Lb-Aw-Rac-Spt CMT en

Wire welding
system
(CMT Fronius
Generator)
Technical specifications for

GaTeWayFRonius System
(GTWFR) serial connection with
Robot Racer7-1.4 Rel. 2.1
CR00758127-en_00/2016.12
Instruction handbook
The contents of this handbook are the property of COMAU S.p.A.
Any reproduction, even partial, is prohibited without prior written authorization from COMAU S.p.A.
COMAU reserves the right to change, without prior notice, the characteristics of the product presented in this
handbook.
Copyright © 2016 by COMAU - Date of publication 12/2016

Comau Robotics Product Instruction
SUMMARY
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Documents storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Limits on the handbook contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Symbols used in the handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Modification History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. SAFETY REQUIREMENTS FOR CONTINUOUS WIRE WELDING . . . . . . . . . . . . . . ...9

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Information regarding the process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Protection of the eyes and the body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Protections against gas, fumes and fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2. WIRE WELDING SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16

General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3. C5G / C5COMPACT CONTROL UNIT CUSTOMIZATION . . . . . . . . . . . . . . . . . . . . ...21

Torch cleaner connection kit (in the Control Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Plate for arc outfitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control Unit
High Speed Input kit (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Serial port RS422 COM1 on module AMS-APC820/830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
I/O cable between Control Unit and Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4. ROBOT CUSTOMIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...30

Robot outfitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dressing cable CMT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Wire buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wire feeder unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Welding torch push pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3
SUMMARY
Anti-collision kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Devices for the calculation/check of the TCP (Tool Center Point) . . . . . . . . . . . . . . . . . . . . . . . 36
Tool Master (Calibrated tool unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Reference tip (optional, as an alternative to TCP Check) . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TCP Check (optional, as an alternative to the reference tip) . . . . . . . . . . . . . . . . . . . . . . . . . 39
Supporting stand for Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Balancer unit (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5. WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Generator connection to the power supply mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Generator connection to the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Type of cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Communication mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Generator order part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
RS422 Serial cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Welding ground connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Transport trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3x500V autotransformer (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
RCU 5000i remote control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6. TORCH CLEANING UNIT AND LUBRICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..52

Mechanical milled torch cleaning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Digital I/Os cable from Torch cleaning unit towards Control Unit. . . . . . . . . . . . . . . . . . . . . . . . 55
Wire cutter (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7. COIL HOLDER SUPPORT AND WIRE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..57

Coil holder support on Wire feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Marathon pack kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8. SMARTARC APPLICATION SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..60
4
PREFACE
PREFACE
This chapter deals with the following topics:
– Reference documentation
– Documents storage
– Limits on the handbook contents
– Symbols used in the handbook
Reference documentation
This document concerns the application Wire welding system.
The complete set of manuals Wire welding system is composed of:
Comau Wire welding system – Technical specifications

– Integration, Transport and Installation
– Maintenance
Programming, – Software application of the SmartArc
specific for welding Wire welding system
Wiring diagram of Wire welding system
These handbooks must be integrated with the following documents:
Comau Control Unit – Technical Specifications

– Transport and installation
– Maintenance
– Use of the Control Unit
– Electrical circuit diagram
Robot – Technical Specifications
– Transport and installation
– Maintenance
– Electrical circuit diagram
Programming – PDL2 Programming Language Manual
– VP2 - Visual PDL2
– Motion programming
5
PREFACE
Fronius – Transpulse Synergic 4000, 5000 (Generator use instruction)

– Transpulse Synergic 4000, 5000 (Additional information, I/O
signals and errors)
– FK 4000 R (Use instructions for the generator cooling system)
– FK 4000 R (Flow meter and water filter installation)
– VR7000 (Wire feeder service installation)
– VR7000 (Wire feeder blowing assembly instructions)
– VR7000 (Wire feeder cover assembly instructions)
– VR7000 (Wire guide sheath on wire feeder unit assembly
instructions)
– BRG 97 N Mechanical torch cleaning unit (operating
instructions)
– Torch for Robot Robacta
– Trolley
– Autotransformer
– RCU5000I Teach Pendant
The list above is complete in order to represent all the
possible configurations and expansion.
Typically it is enough to consult only the specification of
the purchased part.
Documents storage
All provided documentation must be stored nearby the
Robotic system and be available to the personnel working on it, and it must
be preserved intact for all the operating life of the Robotic System.
Limits on the handbook contents

