOINT TO 90 movement of the second arm which moves only axis 1 to the 90 degrees position in the negative direction MOVE CIRCULAR TO POS 100 100 0 0 0 0 VIA POS 0 200 0 0 0 0 pre defined arm movement which joins the start ing point at POS 100 100 0 0 0 0 with a cir cumference that passes through POS 0 200 0 0 0 0 Before performing a movement it is ...

Page 170: ...Type destination file name RD FILE_NAME and press ENTER on the PC at the end of the opera tion the word Done Items between round brackets may be omitted TRANSFERRING FILES FROM CONTROLLER TO PC Typing the command ALT D on the PC it is possible to see change the directory selected Type the command FC Filer Copy RD FILE_NAME and press ENTER on the PC the following message will be displayed Destinati...

Page 171: ...OPT After activating the characters menu type in RD followed by the name of the file to be copied The programming terminal display shows the following message Destination file name After activating the characters menu type in FD followed by the name of the file to be copied FILE TRANSFER FROM FLOPPY DISK TO RAM DISK Press the programming terminal key TOP to return to the main menu and type the com...

Page 172: ... first channel and following for all the others If the ADM module is not the first I O module in the rack the numbering follows the standard one of the modules before it Notes on the Write Modes of ADM MODULE Analogue Outputs The resolution of the analogue outputs is 11 bits from 0 to 10 Vdc justified at the left with 4 bits there fore the word writing mask is the following Where the WORD writing ...

Page 173: ... check is performed on the resolver turn numbers For this reason the user is advised to put the arm in the DRIVE OFF state before switching the system off RECONSTRUCTION OF THE AXIS POSITIONAL VALUE when the controller is turned on the system software reconstructs the axes positional values among the various initialisations The system software verifies this value checking that the difference betwe...

Page 174: ...ity of the user who must provide the instruments to check the positioning of the robot for any subsequent recalibration in particular as regards the position of the reference indexes On some types of robot calibration notches are used instead of reference indexes TURN SET the Turn set operation must be performed when the RPT module optional and or the con trol unit lose the count of the resolver r...

Page 175: ... with the controller off without RPT The operator must move the robot onto the reference indexes as accurately as possible if the robot is not positioned correctly the system alerts the operator with the 59409 SAX joint position not suffi ciently accurate error and then with the 59421 SAX positive adjustment is required error and or with the 59422 SAX negative adjustment is required error Once the...

Page 176: ...ration must be performed with the robot posi tioned on the reference indexes The 61441 SAX incorrect resolver reading error requires switching off the control unit If the error has also caused the RPT module if present to lose the count at the subsequent restart the Turn set opera tion must be performed with the robot positioned on the reference indexes If the control unit has lost the calibration...

Page 177: ...S AXES POS IT ION CAL_DATA SHARED MEMORY RPT option CARS CARL C S C L FILE C3G SYS RAM DISK 4 5 C3G Plus RBC2 7 PRINT ER 1 2 TURN_SET command CALIBRATION command Saving the CALIBRATION CONSTANTS 3 4 5 6 7 in Flash Eprom S AU2 in RPT option in RAM DIS K C3G S YS file in RAM DIS K CALIB1 T XT calibration AS CII file printer hardcopy ROBOT ON INDICES FLASH EPROM SAU2 3 CARL CARS CALIBRAT ION AS CII F...

Page 178: ... it possible to bring the robot to its zero position with a sufficient degree of accuracy however should it be necessary to calibrate the robot or after mechanical disassembly operations that affect the robot geometry special tools must be used The robot calibration procedure depends on the type of robot connected to the control unit refer to the spe cific manual supplied with the robot MAIN OPERA...

Page 179: ...L The teach pendant or PC video will display a binary num ber counting from the right bit 23 if set at 1 indicates consent to enable the compensation software while bit 22 if set at 1 indicates active compensation Moreover it is possible to check whether the off set has been activated using the Configure Controller View command if the offset is activated Y will be displayed in the last column for ...

Page 180: ... obtained through the built in features PDL2 Hdinpos represents the position of the NOMINAL robot For correct robot programming with active compensation the system variable value CNFG_CARE should be kept at TRUE As the wrist fitted on the H4 robot is not round when compensation is applied near the wrist singularity after an instruction of the type Move to 0 25 75 0 12 0 the Joint Display shows 0 2...

