Comau Robotics

Instruction Handbook

Control Unit
Safe Version, Rel. 0/1/2

Maintenance

Suggestions for troubleshooting

Preliminary maintenance plan to guarantee the C5G functionality over the time
Preliminary and Special Maintenance procedures
Spare parts list

CR00757955_en-00/2015.02
The information contained in this manual is the property of COMAU S.p.A.

Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A.

COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation.

Copyright © 2008-2014 by COMAU - Published on 02/2015

 Summary
COMAU

SUMMARY

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Fundamental Requirements applied and respected . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. GENERAL MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

Precautions Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Precautions During Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Precautions at the End of the Maintenance Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance Staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Equipment and Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tightening Torques of the Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3. SUGGESTIONS FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...21

Precautions Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Problem Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diagnostic Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Connectors Identification and Abbreviations, Cables and Modules . . . . . . . . . . . . . . . . . . . . 24
Traceability for Replacement Purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Components Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control Unit Outline Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Causes and Remedies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Comau Customer Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4. HOW TO DISCONNECT THE POWER SUPPLY OF C5G CONTROL UNIT . . . . . . ...32

Precautions and Risks Associated to the Electrical Power Supply Off-Switching . . . . . . . . . . . 32
Switching Off the Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5. HOW TO REACH THE MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...37

Precautions Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

_LB-RC-C5E-MAN_enTOC.fm
3
Summary
COMAU
Risks Associated with the Module Reaching Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Module Location and Access Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Upper Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6. HOW TO MOVE THE ROBOT WHEN THE CONTROL UNIT IS DAMAGED . . . . . . ..43
Precautions Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Risks linked to the Robot motion without connected Control Unit . . . . . . . . . . . . . . . . . . . . . . . 43
Use of the C5G-OBR Brake Releasing Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7. MAINTENANCE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..49

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Summary Diagram of the Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8. PRELIMINARY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..51

Precautions Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Preliminary Maintenance Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ACC: Door closing and gasket efficiency check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ACO: Cleaning the Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ACO: Emptying Condensate Collection Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
E110: Fan Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
E111..E113: Fans Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
UPS: Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

9. SPECIAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..65

Precautions Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Modules Subject to Special Maintenance Activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ACO: Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
ACO: Limit Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
AMS-APC: Module Replacement with Compact Flash Recovery . . . . . . . . . . . . . . . . . . . . . . . 76
Module Replacement AMS-APC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
System Configuration with the TP5 Teach Pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
AMS-ASM32: Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
AMS-IAM: Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

_LB-RC-C5E-MAN_enTOC.fm
4
 Summary
COMAU
AMS-IAM: Safe Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Safe AMS-IAM Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Recovery procedure after the replacement of a axes module . . . . . . . . . . . . . . . . . . . . . . . 102
AMS-PPS: Module Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Fuse Replacement in the Module AMS-PPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Symptoms and Consequences for Breaking the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
ERM1 Light:Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
ERR: Resistance Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
HMK: Hour Meter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
PFG-BCO: Power supply replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
PFG-BCO: Bus Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Safe-key: Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Replacement of Safe-key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Recovery procedure after the Safe-key replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
SDM: Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
SLU: Module Replacement with Recovery
of Safe-Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Module Replacement SLU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Recovery procedure after the replacement of SLU module . . . . . . . . . . . . . . . . . . . . . . . . . 141
TP5: Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Software Loading in TP5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
UPS: Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Fuse Replacement in the UPS Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
X20 - Fieldbus: Modules Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
X20 - I/O Safe: Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
X20 - I/O Safe Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Recovery procedure after the replacement of a module X20 - I/O Safe . . . . . . . . . . . . . . . 155

10. SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...158

Precautions About the Spare Part Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Where to Find the Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Spare Parts for the Basic Model C5G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

11. DISPOSAL AND DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...170

Precautions Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Staff to set the plant out of work and dismantle it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Equipment and Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Setting out of work and dismantling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Removing the cell and battery from the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

_LB-RC-C5E-MAN_enTOC.fm
5
PREFACE
COMAU

PREFACE
This chapter deals with the following topics:
– Reference Documents
– Contents of Manuals of the C5G Control Unit C5G
– Documents Storage
– Limits on the Manual Contents
– Symbols Used in the Manual.

Reference Documents
This document refers to the Control Unit C5G.
The complete set of manuals C5G is composed of:

Comau Control Unit C5G – Technical Specification

Safe – Transport and installation
– Maintenance
– Use of Control Unit.
– Use of RoboSAFE Joint / Speed
functionality *¹
Wiring diagram –
*¹ The hardware functionalities of the C5G Safe Control Unit are reported in the manuals dedicated to the
Safe Control Unit: “Technical Specifications”, “Transport and Installation”, “Maintenance”.

These manuals must be integrated with the following documents:

Comau SMART5 Robot – Technical Specifications *¹

Rel. 2 – Transport and installation *¹
– Maintenance *¹
Programming – PDL2 Programming Language Manual
– VP2 - Visual PDL2
– Motion Programming
Applicability – According to the type of installation
required.
*¹ specific according to type of Robot installed

These manuals mentioned above shall be undamaged as long as the Robotic System
is installed and operates, they shall be always available to the people that operate on
the Robotic System.

HS-RC-C5E-0_01.fm
6 00/0714
 PREFACE
COMAU
Contents of Manuals of the C5G Control Unit
C5G
Device Manual Contents
Control Unit C5G – Technical – Description and general characteristics of the Control Unit
Specification – Guide to the choice of the Control Unit version
– General description upon expandability towards the I/O
signals, communication networks, safeties
– Description and purchase part numbers of the Control Unit
and options.
– Transport and – Information about the preparations and arrangements
installation necessary to install the C5G
– Dimensions and weights, transport and lifting methods
– Procedures for internal components adjustment and options
to the power supply network
– Procedure for connection to the plant energies and the
electric power
– Preliminary procedures for the Control Unit commissioning
– Maintenance – Suggestions for troubleshooting
– Preliminary maintenance plan to guarantee the C5G
functionality over the time
– Preliminary and Special Maintenance procedures
– Spare parts list
– Wiring diagram

Documents Storage
All documents provided shall be stored nearby the Robotic System and be at disposal
of the operators that work with it, the documents shall be maintained intact for the entire
Robotic System life.

Limits on the Manual Contents

Figures inserted in the instructions handbook have the goal to represent the product and
can differ from what actually visible on the Robotic System.

HS-RC-C5E-0_01.fm
00/0714 7
PREFACE
COMAU
Symbols Used in the Manual
This manual contains the WARNING, CAUTION and NOTE symbols.

This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed could cause injuries to the personnel.

This symbol indicates operating procedures, technical information and precautions, if

are not observed and/or correctly performed could cause damage to the equipment.

This symbol indicates operating procedures, technical information and precautions that
are to be underlined.

This symbol indicates the material disposal that is regulated by the WEEE Directive.

This symbol indicates to avoid environmental contamination and to dismiss the

materials on the appropriate collection facility.

HS-RC-C5E-0_01.fm
8 00/0714
 General safety precautions
COMAU

1. GENERAL SAFETY PRECAUTIONS

It deals with a general specification that apply to the whole Robot System. Due to its
significance, this document is referred to unreservedly in any system instructions
handbook.

In this chapter are shown the following topics:

– Responsibilities
– Safety precautions.

1.1 Responsibilities

– The system integrator is responsible for ensuring that the Robotic system (Robot
and Control Unit) are installed and handled in accordance with the Safety
Standards in force in the country where the installation takes place. The application
and use of the protection and safety devices necessary, the issuing of declarations
of conformity and any EC markings of the system are the responsibility of the
Integrator.

– COMAU Robotics shall in no way be held liable for any accidents caused by
incorrect or improper use of the Robotic system (Robot and Control Unit), by
tampering with circuits, components or software, or the use of spare parts that are
not included in the spare parts list.
– The application of these Safety Precautions is the responsibility of the persons
assigned to direct / supervise the activities indicated in the Applicability section are
to make sure that the Authorised Personnel is aware of and scrupulously follow the
precautions contained in this document as well as the Safety Standards in addition
to the Safety Standards applicable to Robotic system (Robot and Control Unit) in
force in the Country where the system is installed.
– The non-observance of the Safety Standards could cause to the operators
permanent injuries or death and can damage the Robotic system (Robot and
Control Unit).

The installation shall be made by qualified installation Personnel and should conform to
all National and Local standards.

1.1.1 Safety Fundamental Requirements applied and respected

The robotic system is composed of C5G Control Unit and Robot series SMART 5
considers as applied and respected the following Safety Fundamental Requirements,
Annex 1 of Directive on Machinery 2006/42/CE: 1.1.3 – 1.1.5 – 1.2.1 – 1.2.2 – 1.2.3 –
1.2.4.3 – 1.2.5 – 1.2.6 – 1.3.2 – 1.3.4 – 1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4 – 1.5.6 – 1.5.8 –
1.5.9 – 1.5.10 – 1.5.11 – 1.5.13 – 1.6.3 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2 – 1.7.4.

ge-0-0-0_01.FM
00/0314 9
General safety precautions
COMAU
In case only a SMART 5 Robot is supplied, the following requirements are regarded as
applied: 1.1.3 – 1.1.5 – 1.3.2 – 1.3.4 – 1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4 – 1.5.6 – 1.5.8 –
1.5.9 – 1.5.10 – 1.5.11 – 1.5.13 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2 – 1.7.4.

1.2 Safety precautions

1.2.1 Purpose
These safety precautions are aimed to define the behaviour and rules to be observed
when performing the activities listed in the Applicabilitysection.

1.2.2 Definitions
Robotic system (Robot and Control Unit)
Robotic system is the workable unit composed of: Robot, Control Unit, Teach Pendant
and other options.

Protected Area
The protected area is the zone confined by the protection barriers and to be used for the
installation and operation of the robot.

Authorised Personnel
Authorised personnel defines the group of persons who have been trained and assigned
to carry out the activities listed in the Applicability section

Staff in charge
The staff in charge to direct or supervise the activities of the workers who have been
trained.

Installation and Putting into Service

The installation is intended as the mechanical, electrical and software integration of the
Robot and Control System in any environment that requires controlled movement of
robot axes, in compliance with the safety requirements of the country where the system
is installed.

Operation in Programming Mode

Operating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual handling of robot axes and programming of
work cycles at low speed, programmed cycle testing at low speed and, when allowed,
at the working speed.

Auto / Remote Automatic Mode

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

Maintenance and Repairs

Maintenance and repairs are activities that involve periodical checking and / or
replacement (mechanical, electrical, software) of Robot and Control System parts or

ge-0-0-0_01.FM
10 00/0314
 General safety precautions
COMAU
components, and trouble shooting, that terminate when the Robot and Control System
has been reset to its original project functional condition.

Putting Out of Service and Dismantling

Putting out of service defines the activities involved in the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.

Integrator
The integrator is the professional expert responsible for the installation and putting into
service of the Robot and Control System.

Misuse
Misuse is when the system is used in a manner other than that specified in the Technical
Documentation.

Action area
The robot action area is the enveloping volume of the area occupied by the robot and its
fixtures during movement in space.

1.2.3 Applicability
These Precautions are to be applied when carrying out the following activities:
– Installation and Putting into Service
– Operation in programming mode
– Auto / Remote Automatic Mode
– Robot axes brake
– Maintenance and Repair
– Putting Out of Service and Dismantling.

ge-0-0-0_01.FM
00/0314 11
General safety precautions
COMAU

1.2.4 Operating modes

Installation and Putting into Service
– Putting into service is only possible when the Robot and Control System has been
correctly and completely installed.
– The system installation and putting into service is exclusively the task of the
authorised personnel.
– The system installation and putting into service is only permitted inside a protected
area of an adequate size to house the robot and the fixtures it is outfitted with,
without passing beyond the protection barriers. It is also necessary to check that
under normal robot movement conditions there is no collision with parts inside the
protected area (structural columns, power supply lines, etc.) or with the barriers. If
necessary, limit the robot working areas with mechanical hard stop (see optional
assemblies). If necessary, limit the robot working areas with mechanical hard stop
(see optional assemblies).
– Any fixed robot control protections are to be located outside the protected area and
in a point where there is a full view of the robot movements.
– The robot installation area is to be as free as possible from materials that could
impede or limit visibility.
– During installation the robot and the Control Unit are to be handled as described in
the product Technical Documentation; if lifting is necessary, check that the
eye-bolts are fixed securely and use only adequate slings and equipment.
– Secure the robot to the support, with all the bolts and pins necessary, tightened to
the torque indicated in the product Technical Documentation.
– If present, remove the fastening brackets from the axes and check that the fixing
of the robot fixture is secured correctly.
– Check that the robot guards are correctly secured and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– Install the Control Unit outside the protected area: the Control Unit is not to be used
to form part of the fencing.
– Check that the voltage value of the mains is consistent with that indicated on the
plate of the Control Unit.
– Before electrically connecting the Control Unit, check that the circuit breaker on the
mains is locked in open position.
– Connection between the Control Unit and the three-phase supply mains at the
works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned
appropriately for the power installed on the Control Unit. See the product Technical
Documentation.
– The power supply cable is to enter the Control Unit through the specific cable entry
and be properly clamped.
– Connect the earth conductor (PE) then connect the power conductors to the main
switch.
– Connect the power supply cable, first connecting the earth conductor to the circuit
breaker on the mains line, after checking with a tester that the circuit breaker
terminals are not powered. Connect the cable armouring to the earth.

ge-0-0-0_01.FM
12 00/0314
 General safety precautions
COMAU
– Connect the signals and power cables between the Control Unit and the robot.
– Connect the robot to earth or to the Control Unit or to a nearby earth socket.
– Check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors could cause permanent damage to the
Control Unit components.
– The C5G Control Unit manages internally the main safety interlocks (gates,
enabling pushbuttons, etc.). Connect the C5G Control Unit safety interlocks to the
line safety circuits, taking care to connect them as required by the Safety
standards. The safety of the interlock signals coming from the transfer line
(emergency stop, gates safety devices etc.) i.e. the realisation of correct and safe
circuits, is the responsibility of the Robot and Control System integrator.

In the cell/line emergency stop circuit the contacts must be included of the control unit
emergency stop buttons, which are on X30. The pushbuttons are not interlocked in the
emergency stop circuit of the Control Unit.

– The safety of the system cannot be guaranteed if these interlocks are wrongly
executed, incomplete or missing.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active under Automatic mode; under Programming mode the power is
powered off immediately. The procedure for the selection of the controlled stop
time (that can be set on SDM board) is contained in the Transport and Installation
Manual of the Control Unit.
– When preparing protection barriers, especially light curtains and access doors,
bear in mind that the robot stop times and distances are according to the stop
category (0 or 1) and the weight of the robot.

Check that the controlled stop time is consistent with the type of Robot connected to the
Control Unit. he stop time is selected using selector switches SW1 and SW2 on the SDM
board.

– Check that the environment and working conditions are within the range specified
in the specific product Technical Documentation.
– The calibration operations are to be carried out with great care, as indicated in the
Technical Documentation of the specific product, and are to be concluded
checking the correct position of the machine.

ge-0-0-0_01.FM
00/0314 13
General safety precautions
COMAU
– To load or update the system software (for example after replacing boards), use
only the original software handed over by COMAU Robotics. Scrupulously follow
the system software uploading procedure described in the Technical
Documentation supplied with the specific product. After uploading, always make
some tests moving the robot at slow speed and remaining outside the protected
area.
– Check that the barriers of the protected area are correctly positioned.

Operation in programming mode

– The robot is only to be programmed by the authorised personnel.
– Before starting to program, the operator must check the Robotic system (Robot
and Control Unit) to make sure that there are no potentially hazardous irregular
conditions, and that there is nobody inside the protected area.
– When possible the programming should be controlled from outside the protected
area.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the hand-held programming unit functions
correctly (slow speed, emergency stop, enabling device, etc.).
– During the programming session, only the operator with the Teach Pendant is
allowed inside the Protected Area
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (DRIVE ON) is always to be controlled from a position
outside the range of the robot, after checking that there is nobody in the area
involved. The Drive On operation is concluded when the relevant machine status
indication is shown.
– When programming, the operator is to keep at a distance from the robot to be able
to avoid any irregular machine movements, and in any case in a position to avoid
the risk of being trapped between the robot and structural parts (columns, barriers,
etc.), or between movable parts of the actual robot.
– When programming, the operator is to avoid remaining in a position where parts of
the robot, pulled by gravity, could execute downward movements, or move
upwards or sideways (when installed on a sloped plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at slow speed has been executed. The
test is to be controlled from a safe distance.
– Special attention is to be paid when programming using the Teach Pendant: in this
situation, although all the hardware and software safety devices are active, the
robot movement depends on the operator.
– During the first running of a new program, the robot may move along a path that is
not the one expected.
– The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the robot position out
of the path that links two steps of the program), could give rise to movements not
expected by the operator when testing the program.

ge-0-0-0_01.FM
14 00/0314
 General safety precautions
COMAU
– In both cases operate cautiously, always remaining out of the robot’s range of
action and test the cycle at slow speed.

Auto / Remote Automatic Mode

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

Robot axes brake

– In the absence of motive power, the robot axes movement is possible by means of
optional release devices and suitable lifting devices. Such devices only enable the
brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enable button) are powered off; also the
robot axes can move upwards or downwards because of the force generated by
the balancing system, or the force of gravity.

Before using the manual release devices, it is strongly recommended to sling the robot,
or hook to an overhead travelling crane.

– Enabling the Brake releasing Module may cause the axes falling due to gravity, as
well as possible impacts due to an incorrect restoring procedure, after applying the
brake releasing module. The procedure for the correct usage of the Brake
releasing Module (both for the integrated one and module one) is to be found in the
maintenance manuals.

ge-0-0-0_01.FM
00/0314 15
General safety precautions
COMAU
– When the motion is enabled again following the interruption of an unfinished
MOVE, the track recovery typical function may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next automatic cycle
restarting. Avoid moving the Robot to positions that are far away from the ones
provided for the motion restart; alternatively disable the outstanding MOVE
programmes and/or instructions.

Maintenance and Repair

– At the COMAU works all robots are lubricated using products that do not contain
any harmful substances. However, in some cases, repeated and prolonged
exposure to such products may cause irritation of the skin and they may be harmful
if swallowed.
First Aid Measures In case of contact with the eyes or skin: rinse the affected
areas with copious amounts of water; should irritation persist, seek medical advice.
If swallowed, do not induce vomiting or administer anything by mouth; see a doctor
as soon as possible.
– Maintenance, trouble-shooting and repairs are only to be carried out by authorised
personnel.
– When carrying out maintenance and repairs, the specific warning sign is to be
placed on the control panel of the Control Unit, stating that maintenance is in
progress and it is only to be removed after the operation has been completely
finished - even if it should be temporarily suspended.
– Maintenance operations and replacement of components or the Control Unit are to
be carried out with the main switch in open position and locked with a padlock.
– Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages coming from connections to peripheral units or external
power sources (e.g. 24 Vdc inputs/outputs). Power off external sources when
operating on parts of the system that are involved.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Faulty components are to be replaced with others having the same Part number,
or equivalent components defined by COMAU Robotics.

After replacement of the SDM module, check on the new module that the setting of the
stop time on selector switches SW1 and SW2 is consistent with the type of Robot
connected to the Control Unit.

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

outside the protected area.
– Trouble-shooting executed on the control is to be carried out, when possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards are to be observed
when operating with hazardous voltages present.
– Trouble-shooting on the robot is to be carried out with the power supply powered
off (DRIVE OFF).
– At the end of the maintenance and trouble-shooting operations, all deactivated
safety devices are to be reset (panels, protection shields, interlocks, etc.).

ge-0-0-0_01.FM
16 00/0314
 General safety precautions
COMAU
– Maintenance, repairs and trouble-shooting operations are to be concluded
checking the correct operation of the Robotic system (Robot and Control Unit) and
all the safety devices, executed from outside the protected area.
– When loading the software (for example after replacing electronic boards) the
original software handed over by COMAU Robotics is to be used. Scrupulously
follow the system software loading procedure described in the specific product
Technical Documentation; after loading always run a test cycle to make sure,
remaining outside the protected area
– Disassembly of robot components (motors, balancing cylinders, etc.) may cause
uncontrolled movements of the axes in any direction: before starting a disassembly
procedure, consult the warning plates applied to the robot and the Technical
Documentation supplied.
– It is strictly forbidden to remove the protective covering of the robot springs.

Putting Out of Service and Dismantling

– Putting out of service and dismantling the Robot and Control System is only to be
carried out by Authorised Personnel.
– Move the robot to transport position and mount the axes locking items (if present),
following the instructions on the plate posted on the robot and its Technical
Documents.
– Before starting to put out of service, the mains voltage to the Control Unit must be
powered off (switch off the circuit breaker on the mains distribution line and lock it
in open position).
– After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the distribution line,
first disconnecting the power conductors, then the earth. Disconnect the power
supply cable from the Control Unit and remove it.
– First disconnect the connection cables between the robot and the Control Unit,
then the earth cable.
– If present, disconnect the robot pneumatic system from the air distribution mains.
– Check that the robot is properly balanced and if necessary sling it correctly, then
remove the robot securing bolts from the support.
– Remove the robot and Control Unit from the working area, following all
prescriptions in the product Technical Documents; in case of lifting, check the
eyebolts fastening and use only suitable slinging devices and equipment.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU Robotics & Service,
or one of its branches, who will indicate, according to the type of robot and Control
Unit, the operating methods in accordance with safety principles and safeguarding
the environment.
– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.

ge-0-0-0_01.FM
00/0314 17
General safety precautions
COMAU

1.2.5 Performance
The performances below shall be considered before installing the robotic system:
– Stop spaces
– Mission time (typical value).

Stop spaces
– Pressing the stop pushbutton (red mushroom-shaped one on WiTP) in category 0
(according to standard EN60204-1), when the Robot is in programming mode (T1),
will result in:

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

Expected Stopping Stopping

Mode Case
speed distance space
Nominal 120 ms 30 mm
T1 250 mm/s
Limit 500 ms 125 mm

Tab. 1.2 - Safety electronics response time in programming mode (T1)

Expected Reaction
Mode Case
speed time
For the safety inputs of the SDM module (e.g.
stop pushbutton of TP in wired version)
For the stop and enabling device inputs from 150 ms
the TP in wireless version, when the safety
T1 250 mm/s
wire transmission is active.
For the time-out of stop input and enabling
device from TP in wireless version, when the 350 ms
safety wire transmission is lost or interrupted.