The images included in the instructions handbook have the purpose to represent the
product
and can differ from what is actually visible on the Robotic System.
6
PREFACE
Symbols used in the handbook

Here are the symbols that represent: WARNING, CAUTION and NOTES and their
meaning.
This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed may cause injuries to the staff.
if are not observed and/or correctly performed may cause equipment damage.
must be underlined.
This symbol indicates that entry is forbidden to persons wearing a pace-maker.
The symbol draws the attention to materials disposal that is regulated by the WEEE
Directive.
The symbol points out to avoid environmental contamination and to properly dismiss the
materials in the appropriate collection sites.
7
MODIFICATION HISTORY
Modification History
The following table shows the history of the Handbook release, with related changes /
improvements made.
Edition of the
Date Contents
Handbook
2016-12 00/2016.12 First release of the handbook
8
SAFETY REQUIREMENTS FOR CONTINUOUS WIRE WELDING
1. SAFETY REQUIREMENTS FOR

CONTINUOUS WIRE WELDING
– Responsibilities
– Information regarding the process
– Protection of the eyes and the body
– Protections against gas, fumes and fire
– Safety requirements
The following safety requirements integrate those for the robotic system, contained in
the Chapter SAFETY REQUIREMENTS of the Control Unit or Robot handbooks.
9
1.1 Responsibilities
Persons wearing a pace-maker are not allowed in any case to operate on arc welding.
Danger of death!
Entry is forbidden to persons wearing a pace-maker.

Danger of death!
– All the activities (installation, startup, operation, maintenance, etc.) on arc welding
systems are only to be carried out by the authorised personnel.
– The integrator is to perform the correct integration of the arc welding system in the
cell. The integrator shall (without however limiting the activities to the indications
below):
• consider the correct installation spaces
• install the exhaust systems for the welding fumes
• install perimeter protections, access doors
• install protective shields for the eyes and against the sparks caused by the
welding process.
It is forbidden to startup the Wire welding system before the machine in which it will be
incorporated has been declared in compliance with the provisions of the applicable
directives.
– During welding operations, there is a risk of injury due to rubbing against the metal
edges of the parts to be welded or burns due to contact with metal parts heated by
the welding. Wear gauntlets.
– The setting of wrong welding parameters can cause damage to the part to be
welded or to welding channel elements such as the welding torch. For this reason
the welding parameters are only to be set by qualified personnel.
10
1.2 Information regarding the process

The electric arc is identified by a very intense source of light and heat; in fact, the electric
current passing into the gaseous atmosphere existing between the electrode and the
part to be welded determines the emission of electromagnetic waves that are perceived
by humans as light and/or heat, according to the wave-length.
Beyond the limits perceptible by man, the arc emits also ultraviolet and infrared rays, but
ionised rays have never been detected.
1.3 Protection of the eyes and the body

The main danger present during the arc welding process is the emission of
electromagnetic waves, caused by the electric arc, having wave lengths that range from
infrared to ultraviolet.
These rays, if they hit the eye, can cause various pathologies: conjunctivitis, burning of
the retina, “glass-blower’s cataract”, deterioration of visual capacity, etc., furthermore
the strong concentration of ultraviolet rays can cause burning of the skin.
Tab. 1.1 - DIN classes of standard adiactinic glass on page 11 indicates the tones of the
glass (always indicated on the glass conforming to relevant standards) to be used
according to the different types of welding executed; mirrored types are indicated to
reduce the action of the infrared rays.
Anti-reflection shields are to be mounted around the welding zone to avoid that other
persons, working in neighbouring zones, are hit by the radiation emitted by the arc.
Never, for any reason whatsoever, look at an electric arc without adequate eye
protection.
The welded piece and the surrounding parts (including the torch) can reach high
temperatures that must be indicated by means of a special sign (by the integrator).
Tab. 1.1 - DIN classes of standard adiactinic glass
CLASS FORESEEN USE CONDITIONS

Electrodes with diameters ranging from 3.25 to 5 mm.
9 For arc welding in protected atmosphere with current intensity up
to 75 A
11
Tab. 1.1 - DIN classes of standard adiactinic glass
CLASS FORESEEN USE CONDITIONS