Page 181: ...1 MAIN OPERATIONS FOR SYSTEM USE 5 1 EMERGENCY PROCEDURES 6 1 MAINTENANCE 7 1 SUMMARY Paragraph Page Cutting off alarms using the EXCL key on PTU4 6 1 Use of the PTU4 as emergency terminal 6 1 Use of the BRAKE RELEASE DEVICE 6 3 EMERGENCY PROCEDURES C3G Plus Operations and Maintenance Manual ...

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Page 183: ...seconds At a change of status Programming Automatic or DRIVE ON DRIVE OFF USE OF THE PTU4 AS EMERGENCY TERMINAL Only for Rel 1 x Through the use of the PTU4 and the insertion of a special connector it is possible to activate manual emer gency movement In this mode the control electronics CONTROL UNIT is excluded and it is possible to move the robot axes one by one at low speed Normally the cell co...

Page 184: ...apter 1 of this manual Robot motion in the Emergency status cannot be uniform Move the robot axes in the most suitable direction to take it back to the normal position paying particular attention to the direction of movement If the robot has overstepped the limit switches movement is only allowed in the opposite di rection to the tripped limit switch Activate the robot motors DRIVE ON Move the rob...

Page 185: ... and the robot therefore all the system safety devices are cut off The brake release operation through C3G BRD must be performed only by skilled personnel Depending on the axes to be moved they may fall due to the effect of gravity slinging the robot is recommended PROCEDURE 1 Deactivate the control unit setting the main switch to OFF 2 Disconnect the motor cable from connector X2 X2 EXT and X3 at...

Page 186: ...ry out 5 Release the brakes using the device and selecting the chosen axis letting go of the release lever the axis stops because the 24 Vdc is cut off 6 Free the axis from the abnormal position 7 Remove the C3G BRD device 8 Restore any damage suffered by the axis 9 Carry out the TURN_SET operation see chapter 2 step 11 of the installation procedure 10 Restore normal system working conditions EMER...

Page 187: ...ntenance 7 3 Main C3G Plus versions SDLP SDMP SDHP connections 7 5 Main C3G Plus versions DDMP DDHP connections 7 14 Diagnostics 7 25 Troubleshooting indications 7 38 Fuses and protections 7 39 Circuit diagrams 7 41 Control Unit 7 43 C3G DBU3 module 7 49 C3G BKM module 7 50 C3G MPI module 7 51 C3G RPT module optional 7 52 Servo Amplifiers Unit SAU2 7 54 System software loading 7 60 List of spare p...

Page 188: ...This page has been intentionally blank Operations and Maintenance Manual C3G Plus ...

Page 189: ...d be touched only holding them by their fastening screws All tripped protection fuses must be replaced only by equivalent ones specified by the manufacturer The use of unspecified fuses may cause danger for the operators and faulty controller operation In the event of cable replacement restore the connections of any screens disconnected previously The replaced cable must bear the COMAU code corres...

Page 190: ...This page has been left intentionally blank MAINTENANCE C3G Plus 7 ii 00 1097 GENERAL RULES ...

Page 191: ...d be checked periodically every 3 months measuring the no load voltage that is not to drop below 3 86 V The CONTROL UNIT buffer battery must be replaced every three years of operation proceeding as follows Open the left cabin door Move the back up battery switch above the Control Unit to OFF Slacken the knobs fastening the back up battery support to the Control Unit remove and disconnect the conne...

Page 192: ...This page has been left intentionally blank MAINTENANCE C3G Plus 7 2 00 1097 PREVENTIVE MAINTENANCE ...

Page 193: ...ERSIONS Main C3G Plus connections Power supply distribution Axes control circuit Serial and parallel line connections Internal external safety device layout System Inputs Outputs User Inputs Outputs DIAGNOSTICS Tests when system is switched on Diagnostic levels Safety circuit test device OPERATING PROBLEMS Help tables for solving operating problems PROTECTIONS Fuses and protections Electromechanic...