– Pressing the stop pushbutton (red mushroom-shaped one on WiTP) in category 1

(according to standard EN60204-1), when the Robot is in automatic mode, under
full extension, full load and maximum speed conditions, will result in the Robot
complete stopping with controlled deceleration ramp.
Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 °
motion, that correspond to about 3000 mm movement measured on TCP flange.
Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5
seconds.
– For each Robot the limit stop distances can be required to COMAU Robotics.

Mission time (typical value)

– We remind you that the safety system efficiency covering is equal to 20 years
(mission time of safety-related parts of control systems (SRP/CS), according to EN
ISO 13849-1).

ge-0-0-0_01.FM
18 00/0314
 General Maintenance Precautions
COMAU

2. GENERAL MAINTENANCE PRECAUTIONS

This chapter deals with the following topics:
– Precautions Before Starting
– Precautions During Maintenance
– Precautions at the End of the Maintenance Activities
– Maintenance Staff
– Equipment and Tools Required
– Tightening Torques of the Screws.

The maintenance activities that are not described in this manual are not allowed. If it is
necessary, require the manufacturer's intervention.

2.1 Precautions Before Starting

– Most maintenance activities on the Control Unit are to be carried out with electrical
power supply off. In these cases the maintenance sheet is labeled “Main switch
open (OFF)”.
With main switch open, the X120 terminal block and its cable upstream the main
switch are energized. In this case, the procedure for the complete deactivation of
the power supply, requires the mains power supply system powered off
– The maintenance activities relate the cabinet main power supply section only after
disconnecting the power from the mains. In these cases the maintenance sheet is
labeled "Input power supply deactivation" .
– Use original spare parts only. The spare parts are provided by Comau. The spare
part list is described in Cap.10. - Spare Parts.

2.2 Precautions During Maintenance

– If the type of fault allows robot repositioning, it is advised to set it in idle position
before starting the maintenance operations.
– Please remember that, because of to the safety circuits features of the Control Unit,
it is possible to reduce the cover warranty in case of multiple failures (see EN ISO
13849-1 standard).

If maintenance and/or trouble shooting activities are carried out do not stand
near the Robot and move in jog with suitable distance.

HS-RC-C5E-MAN_01.fm
00/0309 19
General Maintenance Precautions
COMAU

2.3 Precautions at the End of the Maintenance

Activities
– At the end of the maintenance operations check the proper functioning of the
Control Unit and the coupled robot. Check the correct execution of some robot
working cycles and the correct functioning of security devices before leaving the
station.

At the end of each maintenance session, the first machine start-up shall be
regarded as a test for the whole plant. During such phase the operator shall
stand outside the Robot range of action but in an position that allows to check
its movements. Moreover, he/she shall have the Teach Pendant at disposal
nearby.

2.4 Maintenance Staff

The staff in charge for maintenance activities shall be instructed in order to operate
properly with lifting means (in case of replacement of the complete Control Unit).
Moreover, the staff shall be warned or trained (in electrical field) and therefore be aware
of the dangers associated with electric energy and of the measures to be taken to
access in safety conditions the Control Unit Modules.

2.5 Equipment and Tools Required

The component securing systems (screws, nuts) have been standardised, using as few
variations as possible.
The minimum required equipment for maintenance intervention of the C5G Control Unit
is divided depending on the type of maintenance operation:
– for preliminary maintenance see par. 8.2 Equipment Required on pag. 51.
– for special maintenance see par. 9.2 Equipment Required on pag. 65.

2.6 Tightening Torques of the Screws

While disassembling and re-assembling the components comply with the screw
tightening torques settings. If not otherwise specified, apply the tightening torques
corresponding to the screw typology used.

Do not over tight, as you may damage the thread and therefore the item position in its
seat.
Do not under tight, as it may cause the item falling and/or overheating (and consequent
breaking) due to an incorrect adherence to the dissipating frame.

HS-RC-C5E-MAN_01.fm
20 00/0309
 Suggestions for troubleshooting
COMAU

3. SUGGESTIONS FOR TROUBLESHOOTING

This chapter deals with the following topics:
– Precautions Before Starting
– Methods
– Control Unit Outline Diagrams
– Causes and Remedies
– Comau Customer Centre

3.1 Precautions Before Starting

– Read carefully the instructions described in Cap.2. - General Maintenance
Precautions

3.2 Methods
– Problem Analysis
– Diagnostic Messages
– Connectors Identification and Abbreviations, Cables and Modules
– Traceability for Replacement Purposes
– Components Replacement

3.2.1 Problem Analysis

The C5G Control Unit provides information on the System status using:
– LEDs, positioned on modules and boards
– diagnostic messages, displayed on the Teach Pendant.
For troubleshooting operation it could be useful to use one or both modes (LEDs,
messages), depending on the system status:
– during the boot phase, the Teach Pendant is not functional and it is necessary to
consult the warning messaged issued by LEDs present on the modules
– when the Teach Pendant is enabled, the Diagnostic Messages provided are more
efficient
– in all cases, in particular for the auxiliary circuit power supplies, LEDs represent the
most immediate diagnostic procedure
– the pin-out structures given in the tables in Cap. Details about the C5G Control Unit
in the “Technical Specifications” manual allow to check the availability of the
expected corresponding signal
– for the connection among modules and further information about the circuits,
referto the Control Unit.

HS-RC-C5E-MAN_02.fm
01/1014 21
Suggestions for troubleshooting
COMAU

3.2.2 Diagnostic Messages

Diagnostic messages are codified by means of numerical codes combined to a short
description and can be seen on the teach pendant.
To facilitate the understanding of the message, find the cause that generated it and the
corresponding remedy to be taken, it is possible to use the WinC5Gsoftware.
In the main window of the software (Fig. 3.1) the above information can be viewed. To
call up the information, indicate the error code in field (A).

Fig. 3.1 - WinC5G Main Window Regarding Error Codes

3.2.2.1 Meaning of the Format

The error messages are displayed on the Teach Pendant and WinC5G software and
also stored in a file named ERROR.LOG. It deals with a Control Unit memory resident
file that can be recalled if a message is erased or the user wishes to check which alarms
occurred.
The messages format is the following:

xxxx.yyyyy-zz : Text

Tab. 3.1 - Message Format

Position Description
Progressive number of the stored event.
xxxx
Messages identified with ---- are not stored.
yyyyy Error code
zz Seriousness level (see details in Tab. 3.2)
Text Message text

es. ----.28808-10 : Safety gates

The error message meaning is the following:

HS-RC-C5E-MAN_02.fm
22 01/1014
 Suggestions for troubleshooting
COMAU
– ----- (the message is not stored)
– 28808 (error numerical code)
– 10 (seriousness level)
– Safety gates (message text featuring the fault detected on the plant).

3.2.2.2 Alarms Resetting

Find below the quitting procedures as a function of the alarm seriousness level:

Tab. 3.2 - Seriousness Level and Corresponding Restore Procedure

Seriousne
Meaning Impact on the system Action restore
ss level
00 Informative message None None
01 Informative message None None
02 Warning No impact on the Control Unit None
status.
03 Not used
04 PDL2 Program error Program in PAUSE or HOLD – Reset the fault by pressing the
mode, if it deals with a RESET push-button (push-buttons
holdable program. Ctrl + Home on WinC5G)
– Solve the anomaly of the program.
– Restart the program.
05 Not used
06 PDL2 Program error All programmes in PAUSE or – Reset the fault by pressing the
HOLD mode, if it deals with a RESET push-button (push-buttons
holdable program. Ctrl + Home on WinC5G)
– Solve the anomaly of the program.
– Restart all the programs.
07 Not used
08 Hold HOLD – Reset the fault by pressing the
RESET push-button (push-buttons
Ctrl + Home on WinC5G)
– Troubleshoot the cause that
generated the alarm.
– Restore the program by pressing
START push-button
09 Not used
10 Driving devices off HOLD and following DRIVE – Reset the fault by pressing the
OFF RESET push-button (push-buttons
Ctrl + Home on WinC5G)
(stop according to category 1, – Troubleshoot the cause that
in compliance with standard generated the alarm.
EN 60204-1)
– DRIVE ON
– Restore the program by pressing
START push-button

HS-RC-C5E-MAN_02.fm
01/1014 23
Suggestions for troubleshooting
COMAU
Tab. 3.2 - Seriousness Level and Corresponding Restore Procedure

Seriousne
Meaning Impact on the system Action restore
ss level
11 Driving devices off DRIVE OFF – Reset the fault by pressing the
RESET push-button (push-buttons
(stop according to category 0, Ctrl + Home on WinC5G)
in compliance with standard – Troubleshoot the cause that
EN 60204-1) generated the alarm.
– DRIVE ON
– Restore the program by pressing
START push-button
12 Driving devices off HOLD, DRIVE OFF and – Reset the fault by pressing the
DEACTIVATE RESET push-button (push-buttons
Ctrl + Home on WinC5G)
(stop according to category 1, – Troubleshoot the cause that
in compliance with standard generated the alarm.
EN 60204-1 and programs
– DRIVE ON
deactivation)
– Restore the programs by pressing
the START push-button
13 Fatal error Stops the Robot according to – Troubleshoot the cause that
category 0 (in compliance with generated the alarm.
standard EN 60204-1) and – Turn off the Control Unit and wait at
deactivate all PDL2 programs least 30 seconds to allow the UPS
(DEACTIVATE) and leaves module to be deactivated
the system in minimum
– Turn on the Control Unit
configuration.
14 Fatal error Stops the Robot according to – Troubleshoot the cause that
category 0 (in compliance with generated the alarm.
standard EN 60204-1) and – Turn off the Control Unit and wait at
deactivate all PDL2 programs least 30 seconds to allow the UPS
(DEACTIVATE) and leaves module to be deactivated
the system in minimum – Turn on the Control Unit
configuration.
15 Fatal error Stops the Robot according to – Troubleshoot the cause that
category 0 (in compliance with generated the alarm.
standard EN 60204-1) and – Turn off the Control Unit and wait at
deactivate all PDL2 programs least 30 seconds to allow the UPS
(DEACTIVATE) and leaves module to be deactivated
the system in minimum
– Turn on the Control Unit
configuration.

3.2.3 Connectors Identification and Abbreviations, Cables and

Modules
All connectors and cables present in the Control Unit are clearly signed and uniquely
identified in order to allow rapid identification of the connection and Traceability for
Replacement Purposes (see par. 3.2.4 on pag. 25).
The abbreviation is posted both on the movable and the fixed connector. In the case of
the latter, the abbreviation is silk-screen printed nearby the component.

HS-RC-C5E-MAN_02.fm
24 01/1014
 Suggestions for troubleshooting
COMAU
Fig. 3.2 - Abbreviation example on connector and cable

Each connector ending on the modules is identified by the letter “X” followed by
aprogressive number and the abbreviation of the corresponding component (example
X9 / CPU, X100 / FIA, etc.).
The connector abbreviation is clearly silk-screen printed on the component.

Fig. 3.3 - Abbreviation example on connector

3.2.4 Traceability for Replacement Purposes

Each cable / component is codified with a label containing serial number (S/N) and the
purchase part number (P/N).
Codes are so defined:
– S/N followed by 4 digits (production year and month) and two alphabetical letters
– P/N followed by 8 digits (purchase part no.), one separation point and two digits for
review.

HS-RC-C5E-MAN_02.fm
01/1014 25
Suggestions for troubleshooting
COMAU

3.2.5 Components Replacement

For the replacement of components, it is recommended to identify the damaged
component throughConnectors Identification and Abbreviations, Cables and Modules
such as to be able to replace them with an identical spare part.
Cap.10. - Spare Parts provides codes and descriptions of components available as
spare parts.
Spare parts can be acquired directly by Comau at the addressed listed on par. 3.5
Comau Customer Centre on pag. 31 where it is also possible to ask for repair of the
damaged component.

Do not carry out autonomous or not authorized repairs on the damaged modules.
Repairs can be made only by Comau.

3.3 Control Unit Outline Diagrams

In the following pages are shown the outline wiring diagrams of the main system inter
connections.

For all necessary connection information and details, refer to the Control Unit and Robot
wiring diagrams.

HS-RC-C5E-MAN_02.fm
26 01/1014
 LINE OPD
400V~ to 500V~ USB
h 123

01/1014
R S T
X120 PE Ext. FAN Int. FAN
CR17.2300.60xx E113 E112 E111 E110
COMAU

USB CR17.1307.80xx

CR17.2305.62xx 24V ESM Supply & 24V Supply Distribution Command

SHEET 2
Q100 24V Supply Distribution
CR17.2306.60xx
CR17.2301.60xx
Ballast

HS-RC-C5E-MAN_02.fm
SHEET 2 CAN Bus Internal
X1
Encoder Axis 1-6

CR17.2315.61xx

LINE X4 X3 X108 X109 X100 X101 X107 JP200

CR17.2304.61xx
X10
FILTER
ETH PowerLink
X2
Z1
DC bus

CR17.2315.61xx
ready

4 3 2 1 X3A X3A X1 X1 X2 X3 X3A X2 X11 X3A X2 X11 X3A X2 X11

USB X3B X3B X11 X3B X11 X3B X11

APC PPS ASM IAM1 IAM2 IAM3

Inverter Inverter Inverter
Acopos Passive Aux.. SDM X310
Axis Axis Axis
PC Power Supply

CR17.2302.60xx
Module 1 Module 2 Module 3 Safety & Distribution Module X311
Supply Module
1 1 1

X5B
X5B
X5B

X5A
X5A
X5A
CR17.2413.80xx
X312
SAFE SAFE SAFE

X4A
X4A
X4A

X4B
X4B
X4B

X5A
X119 COM ETH

X5B
X1
2 1 2 1 CAN
X106

Brake
A
Power Supply Line

Fases Motor
CR17.2303.60xx X103 B

C
CR17.2314.61xx CAN Bus Internal X119 X112 X110 X104 X124 X126 X128 X102 X122 X302

TP E-Stop, En.Dev., 24V Supply.

PLUG PLUG PLUG PLUG
Diagram available for Safe C5G Control Unit (Europe Version)

CR17.2315.61xx
TP Ethernet
CR17.2316.62xx
CR17.2317.61xx

ETH PowerLink

CR17.2307.61xx

X3A X3B X3C

X2

CR17.2312.65xx
UPS
CR17.2309.61xx
CR17.2310.60xx

Internal main connections

X1

CR17.2308.6xxx
+24V DriveOFF

CIP
X124 X60 CONNECTOR X10 CONN. X30 CONN.
TP5

1
SAFE DRIVE MODULE WITH SAFE SPEED CONTROLLED

400 Vac, 24 Vdc Power supply distribution

27
Suggestions for troubleshooting
28
X109/CAB

X109/CAB

CR17.2327.6xxx
ERM-1 LIGHT
Drive ON.
CR17.2305.62xx Progr. Status
SHEET 1 X4 X3 X108 X109 X100 X101 X107 JP200
X10
Suggestions for troubleshooting

ETH PowerLink 24V Safe Logic Unit & Bus Coupler Supply
SHEET 1

SDM X310

Safety & Distribution Module X311

X312

X106

X103 B

C
X119 X112 X110 X104 X124 X126 X128 X102 X122 X302

SLU PFG SI SO
Safe Powerlink Safe Safe
Logic Fieldbus Input Output
Unit Gateway

CR17.2327.6xxx

Internal main connections

CIP
X52 SAFE EXTERNAL PLC

400 Vac, 24 Vdc Power supply distribution

01/1014
HS-RC-C5E-MAN_02.fm
COMAU
 Suggestions for troubleshooting
COMAU
Diagram available for Safe C5G Control Unit (Europe)

SDM MODULE
X30 X102 X103
1A
24V INTP 24V INT. 1 A
1
2
8
24V EXT. 1 B
29
FIELD BUS 2

24V EXT. 1 C
15
0V 2
22

0V
INT./EXT.
2

9
X106
24V I/O 1
16
2
23
0V 3
30
24V SAFE 4

X122
X124
24V SAFE
1

0V
2

24V I/O
3

JP200 24V EXT. FIELD BUS

4

10

X126
24V EXT. 8A DRIVE ON
24V SAFE
1

24V INT. 7

SL2 P8A PSF 0V

2

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

1A 5A 0V
2

24V I/O
3
DRIVE OFF
9

24V EXT. FIELD BUS

24V DRIVE OFF

4
24V ROBOT

10
24V FANS

24V INT.
0V

0V

0V

0V

X119 X110
X2 X1
78 79 43 42

INT./EXT. FANS
A B

12 36 10d 11d

X10 X60 X124

24V ROBOT SUPPLY

iTP - TP5

24 Vdc Power supply

distribution
ROBOT BRAKES RELEASER

Note: the fuses inside the Safety Distribution Module (SDM) are of self-restoring fuses.

HS-RC-C5E-MAN_02.fm
01/1014 29
Suggestions for troubleshooting
COMAU

3.4 Causes and Remedies

Tab. 3.3 - System Conditions and the Method of Detection of the Fault

Functional phase
The cause Information for the fault resolution
The fault
Power supply
Some LEDs switched on The temperature probe on the Identify the cause for the overheating of
the AMS-PPS module, all transformer intervened, interrupting the transformer compartment, which in
the remaining modules precautionary the BUS-DC power turn makes it difficult to dissipate the
with the LEDs switched off supply. heat generated by the transformer.

If the main switch remained closed with Clean the air inlet / outlet mouths of the
the following intervention of the probe, transformer compartment, clean /
the LEDs status on the AMS-PPS checkthe efficiency of the fan installed
module is: inside the transformer compartment.
– [24V] Steady on Green; Check the environmental conditions
– [RDY] Flashing Green; (ambient temperature beyond the limits
– [R/E] Flashing Green/Red given in the technical features, C5G
ACO conditioner option inefficient).
If the main switch has been closed and
the probe was already active, the LEDs
status on the AMS-PPS module is:
– [24V] Steady on Green;
– [ERR] Slow flashing Red;
– [R/E] Slow flashing Red
Absence of 24 Vdc The AMS-ASM32 module is Replace the AMS-ASM32 module (see
supplied by AMS-ASM32 disconnected or damaged. the procedure given in par. 9.7
module and LEDs [ERR] + AMS-ASM32: Module Replacement on
[RDY] flashing every 3 pag. 87).
seconds
Absence of the power Failure of one or more fuses on the Replace the fuses.
supply C5G-EXU modules
– BUS DC and/or 24
Vdc on the The condition of complete efficiency is
C5G-ACPWx axes highlighted by the state of the LEDs,as
expansion shown below:
or – [24V] green, steady on
– 24 Vdc on the axis – [OLDC] red, off
expansion – [OL24] red, off
C5G-ABSL (only for – [OLD] red, off
applications with – [HLD] orange, off
Robot Laser) – [NLD], bright green

HS-RC-C5E-MAN_02.fm
30 01/1014
 Suggestions for troubleshooting
COMAU

3.5 Comau Customer Centre

In case of need it is possible to contact the Comau Assistance centre at the following
addresses:

Sector Address Service provided

Assistance in trouble shooting and
Causes and remedy [email protected]
software options requirement
Spare parts [email protected] To require spare parts
Repairs [email protected] To require repair activities

As an alternative refer to the manufacturer according to what it is indicated on par. 2.5.4

Name and Address of the Manufacturer on pag. 30 in the "Technical Specifications"
handbook.

HS-RC-C5E-MAN_02.fm
01/1014 31
How to disconnect the power supply of C5G Control Unit
COMAU

4. HOW TO DISCONNECT THE POWER SUPPLY

OF C5G CONTROL UNIT
This chapter deals with the following topics:
– Precautions and Risks Associated to the Electrical Power Supply Off-Switching
– Switching Off the Electrical Power Supply.

4.1 Precautions and Risks Associated to the Electrical

Power Supply Off-Switching
– After switching off the Control Unit wait for at least 30 seconds before switching it
back on.
– Before removing any connector wait for at least 30 seconds and make sure that all
leds are off.
Failure to comply with those warnings may result in:
• in the jamming of one or more modules
• in the damaging of one or more modules functionality.
– In case one or more module stop, switch off the system and wait for at least 30
seconds before switching the power supply back on.
– If installed, X120 connector shall not be used for the power supply powering-off
(C5G-MCK option).
– To increase the battery life do not switch off the Control Unit before carrying out the
software shutdown.
– The software shutdown procedure enables the files and applications closing
without requiring the buffer buttery

If the Control Unit is powered off when the robot is moving it force the system and
consequently the Robot to carry out an immediate stop without any deceleration ramp,
with consequent solicitation of the cinematic chain, trajectory direction deviation
(unforeseeable because of force of gravity) and consequent risks of crashes. If this
stopping mode is continuously repeated, the Robotic System and / or the equipment
connected to the Robot gets damaged.

Pay attention to the interconnected voltages, usually identified with orange coloured
connectors.

HS-RC-C5E-MAN_09.fm
32 01/1014
 How to disconnect the power supply of C5G Control Unit
COMAU

4.2 Switching Off the Electrical Power Supply

State: – Before powering off the electrical

power, it is advised to disable the
Robotic system by means the
shutdown software procedure.
Material: – Padlock (not supplied)
Europe: min. 4 mm / max 8 mm
(min. 0.15 in / max 0.31 in),
North America: external min. 5 mm /
max 8 mm (min. 0.20 in / max 0.31 in)
internal min. 1/4 in / max 0,31 in.
Equipment: – Not required

Preliminary procedures/ notes

– Most maintenance activities on the Control Unit are to be carried out with
electrical power supply off. In those cases the maintenance sheet features the
wording “Main switch open (OFF)”.
– Some activities, especially those related to the box main power supply section,
are to be carried out only after switching off the mains electrical power supply In
those cases the maintenance card features the wording “Input electrical power
supply off".
The main switch located on the Control Unit disconnects the power to the
robot (or robots) connected to it only and occasionally to the application.
–To verify the area or devices powered by a specific Control Unit it may be
necessary to refer also to the Usage Instruction Manual related to the
machine where the robot system is integrated.

HS-RC-C5E-MAN_09.fm
01/1014 33
How to disconnect the power supply of C5G Control Unit
COMAU

Operating procedure
Main switch open (OFF)
Main switch on C5G Control Unit (European version)

Main switch on C5G Control Unit (North America version) - In the case of Robot
maintenance

A A

Main switch on C5G Control Unit (North America version) - In the case of Control Unit
maintenance

A A

a. Carry out the software shutdown. Act on the specific control on the Teach
Pendant.

b. Wait for the shutdown procedure to end.

