LB MP HN-STM en

Comau Robotics
Instruction Handbook
Handling System -
Media Panel
Installation on the Control Unit
Technical specifications, Transportation, Installation

and Maintenance
Description, available versions and technical characteristics of the Media Panel

Integration principles of the Media Panel and description of the options available
Information on preparations and pre-settings necessary for the Media Panel's installation
Dimensions and weights, transport and hoisting methods of the Media Panel
Installation procedure of the Media Panel
Preventive and extraordinary maintenance procedures and Spare Parts List
CR00757700-en_00/2014.12
The information contained in this manual are the property of COMAU S.p.A.
The reproduction, even partial, without prior written authorisation by COMAU S.p.A. is forbidden.
COMAU reserves the right to modify, without notice, the characteristics of the product dealt with in this manual.
Copyright © 2014 by COMAU - Published on 03/2015

Summary
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Documents preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limits on the manual content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Fundamental Requirements applied and respected . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2. DESCRIPTION OF THE MEDIA PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...17

Technical features of the Media Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3. INSTALLATION OF THE MEDIA PANEL INSIDE THE HANDLING SYSTEM . . . . ...20

Installation summarizing table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4. INSTALLATION SUGGESTIONS, LIFTING AND HANDLING PROCEDURE . . . . . ...21

Staff assigned to the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation environment requirements and suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Weights and dimensions of the C5G Control Unit with Media Panel . . . . . . . . . . . . . . . . . . . . . 23
C5G version with Media Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
C5G version with lifting platform and Media Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dimensions and installation space of the C5G Control Unit with Media Panel . . . . . . . . . . . . . 25
Dimensions and installation space of the C5G Control Unit with Media Panel . . . . . . . . . . . 25
Procedure for hoisting and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lifting of the C5G and Media Panel packaged in a sealed box . . . . . . . . . . . . . . . . . . . . . . . 28
Lifting of the C5G and Media Panel without packing, on pallet (europallet 1200 x 800 mm). 29
Lifting of the C5G and Media Panel without pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Procedure to remove the container, protection tarpaulin and pallet . . . . . . . . . . . . . . . . . . . . . 31
Positioning and anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
_LB_MP_HN.STM_ENTOC.fm
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Summary
5. MEDIA PANEL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..33

Connections to the power supply networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connection of Media Panel to compressed air power supply mains . . . . . . . . . . . . . . . . . . . 33
Connection of the Media Panel to the C5G Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6. ACTIVATION OF THE HANDLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..38

Power-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Air pressure switch calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Media Panel - CR16656280 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7. GENERAL MAINTENANCE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..42
8. GENERAL MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43

General precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Maintenance staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assembly notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Disposal of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Maintenance operation sheets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Disconnection of power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Disconnection of electrical power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disconnection of compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9. MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..55

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Summary of intervention points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10. PRELIMINARY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..56

Preventive maintenance plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Air filter: cleaning and condensate discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Air filter: cleaning and discharge of condensate on the Media Panel - CR16656280 . . . . . . 59
11. SPECIAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..61

Air filter: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Air filter: replacement on the Media Panel - CR16656280 . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Pressure gauge: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Pressure gauge: replacement on the Media Panel - CR16656280 . . . . . . . . . . . . . . . . . . . . 65
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Summary
12. MEDIA PANEL SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...66
3
Preface
PREFACE
In this chapter are shown the following topics:
– Reference documents
– Documents preservation
– Limits on the manual content
– Symbols used in the manual
Reference documents
This document concerns the Robotic system (Robot and Control Unit).
The complete set of Robotic system (Robot and Control Unit) manuals consists of:
Comau Spot Welding – Technical specifications

System Medium – Transport, Installation, Integration
Frequency – Maintenance
Software – SmartHand Application Software
Wiring diagram
These manual must be integrated with the following documents:
Comau C5G Control Unit – Technical specifications

– Transport and installation
– Maintenance
– Use of C5GControl Unit
SMART5 Robot – Technical specifications
– Transport and installation
– Maintenance
Programming – PDL2 Programming Language Manual
– VP2 - Visual PDL2
– Motion Programming
Altersys PLC Programming – Workbench of ISaGRAF
The manual mentioned above shall be undamaged as long as the Robotic System is
installed and operates, they shall be always at disposal of those operating on the
Robotic System
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Preface
Documents preservation
All the documents provided should be stored near the
Robotic system and be available for all the people that work on it and it must
be preserved intact for all the operative life of the Robotic System.
Limits on the manual content

The figures inserted in the instruction manual have the purpose to represent the product
and can differ from what is actually visible on the Robotic System.
00/0610 5
Symbols used in the manual
Below are listed the symbols that represent: WARNING, CAUTION and NOTES and
their meaning
This symbol indicates operating procedures, technical information and precautions that
if not observed and/or performed correctly could cause injuries to the personnel.
if not observed and/or performed correctly could cause damage to the equipment.
are to be underlined.
This symbol indicates that entry is forbidden to persons wearing a pace-maker.
The symbol calls the attention to the material disposal that is regulated by the WEEE
Directive
The symbol calls the attention on avoiding environmental contamination and suggest to
dismiss the materials on the appropriate collection facility.
6 00/0610
General safety precautions
1. GENERAL SAFETY PRECAUTIONS
It deals with a general specification that applies to the whole Robot System. Due to its
significance, this document is referred to unreservedly in any system instructions
handbook.