Page 194: ...and meaning SAU2 main components layout Additional axes Soft start circuit enabling disabling Axes electric limit switch enabling disabling Replacements SYSTEM SOFTWARE System software loading Subsequent system software loading with same version or later versions Software operations for robot replacement Software operations for controller replacement Software operations for updating characterisati...

Page 195: ...Main C3G Plus Connections C3G Plus MAINTENANCE 08 0702 7 5 FUNCTIONAL LAYOUTS C3G Plus sdlp sdmp sdhp VERSIONS ...

Page 196: ...Power Supply Distribution Page 1 of 2 MAINTENANCE C3G Plus 7 6 04 0799 FUNCTIONAL LAYOUTS C3G Plus sdlp sdmp sdhp VERSIONS Machine line Robot Only for Rel 1 x ...

Page 197: ...Power Supply Distribution Page 2 of 2 C3G Plus MAINTENANCE 00 1097 7 7 FUNCTIONAL LAYOUTS C3G Plus sdlp sdmp sdhp VERSIONS ...

Page 198: ...Axes Control Circuit MAINTENANCE C3G Plus 7 8 00 1097 FUNCTIONAL LAYOUTS C3G Plus sdlp sdmp sdhp VERSIONS ...

Page 199: ...Serial and Parallel Line Connections C3G Plus MAINTENANCE 04 0799 7 9 FUNCTIONAL LAYOUTS C3G Plus sdlp sdmp sdhp VERSIONS Only for Rel 1 x ...

Page 200: ...Internal External Safety Device Layout Page 1 of 2 MAINTENANCE C3G Plus 7 10 08 0702 FUNCTIONAL LAYOUTS C3G Plus sdlp sdmp sdhp VERSIONS ...

Page 201: ...Internal External Safety Device Layout Page 2 of 2 C3G Plus MAINTENANCE 08 0702 7 11 FUNCTIONAL LAYOUTS C3G Plus sdlp sdmp sdhp VERSIONS ...

Page 202: ...System Inputs Outputs MAINTENANCE C3G Plus 7 12 04 0799 FUNCTIONAL LAYOUTS C3G Plus sdlp sdmp sdhp VERSIONS excluded SMART H4 X200 on SMART H4 X8 H4 Spot X9 H4 Handling ...

Page 203: ...User Inputs Outputs C3G Plus MAINTENANCE 04 0799 7 13 FUNCTIONAL LAYOUTS C3G Plus sdlp sdmp sdhp VERSIONS excluded SMART H4 for SMART H4 ...

Page 204: ...Main C3G Plus Connections DDMP DDHP Versions MAINTENANCE C3G Plus 7 14 01 0498 FUNCTIONAL LAYOUTS C3G Plus ddmp ddhp VERSIONS ...

Page 205: ...Power Supply Distribution Page 1 of 2 C3G Plus MAINTENANCE 01 0498 7 15 FUNCTIONAL LAYOUTS C3G Plus ddmp VERSIONS ...

Page 206: ...Power Supply Distribution Page 2 of 2 MAINTENANCE C3G Plus 7 16 01 0498 FUNCTIONAL LAYOUTS C3G Plus ddmp VERSIONS ...

Page 207: ...Machine 1 Axes Control Circuit C3G Plus MAINTENANCE 01 0498 7 17 FUNCTIONAL LAYOUTS C3G Plus ddmp VERSIONS ...

Page 208: ...Machine 2 Axes Control Circuit MAINTENANCE C3G Plus 7 18 04 0799 FUNCTIONAL LAYOUTS C3G Plus ddmp VERSIONS ...

Page 209: ...Serial and Parallel Line Connections C3G Plus MAINTENANCE 04 0799 7 19 FUNCTIONAL LAYOUTS C3G Plus ddmp VERSIONS ...

Page 210: ...Internal External Safety Device Layout Page 1 of 2 MAINTENANCE C3G Plus 7 20 08 0702 FUNCTIONAL LAYOUTS C3G Plus ddmp VERSIONS ...

Page 211: ...Internal External Safety Device Layout Page 2 of 2 C3G Plus MAINTENANCE 08 0702 7 21 FUNCTIONAL LAYOUTS C3G Plus ddmp VERSIONS ...