Electrodes with diameters over 5 mm.
10 For arc welding in protected environment with current intensity
up to 200 A
Electrodes with diameters over 5 mm.
up to 250 A
Electrodes that have a very strong luminous effect.
up to 300 A
To weld parts with very thick walls.
over 300 A and up to 500 A
12
1.4 Protections against gas, fumes and fire

In arc welding considerable quantities of fumes and gas are released, the quality of
which depends on the type of weld material and the quantity of power used.
When welding with covering gas (CO2 and Argon) it happens that, due to the effect of
the high temperatures, the CO2 separates into O+CO recomposing again in CO2 after
cooling. Therefore, close to the operator’s respiratory organs there is a considerable
quantity of oxygen and carbon oxide, as well as small quantities of ozone.
Owing to the effect of the base metal (steel) during the welding a development of Iron
Oxide fumes also takes place, but usually the quantity does not exceed the allowed
limits of 10 mg/cu m of air. The welding of galvanised or painted parts is particularly
hazardous.
During welding, vapours are also formed by microscopic particles produced by the
combustion and in part by metal volatilization. At a certain distance from the arc these
vapours condense into very fine particles that in their turn coagulate in larger particles
reaching dimensions that however never exceed 1 micron (1 thousandth of a millimetre).
It has been ascertained that these powders are usually inert, i.e. they do not contain
silica, so they do not cause silicosis risks. These powders, because of their dimensions,
are not treated by natural human filtering devices, determining the risk of
PNEUMOCONIOSIS.
It is important to install appropriate fume exhausts near the point where the operations
take place.
Avoid welding on parts that are painted, galvanised or soiled by grease, oil or other.
It is also necessary to be vary careful when handling freshly welded parts because of
obvious burning hazards caused by the heat of the part.
Make sure that in the immediate vicinity of the welding station there are no bins
containing petrol, diesel, solvents, rags or other inflammable materials.
13
1.5 Safety requirements
1.5.1 Applicability
These requirements must be applied when carrying out the following activities:
– Installation and Startup on page 14;
– Functioning in Programming mode on page 15;
– Maintenance and Repair on page 15;
– Decommissioning and Dismantling on page 15
1.5.2 Operating modes

Installation and Startup
– When foreseen, connect the Robot pneumatic system to the air distribution line and
carefully check that the setting of the system is the foreseen pressure value: a
wrong setting of the system pressure influences the correct Robot motion.
– Install filters on the pneumatic system for condensate collection.
– The robotized welding system must be installed in the specific areas designed for
this purpose.
– The electrical connections must be made on the system powered off and, after the
connection has been made, all protective coverings against accidental contacts
must be restored.
– The supply voltage and cable cross sections of the welding system must be those
specified in the technical documentation of the product.
– The electrical connections to the welding system must be made so as to avoid all
negative effects on the functioning of the system devices, caused by inductive or
capacitive interferences.
– Connection between the plant mains and the generator are to be by means of the
power plug provided on the generator.
– It is not allowed to modify the components of the welding system during installation.
Unforeseen drilling or cutting operations on the system components could
compromise the safety level provided by the manufacturer.
– Before starting welding activities, make sure that there is no inflammable material
nearby the welding protection.
– The system is only to be used for ARC WELDING. Improper use of the system
could cause damage to persons, user, equipment or an environment hazard risk.
14
Functioning in Programming mode

– The torch (integral to the Robot wrist) moves with continual motion at a speed of
less than 250 mm/s if the controller is in programming mode and faster than 250
mm/s in automatic mode. Therefore consult the safety requirements regarding
Robot motion in different machine states, contained in the chapter “GENERAL
SAFETY REQUIREMENTS” of the Robot.
Maintenance and Repair

– Any maintenance operation is to be carried out only by qualified and authorized
personnel.
– Maintenance operations on the welding system must be carried out with the system
powered off. For this purpose make sure that any interconnected voltages have
been deactivated and if necessary wait before operating for sufficient time for the
discharging of the capacitors present in some system circuits.
The Control Unit and Generator electric circuits are supplied independently. Always
open both main switches.
The auxiliary 24 Vdc power supply may be supplied from an external source, or by
the Robot control or by the line.
The input terminals and the wiring elements up to the input terminals of the main switch
remain live when the main switch is open.
– If protections are removed for replacement of components, they are to be carefully

reinstalled in order to ensure the safety level provided by the manufacturer.
– If components are replaced, the spare parts used are to have the same safety class
and use as those installed (see the spare parts recommended by COMAU
Robotics & Final Assembly).
– After any type of component has been replaced, check the serviceability
(especially for safety devices) before resuming system automatic operation.
– After replacement, any discharged batteries are not to be opened, recharged,
thrown in the fire or other. For their disposal, abide by the laws in force.
Decommissioning and Dismantling