– 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.
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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.
In case that is provided only the Robot SMART 5 series, are considered applicable the
requirements: 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 define the behaviour and rules to be observed when
performing the activies listed in the Applicability section.
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 referred to in the
paragraph above.
Installation and Putting into Service

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

Installation and Putting into Service
– Putting into service is only possible when the Robot and Control System has been
correctly and completely installed.
– The system installation and putting into service is exclusively the task of the
authorised personnel.
– The system installation and putting into service is only permitted inside a protected
area of an adequate size to house the robot and the fixtures it is outfitted with,
without passing beyond the 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).
– 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.
– Connect the signals and power cables between the Control Unit and the robot.
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– 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 push-buttons, 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 push-buttons are not interlocked in the
emergency stop circuit of the Control Unit.
– The safety of the system cannot be guaranteed if these interlocks are wrongly
executed, incomplete or missing.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active 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. The stop time is selected using selector switches SW1 and SW2 on the
SDM board.
– Check that the environment and working conditions are within the range specified
in the specific product Technical Documentation.
– The calibration operations are to be carried out with great care, as indicated in the
Technical Documentation of the specific product, and are to be concluded
checking the correct position of the machine.
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– 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.
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– In all 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 restoration, 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.
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– 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.).
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– 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.
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1.2.5 Performance
The performances below shall be considered before installing the robotic system:
– Stop spaces
– Mission time (typical value).
Stop spaces
– With Robot in programming mode (T1), if you press the stop push-button (red
mushroom-shaped one on WiTP) in category 0 (According to Standard
EN60204-1), you will obtain:
Tab. 1.1 - Stopping spaces in programming mode (T1)
Expected Stopping Stopping

Mode Case
speed time space
Nominal 120 ms 30 mm
T1 250 mm/s
Limit 500 ms 125 mm
Tab. 1.2 - Safety electronics reaction time in programming mode (T1)
Expected Reaction
Mode Case
speed time
For the safety inputs of the SDM module (e.g.
stop push-button 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.
– Considering the Robot in automatic mode, under full extension, full load and
maximum speed conditions, if you press the stop push-button (red
mushroom-shaped one on WiTP) in category 1 (according to standard EN60204-1)
you will trigger the Robot complete stop 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).
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Description of the Media Panel
2. DESCRIPTION OF THE MEDIA PANEL

– Technical features of the Media Panel.
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2.1 Technical features of the Media Panel

The Media Panel includes the part dealing with the air distribution and treatment for the
handling application. For pneumatic connections suitable connecting nozzles are fore-
seen both in input and output.
The Media Panel is able to monitor and treat the compressed air necessary for the prop-
er operation of a robotic handling system.
If foreseen by the model, the Media Panel can be installed on the right or left side of the
Control Unit; if required or permitted in the configuration, you can install both left and
right models.
There are electrical connections between the Media Panel and the Control Unit. These
connections are made by means of a terminal board on the Control unit.
Electrical connection cables enter the box through cable glands.
Below are the specifications of the following Media Panels:
– Media Panel Handling CR16656280
Media Panel Handling - CR16656280
Features
Air connection power supply: Max. Pressure 1 MPa
Fluid temperature t° max: +50°C (+122 °F)
Fluid temperature t° min: +2°C (+35.6 °F)
Dimensions (Height x width x depth): 520 x 385 x 240 mm (20.47 x 15.15 x 9.44 in)
Weight: 14 kg / 33 lb without package
Foreseen installation: on the right side of the Control Unit
Order part no.
Media Panel Handling. CR16656280
The Media Panel is made of a single section:
– Media Panel - pneumatic section, compressed air for the handling system.
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Fig. 2.1 - Media Panel - pneumatic section
A - Air inlet from the plant.

Straight fitting M22x1,5 female cone.
B - Hose fitting M22x1,5 male cone.
C - Brass ball valve.
D - Regulator filter.
E - Pressure gauge.
F - Pressure switch.
G - Air outlet to Robot.

Straight fitting M22x1,5 female cone.
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Installation of the media panel inside the Handling System
3. INSTALLATION OF THE MEDIA PANEL

INSIDE THE HANDLING SYSTEM
This chapter contains the descriptions of the procedures necessary for installation and
connection of the Media Panel, summarized in Installation summarizing table.
3.1 Installation summarizing table

The table below summarises the installation sequence for the Media Panel.
The table can be used as a check list for the progress of the installation activities. In this
case it is advised to copy the table below and fill in the “Done” column at the end of each
operation.
Tab. 3.1 - Installation summarizing table
Step Operation Done

Preparation for installation
1 Equipment
2 Installation environment requirements and sugges-
tions
Lifting and Motion
3 Weights and dimensions of the C5G Control Unit
with Media Panel
Installation procedure
4 Connection of Media Panel to compressed air power
supply mains
Activation procedure
5 Power-on
6 Air pressure switch calibration
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Installation suggestions, lifting and handling procedure
4. INSTALLATION SUGGESTIONS, LIFTING

AND HANDLING PROCEDURE
This chapter deals with the following topics:
– Staff assigned to the installation.
– Equipment.
– Installation environment requirements and suggestions.
– Weights and dimensions of the C5G Control Unit with Media Panel.
– Dimensions and installation space of the C5G Control Unit with Media Panel.
– Procedure for hoisting and handling.
4.1 Staff assigned to the installation