Page 212: ...System Inputs Outputs MAINTENANCE C3G Plus 7 22 04 0799 FUNCTIONAL LAYOUTS C3G Plus ddmp VERSIONS X200 for SMART H4 X8 H4 Spot X9 H4 Handling ...

Page 213: ...User Input Output IOM Slot 4 C3G Plus MAINTENANCE 04 0799 7 23 FUNCTIONAL LAYOUTS C3G Plus ddmp DDHP VERSIONS excluded SMART H4 for SMART H4 ...

Page 214: ...User Input Output IOM Slot 6 MAINTENANCE C3G Plus 7 24 04 0799 FUNCTIONAL LAYOUTS C3G Plus ddmp ddhp VERSIONS excluded SMART H4 for SMART H4 ...

Page 215: ...roprocessor 68020 ROM checksum checks that the checksum on the BootROM is correct RAM test checks each single word of the local and shared RAM It is not a destructive test as it stores and recovers the original contents of the RAM The shared RAM is checked from every board to verify that it can be accessed by all boards Timer test checks the interval timers for accurate synchronisation UART test c...

Page 216: ...m 5 CPU test 6 TOD clock 7 DSP test 8 Image register test 9 DS WD image register test 10 JMP image register test 11 MCR image register test 12 FORCE image register test 13 Shadow image register test 14 GCSR test 15 Timer test 16 Data bus test 18 Address line test 20 Memory protection test 21 Floating point compressor test UNFORESEEN ASYNCHRONOUS EVENT CODES In this case the secondary code represen...

Page 217: ...e tests that are performed during system initialisation by modules RBC2 RBC0 and SCC2 SCC0 The tests of modules RBC2 and SCC2 are not displayed at the same time on the display of the PTU4 but one at a time in the following order 1 Local Diags on Board RBC0 2 Diagnostics on Board SCC0 PTU4 Display during System Initialisation C3G Plus MAINTENANCE 00 1097 7 27 CICLO LED ON OFF Pausa Lunga Codice Pri...

Page 218: ...t due to high temperature Timer 2 fault Bus time out fault Unexpected interrupt Unexpected bus error Diagnostics test being run Bus interface fault AC power fail test not passed RESET register fault I O Base fault Physical address register fault Logical address register fault Exception register fault Output register fault System fail generator fault Cooperative test fault Internal DMA SCC fault Un...

Page 219: ...r 11 seriousness level DRIVE OFF effect on controller status Safety gates or Emergency stop text of message with fault detected on the system Below is a list of the levels of seriousness of the system and their meaning Level of se riousness Meaning Effect of Problem Reset Action 00 Informative message None 01 Informative message None 02 Warning No effect on control status 03 Not used 04 PDL2 progr...

Page 220: ...mes DEACTIVATE and in terrupts all system soft ware Reset re supplying the control system or using the CONFIGURE CNTRLER RESTART WARM command The message text between the higher and lower than symbols is replaced by specific error information Through the PCINT programme it is possible to display on the personal computer all the controller error mes sages with the explanation of the cause and remed...

Page 221: ...SAFETY CIRCUIT TEST DEVICES Connector X113 test device C3G Plus MAINTENANCE 04 0799 7 31 diagnostic C3G Plus ...

Page 222: ...4Vdc present E Stop button on control panel OK Off Internal SIM or external 24Vdc failure E Stop button on control panel pressed SIM module V1 Power supply fuse F116 check X30 connection if external 24Vdc is used E Stop button on control panel pressed TP3 TP4 On E Stop button on PTU4 OK Off E Stop button on PTU4 pressed E Stop button on PTU4 pressed TP6 TP7 On Enable button on PTU4 pressed in PROG...

Page 223: ...ON ENABLE Off relay K6 SIM TP21 On safety flange and robot 1 alarm OK Off safety flange or robot 1 alarm relay K2 K3 SIM TP30 On safety flange and robot 2 alarm if present OK Off safety flange or robot 2 alarm relay K7 K8 SIM TP22 TP23 On Control unit OK electronics on Off relay K9 SIM TP24 TP25 On safety relay on RBC2 module OK Off safety relay on RBC2 module TP26 TP27 On safety relay on SCC2 and...