HS-RC-C5E-MAN_09.fm
34 01/1014
 How to disconnect the power supply of C5G Control Unit
COMAU
Operating procedure (Continued)
c. In the case of Robot maintenance or Europe Control Unit:

c.1 With closed cabinet door, set the Q100 main switch handle (A) in 0 (OFF)
position.

c.2 Move the lever (B) to access the slot.

c.3 Insert the padlock into the slot (C) available on the external maneuver.

d. In the case of North America Control Unit maintenance

d.1 With closed cabinet door, set the Q100 main switch handle (A) in 0 (OFF)
position.

d.2 Open the cabinet door

d.3 Insert the padlock into the slot (D) available on the internal maneuver.
e. On completion of maintenance

f. Remove the padlock only at the end of the maintenance activity.

g. The padlock is not supplied together with the electric box.

With main switch switched on, X120 connector (when present) and the
cables upstream the main switch are under voltage.

HS-RC-C5E-MAN_09.fm
01/1014 35
How to disconnect the power supply of C5G Control Unit
COMAU
Operating procedure (Continued)
Input power supply deactivation
(if the optional connector X120 is not installed)

a. Perform the power supply off-switching as specified in Main switch open (OFF).

b. Open and padlock the main switch upstream the Control Unit. The padlock is not
supplied together with the Control Unit.
Input power supply deactivation
(if the optional X120 connector is installed)
If available, X120 connector shall not be removed with Q100 main switch
closed.

a. Perform the power supply off-switching as specified in the previous steps.

b. This activity requires the removal of X120 connector, located in the box lower
area.
c. Release the levers (D).

d. Remove the X120 mating

connector

Follow-up procedure
– Not necessary on C5G Control Unit (European Version)
– On C5G Control Unit (America Version), when closing the door at the end of the
maintenance:
• do not damage the control and extension shaft
• close the doors with care, avoiding excessive pressure.
• secure the door acting on the lock.

HS-RC-C5E-MAN_09.fm
36 01/1014
 How To Reach The Modules
COMAU

5. HOW TO REACH THE MODULES

This chapter deals with the following topics:
– Precautions Before Starting
– Risks Associated with the Module Reaching Procedures
– Module Location and Access Methods

5.1 Precautions Before Starting

– Read carefully the instructions described in Cap.2. - General Maintenance
Precautions
– Reach for the internal modules only after disconnecting the power.

5.2 Risks Associated with the Module Reaching

Procedures
– Reaching the modules from the rear door does not endanger the operator. The
internal electric components are protected with the degree of IP2x.
– Reaching the modules after the rear panel removal, generates the following
risks:
• burn, due to the high temperature of the recovery resistance and on the rear
panel of the sink of CPU, power supplies and power modules
• cut / abrasion, due to rotating fans, (only if the powering has not been turned
off as required).

HS-RC-C5E-MAN_03.fm
01/1014 37
How To Reach The Modules
COMAU

5.3 Module Location and Access Methods

The modules can be reached through:
– Front Door
– Upper Panel
– Rear Panel.
Find in Tab. 5.1 (in alphabetical order) the modules and components that are included
in the maintenance plan and the related access point.

Tab. 5.1 - Modules / Components List and Access Point

Module / component Access point

ACE - Arm Controller Electromechanical

Upper Panel
(ACE)

ACC - CPU, power supplies and power Front Door (see par. 5.3.1 on
modules pag. 40)

Front Door (see par. 5.3.1 on

CIP - Connector Interface Panel (CIP)
pag. 40)

Rear Panel (see par. 5.3.3 on

pag. 42) and
ERR - Energy Recovery Resistance
Upper Panel (see par. 5.3.2 on
pag. 41)

Upper Panel (see par. 5.3.2 on

FAN - Internal ventilation system - E110
pag. 41)

Rear Panel (see par. 5.3.3 on

FAN - Internal ventilation system - E111..E114
pag. 42)

HS-RC-C5E-MAN_03.fm
38 01/1014
 How To Reach The Modules
COMAU
Tab. 5.1 - Modules / Components List and Access Point (Continued)

Module / component Access point

Front Door (see par. 5.3.1 on

OPD - Operator Panel Devices (OPD)
pag. 40)

Front Door (see par. 5.3.1 on

SDM - Safety Distribution Module (SDM)
pag. 40)

Front Door (see par. 5.3.1 on

pag. 40)
It can be necessary to
UPS - Uninterruptible Power Supply (UPS) remove a panel
C5G-OPK: Options
Plate Kit

Front Door (see par. 5.3.1 on

Complete Safe Kit
pag. 40)

HS-RC-C5E-MAN_03.fm
01/1014 39
How To Reach The Modules
COMAU

5.3.1 Front Door

Equipment
Supplied FIST key
(Spare part Comau 19920154)
1
Fixing screws:
Not foreseen

Warning!
– IP2x Protection
degree on terminal
3 blocks
2
Precautions
– Whenever possible, turn off the
electrical energy before starting
to work inside the cabinet.
– On the North America version, it
is necessary to rotate the main
switch in the OFF position
before opening the door.

Front door opening operating procedure

a. Act with the supplied key by turning it 90° clockwise (1).

b. Open the door (2).

c. The door is supplied with a special item that locks it in open position (3).

Front door closing operating procedure

a. Make sure the internal lever lock is vertical and facing upwards.

b. Unlock the door acting on the lower locking item (3).

c. Close the door.

d. Lock the door using the supplied key, turning it by 90° counter-clockwise.

e. Do not leave the key in the lock.

HS-RC-C5E-MAN_03.fm
40 01/1014
 How To Reach The Modules
COMAU

5.3.2 Upper Panel

Equipment
Allen wrench 3 mm
Fixing screws:
1
Hex socket flat 2 pcs
countersunk head
screws M5

Warning!
– IP2x Protection
degree on terminal
blocks
2
– Presence of voltage on X120
3 terminal block even with main
switch open
Precautions
– Always turn off the electrical
energy from the mains before
accessing the upper panel.
– Disconnect and padlock on the
energy supply point.

Cabinet upper panel opening operating procedure

a. Unscrew the 2 hex socket flat countersunk head screws and the 4 eyebolts
located on the panel (1).

b. Lift and remove the panel slightly (2) and pay attention to the ground connection
on the panel (3).

c. Disconnect the ground wire (3) from the movable panel side.

Cabinet upper panel closing operating procedure

a. Connect the ground wire (3).

b. Lay the panel and tighten the 2 hex socket flat countersunk head screws, without
exaggerating on tightening torque.

c. Tighten the 4 eyebolts, checking the presence of 4 O-Rings in teflon.

HS-RC-C5E-MAN_03.fm
01/1014 41
How To Reach The Modules
COMAU

5.3.3 Rear Panel

Equipment
Allen wrench 3 mm
1 Fixing screws:
Socket hex head 2 pcs
screws M4

Warning!
– Rotating fan
– Hot surfaces
2 3 4
Precautions
– Always turn off the electrical
energy from the mains before
accessing the rear panel.
– Beware of hot surfaces:
recovery resistance and heat
sink.
x3

Cabinet rear panel opening operating procedure

a. Unscrew the 2 socket head cap screws located to the panel high extremities (1).

b. Remove the panel (2) and lift it (3) releasing it from the 3 lower pins.

Cabinet rear panel closing operating procedure

a. Lay the panel on the lower part of the cabinet and matching the 3 pins with the
holes at the panel base (4).

b. Bring the panel near the cabinet.

c. Screw the 2 socket hex head screws without applying an excessive torque.

HS-RC-C5E-MAN_03.fm
42 01/1014
 How To Move The Robot When The Control Unit Is Damaged
COMAU

6. HOW TO MOVE THE ROBOT WHEN THE

CONTROL UNIT IS DAMAGED
This chapter deals with the following topics:
– Precautions Before Starting
– Risks linked to the Robot motion without connected Control Unit
– Use of the C5G-OBR Brake Releasing Module

6.1 Precautions Before Starting

– Read carefully the instructions described in Cap.2. - General Maintenance
Precautions
– The “integrated brake releasing device” located on the Robot may not function if
the Control Unit is damaged. Otherwise may be used the C5G-OBR Brake
Releasing Module (optional). The C5G-OBR Brake Releasing Device Module is to
be used as alternative solution, when the use of the Teach Pendant is not possible.
– The C5G-OBR Brake Releasing Module functioning principle is to supply the motor
brakes with 24Vdc from external source. The command may therefore generate
possible dropping risks (refer to par. 6.2 Risks linked to the Robot motion without
connected Control Unit on pag. 43).
– The “integrated brake releasing device” usage procedures are to be found in each
specific Robot maintenance manual.

6.2 Risks linked to the Robot motion without

connected Control Unit
– The axis brake releasing operation generates falling risk of the axis subject to
gravity.
– The C5G-OBR Brake Releasing Module excludes all the system safety devices:
emergency stop, enabling device push-button, general stop and fence.
– Depending of the load applied to the Robot wrist and position, the axes may move
unpredictably and induce a dropping path that is not perpendicular to the ground.
– While carrying out these activities, the operators shall never stand in the operating
area and in particular under the Robot axes.
– Suitable lifting means may be required to lift the axes and equipment installed on
the Robot wrist, due to their weight (e.g. crane or overhead crane).
– In case of person get caught in the machine, carry out a brake releasing instruction,
only if you are sure that the person does not undergo a higher pressure caused by
the weight of the released axes.
– If not differently specified, the contemporaneous use of 2 or more connectors can
generate additional risks.
– At the end of the operation carry out the Turn-Set procedure on all axes.

HS-RC-C5E-MAN_08.fm
01/0113 43
How To Move The Robot When The Control Unit Is Damaged
COMAU
– Respect the couplings between the Robots, the connector to be used, the selection
on the selector switch on the brake releasing device module and the related axis,
described in Tab. 6.1.

The selected axis on selector may not correspond to the axis number defined in the
Robotic System. Before driving the axis release check the proper selection on the
selector switch and the corresponding coupled axis: a neglected coupling can cause
accidental fall due to gravity of an axis / arm / satellite.

Tab. 6.1 - Matching Robot / Table, Connector and Released Axes

Mating Selected axis on selector of the C5G-OBR module

Connector connector
1 2 3 4 5 6 7/8/9/10
on Robot to be used
base / table on
or other C5G-OBR Released axis on Robot / Positioner / Table
module
Robot
SiX / NS /
NM / NJ / X2 X2 1 2 3 4 5 6 --
NJ4

PAL X2 X2 1 2 3 -- -- 6 --

PAL 470 X2 X2 1 2 3 -- 5 6 --

PRESS
X2 X2 1 2 3 4 5 6 --
100

X2 X2 1 2 3 4 5 6 --
PRESS Directly on
130 SH axis 1 slave MTR7 1 -- -- -- -- -- --
motor
Laser X2 X2 1 2 3 4 -- -- --
Slides
TR AUX -- -- -- -- -- -- Axis x
Positioners
MP XMTRx MTR7 Axis x -- -- -- -- -- --

PTDV X2 X2 10 9 *¹ 8 *¹ -- -- -- --

PTDO X2 X2 10 (No) 9 *¹ 8 *¹ -- -- -- --
Tables
TR XMTRx MTR7 Axis x -- -- -- -- -- --
Additional axes
Additiona
XMTRx MTR7 Axis x -- -- -- -- -- --
l axes

-- = non influential selection because of absence of axis on Control Unit

*¹ = auxiliary axes on positioners (satellites)
Axis x = depends on assignment of axis number on the system
No = axis present on the Control Unit, but brake releasing function not available

HS-RC-C5E-MAN_08.fm
44 01/0113
 How To Move The Robot When The Control Unit Is Damaged
COMAU
XMTRx = from XMTR7 to XMTR10, according to the configuration of the installed table.

6.3 Use of the C5G-OBR Brake Releasing Module

State: – Power off

Material: – Power supply cable with suitable plug
on the connection point of the electric
power (not included in the option
C5G-OBR brake releasing module)
Equipment: – C5G-OBR Brake Releasing Module
– Suitable lifting means to support the
Robot axes subject to gravity

Typical Robot Representative Image

Preliminary procedures / notes

The axis brake releasing operation generates falling risk of the axis subject
to gravity. Please refer to par. 6.2 Risks linked to the Robot motion without
connected Control Unit on pag. 43.
–In the C5G-OBR Option Brake Release Module C5G-OBR includes a
movable plug suitable for the panel socket located on the module rear side
Before the first use, connect a power supply cable with suitable plug to the
mono-phase power supply system present in the plant.
– Provide power to the module (from 100 to 230 Vac, 1.5 A @ 120 Vac / 0.7 A @
230 Vac). The cable section shall be at least 0.5 mm² / 20 AWG. Adjust the
section according to the cable length and the protection upstream.
Be sure that the powering supply voltage is suitable for the brake releasing
model.

This procedure describes the typical operations useful for the majority of
Robots and Positioners.
See the Robot specific manual to obtain specific details.

Operating procedure
a. Support the robot axes subject to gravity with crane or overhead crane. Use
ropes or bends. Do not use chains. See the Robot manual to detect the most
suitable points to sling the Robot.

HS-RC-C5E-MAN_08.fm
01/0113 45
How To Move The Robot When The Control Unit Is Damaged
COMAU
Operating procedure (Continued)
b. To release the 6 Robot axes:
• Disconnect the power connector X2 on the Robot base. The position of the
connector differs depending on the type of robot (if necessary, consult the
manual of the Robot).
• Connect the mating
connector (A) to the X2
connector on the Robot
base. The mating
connector (B) shall not be
used and can be leaned
on the floor.

c. In order to release the axes from 7 to 10:

• Disconnect the power connector of the considered axis. The connector
position differ depending on the type of installation.
• Connect the mating
connector (B) to the
connector of the related
axis to be released. The
mating connector (A)
shall not be used and
can be leaned on the
floor.

d. Provide input (C) power supply

to the releasing module.

e. The presence of power supply

is signalled by the switching on
of the green led (D).

Representative image

HS-RC-C5E-MAN_08.fm
46 01/0113
 How To Move The Robot When The Control Unit Is Damaged
COMAU
Operating procedure (Continued)
f. On the selector (E) select the axis to be released.

g. Se sure to strain the ropes used to support the axes subject to gravity.
h. To release the 6 Robot axes:
• To release axes from 1 to
6 they can be singularly
selected with their related
position.

i. In order to release the axes

from 7 to 10:
• The axes from 7 to 10 are
connected with a
dedicated connector,
which can be connected
with one axis at a time,
and enabled only by
means of selector in
“7-8-9-10” position.
j. Use the lever push-button (F) to release the interested axis. Activate the
push-button with short pressure and check the effect of the motion caused by the
axis released by the brake. Contemporaneously release gradually the the ropes
used to support the axes subject to gravity.

k. The push-button release stops the motion thanks to the brake action (maintained
operate switch).

HS-RC-C5E-MAN_08.fm
01/0113 47
How To Move The Robot When The Control Unit Is Damaged
COMAU

Follow-up procedure
– Restore the connections of the power connectors on the Robot and/or the
interested axes.

Restore the robot function after the use of the C5G-OBR brake releasing
module

The motion through break release module C5G-OBR leads to axes

Turn-set lost; therefore it is very important to restore properly the
function before the first use:
–Before running the Drive On, do not stand under the Robot and be
sure that nothing stands under the axes subjected to gravity.
–In Turn-set condition, during Drive on axes subjected to gravity can
fall, and in case of very big and long arms Robot, can reach some
centimetres.

To restore the Turn-set condition follow the instructions below**:

a. position the Robot axes nearby the calibration notches. In order to align properly
"by sight", use dowel pin with suitable diameter

b. carry out the CAT command. Wait for Turn-set adjustment, at the end of which
the transducer "timing" is obtained and the related position storage.

c. restart the program having care to carry out some low speed cycles to check the
proper functioning.

** The complete and detailed procedure to carry out the Turn-set is

described in the Robot maintenance manual.

HS-RC-C5E-MAN_08.fm
48 01/0113
 Maintenance Structure
COMAU

7. MAINTENANCE STRUCTURE

7.1 Overview
The Control Unit maintenance is divided into:
– Summary Diagram of the Maintenance Operations
– Preliminary Maintenance
– Special Maintenance
.

It is recommended to carry out preliminary maintenance activities periodically, to

preserve the Control Unit functional features longer.
In case of poor or missing preventive maintenance activities during the warranty
period, this will be regarded as prejudicial to the warranty itself.

7.2 Summary Diagram of the Maintenance Operations

Figure Fig. 7.1 gives a schematic diagram of the complete maintenance plan where are
identified the positions and frequency of maintenance operations to be performed.
In the innermost rectangle are indicated the daily periodicity, in those concentric
(increasingly external) are shown in ascending order the following intervals.
In the figure are shown the intervention points which can be identified with the
references presents in the summarising tables in Tab. 8.2 - Preliminary Maintenance
Plan and Tab. 9.2 - Special Maintenance Activities.

HS-RC-C5E-MAN_10.fm
01/1014 49
Maintenance Structure
COMAU
Fig. 7.1 - Summary Diagram of the Maintenance Operations

Fault S1 - S2 S7
1800

1080

720

480

360

240 P2
180

90

30

P3
P4

P1
S3 - S6

S5 - S15
S14 S4

S8
P6

S9
S17 - S18 - S19

S11 - S12 - S16

S10

S13
P5
P5

P1

HS-RC-C5E-MAN_10.fm
50 01/1014
 Preliminary Maintenance
COMAU

8. PRELIMINARY MAINTENANCE
This chapter deals with the following topics:
– Precautions Before Starting
– Equipment Required
– Preliminary Maintenance Plan

8.1 Precautions Before Starting

– Read carefully the instructions described in Cap.2. - General Maintenance
Precautions
– To guarantee the Control Unit proper operation, it is necessary to carry out
periodically preliminary maintenance activities, to reduce the amount of faults
caused by the ordinary deterioration over time, and preserve its functional features.

In case of poor or missing preventive maintenance activities during the warranty

period, this will be regarded as prejudicial to the warranty itself.

8.2 Equipment Required

The minimum equipment necessary to carry out preliminary maintenance activities on
the C5G Control Unit is:

Tab. 8.1 - Equipment Required

Vacuum cleaner
Brush with soft bristles
Set of blade cut and cross-tip screwdrivers
Set of Allen wrenches (sizes in mm)
Environment-friendly solvent
Containers
Gloves

HS-RC-C5E-MAN_04.fm
01/0113 51
Preliminary Maintenance
COMAU

8.3 Preliminary Maintenance Plan

Find in Tab. 8.2 the preliminary maintenance schedule based on the frequency.
In the following section, the maintenance sheets are ordered in alphabetical order
according to the abbreviation.

Tab. 8.2 - Preliminary Maintenance Plan

Frequency Intervention / Sheet Ref. ¹

when other operations are ACC: Door closing and gasket efficiency check (see par. 8.4 on P1
performed pag. 53)
Efficiency check of warning signs
depends of the installation ACO: Emptying Condensate Collection Tank P3
environment
8 months E111..E113: Fans Cleaning (see par. 8.8 on pag. 60) P5
8 months Circuits check and safety devices.
At least every 8 months check the functionality:
– of the emergency push-button by checking the actual
functionality of the two channels
– of the enabling push-button by checking the actual
functionality of the two channels. The diagnostic of the C5G
checks the efficiency of the safety circuits on and, in the event of
a fault, displays an appropriate message on the Teach Pendant.
– of the emergency stop inputs, Auto Stop (Gates) and
General Stop checking the actual functionality of the two
channels. The diagnostic of the C5G checks the efficiency of the
safety circuits on and, in the event of a fault, displays an
appropriate message on the Teach Pendant.
– of the safety relay Pilz present in the options C5G-IEAK
(when it is present).
Also refer to the manual of the cell in which will be
employed the C5G.

8 months ACO: Cleaning the Condenser (if is present). P2

16 months E110: Fan Cleaning (see par. 8.7 on pag. 58) P4
3 years (2 years *¹) UPS: Battery Replacement (see par. 8.9 on pag. 62) P6

We recommend the replacement of the preventive battery if the

installation place is subject to repeated absences of the power
supplies or switching off without invoke the shutdown software
procedure. This advanced replacement guarantees the best
performances in every situation.
Note: If the Control Unit operates in an environment with continuous
temperatures above 35 ° C, the battery life is significantly reduced.

¹ The reference is to be found in Fig. 7.1 - Summary Diagram of the Maintenance

Operations on pag. 50.

HS-RC-C5E-MAN_04.fm
52 01/0113
 Preliminary Maintenance - ACC
COMAU

8.4 ACC: Door closing and gasket efficiency

check
Arm Controller Cabinet

State: – Irrelevant
Material: – Not required
Equipment: – Not required

Frontal view

Preliminary procedures / notes

– The electrical cabinet door shall remain closed to guarantee the efficiency of the
cooling system and prevent contamination from entering in the cabinet. The IP
54 protection class of the cabinet guarantees that this efficiency is maintained.
– The deterioration of the gaskets performances may have a detrimental impact on
this situation.

Operating procedure
a. Check the gaskets efficiency and the correct positioning in their seat along the
entire door perimeter.

b. If necessary, replace the gaskets.

Follow-up procedure
– Not required

HS-RC-C5E-ACC_01.fm
01/1014 53
Preliminary Maintenance - ACO
COMAU

8.5 ACO: Cleaning the Condenser

Air Conditioner Option

State: – Main switch open (OFF)

Material: – Not required
Equipment: – Cross tip screwdriver
– Brush with soft bristles
– Vacuum cleaner
– Environment-friendly solvent

Frontal view

Preliminary procedures / notes

– The conditioner does not require any maintenance activities. The detection oil
traces are symptoms of leakages from the cooling circuit and replacement is
necessary (see card ACO: Replacement).
– The amount of dirt inside the conditioner depends on the quality of the installation
environment air. The times specified in maintenance plan refer to a typical
condition.
Before removing the cover of the air conditioner make sure the power
supply is disconnected and the internal fan is stopped.

It is advised not to use compressed air, because it would be impossible to

control the removed dirt, risking the projection against the face of the
operator.

Operating procedure
a. The cleaning includes the fan, the condenser and the inlet and outlet air
environment openings.
b. Unscrew screws that are holding the cover of the air conditioner.

c. Lift the cover and remove the ground wire connection.

d. Use a brush to remove the dirt, at the same time sucking up with the vacuum
cleaner to collect the dirt. Possible persistent dirt may be removed using an
ecological solvent.

e. Make sure the condensate drainage opening and related pipe are not obstructed.