Staff assigned to the installation must be trained to correctly operate hoisting equipment.
Moreover, the staff must warned or trained (in the electrical field) and therefore be aware
of the dangers associated with electrical power and be conversant with any measures
to be taken on:
electric connections on power supply and interconnection signals (safety signals and
check signals).
4.2 Equipment
The installation of the Handling System requires the following equipment:
– hoisting system (crane);
– standard tools such as screwdrivers, wrenches and sundry.
Clamp for MULTICONTACT M-PZ-13 cable terminal with matrix for 35 sqmm
MES-PZ-TB13/35 conductors.
4.3 Installation environment requirements and

suggestions
The integrator is to provide and install the following systems and structures:
– install perimeter protections, access doors.
Furthermore, the integrator must take into account the provisions of the directives and
standards in force, in order to correctly integrate in a cell, and in total safety, the Han-
dling System.
The putting into service of the Handling System is forbidden unless the machine in which
it will be incorporated is certified as conforming to the provisions of applicable directives.
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According to the configuration, the power supply cable connection on the main switch of
the C5G Control Unit can be upstream or downstream.
22 01/0114
4.4 Weights and dimensions of the C5G Control Unit

with Media Panel
4.4.1 C5G version with Media Panel

A
B
d w
Supply C5G Control Unit with Media Panel

conditions On platform - A In closed container - B
150 kg 205 kg
Weight *¹
331 lb 452 lb
1200x800x1330 mm 1000x800x1400 mm
Dimensions *²
47.2 x 31.5 x 52.4 in 39.4 x 31.5 x 55.1 in
Without packing (configuration C)
140 kg
Weight *¹
309 lb
Sizes
Installation see par. 4.5
areas
*¹ typical weight. This may vary depending on the outfitting installed inside the C5G.
*² approximate dimensions of the Control Unit (width x depth x height)
01/0114 23
4.4.2 C5G version with lifting platform and Media Panel

A
B
d w
Supply C5G Control Unit with Media Panel

conditions On platform - A In closed container - B
172 kg 220 kg
Weight *¹
379 lb 485 lb
1200x800x1430 mm 1000x800x1500 mm
Dimensions *²
47.2 x 31.5 x 56.2 in 39.4 x 31.5 x 59 in
Without packing (configuration C)
152 kg
Weight *¹
335 lb
Sizes
see par. 4.5
Installation areas
*¹ typical weight. This may vary depending on the outfitting installed inside the C5G.
*² approximate dimensions of the Control Unit (width x depth x height)
24 01/0114
4.5 Dimensions and installation space of the C5G

Control Unit with Media Panel
4.5.1 Dimensions and installation space of the C5G Control Unit

with Media Panel
B B’
A’ C
C’
A C”
E G
Composition of the C5G Control Unit with Media Panel

Quota
With Media Panel (1) with lifting platform and Media Panel (2)
A 1060 mm (41.7 in)
A' 800 mm (41.14 in)
B 1110 mm (43.70 in) 1210 mm (47.63 in)
B’ (1110) mm (1210) mm
C 510 mm (20.08 in)
C’ 560 mm (22.05 in)
C’’ 590 mm (23.23 in)
D 70 mm (2.75 in)
E 400 mm (15.75 in) *¹
F 600 mm (23.62 in)
G 800 mm (31.49 in)
Notes:
*¹ Minimum size to guarantee ventilation. These areas do not allow access to the rear
wall for maintenance purposes, so an ergonomic analysis is required to ensure access.
01/0114 25
In addition:
Do not obstruct re-circulation of warm air expelled and leave the space above the Con-
trol Unit free.
26 01/0114
4.6 Procedure for hoisting and handling
The C5G Control Unit and Media panel are assembled in a single unit. The handling and
installation procedures, therefore, always refer to the complete system.
01/0114 27
4.6.1 Lifting of the C5G and Media Panel packaged in a sealed

box
Data for lifting
Weight to be 205 kg
lifted*¹: 452 lb
*¹ The weight stated can change
depending on the configuration.
Always refer to the data tag
affixed to the Control Unit.
With crane or overhead crane A
Number of ropes: 2
Ropes length 6000 mm
With forklift truck B
Forks length: >1000 mm
Forks pitch: 530 mm
Eyebolts
On Control Unit 4 x M12 female
Operating procedure with crane or overhead crane A

a. Insert the two ropes under the container as shown in the drawing.
b. Join the two ends to the lifting hook.
c. Lift and move near the installation area.
d. Once the installation area has been reached, remove the ropes.
e. Continue the procedure described on par. 4.7 Procedure to remove the

container, protection tarpaulin and pallet on page 31.
Operating procedure with forklift truck B

a. Prepare the centre distance of the forks as required.
b. Be sure that the forks extremities jut out on the opposite side of the container.
d. Continue the procedure described on par. 4.7 Procedure to remove the

28 01/0114
4.6.2 Lifting of the C5G and Media Panel without packing, on

pallet (europallet 1200 x 800 mm)
Data for lifting
Weight to be 160 kg
lifted*¹: 353 lb
*¹ The weight stated can change
depending on the configuration.
Always refer to the data tag
affixed to the Control Unit.
Number of ropes: 4
Forks length: >1000 mm
Forks pitch: 530 mm
Eyebolts

a. Fasten hooks and ropes to the eyebolts mounted on the cabinet, as described in
the drawing (also when there is the air conditioner).
b. Lift and move near the installation area.
c. To optimise operations in removing the pallet.
d. Having reached the installation area, it is not necessary to remove the ropes and
hooks. Continue with the procedure at par. 4.7 Procedure to remove the

b. Be sure that the forks extremities jut out on the opposite side of the container.
d. Continue the procedure described on par. 4.7 Procedure to remove the