Page 224: ...and safety relay contacts of modules RBC2 SCC2 and SAU2 are OK without turning the robot motors on The 2nd microswitch in the centre of the connector test device is to temporarily bridge the safety relays of module SCC2 and SAU2 machine 1 thus locating the cause of the problem The 3rd microswitch at the bottom of the connector test device is for temporarily bridging the safety relays of module SCC...

Page 225: ...X30 connector test device C3G Plus MAINTENANCE 01 0498 7 35 diagnostic ...

Page 226: ...2 U3 U4 Represent 4 digital input signals SDIN 13 14 15 16 available to the user Bistable It works in AUTOMATIC Local and AUTOMATIC Remote OPTIONAL SAFETY STOP This is to check the safety circuit if installed if not it has no function BISTABLE It works in AUTOMATIC Local and AUTOMATIC Remote MEANING OF THE LEDS START HOLD It turns on when the START microswitch has been pressed in AUTOMATIC Remote ...

Page 227: ...p part of the device see previous figure make it possible to connect the controller safety provisions also during system installation The diagram on the right hand side of the connector shows the various connections to be made for perform ing these operations for further information refer to chapter 2 step 7 of the installation procedure in this manual CONNECTIONS ON THE FIRST WEIDMULLER CONNECTOR...

Page 228: ...status Check whether the motor windings are open or in short circuit Short circuit or open circuit check on motor wiring from SAU2 to motor If there is no short circuit or open circuit replace the Axis power module C3G Plus and Robot Circuit Diagram SAU2 signals tables on Cir cuit diagram Consult cause remedy with PCINT programme 61442 11 SAX xxx following error out of range During a movement of t...

Page 229: ... Vac monophase supply for conditioner op tional F108 250V 1 5kA 6 3A time lag fuse Supplies SAU 2 CU power module PWR3 backup module BKM SAU2 and BKM fans E110 E111 F109 F110 F111 250V 1 5kA 6 3A time lag fuse 19 Vac three phase supply for services 24 Vdc power module V1 F113 250V 1 5kA 4A Quick Acting Fuse 24 Vdc internal supply to robot external field X30 CU fans IOM module F116 250V 1 5kA 2A Qu...

Page 230: ...pped Thermal probe S2 warnings terminal strip X120 With versions DDMP DDHP of the C3G Plus the thermal probe S2 terminals are in terminal strip X119 TERMINAL LED WARNING 33 RED OFF Thermal probe S2 for protection of transformer T100 trip ped 36 RED ON Presence of 24 Vdc supply for thermal probe S2 33 36 WARNING ON ON 24 Vdc supply present OFF ON Thermal probe S2 tripped OFF OFF 24 Vdc supply absen...

Page 231: ...he documentation for the robot system in special folders separate from the controller circuit diagrams EXAMPLE C3G Plus MAINTENANCE 01 0498 7 41 CIRCUIT DIAGRAMS SCHEMI ELETTRICI APPLICATION BOX SCHEMI ELETTRICI CELLA SCHEMI ELETTRICI ALLESTIMENTI ATTREZZATURE ROBOT CIRCUIT DIAGRAM CONTROL SYSTEM CIRCUIT DIAGRAM APPLICATION BOX CIRCUIT DIAGRAMS CELL CIRCUIT DIAGRAMS FITTINGS EQUIPMENT CIRCUIT DIAG...

Page 232: ...This page has been left intentionally blank MAINTENANCE C3G Plus 7 42 00 1097 CIRCUIT DIAGRAMS ...

Page 233: ...upply output measurement referring to black GND test point 12 V RED Makes it possible to check the presence of 12V at the power supply output measurement referring to black GND test point 12 V RED Makes it possible to check the presence of 12V at the power supply output measurement referring to black GND test point GND BLACK Reference test point for measurement on all the other test points AC FAIL...

Page 234: ...hen the RBC module carries out the Master functions of the VME Bus SYF RED It turns on when a fault has been detected at VME Bus or VME master board SYSFAIL level SFT RED It turns on when the safety chain relay is opened RBC Module Connectors Connector Pin no Functions J3 female 25 FDU SERIAL LINE serial line EIA RS232 RS422 with modem signals for connection with Floppy Disk Unit RS422 or with the...