HS-RC-C5E-ACO_01.fm
54 00/0211
 Preliminary Maintenance - ACO
COMAU
Operating procedure (Continued)
f. In case the thermostat setting
gets accidentally modified,
reset the default value of 45 °C.

g. Replace the cover restoring the ground wire connection.

h. Retighten the cover fixing screws.

Follow-up procedure
– Not required

HS-RC-C5E-ACO_01.fm
00/0211 55
Preliminary Maintenance - ACO
COMAU

8.6 ACO: Emptying Condensate Collection Tank

Air Conditioner Option

State: – Irrelevant
Material: – Not required
Equipment: – Not required

Frontal view

Preliminary procedures / notes

– The emptying frequency depend on the environment humidity, therefore shall be
adjusted accordingly.

Operating procedure
a. Pull out the pipe (A) from the
tank (B).

b. Slip off the tank (B) from the

support.

c. Open the plug and empty the

tank in any water collection well.

d. Close the plug and reinsert the tank (B) in the support item.

e. Reinsert the tube.

HS-RC-C5E-ACO_03.fm
56 00/0211
 Preliminary Maintenance - ACO
COMAU

Follow-up procedure
– Not required

HS-RC-C5E-ACO_03.fm
00/0211 57
Preliminary Maintenance - E110
COMAU

8.7 E110: Fan Cleaning

Fan

State: – Main switch open (OFF)

Material: – Not required
Equipment: – 3 mm Allen wrench
– Brush with soft bristles
– Vacuum cleaner
– Gloves

Frontal view

Preliminary procedures / notes

– To ensure the control unit smooth operating, it is necessary to guarantee the
efficiency of the cooling system.
– The amount of dirt on the cooling fan depends on the quality of the air circulating
in the installation area. The times specified in maintenance plan refer to a typical
condition.
Before removing the panel, make sure the power supply is turned off and
the fan is stopped.

It is advised not to use compressed air, because it would be impossible to

control the removed dirt, risking the projection against the face of the
operator.

Operating procedure
a. The cleaning procedure involves the fan and adjacent area.
b. Remove the Upper Panel (see par. 5.3.2 on pag. 41)to reach the upper area.

c. Use a brush to remove the dirt, at the same time sucking up with the vacuum
cleaner to collect the dirt.

HS-RC-C5E-E110_01.fm
58 00/0309
 Preliminary Maintenance - E110
COMAU
Operating procedure (Continued)
d. The area to be cleaned is the
fan (A) one.
Be careful and make sure
the X120 terminal block is
not powered.

e. Remove dirt with the help of the

brush, acting especially within
the fan blades (A).

f. Remove the Upper Panel (see

par. 5.3.2 on pag. 41).

g. If impurities are found inside the cabinet, check the gaskets conservation status.
Refer to on par. 8.4 ACC: Door closing and gasket efficiency check on pag. 53.

Follow-up procedure
– Not required

HS-RC-C5E-E110_01.fm
00/0309 59
Preliminary Maintenance - E111..E113
COMAU

8.8 E111..E113: Fans Cleaning

Fan

State: – Main switch open (OFF)

Material: – Not required
Equipment: – 3 mm Allen wrench
– Brush with soft bristles
– Vacuum cleaner
– Gloves

Rear view

Preliminary procedures / notes

– To ensure the control unit smooth operating, it is necessary to guarantee the
efficiency of the cooling system.
– The dirt quantity present on the fans and the cooling channel depend on the air
quality present in the installation area. The times specified in maintenance plan
refer to a typical condition.
– The control Unit in rel. 0 can be provided with fans from E111 to E114.
Before removing the panel be sure that the electrical power is powered off
and fans are stopped.

Pay attention to the recovery resistance that can be very hot.

It is advised not to use compressed air, because it would be impossible to

control the removed dirt, risking the projection against the face of the
operator.

Operating procedure
a. The cleaning comprises: the fans, the heat sink, the air passage channel air and
the panel grids
b. Remove the Rear Panel (see par. 5.3.3 on pag. 42)to reach the rear part of the
cabinet.

c. Use a brush to remove the dirt, at the same time sucking up with the vacuum
cleaner to collect the dirt.

HS-RC-C5E-E1xx_01.fm
60 01/0113
 Preliminary Maintenance - E111..E113
COMAU
Operating procedure (Continued)
d. The area to be cleaned is the
fan (A) and heat sink (B) one.
Pay attention to the
recovery resistance that
can be very hot.

e. Remove the dirt using the

brush, in particular on the fan
blades (A) inside area.

f. Remove the dirt from the panel

grids (C) .

g. Reassemble the Rear Panel

(see par. 5.3.3 on pag. 42).

Follow-up procedure
– Not required

HS-RC-C5E-E1xx_01.fm
01/0113 61
Preliminary Maintenance - UPS
COMAU

8.9 UPS: Battery Replacement

Uninterruptible Power Supply

State: – Irrelevant *¹
Material: – Battery (see Tab. 10.3
- Uninterruptible Power Supply (UPS)
on pag. 161)
Equipment: – Cross-tip screwdriver

Frontal view

Preliminary procedures/ notes

Handle the battery with care. Use only batteries supplied as spare parts.
Do not damage the casing to prevent corrosive fluid leakages.
The positive and negative contacts of the battery must not be shorted: Be
careful during the removal and installation.

The battery pack must be disposed of respecting the environment and laws
in force.

*¹ If optional modules are installed that do not allow to reach the UPS module, were
commend turning the Control Unit off before carrying out the procedure (refer to the
Main switch open (OFF).

Operating procedure
a. The UPS module is usually reachable and there is no need to remove other
components. In this case go on with the procedure from point c.

HS-RC-C5E-UPS_01.fm
62 01/1014
 Preliminary Maintenance - UPS
COMAU
Operating procedure (Continued)
b. If there are optional modules on the options plate C5G-OPK that impends the
access, it is advisable to operate in the following way:

b.1 switch off the Control Unit.

b.2 if it is possible, release the UPS module from the omega guide (release lever in
the upper part) passing behind the components / C5G-OPK options plate and
rest the UPS module on the pavement inside of the electric cabinet (carefully to
avoid abrasions caused by crashes and strips with the metal sheet of the
C5G-OPK plate).

b.3 or, remove the optional module mounted rightmost order to access the front side
of the UPS module. Usually it is not necessary to disconnect the cables of the
option and it can be moved on the side, allowing to enter the module.
c. Remove the fuse before acting
on the C5G-UPS module (1).

d. Loosen the cover fixing screw

by 4-5 turns (2). If it is not
removed completely, it will be
easier to mount it back.

e. Lift and remove the battery

cover (3).

f. Disconnect (4) the cables from

the battery terminals.

g. Remove the battery by pulling

the tag (5).

HS-RC-C5E-UPS_01.fm
01/1014 63
Preliminary Maintenance - UPS
COMAU
Operating procedure (Continued)

h. Fit in the new battery and carry out the steps above in reverse order.

i. Connect the cable according to the polarity.

j. Fix the cover and fit the slot in the screw pressing slightly.

k. Tighten the screw without overdoing.

l. Insert the fuse.

m. If it was necessary to remove one or more modules:

m.1 Fix the UPS module on the omega guide.

m.2 Reassemble the removed panel option.

Transfer the exhausted battery in the appropriate collection centers.
For further details, please refer to Cap. Disposal and Dismantling on
pag. 170

Follow-up procedure
– In order to be operational again, the battery takes about 3 ore to complete the
total charge.
– During the charging period, the Control Unit may not be able to guarantee
controlled shutdowns in case of powering interruption. Always perform the
suitable shutdown software procedure

HS-RC-C5E-UPS_01.fm
64 01/1014
 Special Maintenance
COMAU

9. SPECIAL MAINTENANCE
This chapter deals with the following topics:
– Precautions Before Starting
– Equipment Required
– Modules Subject to Special Maintenance Activities

9.1 Precautions Before Starting

– Read carefully the instructions described in Cap.2. - General Maintenance
Precautions

The maintenance activities that are not described in the following sheets shall be
performed by Comau qualified staff.

9.2 Equipment Required

The minimum equipment necessary to carry out special maintenance of the C5G
Control Unit is:

Tab. 9.1 - Equipment Required

Set of flat tip screwdrivers
Set of cross-tip screwdrivers
Set of allen wrenches (sizes in mm) together with extensions
Set of socket wrenches (sizes in mm)
Set of open-end wrenches (sizes in mm)
Socket sets for hex nuts with external hex (sizes in mm)
Sets of crowfoot inserts for torque wrenches (sizes in mm)
Racket torque wrench (or screwdriver) with inserts and extension rod up to 260 mm,
adjustment field about 1 to 6 Nm.
Antistatic wrist strap
Personal Computer supporting the WinC5G software properly installed.
Disk On Key or other storage support, connection via USB
If the whole Control Unit has to be replaced, lifting mean suitable for the installation
area (crane or lift truck)
In case of activities on multi-pin connectors, contacts gripper Harting Part No.09 99
000 0001, contacts puller Harting Part no. 009 99 000 0012 and Harting contacts.
Ethernet connection cable category 5e

HS-RC-C5E-MAN_05.fm
01/0215 65
Special Maintenance
COMAU

9.3 Modules Subject to Special Maintenance Activities

If it is necessary replace the damaged parts, follow the procedures in the subsequent
maintenance sheets.
The sheets, summarized alphabetically by acronym, are reported in the Tab. 9.2.

Tab. 9.2 - Special Maintenance Activities

Intervention / Sheet Ref.¹

ACO: Replacement (see par. 9.4 on pag. 67) S1
ACO: Limit Switch Replacement (see par. 9.5 on pag. 72) S2
AMS-APC: Module Replacement with Compact Flash Recovery (see par. S3
9.6 on pag. 76)
AMS-ASM32: Module Replacement (see par. 9.7 on pag. 87) S4
AMS-IAM: Module Replacement (see par. 9.8 on pag. 90) S5
AMS-PPS: Module Replacement (see par. 9.10 on pag. 105) S6
HMK: Hour Meter Replacement (see par. 9.13 on pag. 116) S7
SDM: Module Replacement (see par. 9.17 on pag. 133) S8
UPS: Module Replacement (see par. 9.20 on pag. 146) S9
PFG-BCO: Power supply replacement (see par. 9.14 on pag. 118) S11
PFG-BCO: Bus Controller Replacement (see par. 9.15 on pag. 121) S12
ERR: Resistance Replacement (see par. 9.12 on pag. 112) S13
X20 - Fieldbus: Modules Replacement (see par. 9.21 on pag. 149) S14
AMS-IAM: Safe Module Replacement (see par. 9.9 on pag. 96) S15
ERM1 Light:Replacement (see par. 9.11 on pag. 110) S16
Safe-key: Replacement (see par. 9.16 on pag. 124) S17
SLU: Module Replacement with Recovery of Safe-Key (see par. 9.18 on S18
pag. 137)
X20 - I/O Safe: Module Replacement (see par. 9.22 on pag. 152) S19
TP5: Replacement (see par. 9.19 on pag. 143) S10

¹ The reference is to be found in Fig. 7.1 - Summary Diagram of the Maintenance

Operations on pag. 50.

HS-RC-C5E-MAN_05.fm
66 01/0215
 Special Maintenance - ACO
COMAU

9.4 ACO: Replacement

Air Conditioner Option

State: – Main switch open (OFF)

Material: – Air conditioner complete with cabinet
roof (see Tab. 10.8 - Conditioning)
Equipment: – M8 male eyebolts, supplied with the
air conditioner
– Lifting system with 40 kg capacity (ex.
crane), with 2 cables of 1 m length with
hook / shackle (Note: inside diameter
of conditioner eyebolt is equal to
20 mm)
– Cross cut screwdriver
– Blade medium cut screwdriver
– 3 mm Allen wrench

Frontal view

Preliminary procedures / notes

– The compressor lubrication oil should stabilize. For this reason, wait at least 8
hours before starting up the air conditioner.
– The procedure may be applied both in case of replacement of the conditioning
device on the Control Unit roof and on the Application Box roof, adapting the
references to the Control Unit to the Application Box.

Operating procedure
a. On the air conditioner, remove
the 2 upper round head screws
(A) that cover the eyebolt holes.

b. On the air conditioner, screw to

replace the 2 M8 eyebolts (B).
The eyebolts are usually
supplied with the Control Unit (if
is equipped with the option). In
case they are no longer
available, use the ones
supplied with the new air
conditioner.

HS-RC-C5E-ACO_02.fm
00/0211 67
Special Maintenance - ACO
COMAU
Operating procedure (Continued)
c. On the C5G, unscrew and
remove the 4 female eyebolts
M12 (C) on the roof.

d. On the C5G, unscrew the 2

countersunk hex head screws
M4 (D).

e. Disconnect the air conditioner

cable connection inside the
cabinet. It may be necessary to
remove 2 or more plastic
clamps (E). The cable is
connected on the terminal block
on the cabinet.

f. From inside the cabinet

disconnect the ground wire
connected to the roof. Leave
connected the wire on the
cabinet.

g. Pull the condensate drain pipe

from the collection tank and the
eyebolt.

HS-RC-C5E-ACO_02.fm
68 00/0211
 Special Maintenance - ACO
COMAU
Operating procedure (Continued)
h. By means of 2 ropes and a
suitable lifting system, anchor
to the 2 eyebolts on the
conditioner. Lift perfectly
vertical, such as not to damage
the threaded bars that come out
the Control Unit, seat of the
removed eyebolts. Note: the
air conditioner weighs 35 kg
i. Place on the floor the removed
air conditioner, remove the
anchoring system and lift and
place the new air conditioner on
the Control Unit. Be careful with
the power supply cable coming
out from the conditioner and the
earth wire for the metallic roof
connection. Keep the air
conditioner in front position (the
blind panel is located frontally).

j. Arrange the connecting cable

tidily inside the Control Unit.

k. Fix with the help of plastic

clamps (E) the cable.

HS-RC-C5E-ACO_02.fm
00/0211 69
Special Maintenance - ACO
COMAU
Operating procedure (Continued)
l. Connect the cable end on the
terminal block (F) on the
cabinet, respecting the
numbering placed on the wires.
The connection is on the lower
side.

m. Restore the connection of the ground wire of the roof.

n. On the C5G, screw in the 4
female eyebolts M12 (C) on the
roof, that are supplied with
plastic washers.

o. On the C5G, screw the 2

countersunk hex head screws
M4 (D).

p. On the conditioner, remove the

2 eyebolts M8 (B) and screw to
replace the 2 round head
screws (A). Put the eyebolts in
the Control Unit pocket, not to
lose them.

HS-RC-C5E-ACO_02.fm
70 00/0211
 Special Maintenance - ACO
COMAU
Operating procedure (Continued)
q. Insert the new condensate
drainage pipe in the eyebolt and
then in the collecting can. Pay
attention the path of the pipe
that must be turned always
down. Cut off the excess of the
pipe.

Follow-up procedure
– Make sure that have elapsed at least 8 hours for stabilisation without tipping the
air conditioner) before starting up the air conditioner.
– The air conditioner start-up is performed only when the cabinet door(s) is/are in
closed position, controlled by the limit switch(es).

HS-RC-C5E-ACO_02.fm
00/0211 71
Special Maintenance - ACO
COMAU

9.5 ACO: Limit Switch Replacement

Air Conditioner Option

State: – Main switch open (OFF)

Material: – Limit switch (see Tab. 10.8
- Conditioning)
Equipment: – Cross cut screwdriver
– Blade medium cut screwdriver
– 3 mm Allen wrench

Frontal view

Preliminary procedures / notes

– This procedure can be used both in Control Unit limit switch replacement case
and Application Box, by adapting the Control Unit references to the Application
Box.

Operating procedure
a. Remove the limit switch (A)
unscrewing the fixing screws.

b. Disconnect the wires directly

from the limit switch terminal
blocks.

c. Disassemble the cable from the

damaged limit switch and
assemble it on the new limit
switch.

d. Plug the cable into the cable

gland.
e. Connect the wires according to the original position. In Fig. 9.1 and Fig. 9.2 are
given the limit switch wiring diagrams.

f. Tighten the cable gland.

HS-RC-C5E-ACO_04.fm
72 00/0411
 Special Maintenance - ACO
COMAU
Operating procedure (Continued)
g. According to the installation
position, fix the limit switch
respecting the distances
indicated in the drawing at the
side.
– (B): installation bracket inside
the Control Unit
– (C): installation bracket inside
the Application Box.
– *: corresponds to the limit
switch face profile

h. Tighten the screws and check

that the quota has not changed.

i. Close the door without overdoing and make sure the limit switch actuator stroke
is not too excessive.

Follow-up procedure
– The air conditioner start-up is performed only when the cabinet door(s) is/are in
closed position, controlled by the limit switch(es).

HS-RC-C5E-ACO_04.fm
00/0411 73
Special Maintenance - ACO
COMAU
Fig. 9.1 - Limit Switch on Control Unit: Connection Diagram

Air Conditioner

Q122: magneto-thermal automatic switch inside Control Unit

S102: limit switch inside Control Unit

HS-RC-C5E-ACO_04.fm
74 00/0411
 Special Maintenance - ACO
COMAU
Fig. 9.2 - Limit Switch on Application Box: Connection Diagram

Air Conditioner

Q122: magneto-thermal automatic switch inside Control Unit

S102: limit switch inside Control Unit
S103: limit switch inside Application Box

HS-RC-C5E-ACO_04.fm
00/0411 75
Special Maintenance - AMS-APC
COMAU

9.6 AMS-APC: Module Replacement with

Compact Flash Recovery
Acopos PC

State: – Main switch open (OFF)

Material: – Module AMS-APC
(see Tab. 10.4 - CPU, power supplies
and power modules on pag. 162)
Equipment: – Flat cut screwdriver (3.5 x 0.6)
– Ratcheting torque wrench (or
screwdriver), allen insert 5 mm,
extension rod up to 260 mm
– Rag

Frontal view

Preliminary procedures / notes

It is not allowed to replace AMS-APC820 modules with AMS-APC830
modules and vice versa.

– The complete procedure is divided into the following main steps:

• par. 9.6.1 Module Replacement AMS-APC on pag. 76
• par. 9.6.2 System Configuration with the TP5 Teach Pendant on pag. 81.

9.6.1 Module Replacement AMS-APC

Operating procedure - Module replacement

a. Disconnect the connectors on
the upper side of the module.
According to the type of
connector, it may be necessary:
– unscrew the screws before
removing the connector
– (A): press the label and keep it
pressed during the extraction

HS-RC-C5E-AM-APC_01.fm
76 00/0914
 Special Maintenance - AMS-APC
COMAU
Operating procedure - Module replacement (Continued)
b. Remove any other connectors and/or USB flash disk inserted into the USB ports
ofAMS-APC, including the XD port: below the module, under the door in
transparent lexan.
c. Unscrew the Allen screw (F)
and remove it.

d. Unscrew the Allen screw (G)

until it spins freely. The screw is
of unmissable type and should
not be removed.

HS-RC-C5E-AM-APC_01.fm
00/0914 77
Special Maintenance - AMS-APC
COMAU
Operating procedure - Module replacement (Continued)
e. Remove the module slightly
outdistancing the lower part,
then lift it.

f. In case of resistance due to the

friction with the adjoining
modules:
– loosen all Allen screws of the
adjoining module.
– if that is not sufficient, continue
to loosen all the screws of all
modules.

Representative image shown with the AMS-IAM module

g. Remove the Compact Flash
present in the slot 1.

h. The removal requires opening

of the door (H). To extract press
the push-button near to the
Compact Flash (L), which
consequently raises.

i. On the new module AMS-APC:

i.1 reinsert the removed Compact

Flash in the slot 1 (M).

HS-RC-C5E-AM-APC_01.fm
78 00/0914
 Special Maintenance - AMS-APC
COMAU
Operating procedure - Module replacement (Continued)
i.2 Lift the front door and check that
the 4 rotary selector switches
are configured with the number
0 (zero).

i.3 Check that the bottom selector

switch rotating is configured
with the number 3.

j. Make sure the module bottom wall and the supporting area on the heat sink are
both perfectly clean.
k. Reassembly the new module in
the slot, firstly hooking it from
the upper part, then lower it
while pushing against the heat
sink.

l. Tighten the allen screws (G) to

5 Nm.

HS-RC-C5E-AM-APC_01.fm
00/0914 79
Special Maintenance - AMS-APC
COMAU
Operating procedure - Module replacement (Continued)
m. Tighten the allen screws (F) to
5 Nm.

n. Reinsert all the connectors (A), making sure the fitting is followed by a sharp
“click” indicating the fitting has been completely accomplished. Pay attention to
the connectors orientation, which may help to find out the location on the
removed AMS-APC module.

o. Replace any other connectors and USB Flash Disk removed earlier.

p. If necessary, refer to the connectors and modules table included in the diagram
fixed inside the Control Unit door.

q. Lower the lexan cover lower on module.

r. Note: At the first startup after replacement ofAMS-APC:

• the Control Unit will start in minimal configuration and many commands will
not be available until the update configuration procedure has not been
completed (the parameters are residing only on the Compact Flash);
• may take a few minutes before the system is ready and the Teach Pendant
ready for use. The cause is the need to update the firmware inside of the
module. In this case, with the started system and at the end of the steps
listed below, may be necessary the switching off and the following restart
(however reported in the messages on the Teach Pendant).

s. Then turn on the Control Unit and wait for the Teach Pendant is operational and
functioning. In case of using a Wireless Teach Pendant may be necessary to
perform the Pairing procedure, possibly anticipated by the emergency Unpairing
procedure (The Pairing and Unpairing procedure are described in ''Control Unit
Use'' manual.

t. On the Control Unit selector switch mode, select the PROG module. The selector
switch is on the Teach Pendant (TP wired) or on the docking station (TP
wireless).

u. If you have the TP5 Teach Pendant, continue with the procedure given in the
par. 9.6.2 System Configuration with the TP5 Teach Pendant on pag. 81.