01/0114 29
4.6.3 Lifting of the C5G and Media Panel without pallet

Data for lifting
Weight to be 140 kg
lifted*¹: 309 lb
*¹ The weight stated can change depending
on the configuration. Always refer to the data
tag affixed to the Control Unit
Number of ropes: 4
Forks length: > 900 mm
Forks pitch: 620 mm
Forks inlet hole: 175 mm
Do not use the transpal-
let because it poses a
risk of overturning and
damaging the cabinet.
Eyebolts

a. Fasten hooks and ropes to the 4 eyebolts mounted on the cabinet, as described
in the drawing (also when there is the air conditioner).
b. Lift and move near the installation area.

b. Be sure that the forks extremities jut out on the opposite side of the Control Unit.
c. Lift and maintain parallel to the floor. Then move near the installation area.
During movements:
•Do not lift more than 50 cm.
•Keep the Control Unit in a flat position and do not tilt or overturn it.
30 01/0114
4.7 Procedure to remove the container, protection

tarpaulin and pallet
Status: – Not applicable

Material: – Not necessary
Equipment: – In case of container removal
• Iron lever (crowbar)
– Gloves
– 13 mm socket wrench
Removal of the package envisages:

– Operating procedure to remove the container (if it is used).
– Operating procedure to remove the tarpaulin.
– Operating procedure to remove the pallet.
Operating procedure to remove the container

a. Use a crowbar on the sides of
the container and remove the
sides.
Hands must be protect-
ed by gloves because
the presence of nails
and wood splinters can
cause injuries.
b. Continue the Operating procedure to remove the tarpaulin described below.
Operating procedure to remove the tarpaulin

a. Remove the Adhesive tape and the protection packing.
b. Continue the Operating procedure to remove the pallet described below.
01/0114 31
Operating procedure to remove the pallet

a. Unscrew the four screws with
the 13 mm socket wrench.
b. Remove the wooden beams

that pass through the lifting
platform or the wooden wedges
locking the wheels (if present).
c. Lift the C5G from the pallet

using a crane / overhead crane
or forklift truck as described in
par. 4.6.3 Lifting of the C5G and
Media Panel without pallet on
page 30 and move it near the
installation area.
Collect the wooden parts, the protection structure and the screws and
dispose of them, protecting the environment.
4.7.1 Positioning and anchoring

a. Place the system on the floor.
Avoid pushing the system to move it in order to avoid unexpected falls. Adapt the re-
quired movement by using a crane or hoist.
b. Guarantee adequate space to access the rear side of the cabinet.
Minimum spaces are those listed in par. 4.5 Dimensions and installation space of the
C5G Control Unit with Media Panel on page 25.
32 01/0114
Media Panel Connections
5. MEDIA PANEL CONNECTIONS

This chapter contains:
– Connections to the power supply networks:
• Connection of Media Panel to compressed air power supply mains.
• Connection of the Media Panel to the C5G Control Unit.
5.1 Connections to the power supply networks

The Handling System requires the following connections to the mains power supply:
– Connection of Media Panel to compressed air power supply mains.
5.1.1 Connection of Media Panel to compressed air power

supply mains
The connection to the compressed air power supply mains must be carried out on Media
Panel; Input of the pneumatic power supply is on the upper side.
Tab. 5.1 contains the pneumatic connection specifications.
Tab. 5.1 - Splitter Compressed air supply specifications
Media Panel code Supply fitting /pipe

CR16656280 Straight fitting M22x1,5 female cone.
Depending on the model, see:
– Compressed air Media Panel.
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5.1.1.1 Compressed air Media Panel

– Media Panel CR16656280.
5.1.1.1.1 Media Panel CR16656280
Status: – Water power supply powered off

directly from mains
Material: – Connection pipes
Equipment: – 24, 27 mm fixed wrenches
Preliminary procedures / notes

– The connection is made directly to the Media Panel input pipe.
Operating procedure
a. Position manual ball valve A in
the closed position.
b. Connect the air supply hose

from the plant network. A hose
fitting B Aeroquip 07-001-13-08
M22x1.5 male cone is supplied
for the air connection.
c. In order to prevent the pipe rotating, tighten the fittings using the 24 mm socket
hex wrench as counter-wrench.
Before connecting, make sure that there is no pneumatic power in the pow-
er supply line.
Follow-up procedure
Do not open the manual valve to supply the pneumatic panel until the in-
stallation procedure has been completed.
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5.1.2 Connection of the Media Panel to the C5G Control Unit

The electrical connection between the Media Panel and the Control Unit is made via the
connection cable of the Media Panel itself.
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Fig. 5.1 - Media Panel - Control Unit connection cable diagram
Lato Unita’ di Controllo
Lato Media Panel
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5.1.2.1 Media Panel CR16656280

Status: – Power off
Material: – Connection cable
Equipment: – Not necessary

– The connection cable is already present along with the supply of the Media
Panel.
Operating procedure
a. Fit the "Additional SDM input 1"
option (code Comau
CR17240162) inside the
Control Unit C5G and connect
the cable from the Media Panel
to the X73 connector.
Before connecting, make sure that there is no pneumatic power in the pow-
er supply line.
Follow-up procedure
Do not open the manual valve to supply the pneumatic panel until the in-
stallation procedure has been completed.
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Activation of the Handling System
6. ACTIVATION OF THE HANDLING SYSTEM