– If present, disconnect the Robot pneumatic system from the air distribution mains.
– Disconnect the welding channel pneumatic system from the air distribution mains.
15
WIRE WELDING SYSTEM DESCRIPTION
2. WIRE WELDING SYSTEM DESCRIPTION

– General overview
– Configuration
2.1 General overview

Wire welding system performs the welding with the following processes (according to
the generator used)
– MIG/MAG synergic
– MIG/MAG pulsed synergic
The Wire welding system is an application composed of
– C5G / C5Compact Control Unit customization *¹

– Robot customization *¹
• Robot outfitting
• Wire feeder unit *¹
• Welding torch push pull *¹
• Anti-collision kit
• Tool Master (Calibrated tool unit)
• Supporting stand for Robot
– Welding generator *¹ with:
• GTWFR (GaTeWayFRonius) system connected to the Control Unit through
the serial port of the APC820/830 module (in RS422 mode)
• RS422 Serial cable
• Welding ground connection cable
– Torch cleaning unit and lubricator *¹
– Coil holder support and Wire unit
– SmartArc Application Software; the information on software can be found in the
"Software application of the SmartArc Wire welding System" handbook
The arc welding application cannot be installed on systems other than those indicated
above.
*¹ For further details regarding the machine parts (Control Unit, COMAU Robot, Fronius
Generator, etc.) see the related instructions handbooks indicated in par. Reference
documentation on page 5.
16
Fig. 2.1 - Control Unit connection principle
A C5G / C5Compact Control Unit customization

B Robot customization
C Welding generator
D Torch cleaning unit and lubricator
E Welding torch push pull
The Wire welding system is available in several configurations distinguished by:

– welding process used
– communication mode between C5G / C5Compact Control Unit customization and
Welding generator
– type of cooling used.
Tab. 2.1 - Wire welding systemconfiguration
Communication
Process Cooling Generator Robot Control Unit Structure
mode
Configuration with C5G Control Unit
MIG/MAG synergic Fig. 2.2
TPS4000 Racer7
MIG/MAG pulsed Serial GTWFR Water C5G and
SER CMT - 1.4
synergic Tab. 2.2
Configuration with C5Compact Control Unit
MIG/MAG synergic Fig. 2.3
TPS4000 Racer7
MIG/MAG pulsed Serial GTWFR Water C5Compact and
SER CMT - 1.4
synergic Tab. 2.2
17
2.2 Configuration
Below are given:
– Principle diagram of the configurations with Robot Racer 7-1.4 and C5G Control
Unit
– Principle diagram of the configurations with Robot Racer 7-1.4 and C5Compact
Control Unit
18
Fig. 2.2 - Principle diagram of the configurations with Robot Racer 7-1.4
and C5G Control Unit
Fig. 2.3 - Principle diagram of the configurations with Robot Racer 7-1.4
and C5Compact Control Unit
19
Tab. 2.2 - Structure
Item Choice of
Description
Fig. 2.2 configuration
C5G / C5Compact Control Unit customization
A C5G / C5Compact Control Unit customization - ACC1 *¹
Torch cleaner connection kit (in the Control Unit) and connection cable to the
A1 *¹
torch cleaner
A2 Control Unit High Speed Input kit (optional) *³
A3 Plate for arc outfitting *¹
A4 Serial port RS422 COM1 on module AMS-APC820/830 *¹
A5 Serial interface cable to Generator *¹
A6 I/O cable between Control Unit and Robot *¹
Robot customization
B Robot customization *¹
B1 Supporting stand for Robot *³
B2 Robot outfitting *¹
Welding generator
C Welding generator *¹
C1 Dressing cable CMT *¹
C2 Transport trolley *³
C3 Welding ground connection cable *¹
C4 3x500V autotransformer (optional) *³
RCU 5000i remote control unit *¹
C5
Connection cable extension 5 m *³
Torch cleaning unit and lubricator
D Torch cleaning unit and lubricator *¹
Complete configuration components
E Welding torch push pull body kit *²
F Balancer unit (optional) *³
G1 OctagonalMarathon pack kit
G2 CircularMarathon pack kit
*²
H Coil holder support on Wire feeder
J Wire buffer *¹
K Wire buffer holder *¹
L Wire feeder unit *¹
M Anti-collision kit *¹
TCP Check (optional, as an alternative to the reference tip) *³
N Supporting column (optional) *³
Reference tip (optional, as an alternative to TCP Check) *³
P Tool Master (Calibrated tool unit) *¹
*¹ mandatory component in the configuration