HS-RC-C5E-AM-APC_01.fm
80 00/0914
 Special Maintenance - AMS-APC
COMAU

9.6.2 System Configuration with the TP5 Teach Pendant

Operating procedure - system configuration with the TP5 Teach Pendant

Access to the Control Unit with maintainer's rights
a. Log in with the maintenance
wrights:

a.1 Access the “Home” page (press

the Menù key, then press
Home)

a.2 Press the “Login” key

a.3 Use the virtual keyboard to fill in

the user name with the "MU"
value and confirm with the
Enter key.

a.4 Use the virtual keyboard to fill in

the password with the "MU"
value and confirm with the
Enter key.
Loading the system configuration
b. Run the configuration loading

b.1 Access the “Configure” page

(press the Menù key, then press
Setup, System, Configure key).

HS-RC-C5E-AM-APC_01.fm
00/0914 81
Special Maintenance - AMS-APC
COMAU
Operating procedure - system configuration with the TP5 Teach Pendant
b.2 Choose with the softkey "..." the
adequate configuration file, so
typically referred to as:
UD:/sys/cnfg/CNTRLC5G_xxx.
C5G (xxx = serial number of
C5G).

b.3 Press the “Load” key and

confirm with “Yes” key.

Run the axes Turn Set

c. The system loses absolute reference coordinates and requests the Turn Set
procedure. In order to:

c.1 position each Robot single axis on the calibration notch in jog mode;

c.2 access the “Calib” page (press the Menù key, then press Setup, Motion, Calib
key).

c.3 select one axis at a time and confirm with "Turn Set" key;

c.4 if necessary, consult the procedure in the “Control Unit Use” manual.
Saving the new configuration
d. Save the system configuration
(this operation aligns the
contents of all storage areas of
the Control Unit):

d.1 Access the “Configure” page

(press the Menù key, then press
Setup, System, Configure key).

HS-RC-C5E-AM-APC_01.fm
82 00/0914
 Special Maintenance - AMS-APC
COMAU
Operating procedure - system configuration with the TP5 Teach Pendant
d.2 The configuration file that
appears on the screen is the
default, so typically referred to
as:
UD:/sys/cnfg/CNTRLC5G_xxx.
C5G (xxx = serial number of
C5G).

d.3 Press the “Save” key and

confirm with “Yes” key.

d.4 Reset the possible alarms "64584 New restart sequence" and "64569 Detected
the new system software restart" In order to access the “Alarm” (press the Menù
key, then Alarm key).
The system restart
e. Restart the system:

e.1 Access the “Home” page (press

the Menù key, then press
Home)

e.2 Press the “Restart” key

e.3 Use the arrows, select the item

1 “Complete (Cold)” and
confirm with “Enter” key.

e.4 Confirm with "Ok" key

HS-RC-C5E-AM-APC_01.fm
00/0914 83
Special Maintenance - AMS-APC
COMAU
Operating procedure - system configuration with the TP5 Teach Pendant
Access to the Control Unit with maintainer's rights
f. Log in with the maintenance
rights:

f.1 Access the “Home” page (press

the Menù key, then press
Home)

f.2 Press the “Login” key

f.3 Use the virtual keyboard to fill in

the user name with the "MU"
value and confirm with the
Enter key.

f.4 Use the virtual keyboard to fill in

the password with the "MU"
value and confirm with the
Enter key.
Load the machine description parameters, calibration constants, value of the
hour meter
g. Run the loading of parameters:

g.1 Access the “Configure” page

(press the Menù key, then press
Setup, Motion, Calib key).

HS-RC-C5E-AM-APC_01.fm
84 00/0914
 Special Maintenance - AMS-APC
COMAU
Operating procedure - system configuration with the TP5 Teach Pendant
g.2 Press the “Load” key and
confirm with “Yes” key.

g.3 Exit by pressing the "Esc" key, then select the "Folder back" key.
Saving the new configuration
h. Save the system configuration
(this operation aligns the
contents of all storage areas of
the Control Unit):

h.1 Access the “Configure” page

(press the Menù key, then press
Setup, System, Configure key).

HS-RC-C5E-AM-APC_01.fm
00/0914 85
Special Maintenance - AMS-APC
COMAU
Operating procedure - system configuration with the TP5 Teach Pendant
h.2 The configuration file that
appears on the screen is the
default, so typically referred to
as:
UD:/sys/cnfg/CNTRLC5G_xxx.
C5G (xxx = serial number of
C5G).

h.3 Press the “Save” key and

confirm with “Yes” key.

The system restart

i. Restart the system:

i.1 Access the “Home” page (press

the Menù key, then press
Home)

i.2 Press the “Restart” key

i.3 Use the arrows, select the item

1 “Complete (Cold)” and
confirm with “Enter” key.

i.4 Confirm with "Ok" key

Follow-up procedure
– The maintainer user access (login and password) is restored to the previously
stored in the database and users may not be able to access the "MU" default
login and password.
– Do not stand under the Robot or in the areas nearby.
– Carry out some motion cycles at reduced speed to check the proper functioning.
– Select the AUTO mode and, at reduced speed, check the proper program
functioning.

HS-RC-C5E-AM-APC_01.fm
86 00/0914
 Special Maintenance - AMS-ASM32
COMAU

9.7 AMS-ASM32: Module Replacement

Auxiliary Supply Module

State: – Main switch open (OFF)

Material: – Module AMS-ASM32
(see Tab. 10.4 - CPU, power supplies
and power modules on pag. 162)
Equipment: – Ratcheting torque wrench (or
screwdriver), allen insert 5 mm,
extension rod up to 260 mm

Frontal view

Preliminary procedures / notes

– Not required.

Operating procedure
a. Disconnect the connectors on
the upper side of the module.
According to the type of
connector, it may be necessary:
– (A): direct extraction (connector
without fixing systems)

b. Unscrew the Allen screw (F)

and remove it.

HS-RC-C5E-AM-ASM_01.fm
01/1014 87
Special Maintenance - AMS-ASM32
COMAU
Operating procedure (Continued)
c. Unscrew the Allen screw (G)
until it spins freely. The screw is
of unmissable type and should
not be removed.

d. Remove the module slightly

outdistancing the lower part,
then lift it.

e. In case of resistance due to the

friction with the adjoining
modules:
– loosen all Allen screws of the
adjoining module.
– if that is not sufficient, continue
to loosen all the screws of all
modules.

Representative image shown with the AMS-IAM module

f. Make sure the module bottom wall and the supporting area on the heat sink are
both perfectly clean.

HS-RC-C5E-AM-ASM_01.fm
88 01/1014
 Special Maintenance - AMS-ASM32
COMAU
Operating procedure (Continued)
g. Reassembly the new module in
the slot, firstly hooking it from
the upper part, then lower it
while pushing against the heat
sink.

h. Tighten the Allen screw (G) to

5 Nm.

i. Tighten the Allen screw (F) to

5 Nm.

j. Reinsert all the connectors (A).

k. If necessary, refer to the connectors and modules table included in the diagram
fixed inside the Control Unit door.

l. Lower the lexan cover lower on module.

Follow-up procedure
– Not necessary.

HS-RC-C5E-AM-ASM_01.fm
01/1014 89
Special Maintenance - AMS-IAM
COMAU

9.8 AMS-IAM: Module Replacement

Inverter Axis Module

State: – Main switch open (OFF)

Material: – Module AMS-IAM
(see Tab. 10.4 - CPU, power supplies
and power modules on pag. 162)
Equipment: – Flat cut screwdriver, nano (4 x 25)
– Flat cut screwdrivers (3 x 15 and 6 x
15)
– Ratcheting torque wrench (or
screwdriver), allen insert 5 mm,
extension rod up to 260 mm
– Antistatic wrist strap

Frontal view

Preliminary procedures / notes

– The antistatic wrist strap can be connected on one of the pins available inside the
(CIP) galvanized connector panel. The connection efficiency is guaranteed only
if the Control Unit is earthed.
– The antistatic wrist strap shall be worn during the transducer modules
disassembly and assembly procedure. During the other activities the antistatic
wrist strap is not required.
– The procedure shows images and explanations for the AMS-IAM double module.
In case of single module, the number of connectors and the fixing screws are
halved.

Operating procedure
a. Disconnect the connectors on
the upper side of the module.
According to the type of
connector, it may be necessary:
– (A): to unscrew the screws
before removing the connector
– (B): to carry out a direct removal
(connector without fixing
systems)
– (C): to press the tab and keep it
pressed during the removal

HS-RC-C5E-AM-IAM_01.fm
90 01/1014
 Special Maintenance - AMS-IAM
COMAU
Operating procedure (Continued)
b. Disconnect the connectors on
the module lower side by
removing the connectors (D).

c. Unscrew the screws (E), lift the

terminal block and move it away
from the module.

d. Unscrew the Allen screws (F)

and remove them.

e. Unscrew the Allen screws (G)

until they spin freely. The
screws are unmissable type
and should not be removed.

HS-RC-C5E-AM-IAM_01.fm
01/1014 91
Special Maintenance - AMS-IAM
COMAU
Operating procedure (Continued)
f. Remove the module slightly
outdistancing the lower part,
then lift it.

g. In case of resistance due to the

friction with the adjoining
modules:
– loosen all Allen screws of the
adjoining module.
– if that is not sufficient, continue
to loosen all the screws of all
modules.

h. Wear the antistatic wrist strap.

i. Check the transducer (H)

module type. The abbreviation
is printed on the metallic front
area:

– Interface module
Encoder AMS-ETI22:
ENDAT 2.2 / AC0120-2

– Interface module
Resolver AMS-RTI:
Resolver / AC0122
j. Prepare a new axes module with interface module/s consistent with the removed
items.
k. The transducer interface module (e.g. module AMS-ETI22) may vary between
the module. It is recommended to replace with new components both for the
AMS-IAM module and the interface one, being very carefully not to change the
model.

HS-RC-C5E-AM-IAM_01.fm
92 01/1014
 Special Maintenance - AMS-IAM
COMAU
Operating procedure (Continued)
l. Open the front door (L) by
levering with a screwdriver on
the upper part.

m. Record the IP address of

AMS-IAM module available on
the rotating selector switches
(M) to be able to set it in the new
module.

n. If necessary, remove the

interface module:

n.1 Using a screwdriver, push

gently upwards, levering on the
inside tooth (J) available on the
interface module.

HS-RC-C5E-AM-IAM_01.fm
01/1014 93
Special Maintenance - AMS-IAM
COMAU
Operating procedure (Continued)
n.2 Remove the module (K) while
keeping on pushing gently.

n.3 Repeat the procedure for the

second module.

o. Make sure the module bottom wall and the supporting area on the heat sink are
both perfectly clean.
p. Reassembly the new module in
the slot, firstly hooking it from
the upper part, then lower it
while pushing against the heat
sink.

q. Tighten the Allen screws (G) to

5 Nm.

r. Tighten the Allen screws (F) to

5 Nm.

HS-RC-C5E-AM-IAM_01.fm
94 01/1014
 Special Maintenance - AMS-IAM
COMAU
Operating procedure (Continued)
s. Reinsert all the connectors (C), making sure the fitting is followed by a sharp
“click” indicating the fitting has been completely accomplished.

t. Reinsert the connectors (B).

u. Reinsert the connectors (A) the corresponding screws (do not overtighten the
screws).

v. Reinsert the terminal block and tighten the screws (E).

w. Reinsert the connectors (D).

x. If necessary, refer to the connectors and modules table included in the diagram
fixed inside the Control Unit door.

y. Lower the lexan lower cover on the module.

z. Set the IP address on the
rotating selector switches (M) of
AMS-IAM module according to
the values in the removed
module.

aa. Close the door (L).

ab. At the first start after theAMS-IAMreplacement, the Control Unit automatically
checks and updates if necessary the internal firmware of the module. The current
updating procedure and the complete updating confirmation appears in the TPInt
page. Do not interrupt the procedure. During updating it is not possible to carry
out any motion instruction.

Follow-up procedure
– Do not stand under the Robot or in the areas nearby.
– Carry out some motion cycles at reduced speed to check the proper functioning.
– Select the AUTO mode and check the proper operating at reduced speed.

HS-RC-C5E-AM-IAM_01.fm
01/1014 95
Special Maintenance - AMS-IAM
COMAU

9.9 AMS-IAM: Safe Module Replacement

Inverter Axis Module

State: – Main switch open (OFF)

Material: – Module AMS-IAM
(see Tab. 10.10 - Complete Safe Kit
on pag. 169)
Equipment: – Flat cut screwdriver, nano (4 x 25)
– Flat cut screwdrivers (3 x 15 and 6 x
15)
– Ratcheting torque wrench (or
screwdriver), allen insert 5 mm,
extension rod up to 260 mm
– PC with Ethernet port
– Browser web (preferably updated
Mozilla Firefox, Google Chrome or
Apple Safari versions)
– Operating system (Microsoft®
Frontal view
Windows®, Apple OSx or Linux
distribution are preferred)
– Ethernet connection cable category
5e (it is suggested to use the crossed
cable in case of point to point
connection)

Preliminary procedures / notes

– The procedure shows images and explanations for the AMS-IAM double module.
In case of single module, the number of connectors and the fixing screws are
halved.
– The complete procedure is divided into the following main steps:
• par. 9.9.1 Safe AMS-IAM Module Replacement on pag. 97
• par. 9.9.2 Recovery procedure after the replacement of a axes module on
pag. 102

HS-RC-C5E-AM-IAM_Safe_01.fm
96 01/1014
 Special Maintenance - AMS-IAM
COMAU

9.9.1 Safe AMS-IAM Module Replacement

Operating procedure
a. Disconnect the connectors on
the upper side of the module.
According to the type of
connector, it may be necessary:
– (A): to unscrew the screws
before removing the connector
– (B): press the label and keep it
pressed during the removal

b. Disconnect the connectors on

the module lower side by
removing the connectors (C).

c. Unscrew the screws (D), lift the

terminal block and move it away
from the module.

d. Unscrew the Allen screws (E)

and remove them.

e. Unscrew the Allen screws (F)

until they spin freely. The
screws are unmissable type
and should not be removed.

HS-RC-C5E-AM-IAM_Safe_01.fm
01/1014 97
Special Maintenance - AMS-IAM
COMAU
Operating procedure (Continued)
f. Remove the module slightly
outdistancing the lower part,
then lift it.

g. In case of resistance due to the

friction with the adjoining
modules:
– loosen all Allen screws of the
adjoining module.
– if that is not sufficient, continue
to loosen all the screws of all
modules.

h. Open the front door (G) by

levering with a screwdriver on
the upper part.

HS-RC-C5E-AM-IAM_Safe_01.fm
98 01/1014
 Special Maintenance - AMS-IAM
COMAU
Operating procedure (Continued)
i. Record the IP address of
AMS-IAM module available on
the rotating selector switches
(H) to be able to set it in the new
module.

j. Make sure the module bottom wall and the supporting area on the heat sink are
both perfectly clean.
k. Reassembly the new module in
the slot, firstly hooking it from
the upper part, then lower it
while pushing against the heat
sink.

HS-RC-C5E-AM-IAM_Safe_01.fm
01/1014 99
Special Maintenance - AMS-IAM
COMAU
Operating procedure (Continued)
l. Tighten the Allen screws (F) to
5 Nm.

m. Tighten the Allen screws (E) to

5 Nm.

n. Reinsert all the connectors (B), making sure the fitting is followed by a sharp
“click” indicating the fitting has been completely accomplished.

o. Reinsert the connectors (A) the corresponding screws (do not overtighten the
screws).

p. Reinsert the terminal block and tighten the screws (D).

q. Reinsert the connectors (C).

r. If necessary, refer to the connectors and modules table included in the diagram
fixed inside the Control Unit door.

s. Lower the lexan lower cover on the module.

HS-RC-C5E-AM-IAM_Safe_01.fm
100 01/1014
 Special Maintenance - AMS-IAM
COMAU
Operating procedure (Continued)
t. Set the IP address on the
rotating selector switches (H) of
AMS-IAM module according to
the values in the removed
module.

u. Close the door (G).

v. At the first start after theAMS-IAMreplacement, the Control Unit automatically

checks and updates if necessary the internal firmware of the module. The current
updating procedure and the complete updating confirmation appears in the TPInt
page. Do not interrupt the procedure. During updating it is not possible to carry
out any motion instruction.

HS-RC-C5E-AM-IAM_Safe_01.fm
01/1014 101
Special Maintenance - AMS-IAM
COMAU

9.9.2 Recovery procedure after the replacement of a axes

module

Pre-settings
• The Robotic system must be set in Programming (T1) mode
• Motors must be off.

Operating procedure
a. When restarting the system, wait for the restart. The restart procedure may take
about 10 minutes to allow the firmware loading. During charging, the LED R/E on
the axis module lights up in flashing mode.

b. When the loading is finished, the LED R/E must be a steady green.

c. Access the RoboSAFE configuration Web pages (access procedures are given
in the "RoboSAFE Functionality Use" manual).

d. Pay attention before confirming the acknowledgement of the replaced Safe

Modules:
• after the replacement of one or more safe modules, up to 4 modules, it is
necessary to Acknowledge the push-button which identifies the number of
replaced modules;
• after the replacement of 5 or more modules safe use the "N" push-button.

e. Before the request for Acknowledge, the status LED is yellow and the Message
Bar shows the message "Please, ack xx new module".
f. From the Access page to the
maintenance functionality
(Service), press the
push-button showing the
number of replaced modules, or
"N" in the case of replacement
of 5 or more.

g. Wait for the shutdown

procedure to end.

h. On the Teach Pendant, run the Restart Cold command; wait for the system
restart.

HS-RC-C5E-AM-IAM_Safe_01.fm
102 01/1014
 Special Maintenance - AMS-IAM
COMAU
Operating procedure (Continued)
i. Access the Web pages; on
Service Web page, press the
"RECOVERY MODE"
push-button.

j. the system asks for

confirmation of the change
mode; answer by pushing the
Yes push-button.

k. the new Recovery Mode state is

highlighted by the yellow LED
on the push-button and the text
below.

l. From this moment is possible to enable DRIVE ON and move in Jog mode.

m. Move in JOG the Robot axes to get them the as close as possible to the
calibration position.

n. Run the turn-set on the axes subject of maintenance.

o. When is close to the calibration position and without risk of impacts with the
structures of the cell, run the command "Execute Move to $CAL_SYS" (or
"Execute Move to $CAL_USER" if it has been customized calibration position).
p. On the Web page, press the
"NORMAL MODE" push-button
and confirm with the "Yes

q. Wait for the complete return in the Normal Mode, which also includes the
restoration of the consistency of the encoder positions; completion is shown by
the green LED on the button.

r. At the end of the procedure and confirmation of successful completion, the LED
status should be green.

HS-RC-C5E-AM-IAM_Safe_01.fm
01/1014 103
Special Maintenance - AMS-IAM
COMAU

Follow-up procedure
– Do not stand under the Robot or in the areas nearby.
– Carry out some motion cycles at reduced speed to check the proper functioning.
– Select the AUTO mode and check the proper operating at reduced speed.

HS-RC-C5E-AM-IAM_Safe_01.fm
104 01/1014
 Special Maintenance - AMS-PPS
COMAU

9.10 AMS-PPS: Module Replacement

Passive Power Supply

State: – Main switch open (OFF)

Material: – Module AMS-PPS
(see Tab. 10.4 - CPU, power supplies
and power modules on pag. 162)
Equipment: – Allen key 5 mm T, length 250 mm,
torque

Frontal view

Preliminary procedures / notes

– Before replacing the module after diagnosing a non-functioning, it is advisable to
check the fuse efficiency on the module (see Fuse Replacement in the Module
AMS-PPS (see par. 9.10.1 on pag. 109) and Symptoms and Consequences for
Breaking the Fuse (see par. 9.10.2 on pag. 109)).

Operating procedure
a. Disconnect the connectors on
the upper side of the module.
According to the type of
connector, it may be necessary:
– (A): direct extraction (connector
without fixing systems)
– (B): press the label and keep it
pressed during the removal

HS-RC-C5E-AM-PPS_01.fm
01/1014 105
Special Maintenance - AMS-PPS
COMAU
Operating procedure (Continued)
b. Disconnect the connectors on
the module lower side by
removing the connectors (D).

c. Unscrew the Allen screws (F)

and remove them.

d. Unscrew the Allen screws (G)

until they spin freely. The
screws are unmissable type
and should not be removed.

HS-RC-C5E-AM-PPS_01.fm
106 01/1014
 Special Maintenance - AMS-PPS
COMAU
Operating procedure (Continued)
e. Remove the module slightly
outdistancing the lower part,
then lift it.

f. In case of resistance due to the

friction with the adjoining
modules:
– loosen all Allen screws of the
adjoining module.
– if that is not sufficient, continue
to loosen all the screws of all
modules.

Representative image shown with the AMS-IAM module

g. Make sure the module bottom wall and the supporting area on the heat sink are
both perfectly clean.
h. Reassembly the new module in
the slot, firstly hooking it from
the upper part, then lower it
while pushing against the heat
sink.

HS-RC-C5E-AM-PPS_01.fm
01/1014 107
Special Maintenance - AMS-PPS
COMAU
Operating procedure (Continued)
i. Tighten the Allen screws (G) to
5 Nm.

j. Tighten the Allen screws (F) to

5 Nm.

k. Reinsert all the connectors (B), making sure the fitting is followed by a sharp
“click” indicating the fitting has been completely accomplished.

l. Reinsert all the connectors (A) and (D).

m. If necessary, refer to the connectors and modules table included in the diagram
fixed inside the Control Unit door.

n. Lower the lexan lower cover on the module.

o. At the first start after theAMS-PPSreplacement, the Control Unit automatically
checks and updates if necessary the internal firmware of the module. The current
updating procedure and the complete updating confirmation appears in the TPInt
page. Do not interrupt the procedure. During updating it is not possible to carry
out any motion instruction.

Follow-up procedure
– At the first startup after theAMS-PPS replacement may take a few minutes before
the system is ready and the programming terminal ready to be used. The cause
is the need to update the firmware inside of the module. In this case, with the
started system, may be necessary to switch off and the following restart (however
reported in the messages on the Teach Pendant).