This chapter contains:
– Power-on.
– Air pressure switch calibration.
6.1 Power-on
Proceed as follows:
a. Power the C5G Control Unit, as indicated in the Instructions for use manual.
For information regarding faults that could occur on the C5G Control Unit, see
the Instructions handbook.
b. Make sure that the devices connected to compressed air and to cooling water are
connected properly and are firmly fastened.
Pipes that are not correctly secured and/or are not connected at the ends
could cause back-lashing with the risk of impact with persons and objects sit-
uated near them.
c. Open the pneumatic system cut-out ball valve installed on the Media panel.
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6.2 Air pressure switch calibration

– Media Panel - CR16656280.
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6.2.1 Media Panel - CR16656280

Status: – System on
Material: – Not required
Equipment: – Small flat blade screwdriver

– The following procedure describes the steps to calibrate the pressure switch
intervention threshold.
– Should the pressure switch calibration have to be checked, adjust by rotating the
screwdriver in a clockwise direction until input is in OFF (0) and then follow the
operations described below.
The input is managed by the SmartHand software, configured at the user's
discretion.
Operating procedure
a. Shut off the air via the ball valve A
and release the pressure
downstream (to carry out this
operation, act on the discharge B of
the filter, lifting it to cause the
discharge).
b. Pressurise the system by opening

the ball valve.
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Operating procedure
c. Remove the fixing screw C in the
upper part of the pressure switch
(NOTE: do not remove the plastic
cap), insert a suitably sized flathead
screwdriver into the hole to perform
the calibration.
At this point, one of the following
conditions may occur:
– if the input remains OFF (0):
• slowly turn the screwdriver
counter-clockwise until the
input goes to ON (1);
• rotate the screwdriver further
by approx. 1/2 turn in the same
direction.
– if the input is to ON (1):
• the calibration is correct.
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General maintenance standards
7. GENERAL MAINTENANCE STANDARDS

– Before performing any maintenance operation, please read carefully the chapter 1,
and in particular the paragraph describing the maintenance operations.
– Maintenance on the Handling system is only permitted by specialized and trained
personnel.
– Any removal or installation of electromechanics components, electronic modules,
connectors, cables or any other component must be performed only with main
switch opened. Disconnect the C5G Control Unit power supply (interconnected
voltage)
– Before starting with any maintenance activity, be sure that there are no external
voltages interconnected to the electronic modules and to the Control Unit compo-
nents.
– The circuit breaker and the fuses are dimensioned for the foreseen use of the
circuits and, in case of damage, they can be replaced only with equivalent parts
foreseen in the spare parts catalogue. The use of unforeseen protections may
cause danger to operators and malfunctions to the Handling System.
– In case of cable replacement re-set the connection of screens previously discon-
nected.
– The replaced cable must have the corresponding Comau part number of the
dismissed one.
– Before connecting any cables, refer to the wiring diagrams of the Handling system.
– During the installation of new cables, please avoid anomalous bending radii
prevent abnormal bending radii than the previous. Respect possible fastening
points and determined paths already existing.
– If the cable has a cable clamp, check its proper functioning.
– After any maintenance operation, re-set the protection devices previously
removed.
– After any maintenance work and prior to resuming normal operations, test
operation of the Handling System and more specifically of any replaced
component.
– Should all or part of the Handling System have to be decommissioned, compo-
nents must be separated and disposed of separately. In any case, the disposal of
the control unit must be carried out in compliance with the regulations applicable in
the Country in which the Handling System was installed.
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General maintenance procedures
8. GENERAL MAINTENANCE PROCEDURES

This chapter describes the general procedures for maintenance:
– General precautions.
– Maintenance staff.
– Equipment typically needed to carry out the maintenance activities described in
this manual.
– Assembly notes.
– Disposal of parts.
– Maintenance operation sheets.
– Disconnection of power.
The maintenance activities that are not described in this manual are not allowed. If it is
necessary, require the manufacturer's intervention.
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8.1 General precautions

– The majority of maintenance operations envisaged on the Handling System are to
be carried out with mains power switched off.
• Electric power: In those cases the wording "Disconnection of electrical
power" is specified in the maintenance sheet. The procedure is described in
par. 8.7.1.
• Pneumatic power: In those cases the wording "Disconnection of
compressed air" is specified in the maintenance sheet. The procedure is
described in par. 8.7.2.
– If the type of fault allows robot repositioning, it is advised to set it in idle position
before starting the maintenance operations.
– Check the proper functioning of the Handling System after the completion of
maintenance operations. Check the correct execution of some robot working
cycles before leaving the station.
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8.2 Maintenance staff

Staff in charge for the maintenance should be trained to operate properly with lifting de-
vices.
Moreover, the staff shall be warned or trained and therefore be aware of the dangers
deriving from electrical power and the precautions to enter the machine in safety condi-
tions.
8.3 Equipment
The component securing systems (screws, nuts) have been standardised, using as few
variations as possible. The table below indicates the minimum equipment needed for
maintenance interventions of the inside the cabinet.
Tab. 8.1 - Equipment necessary
Preliminary Maintenance Special Maintenance

Suction type cleaner Set of flat tip screwdrivers
Brush with soft bristles Set of cross-tip screwdrivers
Set of cross-tip screwdrivers Set of Allen wrenches (size in mm)
Set of cross-tip screwdrivers Torx Set of socket wrenches (size in mm)
Set of Allen wrenches (size in mm) Hose clamp wrench
Set of socket wrenches (size in mm) Torque wrench
Set of fixed wrenches (size in mm) Scissor
Wrenches for electric panel Extraction unit
AS-HN-C5E-HSP_12.fm
01/0114 45
8.4 Assembly notes