*² mandatory component with available alternatives
*³ optional component
20
C5G / C5COMPACT CONTROL UNIT CUSTOMIZATION
3. C5G / C5COMPACT CONTROL UNIT

CUSTOMIZATION
A C5G / C5Compact Control Unit

B Robot Racer7-1.4
C Welding generator
D Torch cleaning unit and lubricator
In the Wire welding system, the Control Unit is configured starting from the basic version
and complemented with the following customizations:
– Torch cleaner connection kit (in the Control Unit)
– Plate for arc outfitting
– Control Unit High Speed Input kit (optional), necessary only in certain
configurations
– I/O cable between Control Unit and Robot
Furthermore, the following services already available in the basic version of the Control
Unit have been used:
– Serial port RS422 COM1 on module AMS-APC820/830
21
Fig. 3.1 - Customization and services in the C5G Control Unit
A Torch cleaner connection kit (in the Control Unit)

B Plate for arc outfitting
C Control Unit High Speed Input kit (optional)
D Serial port RS422 COM1 on module AMS-APC820/830
E I/O cable between Control Unit and Robot
Fig. 3.2 - C5Compact Control Unit customization
A Torch cleaner connection kit (in the Control Unit)

B Plate for arc outfitting
C Control Unit High Speed Input kit (optional)
D Serial port RS422 COM1 on module AMS-APC820/830
E I/O cable between Control Unit and Robot
22
3.1 Torch cleaner connection kit (in the Control Unit)

The command and control signals directed to the torch cleaner device, and the
anti-collision kit on the Robot are collected and divided in the Control Unit thanks to the
"Torch cleaner connection kit"
Each kit includes cables and connectors inside the cabinet, cables that merge to the X8
connector and the Digital I/Os cable from Torch cleaning unit towards Control Unit (for
details on the latter, see par. 6.2).
Torch cleaner connection kit in the C5G Control Unit
23
Torch cleaner connection kit in the C5Compact Control Unit
The torch cleaner connection kit order part numbers are given in the par. 6.2.
For further information see the electrical circuit diagram of Wire welding system.
24
3.2 Plate for arc outfitting

The plate for arc outfitting is the plate on which are fixed all the connectors that connect
the cables directed towards the devices foreseen in the Wire welding system and for
which is foreseen the interruption on cabinet base (typical the connector X8 of the Torch
cleaner connection kit (in the Control Unit) (see par. 3.1 on page 23)).
The plate for Arc outfitting is installed on the connector panel on Control Unit base, to
be able to connect the following options:
– Torch cleaning unit and lubricator
– TCP Check (optional, as an alternative to the reference tip)
Plate for configuration with
C5G Control Unit
Plate for configuration with

C5Compact Control Unit
Tab. 3.1 - Arc outfitting plate order part numbers
Description Comau Part No.

Plate for arc outfitting CR16101280
Plate for arc outfitting CR16504880
25
3.3 Control Unit

High Speed Input kit (optional)
The high speed inputs kit option is used if the configuration includes the option TCP
Check (optional, as an alternative to the reference tip) (see par. 4.5.3 on page 39).
Through this option, the signal coming from the TCP Check (optional) is read by the
Control Unit and processed by the application software to implement the necessary
correction of the position.
Fig. 3.3 - C5G-HSK: High Speed Input Kit
A C5G-HSM5
X136 signal for per HSI1, including power supply 24Vdc
X137 signal for per HSI3, including power supply 24Vdc
passing towards the first module AMS-IAM and X10 connection (Robot
X138
signals)
Tab. 3.2 - High speed input kit order part numbers

High Speed Input Kit (C5G-HSK5) CR17132680
High Speed Input Kit Compact (C5G-HSKC) CR17132681
The option is the same available in the Control Unit.