HS-RC-C5E-AM-PPS_01.fm
108 01/1014
 Special Maintenance - AMS-PPS
COMAU

9.10.1 Fuse Replacement in the Module AMS-PPS

Operating procedure
a. Lift the lower door to cover the
cables and unscrew the fuse
holder plug.

b. Verify the fuse efficiency by

testing continuity.

c. If necessary, replace the fuse

(Fuse):
– quick type, 10.3 x 38 mm, 600V,
30A

9.10.2 Symptoms and Consequences for Breaking the Fuse

Operating procedure
a. The fuse intervention (Fuse) excludes the recovery resistance from Bus-DCwith
the following overvoltage on the bus and the error appearance:
– 60948 11-DRIVE OFF Axis <axis_num> Arm <arm_num> <axisType> -
7200:DC bus - Overvoltage
– 60950 11-DRIVE OFF Axis <axis_num> Arm <arm_num> <axisType> -
7225:DC bus - Overvoltage

b. This error can also be generated by the interruption of the connection of the
resistance or the breaking of the resistance itself 14.96 ohm)

HS-RC-C5E-AM-PPS_01.fm
01/1014 109
Special Maintenance - ERM1 Light
COMAU

9.11 ERM1 Light:Replacement

Expansion Relay Module 1 Light

State: – Main switch open (OFF)

Material: – ERM1 Light
(see Tab. 10.10 - Complete Safe Kit
on pag. 169)
Equipment: – Not necessary.

Frontal view

Preliminary procedures / notes

– To replace the ERM1 Lightmodules, is necessary to open the front door of the
Control Unit.
– The ERM1 Light module is normally accessible and is not required removal of
other components.

Operating procedure
a. Disconnect the connectors on
the module front side.
According to the type of
connector, it may be necessary:
– (A): direct removal of the
connector
– (B): X411 and X412
connectors, press the label and
keep it pressed during the
removal

HS-RC-C5E-C5G-ERM1Light_01.fm
110 01/1014
 Special Maintenance - ERM1 Light
COMAU
Operating procedure (Continued)
b. Act on the appropriate levers
(C), unhook the upper part of
the omega guide module (D).

c. Remove the module from the

omega guide.

d. Insert the new module on the

omega guide, hooking firstly
from the lower side.

e. Apply a slight pressure on the

upper part of the module, in
order to obtain the correct
coupling of the same on the
omega guide.
If necessary, apply a slight
pressure on the rear side of the
levers (C) in order to facilitate
the insertion of the module on
the omega guide.
f. Reinsert the connectors
previously removed. According
to the type of connector, it may
be necessary:
– (A): direct insertion of the
connector, with reference notch
for correct positioning
– (B): insert the connectors by
ensuring the complete insertion
followed by a sharp click.

Follow-up procedure
– Do not stand under the Robot or in the areas nearby.
– Carry out some motion cycles at reduced speed to check the proper functioning.
– Select the AUTO mode and check the proper functioning at reduced speed.

HS-RC-C5E-C5G-ERM1Light_01.fm
01/1014 111
Special Maintenance - ERR
COMAU

9.12 ERR: Resistance Replacement

Energy Recovery Resistance

State: – Main switch open (OFF)

Material: – C5G-ERR Recovery Resistance (see
Tab. 10.4 - CPU, power supplies and
power modules on pag. 162)
Equipment: – 22 and 24mm open-end wrenches
– Cross cut screwdriver
– Torque wrench with inserts for
cross-cut screws and crowfoot inserts
of 22 and 24 mm
– 3 mm Allen wrench
– Socket for hex nuts with external
hexagon

Rear view

Preliminary procedures / notes

DANGER HIGH TEMPERATURES!
Before carrying out the procedure for replacing the recovery resistance,
make sure that the resistance itself has cooled.
Is recommended to carry out the replacement procedure only after a few
minutes after turning off the Control Unit.

Operating procedure
a. Remove the Upper Panel (see par. 5.3.2 on pag. 41) and Rear Panel (see par.
5.3.3 on pag. 42) as indicated in the relevant procedures.

b. Open the Front Door (see par. 5.3.1 on pag. 40).

c. Open the lower access flap of
the AMS-PPS module.

d. Disconnect the X5B/PPS

connector (A) from the lower
side of the AMS-PPS module.

e. On the X5B/PPS connector,

unscrew the screws (B) of the
terminal blocks and disconnect
the cables from the connector
itself.

f. Position the connector in a

clean place, as it will be used
again later.

HS-RC-C5E-ERR_01.fm
112 01/0215
 Special Maintenance - ERR
COMAU
Operating procedure (Continued)
g. Insert the socket (C) for the hex
nuts on one of the cables just
disconnected.

h. Slide the socket along the

cable, until arriving close to the
coupling point of the recovery
resistance on the inside of the
Control Unit.

i. Using a 22 mm open-end
wrench, unscrew and remove
the fixing nut (D).
Evaluate the use of a second
open-end wrench, to use as the
false wrench on the outside of
the Control Unit.
j. Repeat the operation for the second fixing nut.
Upon removal of the fixing nuts, be careful not to lose the 2 galvanized
iron washers interposed between the nuts and the inside wall of the cabin.

k. Release the resistance (E) from

the bracket (E) and remove it by
pulling it out from the rear side
of the cabin. Pay attention to the
cables connected to it, to
prevent the cables them selves
they hook during extraction
operations.

Upon removal of the recovery resistance, be careful not to lose the 2

teflon gaskets interposed between the recovery resistance and the
outside wall of the cabin.

HS-RC-C5E-ERR_01.fm
01/0215 113
Special Maintenance - ERR
COMAU
Operating procedure (Continued)
l. Reassemble the new recovery
resistance.

m. During the resistance

replacement, insert the gaskets
and washers as shown in the
figure.

Sectional view:
1 = Fixing nut
2 = Galvanized iron washer
3 = Teflon gasket
4 = Recovery resistance
5 = Control Unit rear wall
n. Obtaining the resistance correct
positioning, tighten the fixing
nuts (D).

o. Tighten the nuts with the help

of a socket for hex nuts (C) and
a torque wrench with 22 mm
crowfoot insert.

Representative image with use of open-end wrench.

p. Twist the wires and slide them
inside the Control Unit to reach
the lower side of the AMS-PPS
module.

q. Connect the cables of the

recovery resistance to the
X5B/PPS connector, tightening
the screws (B) of the terminal
blocks to the tightening torque
of 1.4 Nm.

r. Open the lower access flap of

the AMS-PPS module.

s. Connect the X5B/PPS

connector (A) in its seat on the
lower side of the AMS-PPS
module.

HS-RC-C5E-ERR_01.fm
114 01/0215
 Special Maintenance - ERR
COMAU
Operating procedure (Continued)
t. Reassemble the Upper Panel (see par. 5.3.2 on pag. 41) and the Rear Panel
(see par. 5.3.3 on pag. 42) previously removed.

u. Reclose the Front Door (see par. 5.3.1 on pag. 40).

Follow-up procedure
– Do not stand under the Robot or in the areas nearby.
– Carry out some motion cycles at reduced speed to check the proper functioning.
– Select the AUTO mode and check the proper functioning at reduced speed.

HS-RC-C5E-ERR_01.fm
01/0215 115
Special Maintenance - HMK
COMAU

9.13 HMK: Hour Meter Replacement

Hour Meter Kit

State: – Main switch open (OFF)

Material: – Hour meter (see Tab. 10.2 - Operator
Panel Devices (OPD) on pag. 161)
Equipment: – Flat cut screwdrivers

Frontal view

Preliminary procedures/ notes

– The hour-meter module records the Robot working hours. Record the value
displayed by the removed hour-meter and consider the value in the calculation of
future periodic maintenances of the Robot.

Operating procedure
a. Press both side levers (A) on
the inside plastic frame.

b. Keeping pressed the levers, slip

off the frame (B).

HS-RC-C5E-HMK_01.fm
116 00/0309
 Special Maintenance - HMK
COMAU
Operating procedure (Continued)
c. Keeping pressed the levers, slip
off the frame (B).

d. Push the hour-meter outwards.

e. Connect the wires to the new

hour-meter.

f. Insert the new hour-meter in the seat, steering it properly.

g. Keep the hour-meter in position and reinsert the plastic frame, pushing it fully.

Follow-up procedure
– Not necessary.

HS-RC-C5E-HMK_01.fm
00/0309 117
Special Maintenance - PFG-BCO
COMAU

9.14 PFG-BCO: Power supply replacement

Bus Coupler power supply

State: – Main switch open (OFF)

Material: – Power supply of the module
PFG-BCO
(see Tab. 10.9 - X20 - Field Bus
Modules on pag. 167)
Equipment: – Not necessary.

Frontal view

Preliminary procedures / notes

– To replace the Power supply, is necessary to open the front door of the Control
Unit.
– The power supply is installed on the PFG-BCO module that is normally
accessible; is not required removal of other components.

Operating procedure
a. Make a slight pressure on the
release lever (A) in the upper
part of the terminal block (B).

b. While holding pressed the lever

(A), remove the terminal block
before pulling it out from the
upper side and rotating it and
supporting on the lower
coupling point (C).

c. Without disconnecting the

cables, support the terminal
block in such a way as not to
create clutter for subsequent
operations.
The anticipated removal of the terminal block from the power supply, is
essential to avoid possible mechanical damages on the modules during
the later stages of the procedure.

HS-RC-C5E-C5G-PFG-BCO_02.fm
118 01/1014
 Special Maintenance - PFG-BCO
COMAU
Operating procedure (Continued)
d. Make a slight pressure on the
release lever (D) in the upper
part of the power supply.

e. While holding pressed the lever

(D), remove the power supply
(E) from the base (F), pulling it
in the direction indicated by the
arrow in the figure. Do not tilt
the power supply in order to
avoid possible damages to the
connectors.
During the operation of removal
of the power supply, it is
recommended to keep with one
hand the base (F) in position, in
order to avoid possible release
from the omega guide after the
module power supply.
f. Make sure that the connectors areas on the new power supply (E) and the base
(F) are both perfectly clean.
g. Insert the new power supply (E)
holding the module perfectly
aligned to the base (F), to
prevent possible damage to the
connectors.

h. Obtained the correct

positioning, to perform a
pressure such as to ensure
correct coupling of the power
supply (E) to the base (F).

i. Reposition the terminal block

(B) previously removed and full
of connectors on the new power
supply.

j. Insert the terminal block (B)

placing it before the coupling
point (C) on the lower side.

k. Complete the terminal block

insertion, rotating it as indicated
by the arrow in the figure.
Achieved the correct
positioning, make a slight
pressure on the upper side of
the terminal blocks until
obtaining coupling of the
locking lever (A) followed by a
sharp click.

HS-RC-C5E-C5G-PFG-BCO_02.fm
01/1014 119
Special Maintenance - PFG-BCO
COMAU

Follow-up procedure
– Do not stand under the Robot or in the areas nearby.
– Carry out some motion cycles at reduced speed to check the proper functioning.
– Select the AUTO mode and check the proper functioning at reduced speed.

HS-RC-C5E-C5G-PFG-BCO_02.fm
120 01/1014
 Special Maintenance - PFG-BCO
COMAU

9.15 PFG-BCO: Bus Controller Replacement

Bus Controller

State: – Main switch open (OFF)

Material: – Bus Controller of the module
PFG-BCO
(see Tab. 10.9 - X20 - Field Bus
Modules on pag. 167)
Equipment: – Cross cut screwdriver

Frontal view

Preliminary procedures / notes

– To replace the Bus Controller, is necessary to open the front door of the Control
Unit.
– The Bus Controller is installed on the PFG-BCO module that is normally
accessible; is not required removal of other components.

Operating procedure
a. Disconnect the RJ45
connectors (A) on the front of
the bus controller: press the tab
and hold it down during the
extraction.

HS-RC-C5E-C5G-PFG-BCO_01.fm
01/1014 121
Special Maintenance - PFG-BCO
COMAU
Operating procedure (Continued)
b. Make a slight pressure on the
release lever (B) in the upper
part of the bus controller (C).

c. While holding pressed the lever

(B), remove the bus controller
(C) from the base (D) pulling it
out in the direction indicated by
the arrow. Do not tilt the bus
controller in order to avoid
possible damages to the
connectors. During the
operation of removal of the bus
controller, it is recommended to
keep with one hand the base
(D) in position, in order to avoid
possible release from the
omega guide after the bus
controller extraction.
d. Make sure that the connectors areas on the new bus controller (C) and the base
(D) are both perfectly clean.
e. Insert the new bus controller (C)
holding the module perfectly
aligned to the base (D), to
prevent possible damage to the
connectors.

f. Obtained the correct

positioning, verify the correct
coupling of the bus controller
(C) to the base (D).

g. Using a cross tip screwdriver

set the address of the module
on Ethernet POWERLINK
network, acting on the rotary
selector switches "x1" (E) and
"x16" (F). Set exactly the same
address on the removed
module.
For further information see
Tab. 9.3 - Ethernet
POWERLINK network
addresses configurations on
Bus Coupler of the X20
interface modules on pag. 123.

HS-RC-C5E-C5G-PFG-BCO_01.fm
122 01/1014
 Special Maintenance - PFG-BCO
COMAU
Operating procedure (Continued)
h. Reinsert the RJ45 connectors
(A), previously removed by
ensuring the complete insertion
followed by a sharp click.

Tab. 9.3 - Ethernet POWERLINK network addresses configurations on

Bus Coupler of the X20 interface modules

Rotating
selector switch
Function of Bus Coupler module setting Notes about the addresses configuration
(Address)

X16 X1

First module installed 8 1 Address of the first module installed: 129 (0x81)

Second module installed 8 2 Address of the second module installed: 130 (0x82)

Follow-up procedure
– Do not stand under the Robot or in the areas nearby.
– Carry out some motion cycles at reduced speed to check the proper functioning.
– Select the AUTO mode and check the proper functioning at reduced speed.

HS-RC-C5E-C5G-PFG-BCO_01.fm
01/1014 123
Special Maintenance - Safe-key
COMAU

9.16 Safe-key: Replacement

Safe-key

State: – Main switch open (OFF)

Material: – Safe-key
(see Tab. 10.10 - Complete Safe Kit
on pag. 169)
Equipment: – PC with Ethernet port
– Browser web (preferably updated
Mozilla Firefox, Google Chrome or
Apple Safari versions)
– Operating system (Microsoft®
Windows®, Apple OSx or Linux
distribution are preferred)
– Ethernet connection cable category
5e (it is suggested to use the crossed
cable in case of point to point
connection)
Frontal view

Preliminary procedures / notes

– To replace the Safe-key, is necessary to open the front door of the Control Unit.
– The Safe-key is installed on the SLU module located on the lower side of the
Control Unit.
– The SLU module is usually reachable and there is no need to remove other
components.
– The complete procedure is divided into the following main steps:
• par. 9.16.1 Replacement of Safe-key on pag. 124
• par. 9.16.2 Recovery procedure after the Safe-key replacement on
pag. 126

9.16.1 Replacement of Safe-key

Operating procedure
a. To remove the Safe-key,
proceed as follows:

a.1 Gently pull the grey tab

outwards, in order to obtain the
release of the Safe-key.

a.2 Make a slight pressure on the

Safe-key as indicated by the
arrows in the figure.

a.3 Maintaining the pressure, slide

off and remove the Safe-key
from the SLU module.

HS-RC-C5E-SafeKey_01.fm
124 01/1014
 Special Maintenance - Safe-key
COMAU
Operating procedure (Continued)
b. Reinsert the Safe-key inside the
new SLU module and lock the
same acting on the mechanic
block as indicated in the figure.
It is not necessary to make any
pressure on Safe-key to
reinsert within its own seat.

HS-RC-C5E-SafeKey_01.fm
01/1014 125
Special Maintenance - Safe-key
COMAU

9.16.2 Recovery procedure after the Safe-key replacement

Preliminary procedures / notes

The recovery procedure after replacing the Safe-key is divided into the following
steps:
• Preparation of Safe-key (formatting)
• RoboSAFE System Software Loading
• Restoring one previous configuration of the RoboSAFE parameters
• Acknowledgement of a new Safe-Key
• Acknowledgement of new hardware modules installed in the RoboSAFE
system
• Acknowledgement of the new loaded firmware
• Safe Turn-Set Procedure

Operating procedure
Preparation of Safe-key (formatting)
a. Precautions

a.1 The preparation (formatting) will erase the whole content of the Safe-key.
b. Procedure

b.1 From the Access page to the

maintenance functionality
(Service) (access procedures
are shown in the "RoboSAFE
Functionality Use") manual,
press the "Format Safe-Key"
push-button;

b.2 press the "Ok" pushbutton to

start the procedure.
b.3 After setting the Safe-Key:
• the RoboSAFE system cannot be used;
• the status led “RoboSAFE Status” becomes black;
• it is necessary to load the software and the parameters of the RoboSAFE
system, activating in the order:
• RoboSAFE System Software Loading
• Restoring one previous configuration of the RoboSAFE parameters
Until both procedures of
"System software
loading" and "RoboSAFE
parameters setting" are
not carried out, both
buttons are yellow.

HS-RC-C5E-SafeKey_01.fm
126 01/1014
 Special Maintenance - Safe-key
COMAU
Operating procedure (Continued)
RoboSAFE System Software Loading
c. Precautions

c.1 if the procedure is carried out on a Control Unit already configured, all the user's
parameters and the system software will be deleted;

c.2 updated versions of the Comau Safe application can have additional functions
not parametrized.
d. Pre-settings

d.1 In case it is necessary to update the Comau Safe application, it it first necessary
to update the Control Unit system software;

d.2 The Comau Safe application is already present in the Control Unit system
software and it is not provided separately.
e. Procedure

e.1 From the Access page to the

maintenance functionality
(Service) (access procedures
are shown in the "RoboSAFE
Functionality Use") manual,
press the “Reload Software
SM” push-button;

e.2 press the "Ok" pushbutton to

start the procedure;

e.3 if in the Safe-key there is Note: the pushbutton can be yellow if the procedure is
required compulsory.
already the user's
parametrization, it will be not
deleted.
e.4 Following the system software loading.
• the RoboSAFE system cannot be used;
• during the course RoboSAFE software loading procedure, the status LED
is black; at the end, the SLU module restarts;
• after the next restart, the LED turns black, then continue with Restore of a
previous configuration of the RoboSAFE parameters.
Until both procedures of
"System software
loading" and "RoboSAFE
parameters setting" are
not carried out, both
buttons are yellow.

HS-RC-C5E-SafeKey_01.fm
01/1014 127
Special Maintenance - Safe-key
COMAU
Operating procedure (Continued)
Restoring one previous configuration of the RoboSAFE parameters
f. Precautions.

f.1 one wrong or not updated file compromises the safe operating environment of the
Robot with deriving risk (also severe one) for the operator.
g. Procedure

g.1 From the Access page to the

maintenance functionality
(Service) (access procedures
are shown in the "RoboSAFE
Functionality Use") manual,
press the “Restore
Configuration” push-button;

g.2 Select the file “cmu_emoi.zip”

that contains the user's
parameters;

g.3 press the "Upload" push-button

to confirm.
g.4 Check if the original checksum is consistent.
Acknowledgement of a new Safe-Key
h. Procedure

h.1 Before the Acknowledge

requirement, the status led is
yellow and the Message Bar
shows the message "Please,
ack safe key changed";

h.2 From the Access page to the

maintenance functionality
(Service) (access procedures
are shown in the "RoboSAFE
Functionality Use") manual,
press the “Acknowledge
Safe-Key” push-button;

h.3 wait for the shutdown

procedure to end.

HS-RC-C5E-SafeKey_01.fm
128 01/1014
 Special Maintenance - Safe-key
COMAU
Operating procedure (Continued)
Acknowledgement of new hardware modules installed in the RoboSAFE
system
i. Precautions.

i.1 after the replacement of 1 or more safe modules, up to 4 modules, it is necessary

to Acknowledge the push-button which identifies the number of replaced
modules;

i.2 after the replacement of 5 or more safe modules use the "N" push-button;
j. Procedure

j.1 Before the Acknowledge

request, the status LED is
yellow and the Message Bar
shows the message "Please,
ack xx new module".

j.2 From the Access page to the

maintenance functionality
(Service),(access procedures
are shown in the "RoboSAFE
Functionality Use"), press the
push-button showing the
number of replaced modules, or
"N" in the case of replacement
of 5 or more.

j.3 wait for the shutdown

procedure to end.

HS-RC-C5E-SafeKey_01.fm
01/1014 129
Special Maintenance - Safe-key
COMAU
Operating procedure (Continued)
Acknowledgement of the new loaded firmware
k. Precautions.

k.1 The acknowledgement procedure of the firmware can be necessary

independently from the operator's will because it is an automatic-starting
updating:

k.2 necessity is underlined by the yellow colour of the graphical led and also by the
FW-ACKN led (Firmware Acknowledge) present on the SLU module.
l. Procedure

l.1 Before the Acknowledge

requirement, the status led is
yellow and the Message Bar
shows the message "Please,
acknowledge firmware";

l.2 From the Access page to the

maintenance functionality
(Service) (access procedures
are shown in the "RoboSAFE
Functionality Use") manual,
press the “Acknowledge
Firmware” push-button;

l.3 wait for the shutdown

procedure to end.

HS-RC-C5E-SafeKey_01.fm
130 01/1014
 Special Maintenance - Safe-key
COMAU
Operating procedure (Continued)
Safe Turn-Set Procedure
m. Pre-settings.

m.1 The Robotic system must be set in Programming (T1) mode;

m.2 Motors must be off:

n. Procedure

n.1 access the RoboSAFE

configuration Web pages
(access procedures are given in
the "RoboSAFE Functionality
Use" manual); on the Web
Service page, press
"RECOVERY MODE"
push-button;

n.2 the system asks for

confirmation of the change
mode; answer by pushing the
“Yes” push-button.
n.3 the new Recovery Mode state is
highlighted by the yellow LED
on the push-button and the text
below.

n.4 from this moment is possible to

enable DRIVE ON and move in
Jog mode.

n.5 move in JOG the Robot axes to

get them the as close as
possible to the calibration
position;
n.6 run the turn-set on the axes subject of maintenance.

n.7 when is close to the calibration position and without risk of impacts with the
structures of the cell, run the command "Execute Move to $CAL_SYS" (or
"Execute Move to $CAL_USER" if it has been customized calibration position);

HS-RC-C5E-SafeKey_01.fm
01/1014 131
Special Maintenance - Safe-key
COMAU
Operating procedure (Continued)
n.8 on the Web page, press the
"NORMAL MODE" push-button
and confirm with the “Yes”
push-button;

n.9 wait for the complete return in

the Normal Mode, which also
includes the restoration of the
consistency of the encoder
positions; completion is shown
by the green LED on the
push-button.

n.10 at the end of the procedure and

confirmation of successful
completion, the LED status
should be green.