Page 235: ... of the diagnostic tests performed by the microprocessor if no module operating faults have been located WDG RED Turns on after the cutting in of the watchdog circuit for microprocessor malfunctioning BMS GREEN This is on when the SCC module performs VME Bus Master functions SYF RED Turns on when an error is detected at VME bus or VME master board SYSFAIL level SFT RED Turns on when the safety cha...

Page 236: ...he operating system for a maximum of 1 hour during operations of this type Insert the ANNEX completely on the connectors on the SCC2 module after inserting the annex screw spacer pressing in correspondence of the connectors and avoiding touching the components with the fingers Insert the SCC2 module in the special rack slot taking care not to damage the components assembled on both faces hold ing ...

Page 237: ...teach to remote OUT 12 D1 D2 D3 D4 D5 D6 D7 D8 FUSE RED ROSSO RED RED RED RED RED RED RED Alarm to remote OUT 4 DRIVE ON command OUT 1 DRIVE ON enable OUT 2 Spare external output OUT 3 Alarms inhibit OUT 5 Alarm OUT 7 System ON OUT 8 Low voltge during prog OUT 6 Monitor fuse 1 INP FUSE SIM Module connectors Connector Pin no Functions J3 female 15 CONNECTOR WITH OPERATOR PANEL Carries the following...

Page 238: ...G RLO 16 AC 2A Relay Output Module C3G ADM 2 Analogue Output 8 DC Input 8 DC Output The description layout meaning of the leds and instructions for connecting the modules are given in chapter 4 Guide to integration of this manual REPLACEMENTS Specific cautions Comply with the GENERAL RULES FOR MAINTENANCE given in this chapter Special tools unnecessary MAINTENANCE C3G Plus 7 48 07 1200 INPUT OUTPU...

Page 239: ... the GENERAL RULES FOR MAINTENANCE given in this chapter In module replacement operations Open the control unit main switch Disconnect the connection cables to the DC Bus from terminal strip X119 Disconnect connector X114 on the DBU3 module Slacken the fastening screws and remove the module carefully Insert the new module positioning the connection cables accurately Connect the cables of the modul...

Page 240: ...e carrying out any work consider a discharge time of at least 11 minutes for the module condensers The BKM module in the rear compartment of the C3G Plus is connected to connector X1 of module C3G PWR3 of the Control Unit rack in the front part of the controller Before replacing it disconnect con nector X1 remove the module cover disconnect the cables corresponding to connector X1 from termi nal s...

Page 241: ...oard the robot Motor pole detection is active in accordance with a provision made on the motor special jumper LAYOUT REPLACEMENTS Specific cautions Comply with the GENERAL RULES FOR MAINTENANCE given in this chapter If the RPT module optional is present take the utmost care in disassembling the MPI module to avoid any contacts that would damage the RPT module which is sensitive to electrostatic di...

Page 242: ...e Constructively the RPT module is made on two boards RPT MAIN and RPT ANNEX which are interlinked SWITCH SW1 CONFIGURATION Switch SW1 configuration on RPT ANNEX board 1 2 3 4 Description ON ON x N O T U S E D 1200 baud OFF ON x 2400 baud ON OFF x 4800 baud OFF OFF x 9600 baud x x ON RPT n 1 x x OFF RPT n 2 Switch SW1 configuration on RPT MAIN board 1 2 3 4 Description Tx Rx ON ON x x Closing of t...

Page 243: ...ser vices cables connected and with the control unit main switch at ON The protection fuses inside the module must be replaced only by equivalent ones specified by COMAU the use of other fuses may cause danger to the operators and control unit malfunctioning for which COMAU undertakes no liability The replacement of protection fuses with others not foreseen by COMAU refer to parts list does not gu...

Page 244: ...rack with the number of the axes and ratings of the power element associated with them Model Description P N Composition Model 1 C3G SAU2 6 Axes S robot Servo Amplifier 10910180 Ax1 Ax2 Ax3 15 45 Ax4 Ax5 Ax6 4 12 Model 2 C3G SAU2 6 Axes H robot Servo Amplifier 10910280 Ax1 Ax2 Ax3 40 120 Ax4 Ax5 Ax6 15 45 Model 3 C3G SAU2 3 Axes S robot Servo Amplifier 10910380 Ax1 Ax2 Ax3 15 45 Ax4 Ax5 Ax6 option...