Extraordinary maintenance operations must be performed by technicians using the ap-
propriate tools and in accordance with all the standard operating procedures even if
these are not expressly mentioned, including the following:
• Check the O-rings, valve seals and bearings for any signs of wear and replace
these if necessary;
• When reassembling parts, always proceed as follows:
• Apply the recommended thread adhesive to screw threads, see Tab. 8.3 - Typical
uses of AREXONS products (unless otherwise specified) on page 46.
• Use recommended products on sealing surfaces and to fasten components,
see Tab. 8.4 - Adhesive sealants and fasteners on page 47.
• Tighten screws and/or nuts to the prescribed tightening torque, see Tab. 8.2
- Tightening torque for hex head cap screws and socket hex head screws (Nm
± 10%) on page 46.
• Apply AREXONS 52A22 to the outside diameter of seals for Rotary shafts and
rubber sealing plugs.
• Use FUCHS ANTICORIT DFW to protect any exposed machined surfaces.
• When assembling double-lipped Rotary seals or in case of a double seal, fill
the gap between the two lips with "NLGI NR.2” performance grade grease.
Tab. 8.2 - Tightening torque for hex head cap screws and socket hex
head screws (Nm ± 10%)
dxp Class 8.8 screws Class 10.9 screws Class 12.9 screws
3 x 0.5 1.5 1.9 2.3
4 x 0.7 3.1 4.3 5.2
5 x 0.8 6 8.5 10.1
6x1 10.4 14.6 17.5
8 x 1.25 24.6 34.7 41.6
10 x 1.5 50.1 70.5 84.6
12 x 1.75 84.8 119 143
14 x 2 135 190 228
16 x 2 205 288 346
20 x 2.5 400 562 674
24x3 691 971 1170
A tolerance of ± 10% is allowed on tightening torques of screws and ring nuts for the
pre-charging of bearings.
Tab. 8.3 - Typical uses of AREXONS products

(unless otherwise specified)
Screws Screws from M8 Plugs

Material
up to M6 upwards and fittings
Aluminium 52A22 52A22 35A72
Aluminium with Heli-coil 52A22 52A43 -
Steel 52A22 52A43 35A72
Cast iron 52A22 52A43 35A72
AS-HN-C5E-HSP_12.fm
46 01/0114
Tab. 8.4 - Adhesive sealants and fasteners
Application AREXONS
Sealant for flat surfaces 35A73
Polyurethane sealant S006
Bearing fasteners 56A41
High strength fasteners 56A48
Fittings 35A72
8.5 Disposal of parts

Used oil and grease MUST BE DISPOSED OF IN ACCORDANCE WITH THE LAWS
IN FORCE IN THE COUNTRY IN WHICH THE ROBOT IS INSTALLED.
Should it become necessary to dispose of all or part of the robot, the various parts to be
disposed of MUST be collected separately (for example, iron with iron and plastic with
plastic). Such parts MUST also be disposed of in accordance with the laws in force in
the country in which the Robot is installed.
AS-HN-C5E-HSP_12.fm
01/0114 47
8.6 Maintenance operation sheets

The following Maintenance schedules define the maintenance procedures to be per-
formed on the Handling System.
Each sheet contains the following information:
Saying Information description

Status Highlights the condition that the Handling System must
assume before performing the maintenance operation.
Material Necessary material for the activity. This represents both the
spare parts and the consumable material.
Equipment Equipment needed for the maintenance operations.
Preliminary It describes the activities to be performed before the oper-
procedures / notes ating procedure. It explains also the notes that give deeper
information on the activity.
Operating procedure It describes the operating procedure step by step, with
explanation figures, if necessary.
Follow-up procedure It describes the activities to carry out after the operating
procedure. Usually the opposite activity of the preliminary
procedure is shown.
AS-HN-C5E-HSP_12.fm
48 01/0114
8.7 Disconnection of power

The following paragraphs describe the procedures in order to perform:
– Disconnection of electrical power.
– Disconnection of compressed air.
AS-HN-C5E-MAN_01.fm
01/0114 49
8.7.1 Disconnection of electrical power

The following paragraphs describe the procedures for the following Media Panels:
– Media Panel CR16656280.
AS-HN-C5E-MAN_01.fm
50 01/0114
8.7.1.1 Media Panel CR16656280

Status: – Main switch open
Equipment: – Not required

Do not switch off the Control Unit without having performed the software
shut-down procedure first. For the detailed procedure for switching off the
C5G Control Unit, reference must be made to the relative manual.
Operating procedure
Main switch open
a. Perform the shut-down of the C5G Control Unit and set the main switch to OFF.
For detailed information on the shut-down procedure of the C5G, see the
related instructions manual.
b. Bring the compressed air cut-out ball valve to the closed position.
Follow-up procedure
– Not necessary.
AS-HN-C5E-MAN_01.fm
01/0114 51
8.7.2 Disconnection of compressed air

– Disconnection of the compressed air on the Media Panel - CR16656280.
AS-HN-C5E-MAN_01.fm
52 01/0114
8.7.2.1 Disconnection of the compressed air on the Media Panel -