For further information, see the Control Unit “Technical specifications” handbook .
26
3.4 Serial port RS422 COM1 on module

AMS-APC820/830
Sending management commands to the generator is done via the serial protocol RS422
on the same port COM1, available as standard on the module AMS-APC820/830 of the
Control Unit.
The connection is carried on through RS422 Serial cable (see par. 5.8 on page 46) and
the connectors on the ends are directly connected to the ports. The serial cable passes
on Control Unit base through the X90 cable gland connector.
The serial port is that already available in the Control Unit.

For further information, see the Control Unit “Technical specifications” handbook .
27
3.5 I/O cable between Control Unit and Robot

The I/O connection cable between the Control Unit and the Robot is directly connected
to the internal modules of the Control Unit; the other end is connected through the
appropriate connectors on the Robot base. It passes on Control Unit base through the
appropriate cable gland connector.
The cable can be chosen according to four different lengths.
I/O cable between C5G Control Unit and Robot
28
I/O cable between C5Compact Control Unit and Robot
Tab. 3.3 - I/O cable between Control Unit and Robot order part numbers

C5G-SRK05 - Kit consisting of I/O signals cable
CR17433280
Cables length 5 m (16 ft)
CR17433281
CR17433282
CR17433283
C5G-SRC - Kit consisting of I/O signals cable
CR17244460
CR17244461
CR17244462
CR17244463
29
ROBOT CUSTOMIZATION
4. ROBOT CUSTOMIZATION
This chapter contains:
– Robot outfitting consisting of:
– Dressing cable CMT
– Wire buffer
– Wire feeder unit
– Welding torch push pull
– Anti-collision kit
– Devices for the calculation/check of the TCP (Tool Center Point), composed of:
– Tool Master (Calibrated tool unit)
– Reference tip (optional, as an alternative to TCP Check)
– Supporting stand for Robot
– Balancer unit (optional)
The Robot used for the Wire welding system is a Robot Racer7-1.4 COMAU specific for
ARC welding applications.
For all the Robot details, refer to the specific instructions handbook.
30
ROBOT CUSTOMIZATION
4.1 Robot outfitting

The robot outfitting is composed of:
– Dressing cable CMT
– Wire buffer
4.1.1 Dressing cable CMT

The Dressing cable CMT consists of connection pipes and cables between the Wire
feeder unit and the Welding torch push pull.
Tab. 4.1 - Order part numbers Dressing cable CMT

Cables pack 8.25 m (27.06 ft) CR16660580
The electric connection detail of the cables is contained in the application Circuit
Diagram.
31
ROBOT CUSTOMIZATION
4.1.2 Wire buffer

The Wire buffer ensures a perfect synchronization between the wire feeder and the
welding torch.
The device acts as a flywheel and disengages the towing and thrust motor ensuring a
constant and accurate wire movement. It also ensures a precise and resistance free wire
feed.
The wire buffer is installed on Robot through the appropriate mechanical interface
bracket.
Tab. 4.2 - Wire buffer kit for Robot Racer7-1.4 order Part No.

Wire buffer kit Racer7-1.4 CR16507280
32
ROBOT CUSTOMIZATION
4.2 Wire feeder unit

The wire feeder unit, installed on the generator's carriage, is controlled by the generator
itself and is connected to it by means of a cables pack.
Depending on requirements, it is possible to install rollers kit for iron or
Aluminium/CUSI3 wire Ø 1 mm, as indicated in the following table.
To the wire feed unit is connected the Welding torch push pull by means of a wire guide
cable.
Tab. 4.3 - Wire feeder unit order part numbers

FRONIUS VR7000 wire feeder unit CR16657480
Tab. 4.4 - Rollers kit order part numbers

Rollers kit for Aluminium/CUSI3 wire Ø 1 mm (0.039 in) CR16655380
Rollers kit for iron wire Ø 1 mm (0.039 in) CR16655480
Tab. 4.5 - Cables pack order part numbers

Generator / wire feeder cables pack 1.2 m (3.93 ft) 70 mm² CR19076012
33
ROBOT CUSTOMIZATION
4.3 Welding torch push pull