Follow up procedures
After replacing the Safe-key, thoroughly test all the parameters of the
configuration, in order to ensure compliance with the safe areas imposed
to the robot and the system proper functioning.
For more details refer to the "RoboSafe Functionality Use".

HS-RC-C5E-SafeKey_01.fm
132 01/1014
 Special Maintenance - SDM
COMAU

9.17 SDM: Module Replacement

Safety Distribution Module

State: – Main switch open (OFF)

Material: – Module SDM
(see Tab. 10.5 - Safety Distribution
Module (SDM) on pag. 164)
Equipment: – Flat cut screwdriver, nano (4 x 25)
– Flat cut screwdrivers (3 x 15 and 6 x
15)
– Ratcheting torque wrench (or
screwdriver), allen insert 5 mm,
extension rod up to 260 mm

Frontal view

Preliminary procedures/ notes

– Not required.

Operating procedure
a. Disconnect the connectors on
the upper side of the module.
According to the type of
connector, it may be necessary:
– unscrew the screws before
removing the connector
– (A): direct extraction (connector
without fixing systems)
– (B): press the label and keep it
pressed during the removal

b. Disconnect the connectors on

the module front side.
According to the type of
connector, it may be necessary:
– (A): direct extraction (connector
without fixing systems)
– (B): press the label and keep it
pressed during the removal
– (C): unscrew the screws before
removing the connector

HS-RC-C5E-SDM_01.fm
01/1014 133
Special Maintenance - SDM
COMAU
Operating procedure (Continued)
– Note: if the options are installed, the connectors (A) and (B) may differ, as cabled
wires replace the standard version typical bridges.
c. Disconnect the connectors on
the module lower side.
– (B): press the label and keep it
pressed during the removal

d. Unscrew only 2-3 turns the

Allen screw (F) and do not
remove it.

e. Remove the module slightly

lifting the lower part, thus
outdistancing it. The module is
not locked inferiorly.

HS-RC-C5E-SDM_01.fm
134 01/1014
 Special Maintenance - SDM
COMAU
Operating procedure (Continued)
f. At the bench, remove possible connectors still available on the module and
serving as plugs or without connections, such as to guarantee the same functions
and performances for the new module as well (in particular connectors with
bridges). Then insert them on the new module respecting the original position.
g. Make sure the module bottom wall and the supporting area on the heat sink are
both perfectly clean.
h. Reassembly the new module in
the slot, inserting it through the
upper screw, then lower it while
pushing it against the heat sink.

i. Tighten the Allen screw (F) to 5

Nm.

j. Set the time selected on the

stop circuit timer in the SDM
module rotating selector
switches (SW1 and SW2)
consistently with the values in
the module removed. Refer
also to Tab. 9.4 - Time to be set
depending on the Robot Family
on pag. 136 and Tab. 9.5
- Time and position of the
rotating selector switches on
SDM Module on pag. 136.
Usage limitations
– Take into consideration that the resetting or reduction of the controlled stop
time can cause:
• departures out of the planned trajectory due to early insertion of the motors
service brakes.
• possible Robot stress, the motors service brake and impacts caused by the
departures out of the planned trajectory

HS-RC-C5E-SDM_01.fm
01/1014 135
Special Maintenance - SDM
COMAU
Operating procedure (Continued)
k. Reinsert the connectors (A).

l. Reinsert all the connectors (B), making sure the fitting is followed by a sharp
“click” indicating the fitting has been completely accomplished.

m. Reinsert the connectors (C) and screw the corresponding screws (do not
overtighten the screws).

n. If necessary, refer to the connectors and modules table included in the diagram
fixed inside the Control Unit door.

Follow-up procedure
– Do not stand under the Robot or in the areas nearby.
– Carry out some motion cycles at reduced speed to check the proper functioning.
– Select the AUTO mode and check the proper functioning at reduced speed.

Tab. 9.4 - Time to be set depending on the Robot Family

Time to be set on the SDM Module

Robot Family (preferential for the Robot family and typical applications)

SMART 5 Racer
SMART 5 Six / NS
1.5 seconds *¹
SMART 5 NM
SMART 5 NJ
Square YZ-500 2 seconds
SMART NX1-600 2 seconds
SMART NX1-800 6 seconds

Tab. 9.5 - Time and position of the rotating selector switches on SDM
Module
Time (seconds)
0 0.5 1 1.5 *¹ 2 2.5 3 4 5 6

Selector Switch Position

0 1 2 3 *¹ 4 5 6 7 8 9
SW1 / SW2

*¹ Manufacturer’s default value.

HS-RC-C5E-SDM_01.fm
136 01/1014
 Special Maintenance - SLU
COMAU

9.18 SLU: Module Replacement with Recovery

of Safe-Key
Safe LOGIC Unit

State: – Main switch open (OFF)

Material: – Module SLU
(see Tab. 10.10 - Complete Safe Kit
on pag. 169)
Equipment: – Flat cut screwdrivers
– PC with Ethernet port
– Browser web (preferably updated
Mozilla Firefox, Google Chrome or
Apple Safari versions)
– Operating system (Microsoft®
Windows®, Apple OSx or Linux
distribution are preferred)
– Ethernet connection cable category
5e (it is suggested to use the crossed
cable in case of point to point
Frontal view
connection)

Preliminary procedures / notes

– To replace the SLUmodules, is necessary to open the front door of the Control
Unit.
– The SLU module is normally accessible and is not required removal of other
components.
– The complete procedure is divided into the following main steps:
• par. 9.18.1 Module Replacement SLU on pag. 137
• par. 9.18.2 Recovery procedure after the replacement of SLU module on
pag. 141

9.18.1 Module Replacement SLU

Operating procedure
a. Disconnect the RJ45
connectors (A) on the front side
of the module: press the tab and
hold it down during the
extraction.

HS-RC-C5E-SLU_01.fm
01/1014 137
Special Maintenance - SLU
COMAU
Operating procedure (Continued)
b. Make a slight pressure on the
release lever (B) in the upper
part of the terminal block (C).

c. While holding pressed the lever

(B), remove the terminal block
before pulling it out from the
upper side and rotating it and
pivoting on the lower coupling
point (D).

d. Without disconnecting the

cables, support the terminal
block in such a way as not to
create clutter for subsequent
operations.
e. By applying a slight pressure,
lift the levers (E) in order to
obtain the release of the module
from the omega guide.

f. Remove the module from the

omega guide and bring it to the
bench.

g. Remove the Safe-key and keep

it, as it will be installed later on
the new SLU module. Operate
as indicated:

g.1 Gently pull the grey tab

outwards, in order to obtain the
release of the Safe-key.

g.2 Make a slight pressure on the

Safe-key as indicated by the
arrows in the figure.

g.3 Slide off and remove the

Safe-key from the SLU module.

HS-RC-C5E-SLU_01.fm
138 01/1014
 Special Maintenance - SLU
COMAU
Operating procedure (Continued)
h. Reinsert the Safe-key inside the
new SLU module and lock the
same acting on the grey tab as
indicated in the figure.
It is not necessary to make any
pressure on Safe-key to
reinsert within its own seat.

i. Make sure the module bottom wall and the coupling side on the omega guide are
both perfectly clean.

j. Make sure that on new module the levers (E) are raised.

k. Remove the terminal block (C) from the new SLU module by pressing on the
release lever (B), as previously indicated.
l. Position the new module
without terminal block on the
omega guide and carry out the
locking, acting the special
levers (E).

m. Using a flat-head screwdriver,

set the address of the module
on Ethernet POWERLINK
network, acting on the rotary
selector switches "x1" and
"x16”. The hexadecimal value
to be set is 90 (0x90, 144
decimal)
Set on the selector switch "x1"
(F) the value 0.
Set on the selector switch "x1"
(G) the value 9.

HS-RC-C5E-SLU_01.fm
01/1014 139
Special Maintenance - SLU
COMAU
Operating procedure (Continued)
n. Reposition the terminal block
(C) previously removed and full
of connectors on the new SLU
module.

o. Insert the terminal block (C)

placing it before the coupling
point (D) on the lower side.

p. Complete the terminal block

insertion, rotating it as indicated
by the arrow in the figure.
Achieved the correct
positioning, make a slight
pressure on the upper side of
the terminal block until
obtaining coupling of the
locking lever (B) followed by a
sharp click.
q. Reinsert the RJ45 connectors
(A), previously removed by
ensuring the complete insertion
followed by a sharp click.

HS-RC-C5E-SLU_01.fm
140 01/1014
 Special Maintenance - SLU
COMAU

9.18.2 Recovery procedure after the replacement of SLU module

Pre-settings
• The Robotic system must be set in Programming (T1) mode
• Motors must be off.

Operating procedure
a. When restarting the system, wait for the restart. The restart procedure may take
about 10 minutes to allow the firmware loading.

b. When the loading is finished, the LED R/E must be a steady green.

c. Access the RoboSAFE configuration Web pages (access procedures are given
in the "RoboSAFE Functionality Use" manual).

d. Pay attention before confirming the acknowledgement of the replaced Safe

Modules:
• after the replacement of one or more safe modules, up to 4 modules, it is
necessary to Acknowledge the push-button which identifies the number of
replaced modules;
• after the replacement of 5 or more modules safe use the "N" push-button.

e. Before the request for Acknowledge, the status LED is yellow and the Message
Bar shows the message "Please, ack xx new module".
f. From the Access page to the
maintenance functionality
(Service), press the
push-button showing the
number of replaced modules, or
"N" in the case of replacement
of 5 or more.

g. Wait for the shutdown

procedure to end.

h. On the Teach Pendant, run the Restart Cold command; wait for the system
restart.
i. Access the Web pages; on
Service Web page, press the
"RECOVERY MODE"
push-button.

j. the system asks for

confirmation of the change
mode; answer by pushing the
“Yes” push-button.

HS-RC-C5E-SLU_01.fm
01/1014 141
Special Maintenance - SLU
COMAU
Operating procedure (Continued)
k. the new Recovery Mode state is
highlighted by the yellow LED
on the push-button and the text
below.

l. From this moment is possible to enable DRIVE ON and move in Jog mode.

m. Move in JOG the Robot axes to get them the as close as possible to the
calibration position.

n. Run the turn-set on the axes subject of maintenance.

o. When is close to the calibration position and without risk of impacts with the
structures of the cell, run the command "Execute Move to $CAL_SYS" (or
"Execute Move to $CAL_USER" if it has been customized calibration position).
p. On the Web page, press the
"NORMAL MODE" push-button
and confirm with the “Yes”.

q. Wait for the complete return in the Normal Mode, which also includes the
restoration of the consistency of the encoder positions; completion is shown by
the green LED on the push-button.

r. At the end of the procedure and confirmation of successful completion, the LED
status should be green.

Follow-up procedure
– Do not stand under the Robot or in the areas nearby.
– Carry out some motion cycles at reduced speed to check the proper functioning.
– Select the AUTO mode and check the proper functioning at reduced speed.

HS-RC-C5E-SLU_01.fm
142 01/1014
 Special Maintenance - TP5
COMAU

9.19 TP5: Replacement

Teach Pendant 5

State: – Main switch open (OFF)

Material: Depending on requirement:
– C5G-TP5 (see Tab. 10.7 - Teach
Pendant C5G-TP5, with cable)
Equipment: – Medium size cross-tip screwdriver

Frontal view

Preliminary procedures / notes

– The procedure describes the cable replacement, that can be also used to replace
only the Teach Pendant.
The teach pendants C5G-TP5 with 3-positions key selector and C5G-TP5
with 2-positions lever selector do not have similar functions and must not
be inter exchanged.

– To access the connector of the teach pendant it is necessary to open the front
door.
Limit the tightening torque of the screws to avoid damages to the plastic
components.

Operating procedure
a. Unscrew the ring nut (A)

b. Remove the connector (B).

c. While removing the cable (C),

pay attention to the bended
path necessary for the
installation, avoid to pull the
cable prefer to collect it by
pushing it.

HS-RC-C5E-TP_02.fm
01/1014 143
Special Maintenance - TP5
COMAU
Operating procedure (Continued)
d. Lean the teach pendant on a
working bench.

e. Remove the 9 cross cut screws

(D).

f. Lift the cover and lean it on one

side. Pay attention to the flat
cables that shall not be pulled
ore removed.

g. Disconnect the connectors (E)

and (F); pull and extract softly
the connector body.

h. Disconnect the connector (G);

pressing the lever of the RJ45
connector and extract it softly

i. Lift the cable guide (H) and

remove completely the cable.

j. If the cable or the teach pendant are damaged, replace them with new ones.

k. When reassembling continue on reverse order.

l. Resister the cable guide (H).

m. Connect the connectors (E) and

(F).

n. Connect the connector (G). The

complete insertion in identified
by a click.

o. Close the Teach Terminal cover and pay attention not to pinch the cables or
conductors: check that both cables and conductors are positioned in the lower
side of the compartment and are enough distant from the screw fixing holes. In
particular check the flat cables.

p. Close the protection cover.

HS-RC-C5E-TP_02.fm
144 01/1014
 Special Maintenance - TP5
COMAU
Operating procedure (Continued)
q. Retighten the 9 cross screws
(D).

r. When tightening the screws, do

not apply exceeding tightening
torque which could damage the
covering seat.

s. Position the cable (C) in the

original path.

t. Insert the connector (B).

u. Screw again the ring nut to the

bottom (A).

Follow-up procedure
The proper software updating is made automatically during the next start.
When the message that identifies the inspection appears, do not interrupt
the process and wait for further updating.
Then the system restarts automatically with Restart Cold.

9.19.1 Software Loading in TP5

Preliminary procedures/ notes

– After replacement of a teach pendant it is not required any software updating.
– If it is necessary, after restart of the Control Unit one automatic procedure carries
out the required updating drawing the software directly form the system software.
One specific message warns about the current operation. Do not shut off the
Control Unit and wait for the procedure end.

HS-RC-C5E-TP_02.fm
01/1014 145
Special Maintenance - UPS
COMAU

9.20 UPS: Module Replacement

Uninterruptible Power Supply

State: – Main switch open (OFF)

Material: – Complete C5G-UPS Module (refer to
Tab. 10.3 - Uninterruptible Power
Supply (UPS) on pag. 161)
– Fuse, if necessary (refer to Tab. 10.3
- Uninterruptible Power Supply (UPS)
on pag. 161)
Equipment: – Cross-tip screwdriver

Frontal view

Preliminary procedures/ notes

Handle the module with care as it hosts a battery.

This module hosts a battery and shall be disposed of in compliance with

the environmental protection principles and laws in force. For further
details about the battery removal, refer to par. 11.5 Removing the cell and
battery from the Control Unit on pag. 173.
– Before replacing the UPS module due to an alleged fault, make sure it cannot be
ascribed to the battery protection fuse installed on the module (refer to
par. 9.20.1 Fuse Replacement in the UPS Module on pag. 148).

Operating procedure
a. The UPS module is usually reachable and there is no need to remove other
components. In this case go on with the procedure from point c.
b. If there are optional modules on the options plate C5G-OPK that impends the
access, it is advisable to operate in the following way:

b.1 if it is possible, release the UPS module from the omega guide (release lever in
the upper part) passing behind the components / C5G-OPK options plate and
rest the UPS module on the pavement inside of the electric cabinet (carefully to
avoid abrasions caused by crashes and strips with the metal sheet of the
C5G-OPK plate).

b.2 or, remove the optional module mounted rightmost order to access the front side
of the UPS module. Usually it is not necessary to disconnect the cables of the
option and it can be moved on the side, allowing to enter the module.

HS-RC-C5E-UPS_02.fm
146 01/1014
 Special Maintenance - UPS
COMAU
Operating procedure (Continued)
c. Draw out the 4 upper
conductors (A), held in position
by spring block clamp.

d. Draw out the lower connector

(B).

e. Replace the UPS module

f. Reconnect the 4-wire

connectors respecting the
original position, according to
Input/Output polarity and
marking indicated on the
conductors.

g. Insert the lower connector.

h. Fix the UPS module on the omega guide.
i. If it was necessary to remove one or more modules:

i.1 Reassemble the removed panel option.

Confer the UPS module and battery exhausted in the appropriate collection
centers.
For further details, please refer to Cap. Disposal and Dismantling on
pag. 170

Follow-up procedure
– In order to be operational again, the internal battery module takes approximately
3 hours to complete the total charge.
– During the charging period, the Control Unit may not be able to guarantee
controlled shutdowns in case of powering interruption. Always perform the
suitable shutdown software procedure

HS-RC-C5E-UPS_02.fm
01/1014 147
Special Maintenance - UPS
COMAU

9.20.1 Fuse Replacement in the UPS Module

Operating procedure
a. The UPS module is usually reachable and there is no need to remove other
components. In this case go on with the procedure from point c.
b. If there are optional modules on the options plate C5G-OPK that impends the
access, it is advisable to operate in the following way:

b.1 if it is possible, release the UPS module from the omega guide (release lever in
the upper part) passing behind the components / C5G-OPK options plate and
rest the UPS module on the pavement inside of the electric cabinet (carefully to
avoid abrasions caused by crashes and strips with the metal sheet of the
C5G-OPK plate).

b.2 or, remove the optional module mounted rightmost order to access the front side
of the UPS module. Usually it is not necessary to disconnect the cables of the
option and it can be moved on the side, allowing to enter the module.
c. Draw out the fuse (1).

d. Replace with a new fuse,

inserting it steadily in the seat.

e. If the module was removed,

hook the UPS module on the
omega guide.

f. Power on the Control Unit and

check the UPS module
functioning.

HS-RC-C5E-UPS_02.fm
148 01/1014
 Special Maintenance - X20 - Fieldbus
COMAU

9.21 X20 - Fieldbus: Modules Replacement

State: – Main switch open (OFF)

Material: – X20 - Fieldbus Modules, depending on
the needs (see Tab. 10.9 - X20 - Field
Bus Modules on pag. 167)
Equipment: – Not necessary.

Rear view

Preliminary procedures / notes

– To replace the X20 - Fieldbusmodules, is necessary to open the front door of the
Control Unit.
– The X20 - Fieldbus modules are normally accessed and is not required removal
of other components.
– In the procedure are used as reference images related to the DeviceNet Interface
Module. Where not otherwise specified, the procedure is valid for all types of
interface module.

Operating procedure
a. Carry out the opening of the Front Door (see par. 5.3.1 on pag. 40).

HS-RC-C5E-X20-fieldbus_01.fm
01/0215 149
Special Maintenance - X20 - Fieldbus
COMAU
Operating procedure (Continued)
b. Depending on the module to be
replaced, it is necessary:

b.1 for DeviceNet Interface

Modules disconnect the
connector (A); slide out and
remove the connector. Note the
position of the switch of the
terminating resistor (SW) on the
lower side of the module.

b.2 for ProFibus-DP Interface

Modules disconnect the
connector (B); unscrew the
screws and remove the
connector.

b.3 for ProfiNet Interface

Modules disconnect 2
connectors RJ45 (C); press the
tab and hold it down during the
extraction.

c. Make a slight pressure on the

release lever (D) in the upper
part of the interface module (C).

d. While holding pressed the lever

(D), remove the interface
module (E) from the base (F),
pulling it in the direction
indicated by the arrow. Do not
tilt the interface module in order
to avoid possible damages to
the connectors. During the
operation of removal of the
module, it is recommended to
keep with one hand the base
(F) in position, in order to avoid
possible release from the
omega guide after the module
extraction.
e. Make sure that the connectors areas on the new interface module (E) and the
base (F) are both perfectly clean.

HS-RC-C5E-X20-fieldbus_01.fm
150 01/0215
 Special Maintenance - X20 - Fieldbus
COMAU
Operating procedure (Continued)
f. Insert the new interface module
(E) holding the module perfectly
aligned to the base (F), to
prevent possible damage to the
connectors.

g. Obtained the correct

positioning, verify the correct
coupling of the interface module
(E) to the base (F).

h. Depending on the replaced

module, it is necessary:

h.1 for DeviceNet Interface

Modules reinsert the connector
(A) previously removed; insert
the connector by ensuring the
correct connection. Set the
switch of the terminating
resistor (SW) in the same
position it was on the module
just removed.

h.2 for ProFibus-DP Interface

Modules reinsert the connector
(B) previously removed and
tighten the fixing screws.

h.3 for ProfiNet Interface

Modules reinsert the RJ45
connectors (C) previously
removed by ensuring the
complete insertion followed by
a sharp click.

Fieldbus modules will re-configure automatically in the next system

restart.
i. Reclose the Front Door (see par. 5.3.1 on pag. 40).

Follow-up procedure
– Do not stand under the Robot or in the areas nearby.
– Carry out some motion cycles at reduced speed to check the proper functioning.
– Select the AUTO mode and check the proper functioning at reduced speed.

HS-RC-C5E-X20-fieldbus_01.fm
01/0215 151
Special Maintenance - X20 - I/O Safe
COMAU

9.22 X20 - I/O Safe: Module Replacement

Safe I/O Modules

State: – Main switch open (OFF)

Material: – According to the needs:
- Complete Safe Input Module
- Complete Safe Output Module
(see Tab. 10.10 - Complete Safe Kit
on pag. 169)
Equipment: – PC with Ethernet port
– Browser web (preferably updated
Mozilla Firefox, Google Chrome or
Apple Safari versions)
– Operating system (Microsoft®
Windows®, Apple OSx or Linux
distribution are preferred)
– Ethernet connection cable category
5e (it is suggested to use the crossed
Frontal view
cable in case of point to point
connection)

Preliminary procedures / notes

– To replace the X20 - I/O Safemodules, is necessary to open the front door of the
Control Unit.
– The X20 - I/O Safe modules are normally accessed and is not required removal
of other components.
– The following procedure relates to a double module, but it is also valid for a single
module.
– The complete procedure is divided into the following main steps:
• par. 9.22.1 X20 - I/O Safe Module Replacement on pag. 153
• par. 9.22.2 Recovery procedure after the replacement of a module X20 - I/O
Safe on pag. 155

HS-RC-C5E-SAFE_I-O_01.fm
152 01/1014
 Special Maintenance - X20 - I/O Safe
COMAU

9.22.1 X20 - I/O Safe Module Replacement

Operating procedure
a. Make a slight pressure on the
release lever (A) in the upper
part of the terminal block (B).

b. While holding pressed the lever

(A), remove the terminal block
before pulling it out from the
upper side and rotating it and
supporting on the lower
coupling point (C). Repeat the
procedure for the second
terminal block.

c. Without disconnecting the

cables, support the terminal
blocks in such a way as not to
create clutter for subsequent
operations.
The anticipated removal of the terminal block from the I/O module, is
essential to avoid possible mechanical damages on the modules during
the later stages of the procedure.

d. Make a slight pressure on the

lever (D) and remove the I/O
Safe module (E) from the base
(F), pulling it in the direction
indicated by the arrow in the
figure. Do not tilt the module in
order to avoid possible
damages to the connectors.
During the operation of removal
of the module, it is
recommended to keep with one
hand the base (F) in position, in
order to avoid possible release
from the omega guide after the
module extraction.
e. Make sure that the connectors areas on the new module I/O (E) and the base (F)
are both perfectly clean.