CR16656280
Status: – Not influent
Equipment: – Not required

– The manual ball valve on the Media Panel totally cuts off the compressed air
inflow but does not discharge the pressure of downstream circuits.
– If 2 Media Panels are installed, the sectioning must be repeated on both panels.
Operating procedure
Air breaking device closed
a. Position the manual ball valve A
in the CLOSED position.
b. Discharge the pressure from the

pneumatic system.
AS-HN-C5E-MAN_01.fm
01/0114 53
Operating procedure
Discharge the pressure from the pneumatic system
c. Discharge the compressed air
circuit by opening valve B under
the filter.
d. Unscrew valve B rotating it by

1/4 turn.
e. Press and get valve B to retract

by a few millimetres inside the
filter.
f. Keep it pressed until the

pneumatic circuit is completely
discharged.
g. With discharge completed,

release valve B.
h. Close valve B again.
The same procedure must be carried out in order to discharge the conden-
sate and impurities from the filter glass: to do this, before carrying out the
procedure, check that the filter glass is empty; if it is not, carry out the pro-
cedure described at par. 10.2 Air filter: cleaning and condensate discharge
on page 58.
Follow-up procedure
– Not necessary.
AS-HN-C5E-MAN_01.fm
54 01/0114
Maintenance plan
9. MAINTENANCE PLAN
9.1 Overview
The Maintenance of the Handling System is divided into:
• Preliminary Maintenance.
• Special Maintenance.
– detailed with specific procedures described in Maintenance operation sheets;
– graphically summarised in Summary of intervention points.
It is recommended to carry out preliminary maintenance activities periodically, to pre-

serve the Handling Unit's functional features longer.
In case of poor or missing preliminary maintenance activities during the warranty
period, this will be regarded as prejudicial to the warranty itself.
In the representations below are shown the intervention points detectable with the ref-
erences present in the summary statements of Tab. 10.1 - Preventive maintenance plan
on page 57 and Tab. 11.1 - Special maintenance plan on page 61.
9.2 Summary of intervention points
MEDIA PANEL - CR16656280
AS-HN-NJ0-MAN_01b.fm
01/0114 55
Preliminary Maintenance
10. PRELIMINARY MAINTENANCE

To ensure the correct functioning of the Handling System, periodic preventive mainte-
nance must be carried out in order to reduce the causes of failure generated by natural
degradation over time.
The preliminary maintenance operations shall be performed by qualified staff.

Chap. General maintenance procedures on page 43 describes the preliminary opera-
tions on the Control Unit that are to be performed before starting preliminary mainte-
nance activities.
The maintenance activities that are not described in the following chapters shall be per-
formed by Comau qualified staff.
It is recommended to carry out preliminary maintenance activities periodically, to pre-

serve the Control Unit functional features longer.
In case of poor or missing preliminary maintenance activities during the warranty
period, this will be regarded as prejudicial to the warranty itself.
56 01/0114
Preliminary Maintenance
10.1 Preventive maintenance plan

In the Tab. 10.1 is reported the preliminary maintenance plan organized for periodicity.
Tab. 10.1 - Preventive maintenance plan
Frequency Activity Ref. *¹

Media Panel - pneumatic section
as seen – Air filter: cleaning and condensate discharge P1
*¹ The reference is given in par. 9.2 Summary of intervention points on page 55
*² The absence of activity can require a periodic soft lubrication with spray grease.
01/0114 57
Preliminary Maintenance - Air filter
10.2 Air filter: cleaning and condensate discharge

– Air filter: cleaning and discharge of condensate on the Media Panel - CR16656280.
AS-HN-C5E-MAN_04.fm
58 01/0114
10.2.1 Air filter: cleaning and discharge of condensate on the

Media Panel - CR16656280
Status: – Stated in the specific procedure
Material: – Not necessary
Equipment: – Cleaning equipment

– The quantity of grime collected in the filter depends on the in-feeding
compressed air quality and on the system's work times.
– The operations must be carried out on the Media Panel air treatment unit.
Operating procedure
Condensate discharge (to be car-
ried out with pneumatic power
activated):
a. Unscrew valve A rotating it by

1/4 turn.
b. Press and get valve A to retract

by a few millimetres inside the
filter.
c. Keep it pressed until completely

clean and checking the
resulting outflow of clean air.
d. With discharge completed,

release valve A.
e. Close valve A again.
AS-HN-C5E-MAN_04.fm
01/0114 59
Operating procedure (Continued)

Cleaning of filter (to be carried out
with pneumatic power deacti-
vated):
Before carrying out main-

tenance operations dis-
charge the pneumatic
system's pressure.
a. Unscrew the collecting cup B by

hand.
b. Wash and clean the cup.
c. Clean the inner filter.
The use of compressed air is not advisable since it is impossible to check

the grime removed, with the risk of hitting the operator's face.
d. Re-assemble the cup B.
Follow-up procedure
– After opening the compressed air circuit, check that there are no leaks.
AS-HN-C5E-MAN_04.fm
60 01/0114
Special Maintenance
11. SPECIAL MAINTENANCE

To replace damaged items, follow the procedures described in the maintenance sheets.
The special maintenance operations shall be performed by qualified staff.