Page 245: ... additional module can control an Axis 7 slide or external axis or an Axis 8 usually used as motor for the power gripper The position of the module is indicated on the stencilled plate on the drive front panel According to the application either the wires marked as Axis 7 or those marked as Axis 8 are to be con nected to the drive module Those not used are to be connected to the back up terminal b...

Page 246: ...he 24 Vdc of the brakes for releasing the brakes on board robot ENA1 ENA2 ENA3 ENA4 ENA5 ENA6 ENA7 ENA8 green green green green green green green green Off indicates that the corre sponding axis is disabled Flashing indicates that the system is initialising axis self recognition On indicates that the corre sponding axis is enabled MAINTENANCE C3G Plus 08 0702 7 56 SERVO AMPLIFIERS UNIT SAU2 ...

Page 247: ...Indicates that all the cur rents are present J8 50 way connector Makes the interface towards SCC2 through two buses one analogue and the other digital Through the analogue bus SAU2 receives two current references at 120 for each axis controlled Through serial bus EIA RS 485 SAU2 receives commands and gives answers on alarm statuses PWM SYNC reference signal 19 53 kHz for generating PWM command SFT...

Page 248: ...lable including assembly instructions and composed as mentioned in the SAU2 CONFIGURATIONS paragraph When connecting the power modules the phase sequence necessary is U V W When working on the SAU2 follow the rules of safety and the instructions given in the re placements paragraph MAINTENANCE C3G Plus 00 1097 7 58 SERVO AMPLIFIERS UNIT SAU2 ...

Page 249: ...rsons carrying out maintenance or repairs on the SAU2 as abnormal conditions for correct system opera tion may result REPLACEMENTS Specific cautions Carefully follow the GENERAL RULES FOR MAINTENANCE The assembly instructions are included with the components to be replaced Before doing any maintenance work on the SAU2 wait for the DC BUS condensers to discharge discharge time 6 minutes after openi...

Page 250: ...sert the C3G Plus SYSTEM SOFTWARE disk 1 3 in the Floppy Disk unit Turn on the controller moving the main switch to ON The system starts automatically and after an initial test it starts loading the operating system When the programming terminal displays the following flashing message Press any key to continue press any key twice You will then be asked to insert disks 2 3 and 3 3 Insert the disks ...

Page 251: ... OPERATIONS 1 Using the FD Filer Delete command erase the backup files of the user programmes from the C3G RAM DISK COMMAND FD TYPE bk or press and select bk 2 Make a backup of the C3G RAM DISK on Personal Computer or on integrated floppy disk by copying all the files with the FUB Filer Utility Backup command If the PC is used as backup device connect to COMP and activate the video keyboard emu la...

Page 252: ...SUBSEQUENT SYSTEM SOFTWARE LOADING WITH SAME VERSION OR LATER VERSIONS 2 2 MAINTENANCE C3G Plus 7 62 00 1097 SYSTEM SOFTWARE ...

Page 253: ...SOFTWARE OPERATIONS FOR ROBOT REPLACEMENT PRELIMINARY OPERATIONS 1 Replace the robot in compliance with the rules of safety C3G Plus MAINTENANCE 01 0498 7 63 SYSTEM SOFTWARE ...

Page 254: ...mulator of the C3G Plus through the PCINT programme see chapter 3 4 Load the system software again following the procedure described in the previous paragraph 5 Load all the files saved previously in the C3G RAM DISK with the FUR command 6 Take the robot to the calibration notches either by hand or with the Execute command COMMAND EXECUTE TYPE MOVE TO CAL_SYS To better understand the software vers...

Page 255: ...SOFTWARE OPERATIONS FOR CONTROLLER REPLACEMENT 2 2 C3G Plus MAINTENANCE 01 0498 7 65 SYSTEM SOFTWARE ...

Page 256: ...ION FILE PRELIMINARY OPERATIONS 1 Using the FC Filer Copy command copy the C3G SYS file in C3G OLD 2 Take the robot to the calibration notches manually or through the Execute command MOVE TO CAL_SYS MAINTENANCE C3G Plus 7 66 00 1097 SYSTEM SOFTWARE ...