HS-RC-C5E-SAFE_I-O_01.fm
01/1014 153
Special Maintenance - X20 - I/O Safe
COMAU
Operating procedure (Continued)
f. Place the new I/O module (E)
on the base (F) acting in the
direction indicated by the arrow.
Hold the module perfectly
aligned to the base, to prevent
possible damage to the
connectors.

g. Replace both terminal blocks

(B) previously removed and
complete connectors on the
new I/O module:

h. Insert the terminal blocks (B)

placing them before the
coupling point (C) on the lower
side.

i. Complete the terminal blocks

insertion, rotating them as
indicated by the arrow in the
figure. Achieved the correct
position, make a slight pressure
on the upper side of the terminal
blocks until obtaining coupling
of the locking lever (A) followed
by a sharp click.

HS-RC-C5E-SAFE_I-O_01.fm
154 01/1014
 Special Maintenance - X20 - I/O Safe
COMAU

9.22.2 Recovery procedure after the replacement of a module

X20 - I/O Safe

Pre-settings
• The Robotic system must be set in Programming (T1) mode
• Motors must be off.

Operating procedure
a. When restarting the system, wait for the restart. The restart procedure may take
about 10 minutes to allow the firmware loading.

b. When the loading is finished, the LED R/E must be a steady green.

c. Access the RoboSAFE configuration Web pages (access procedures are given
in the "RoboSAFE Functionality Use" manual).

d. Pay attention before confirming the acknowledgement of the replaced Safe

Modules:
• after replacement of 1 or more safe modules, up to 4 modules (both I/O safe
modules on SLU module and Safe axes module on drive) it is necessary to
Acknowledge the push-button which identifies the number of replaced
modules;
• after replacement of 5 or more safe modules (both I/O safe modules on SLU
module and Safe axes module on drive) use the "N" push-button;

e. Before the request for Acknowledge, the status LED is yellow and the Message
Bar shows the message "Please, ack xx new module".
f. From the Access page to the
maintenance functionality
(Service), press the
push-button showing the
number of replaced modules, or
"N" in the case of replacement
of 5 or more.

g. Wait for the shutdown

procedure to end.

h. On the Teach Pendant, run the Restart Cold command; wait for the system
restart.

HS-RC-C5E-SAFE_I-O_01.fm
01/1014 155
Special Maintenance - X20 - I/O Safe
COMAU
Operating procedure (Continued)
i. Access the Web pages; on
Service Web page, press the
"RECOVERY MODE"
push-button.

j. the system asks for

confirmation of the change
mode; answer by pushing the
“Yes” push-button.

k. the new Recovery Mode state is

highlighted by the yellow LED
on the push-button and the text
below.

l. From this moment is possible to enable DRIVE ON and move in Jog mode.

m. Move in JOG the Robot axes to get them the as close as possible to the
calibration position.

n. Run the turn-set on the axes subject of maintenance.

o. When is close to the calibration position and without risk of impacts with the
structures of the cell, run the command "Execute Move to $CAL_SYS" (or
"Execute Move to $CAL_USER" if it has been customized calibration position).
p. On the Web page, press the
"NORMAL MODE" push-button
and confirm with the “Yes”.

q. Wait for the complete return in the Normal Mode, which also includes the
restoration of the consistency of the encoder positions; completion is shown by
the green LED on the button.

r. At the end of the procedure and confirmation of successful completion, the LED
status should be green.

HS-RC-C5E-SAFE_I-O_01.fm
156 01/1014
 Special Maintenance - X20 - I/O Safe
COMAU

Follow-up procedure
– Do not stand under the Robot or in the areas nearby.
– Carry out some motion cycles at reduced speed to check the proper functioning.
– Select the AUTO mode and check the proper functioning at reduced speed.

HS-RC-C5E-SAFE_I-O_01.fm
01/1014 157
Spare Parts
COMAU

10. SPARE PARTS

This chapter deals with the following topics:
– Precautions About the Spare Part Usage
– Where to Find the Spare Parts
– Spare Parts List
– Spare Parts for the Basic Model C5G

10.1 Precautions About the Spare Part Usage

This chapter contains the spare parts list divided according to the modules:
If not expressly cited, the spare part is valid for all the Control Unit sizes.

For C5G Control Unit maintenance use only original spare parts, with particular attention
for the devices uses in the status and safety circuits.

Do not carry out autonomous or not authorized repairs on the damaged modules.
Repairs can be made only by Comau.
Do not use spare parts for different scopes from those indicated.

The characteristics and performances of the spare parts are valid only if the spare part
is used as indicated in the instructions handbook combined with the C5G Control Unit.
The Declaration of Conformity of the Control Unit can be extended to the single spare
parts if they are used as described in the instructions handbook of the related C5G
Control Unit.

HS-RC-C5E-MAN_06.fm
158 01/0215
 Spare Parts
COMAU

10.2 Where to Find the Spare Parts

The original spare parts can be required to the Comau Customer Centre.

10.3 Spare Parts List

– Spare Parts for the Basic Model C5G
• Arm Controller Electromechanical (ACE)
• Operator Panel Devices (OPD)
• Uninterruptible Power Supply (UPS)
• CPU, power supplies and power modules
• Safety Distribution Module (SDM)
• Internal ventilation system
• Teach Pendant C5G-TP5, with cable
• Conditioning
• X20 - Field Bus Modules
• Complete Safe Kit

HS-RC-C5E-MAN_06.fm
01/0215 159
Spare Parts
COMAU

10.4 Spare Parts for the Basic Model C5G

Tab. 10.1 - Arm Controller Electromechanical (ACE)

Arm Controller Electromechanical (ACE) on C5G Control Unit Europe Version

Position Comau part number Description

CR19191126 PKZMO-25magnetic circuit breaker 25 A (Q100)

A PKZO-XH-MCC black handle, 90° turned switch and extension
CR19191127
(Q100)
B CR10140283 EMI filter 8kW 30 A 520 Vac (Z1)
Arm Controller Electromechanical (ACE) on C5G Control Unit North America Version

Position Comau part number Description

CR19230002 SOCOMEC switch disconnector 30 A UL/CSA (Q100)

A CR19230003 SOCOMEC external command handle (Q100)

CR19230004 SOCOMEC extension and internal red handle kit (Q100)

HS-RC-C5E-MAN_06.fm
160 01/0215
 Spare Parts
COMAU
Tab. 10.1 - Arm Controller Electromechanical (ACE) (Continued)

B CR10140283 EMI filter 8kW 30 A 520 Vac (Z1)

Tab. 10.2 - Operator Panel Devices (OPD)

A B C

Position Comau part number Description

A CR17130780 USB Kit

B CR17132480 Hour Meter Kit

C CR17033580 Spare parts for service socket (only for C5G Europe versions)

Tab. 10.3 - Uninterruptible Power Supply (UPS)

COMAU part number: CR10140583

A B

Position Comau part number Description

A CR10140583 C5G-UPS complete

B CR10142483 C5G-UPS blade fuse 30 A (green)

C CR10142283 C5G-UPS battery 12 V 5 Ah, 70 x 106 x 90 mm (W x H x D)

HS-RC-C5E-MAN_06.fm
01/0215 161
Spare Parts
COMAU

Tab. 10.4 - CPU, power supplies and power modules

E
H

G
J

AB CD F

Position Comau part number Description

AMS-APC820,
CR10140783 including Compact Flash 512M, preloaded, without data
(identified on the front module side as ACOPOS multi APC820)
AMS-APC830,
CR10140787 including Compact Flash 512M, preloaded, without data
A (identified on the module front side as ACOPOS multi APC830)
C5G-CF512 Compact Flash 512M, preloaded, without data, for
CR10142983
APC820
C5G-CF512 Compact Flash 512M, preloaded, without data, for
CR10142984
APC830
AMS-PPS8 Passive Power Supply 8 KVA
B CR10140383 for C5G-ACC1 / C5G-ACC2 / C5G-ACC3 series
(identified on the module front side as ACOPOS multi P0220)
AMS-PPS16 Passive Power Supply 16KVA
B CR10140384 for C5G-ACC5
(identified on the module front side as ACOPOS multi P0440)
AMS-ASM32 Auxiliary Supply Module 32 A / 24 Vdc
C CR10140483
(identified on the module front side as ACOPOS multi C0320)

HS-RC-C5E-MAN_06.fm
162 01/0215
 Spare Parts
COMAU
Tab. 10.4 - CPU, power supplies and power modules (Continued)

Position Comau part number Description

AMS-IAM 2,8+2,8 Safe Inverter Axis Module 2,8/10 + 2,8/10
CR10141184 (identified on the module front side as ACOPOS SAFE multi
I0028D)
AMS-IAM5,5+5,5 Safe Inverter Axis Module 5,5/20 + 5,5/20
CR10141284 (identified on the module front side as ACOPOS SAFE multi
D *¹ I0055D)
AMS-IAM11+11 Safe Inverter Axis Module 11/43 + 11/43
CR10141484 (identified on the module front side as ACOPOS SAFE multi
I0110D)
AMS-IAM22+22 Safe Inverter Axis Module 22/85 + 22/85
CR10141584
(identified on the module front side as ACOPOS multi I0220D)
AMS-IAM 2,8+2,8 Inverter Axis Module 2,8/10 + 2,8/10
CR10141183 only additional axis, not Safe
(identified on the module front side as ACOPOS multi I0028D)
AMS-IAM5,5+5,5 Inverter Axis Module 5,5/20 + 5,5/20
CR10141283 only additional axis, not Safe
(identified on the module front side as ACOPOS multi I0055D)
AMS-IAM11+11 Inverter Axis Module 11/43 + 11/43
D *¹ CR10141483 only additional axis, not Safe
(identified on the module front side as ACOPOS multi I0110D)
AMS-IAM22+22 Inverter Axis Module 22/85 + 22/85
CR10141583 only additional axis, not Safe
(identified on the module front side as ACOPOS multi I0220D)
AMS-IAM 44 Inverter Axis Module
CR10142683 only additional axis, not Safe
(identified on the module front side as ACOPOS multi I0440D)
The encoder modules installed on the AMS-IAM Safe are not be
E --
replaced individually.
AMS-ETI22 ETI Encoder Transducer Interface ENDAT2.2
E CR10140883
(identified on the module front side as Endat 2.2 AC0120-2)
F CR10140183 AMS-FMP14 Feed-through Mounting Plate 14 slots

G *³ CR10141983 AMS-AFU ACOPOS Fan Unit

H CR10142383 C5G-APC Lithium Battery 3V 950 mAh

J CR19190057 Fuse 30A, 600V, quick, 10.3 x 38 mm

L CR19191128 C5G-ERR Energy Recovery Resistance 15 ohm 2 kW

*¹ Position and quantity according to the power of the axes installed; replace damaged
axes modules exclusively with the modules of the same power and features. The
modules are NOT interchangeable.
*³ Fan standardized for all modules:
– q.ty 2 installed in the AMS-APC module
– q.ty 1 installed in each AMS-PPS, AMS-ASM 32 module
– q.ty 1 or 2 installed in each AMS-IAM module, depending on the number of slot
taken by the module.

HS-RC-C5E-MAN_06.fm
01/0215 163
Spare Parts
COMAU

Tab. 10.5 - Safety Distribution Module (SDM)

COMAU part number: CR17430081

Position Comau part number Description

A CR17430081 C5G-SDM2 Safety & Distribution Module

B CR17241380 C5G-UCK User Connector Kit for SDM Module

HS-RC-C5E-MAN_06.fm
164 01/0215
 Spare Parts
COMAU

Tab. 10.6 - Internal ventilation system

Position Comau part number Description

A CR17430981 C5G-IFK Internal Fan Kit (E110)

B CR17431081 C5G-FCK Cooling Fan Kit (E111, E112, E113)

HS-RC-C5E-MAN_06.fm
01/0215 165
Spare Parts
COMAU

Tab. 10.7 - Teach Pendant C5G-TP5, with cable

Part No.: COMAU CR17431985, CR17432085

C5G-TP5 (wired), 3 key positions

Position Comau part number Description

Teach Pendant C5G-TP5WC, with cable (key selector switch 3
CR17910085
positions)
A
Teach Pendant C5G-TP510, with cable length 10 m (key selector
CR17910185
switch 3 positions)
- CR17240065 Cable with connectors C5G-TP5C10, length 10 m
Part No.: COMAU CR17432185

C5G-TP5 (wired), 2 positions

Position Comau part number Description

Teach Pendant C5G-TP5WC2, without cable (lever selector
CR17910086
switch 2 positions)
A
Teach Pendant C5G-TP5210, with cable length 10 m (key
CR17910186
selector switch 2 positions)
- CR17240065 Cable with connectors C5G-TP5C10, length 10 m

HS-RC-C5E-MAN_06.fm
166 01/0215
 Spare Parts
COMAU

Tab. 10.8 - Conditioning

Part No.: COMAU CR17133680

Position Comau part number Description

C5G-ACG Conditioner Unit complete with conditioner, metallic
A CR17431880
roof and powering cable for conditioner.
Bipolar limit switch 1NO+ 1NC, NEW ELFIN 50F11
B -- Note: the limit switch model is identical also when installed in the
Application Box
C -- Magneto-thermal switch curve D 2,5-4A, SQUARE D - GV2-P08

D CR19900028 Condensate collecting flask

Tab. 10.9 - X20 - Field Bus Modules

Part No.: COMAU CR17133680

A1 B-C

A2 D-E

A A3 F-G

Position Comau part number Description

A CR10146383 C5G-PFG-BCO Bus Coupler Module on X20 complete interface

A1 CR10143883 Base and system bus interface modules X20 B&R X20BB82

HS-RC-C5E-MAN_06.fm
01/0215 167
Spare Parts
COMAU
Tab. 10.9 - X20 - Field Bus Modules (Continued)
Part No.: COMAU CR17133680
A2 CR10143783 X20 Bus Controller B&R XBC1083
A3 CR10145383 Power supply DC/DC 24V B&R X20PS9400

B CR10145783 C5G-DNM-DNMI DeviceNet Module - DeviceNet Master Interface

C CR10145883 C5G-DNM-DNSI DeviceNet Module - DeviceNet Slave Interface

D CR10145483 C5G-PFM-PDPM ProFibus Module - Profibus-DP Master

E CR10145583 C5G-PFM-PDPS ProFibus Module - Profibus-DP Slave

F CR10145083 C5G-PNC ProfiNet I/O Controller

G CR10145183 C5G-PND ProfiNet I/O Device

HS-RC-C5E-MAN_06.fm
168 01/0215
 Spare Parts
COMAU

Tab. 10.10- Complete Safe Kit

Part No.: COMAU CR10143383

B E

F
D

F1 F2 F3 G H C
Position Comau part number Description

A CR10143183 X20 SLU - Safe Logic Unit

B CR10143283 Safe-Key 2MB B&R MK0201

C CR10143184 Complete Safe Input Module

D CR10143185 Complete Safe Output Module

E CR10156861 C5G-ERM1 ESM Expansion Relay Module 1 LIGHT

F * C5G-PFG-BCO Bus Coupler Module on X20 complete interface

F1 * Base and system bus interface modules X20 B&R X20BB82

F2 * X20 Bus Controller B&R XBC1083

F3 * Power supply DC/DC 24V B&R X20PS9400

G CR10143683 Terminal block B&R X20TB12

H CR10143684 Terminal block B&R X20TB52 for I/O Safe modules

* See Tab. 10.9 - X20 - Field Bus Modules

HS-RC-C5E-MAN_06.fm
01/0215 169
Disposal and Dismantling
COMAU

11. DISPOSAL AND DISMANTLING

This chapter deals with the following topics:
– Precautions Before Starting
– Staff to set the plant out of work and dismantle it
– Equipment and Tools Required
– Setting out of work and dismantling procedure
– Removing the cell and battery from the Control Unit

11.1 Precautions Before Starting

The robot system (consisting of Robot and Control Unit) shall be dismantled in
compliance with the environmental prescriptions and according to the methodologies in
force in the land where it is installed.
Prepare different containers to collect the different materials separately.

11.2 Staff to set the plant out of work and dismantle it

Staff in charge for the dismantling should be instructed to operate correctly with lifting
devices.
Moreover, the staff shall be warned or trained (in electrics) and therefore be aware of
the dangers associated with electric energy and of the measures to be taken when
working on electric connections.

HS-RC-C5E-MAN_07.fm
170 01/1014
 Disposal and Dismantling
COMAU

11.3 Equipment and Tools Required

– Ordinary mechanical and electric equipment.
– Containers.

11.4 Setting out of work and dismantling procedure

In this section are described the main steps to perform the robot system dismantling at
the end of its operating life.
The activities below are to be carried out by the Staff to set the plant out of work and
dismantle it only:

a. create all around the robot system enough space to carry out all movement without
any risk for the staff

b. move the robot to transport position and mount the axes locking items (if present),
following the instructions on the plate posted on the robot and its Technical
Documents.

c. open the Control Unit main switch and lock it in open position

d. disconnect the electric power at the distribution source and lock the switch in open
position.

e. disconnect the powering cable from the Control Unit; disconnect the power wires
first and then the earth one

f. disconnect the multi-pin connectors by the Control Unit and Robot sides

g. if installed, disconnect the pneumatic system from the distribution network and
blow off the residual air

h. before moving the Robot and Control Unit, we recommend to remove possible
batteries, oils and other chemicals (found procedure and location in the next
sections)

i. read carefully and follow the instructions in the chemicals safety sheets not to
endanger the operator and to avoid polluting the environment

The disposing activities shall be carried out in compliance with the laws in force in the
land where the machine is installed: dispose of batteries, oils and chemicals according
to the environmental laws and transfer them to the suitable waste collecting sites.

j. Remove the robot and Control Unit from the working area, following all
prescriptions in the product Technical Documents; in case of lifting, check the
eyebolts fastening and use only suitable slinging devices and equipment

k. Move the Robot and Control Unit to the area intended for the dismantling and
disposal procedures.

HS-RC-C5E-MAN_07.fm
01/1014 171
Disposal and Dismantling
COMAU
l. If the procedure is to be carried out independently, disassemble the components
from up downwards and act with particular care when handling machine units/parts
that may fall due to gravity

Act carefully, to avoid possible parts or components falling during the removal phase, as
this could severely endanger the operators.

m. remove the parts and separate, as much as possible, the different components
based on the materials (plastic, metal, electronic modules, piles, batteries, etc.)
that shall be disposed of applying the waste separation principle. Transfer the
materials resulting from the dismantling to the responsible companies.

The disposing activities shall be performed in compliance with the laws in force in the
land where the machine is installed: dispose of electronic cards and ferrous/plastic
materials according to the law prescriptions and transfer them to the suitable waste
collecting sites.

In case of problems while carrying out the component disassembling, dismantling and
disposing procedures, turn to the manufacturer’s design technical department, which
will specify the operating modalities in compliance with the safety and environmental
protection principles.

HS-RC-C5E-MAN_07.fm
172 01/1014
 Disposal and Dismantling
COMAU

11.5 Removing the cell and battery from the Control

Unit

State: – Electric power off

Material: – Not necessary
Equipment: – Blade cut screwdriver
– Star cut screwdriver
– Container

Preliminary procedures/ notes

– The disposal operations shall be carried out in compliance with the laws in force
in the land where the machine is installed: dispose of batteries, oils and
chemicals according to the environmental laws and transfer them to the suitable
waste collecting sites.
– The Control Unit features the following cells / batteries:
• Button cell in the module AMS-APC820 AMS-APC830(reference A)
• Battery in the C5G-UPS module (reference B)

Operating procedure
Button cell in the module
AMS-APC820
AMS-APC830(reference A)

a. Lift the AMS-APC faceplate

module.

b. Open the access flap.

c. Remove the battery pulling the

tag.

HS-RC-C5E-MAN_07.fm
01/1014 173
Disposal and Dismantling
COMAU
Operating procedure (Continued)
Battery in the C5G-UPS module (reference B)
a. Remove the fuse before acting
on the C5G-UPS module.

b. Remove the cover fixing

screws.

c. Remove the battery cover.

d. Disconnect the cables from the

battery terminals.

e. Remove the battery by pulling

the tag.

Follow-up procedure
Confer the stack and the battery in the appropriate collection centers.

HS-RC-C5E-MAN_07.fm
174 01/1014
 COMAU GLOBAL NETWORK

Original instructions

SalesÊUʳΙÊ䣣Êää{x{äÈÊUÊÃ>iðÀœLœÌˆVÃJVœ“>Õ°Vœ“
ServiceÊUʳΙÊ䣣Êää{x{ǙÊUÊÃiÀۈVi°ÀœLœÌˆVÃJVœ“>Õ°Vœ“
www.comau.com
/ iʈ˜vœÀ“>̈œ˜ÊVœ˜Ì>ˆ˜i`ʈ˜ÊÌ ˆÃÊLÀœV ÕÀiʈÃÊÃÕ««ˆi`ÊvœÀʈ˜vœÀ“>̈œ˜Êœ˜Þ°Ê œ“>ÕÊ-°«°
°ÊÀiÃiÀÛiÃÊ
Ì iÊÀˆ} ÌÊ̜Ê>ÌiÀÊëiVˆwV>̈œ˜ÃÊ>ÌÊ>˜ÞÊ̈“iÊÜˆÌ œÕÌʘœÌˆViÊvœÀÊÌiV ˜ˆV>ÊœÀÊVœ““iÀVˆ>ÊÀi>ܘðÊ
/ iʈÕÃÌÀ>̈œ˜Ê`œiÃʘœÌʘiViÃÃ>ÀˆÞÊà œÜÊÌ iÊ«Àœ`ÕVÌÃʈ˜ÊÌ iˆÀÊÃÌ>˜`>À`ÊÛiÀȜ˜°Ê‡ÊäÓÉ£{ʇÊ/ÕÀˆ˜