Chap. General maintenance procedures on page 43 describes the preliminary opera-
tions on the Control Unit that are to be performed before starting special maintenance
activities.
The maintenance activities that are not described in the following chapters shall be per-
formed by Comau qualified staff.
Tab. 11.1 - Special maintenance plan
Activity Ref.*¹
Media Panel - pneumatic section
– Air filter: replacement S1
– Pressure gauge: replacement S2
*¹ The reference is given in par. 9.2 Summary of intervention points on page 55
01/0114 61
Special Maintenance - Air filter
11.1 Air filter: replacement

– Air filter: replacement on the Media Panel - CR16656280.
11.1.1 Air filter: replacement on the Media Panel - CR16656280

Status: – Disconnection of compressed air
Material: – Air filter (see Tab. 12.1)
Equipment: – Not necessary

Before carrying out maintenance operations discharge the pneumatic sys-
tem's pressure.
AS-HN-C5E-MAN_06.fm
62 01/0114
Special Maintenance - Air filter
Operating procedure
a. Unscrew the collecting cup A by
hand.
b. Dismantle the filter.
c. Mount a new filter.
d. Screw back the collecting

cup A.
Follow-up procedure
AS-HN-C5E-MAN_06.fm
01/0114 63
Special Maintenance - Pressure gauge
11.2 Pressure gauge: replacement

– Pressure gauge: replacement on the Media Panel - CR16656280.
AS-HN-C5E-MAN_07.fm
64 01/0114
Special Maintenance - Pressure gauge
11.2.1 Pressure gauge: replacement on the Media Panel -

CR16656280
Status: – Disconnection of compressed air
Material: – Pressure gauge (see Tab. 12.1)
Equipment: – Philips screwdriver
– 12, 24 mm fixed wrench
– Sealer for fittings, Arexon 35A72-type

– The fittings must be tightened to a suitable torque in order to avoid breakages or
deformations.
Before carrying out maintenance operations discharge the pneumatic sys-
tem's pressure.
Operating procedure
a. Undo screw A.
b. Loosen the cable gland B.
c. Remove cap C.
d. Remove the electrical connection.
e. Unscrew the pressure gauge D.
f. Re-mount a new pressure gauge, following the procedure in reverse order.
g. Use a specific sealer on the pressure gauge's D thread.
– Should the GND terminal not be present on the pressure gauge, suitably isolate
the relative connection wire.
AS-HN-C5E-MAN_07.fm
01/0114 65
Media Panel spare parts list
12. MEDIA PANEL SPARE PARTS LIST

This chapter deals with the list of spare parts for the following Media Panels.
– Code: COMAU CR16656280.
Tab. 12.1 - Spare parts list - Media Panel
Code: COMAU CR16656280
ELETTROTEC
19060528 Pressure gauge PMM 10A 14K
SP1
A
EUROSWITCH
19060528 Pressure switch (alternative) 41V11222
SP1
METALWORK
B CR19064001 1/2” Regulator filter 1425030
ZA1
Diam. 40 0÷1.0 Mpa rear connection SMC

C CR19064007 G46-10-01-LH TA1
1/8”w gauge
BORELLO &
D 19060525 1/2" brass ball valve MAFFIOTTO VH1
24812
E CR18409760 Tubo mandata aria handling DN12 L=5mt -
AS-HN-C5E-MAN_17a.fm
66 01/0114
COMAU Robotics services
Repair: repairs.robotics@comau.com
Training: training.robotics@comau.com
Spare parts: spares.robotics@comau.com
Technical service: service.robotics@comau.com
comau.com/robotics Original instructions

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Comau Robotics

Technical specifications, Transportation, Installation

Description, available versions and technical characteristics of the Media Panel

Copyright © 2014 by COMAU - Published on 03/2015

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

2. DESCRIPTION OF THE MEDIA PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...17

3. INSTALLATION OF THE MEDIA PANEL INSIDE THE HANDLING SYSTEM . . . . ...20

4. INSTALLATION SUGGESTIONS, LIFTING AND HANDLING PROCEDURE . . . . . ...21

5. MEDIA PANEL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..33

6. ACTIVATION OF THE HANDLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..38

7. GENERAL MAINTENANCE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..42

8. GENERAL MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43

9. MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..55

10. PRELIMINARY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..56

11. SPECIAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..61

12. MEDIA PANEL SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...66

Comau Spot Welding – Technical specifications

These manual must be integrated with the following documents:

Comau C5G Control Unit – Technical specifications

Limits on the manual content

This symbol indicates that entry is forbidden to persons wearing a pace-maker.

1. GENERAL SAFETY PRECAUTIONS

In this chapter are shown the following topics:

1.1.1 Safety Fundamental Requirements applied and respected

1.2 Safety precautions

Installation and Putting into Service

Operation in Programming Mode

Auto / Remote Automatic Mode

Maintenance and Repairs

Putting Out of Service and Dismantling

1.2.4 Operating modes

Operation in programming mode

Auto / Remote Automatic Mode

Robot axes brake

– When the motion is enabled again following the interruption of an unfinished

Maintenance and Repair

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

– Maintenance, repairs and trouble-shooting operations are to be concluded

Putting Out of Service and Dismantling

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

Expected Stopping Stopping

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

Mission time (typical value)

2. DESCRIPTION OF THE MEDIA PANEL

2.1 Technical features of the Media Panel

Media Panel Handling - CR16656280

Fig. 2.1 - Media Panel - pneumatic section

A - Air inlet from the plant.

B - Hose fitting M22x1,5 male cone.

C - Brass ball valve.

G - Air outlet to Robot.

3. INSTALLATION OF THE MEDIA PANEL

3.1 Installation summarizing table

Tab. 3.1 - Installation summarizing table

Step Operation Done

4. INSTALLATION SUGGESTIONS, LIFTING

4.1 Staff assigned to the installation

4.3 Installation environment requirements and

4.4 Weights and dimensions of the C5G Control Unit