Page 257: ...eans the updated software version Copy the file in the controller ram disk typing the FC Filer copy command on the PC keyboard At the command prompt specify the source and name of the file e g COMP PTUV_ _ _ HEX if the floppy disk unit is present e g FD PTUV_ _ _ HEX and confirm with ENTER From the PC keyboard type the CCRB Configure Cntrl Restart Bootmon command and enter the password for command...

Page 258: ...kVA version F100 F101 F102 00701020 16 A 14X51 Fuse 3 8 kVA version F100 F101 F102 00701024 50 A 14X51 Fuse 16 5 kVA version F100 F101 F102 00701055 4 A 5x20 quick acting fuse F113 00703604 4 V Battery CU battery 19270068 2 A 250 V 5X20 quick acting fuse F116 19270076 6 3 A 5X20 time lag fuse F105 F106 F108 F109 F111 F110 19800111 Male guide pin HARTING connectors 19800112 Female guide pin HARTING...

Page 259: ...ghting only for Rel 1 x 11974081 Dynamic braking module C3G DBU3 11974281 Multiplexer module C3G MMUX 11977480 SDB3 C3G SDB3 11977481 SDB3 2 C3G SDB3 2 11978980 PTU4 Programming terminal C3G PTU4 19010138 24 Vdc 10 A power supply unit C3G PS4 19010139 24 Vdc 15 A power supply unit C3G PS5 19690101 3 8 kVA transformer T100 19690102 7 kVA transformer T100 19690103 16 5 kVA transformer T100 19900019 ...

Page 260: ...60 Emergency terminal connection cable 11230460 HSIO terminating resistor plug 1123176 Cable from I O module to ECB 11232260 PLC OPP serial line cable 11232360 PLC ECB HSIO serial line cable 11235060 Cable from ADM module to ECB 11244060 Extension cable for C3G PTU4 l 8 m C3G Plus PTE 1124160 Extension cable for C3G PTU4 l 18 m C3G Plus PTE 11961980 I O module connection kit 11962780 ADN module co...

Page 261: ...JB40 00701018 20 A 10x38 fuse F103 F104 SIEMENS 3NW6007 1 00701014 32 A 14X51 fuse 7 kVA version F100 F101 F102 SIEMENS 3NW6112 1 00701020 16 A 14X51 fuse 3 8 kVA version F100 F101 F102 SIEMENS 3NW6005 1 00701024 50 A 14X51 fuse 16 5 kVA version F100 F101 F102 SIEMENS 3NW6120 1 00701027 25 A 500 V two pole fuse holder SIEMENS 3NW7021 00701029 50 A 500 V three pole fuse holder SIEMENS 3NW7131 00701...

Page 262: ...EL A H PKZ2 19270068 5x20 2 A 250 V fuse F116 SCHURTER 0001 1007 19270076 5x20 6 3 A 250 V fuse F105 F106 F108 F109 F110 F111 SCHURTER 0001 2512 19670017 Terminal block X118 X119 WEIDMULLER EW 35 N 3835 6 19670048 Terminal plate X119 WEIDMULLER AP PA N 3803 6 19670050 Terminal plate X118 X119 WEIDMULLER WAP2 5 10N 10500 0 19670054 Terminal protection cap WEIDMULLER WAD5 N 10534 6 19670058 Terminal...

Page 263: ...800123 Through housing for rectangular connector X60 X10 X30 HARTING 09 300240301 19800124 Protection cap for connector X60 X10 X30 HARTING 09 300245405 19800160 Male earth contact block X141 X142 X140 X166 AMP 350669 1 19810063 3NC block S150 RAFI 1 20119 006 19810064 Contact holder block S150 RAFI 5 55101 684 0704 19810083 Yellow disk S150 KLOCK MOEL 05T C3G Plus MAINTENANCE 08 0702 7 73 LIST OF...

Page 264: ...This page has been intentionally blank 7 74 08 0702 MAINTENANCE C3G Plus LIST OF SPARE PARTS ...

Page 265: ...OPERATOR S NOTES C3G Plus NOTES ...

Page 266: ...C3G Plus NOTES ...

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