The welding torch is available with different amperage ranges and different slanting
angles.
The welding torch can be fitted, regardless of the angle of inclination, with contact tip
diameter 0.8 mm (0.031 in), 1.0 mm (0.039 in) and 1.2 mm (0.047 in).
The welding torch requires periodical cleaning to be carried out with the Torch cleaning
unit and lubricator.
The welding torch is equipped with a high dynamic AC servomotor for wire feeding.
Push pull torch
Tab. 4.6 - Welding torch order part numbers
Welding torch kit

Welding torch kit Robacta RA280 angle 22° CR19072009
Robacta Drive kit
Robacta Drive kit (wire feeder system for push pull torch) CR19078049
Wire feeder rollers kit
Robacta Drive rollers kit for wire of diam. 1.2 mm (0.047 in)
CR19078043
A/Mg/CuSi
Robacta Drive rollers kit for iron wire of diam. 1 mm (0.039 in) CR19078044
34
ROBOT CUSTOMIZATION
4.4 Anti-collision kit

The anti-collision kit signals the impact of the torch with parts of fixtures or welded parts
and stops the robot. It is located between the robot wrist and the welding torch.
Tab. 4.7 - Anti-collision kit order part numbers

Anti-collision kit CR16661780
The anti-collision kit has to be enabled. See details in the Integration, Transport and
Installation manual in the chapter “Wire welding systemcomponents installation”.
In order to work properly, the anti-collision kit must be equipped with the Torch cleaner
connection kit (in the Control Unit).
35
ROBOT CUSTOMIZATION
4.5 Devices for the calculation/check of the TCP (Tool

Center Point)
For the calculation/check of the TCP (Tool Center Point), the following devices are
available:
– Tool Master (Calibrated tool unit)
– Reference tip (optional, as an alternative to TCP Check).
In the following diagram the method to calculate the TCP is represented.
A Tool Master (Calibrated tool unit)

B Reference tip (optional, as an alternative to TCP Check)
C TCP Check (optional, as an alternative to the reference tip)
36
ROBOT CUSTOMIZATION
4.5.1 Tool Master (Calibrated tool unit)

The tool master is a calibrated iron round bar section used for the Tool Center Point
(TCP) calculation.
The tool master is supplied with the Robot outfitted for Arc application.
If the Robot is Racer, the Tool Master values to be assigned for the
Tool calculation are:
X = 144 Y=0 Z=7
The tool master A, when necessary, must be installed on the appropriate threaded hole
M6 B on the anti-collision kit.
A Tool Master
B Tool Master seat (threaded hole)
Tab. 4.8 - Tool Master order Part No.

Tool Master (Calibrated tool unit) L=117 81783801
For further programming details, see the installation handbook, in paragraph Tool
Master installation.
37
ROBOT CUSTOMIZATION
4.5.2 Reference tip (optional, as an alternative to TCP Check)

To check the torch alignment, the Reference tip can be installed as an alternative to the
TCP Check.
The reference tip is to be used for manual checks, that do not require precision. For use,
the operator has to manually store the check position (the wire tip aligned to the
reference tip).
Subsequent checks have to be carried out by bringing the Robot in check position and
visually checking the alignment.
It is the task of the integrator to position the reference tip.
Tab. 4.9 - Reference tip order Part No.

Reference tip 166542200400
The reference tip can be replaced by any reference tip decided by the user.
38
ROBOT CUSTOMIZATION
4.5.3 TCP Check (optional, as an alternative to the reference tip)

TCP Check can be installed to control the torch alignment as an alternative to the
Reference tip.
The TCP Check signal is directed through a special cable towards the High Speed Input
(HSI 1, X136/C5G-HSK) on the C5G-HSK module (not included in this option, see
par. 3.3 Control Unit High Speed Input kit (optional) on page 26).
The kit includes:
– the TCP Check, which consists of:
- Aluminium base§
- 2 optical sensors
- one reference tip
– connection cable between TCP Check and Control Unit
– Control Unit internal cable
– “SmartArc Tcp Check“ software option (see Tab. 8.2), to use the TCP Check with
SmartArc sw.
The operating principle consists of an automatic program (not supplied by Comau) in
which the Robot, with appropriate movements, identifies the position of the wire
interrupting the beam emitted by two optical sensors positioned at 90° to each other. The
position calculated by the wire tip (Tool Center Point, TCP) is checked to control that it
is within the range set by the operator and updated in automatic mode.
The X82 connector matched with the cable coming from the TCP Check, merge on the
Plate for arc outfitting.
39
ROBOT CUSTOMIZATION
Tab. 4.10 - TCP Check order part numbers

TCP Check kit for C5G Control Unit
Note: the TCP Check requires the C5G-HSK5 option on Control
CR16502780
Unit (par. 3.3 Control Unit High Speed Input kit (optional) on
page 26)
TCP Check kit for C5Compact Control Unit
Note: the TCP Check requires the C5G-HSKC option on the
CR16504380
Control Unit (par. 3.3 Control Unit High Speed Input kit (optional)
on page 26)
Supporting column
Support column for TCP Check, height 800 mm (31.50 in) 16654580
“TCP Check” Aluminium board dimensions TPC board Supporting Column dimensions
Plan view Frontal view
40
ROBOT CUSTOMIZATION
4.6 Supporting stand for Robot

The Robot Racer always requires the presence of a supporting stand in order to allow
the regular passage of the outfitting from the Robot base.
Tab. 4.11 - Supporting stand for Robot order Part No.

Supporting stand for Robot H=500 mm (1.64 ft) CR82221809
Supporting stand for Robot H=1350 mm (4.26 ft) inclined 30° CR82221812
For further information, see the Robot “Technical specifications“ and “Transport and
Installation“ handbooks.
41
ROBOT CUSTOMIZATION
4.7 Balancer unit (optional)

The balancer unit is used to support the pipes and cables harness and the welding wire.
It is recommended to install the balancer unit to avoid that the pipes and cables harness
interferes with the Robot movements.
A correct installation is composed of:
– support structure A (Planning and carrying out by the integrator)
– balancer B, to be connected to the structure through a carabiner by using one of
the two holes diameter 8mm
(Maximum reach: 4-6 kg)
– cradle C, to be connected through the carabiner of the balancer.
Tab. 4.12 - Balancer unit order Part No.

Balancer unit (4-6 kg) (8.82-13.23 lb) 19060472
Rubber support (cradle) CR19078029
Cradle detail Balancer detail
42
WELDING GENERATOR
5. WELDING GENERATOR
– General information
– Generator connection to the power supply mains
– Generator connection to the Control Unit
– Welding process
– Type of cooling
– Communication mode
– Generator order part numbers
– RS422 Serial cable (external from Control Unit towards Generator)
– Welding ground connection cable for the Generator
– Transport trolley
– 3x500V autotransformer (optional)
– RCU 5000i remote control unit
43
WELDING GENERATOR
5.1 General information

The generator is supplied independently and receives the control signals via RS422
Serial cable connection coming from the Control Unit.
5.2 Generator connection to the power supply mains

The generator is connected to the power supply mains of the plant through the
appropriate power supply cable.
The generator power supply characteristics are listed in Tab. 5.1.
5.3 Generator connection to the Control Unit

The generator includes the RS422 I/O serial module. The GTWFR serial interface
developed for the C5G / C5Compact Control Unit is intended for the exclusive use of
Comau.
The generator RS422 serial port is connected to the serial port COM1 on ASM-APC
module.
44
WELDING GENERATOR
5.4 Welding process

Generators are available for:
– pulsed synergic MIG/MAG with TPS4000 CMT Fronius
5.5 Type of cooling

The generator cooling is carried out by means of a water circuit in the generator.
5.6 Communication mode

The generator's communication takes place by means of RS422 Serial cable (see par.
5.8 on page 46).
5.7 Generator order part numbers

Tab. 5.1 - Codes table
Power supply Comau Part Communication

Fronius Type of process Cooling
characteristics No. method
3x400V +/- 15%
MIG/MAG 3x500V +/- 10% *¹
TPS4000
synergic, pulsed 50 / 60 Hz CR16660280 Serial Water
SER CMT
synergic 12.2 kVA
cos ϕ 0.99
*¹:To be used with 3x500V autotransformer (optional) only
45
WELDING GENERATOR
5.8 RS422 Serial cable

The RS422 serial cable is directly connected to the AMS-APC820/830 module (COM1)
inside the Control Unit and passes towards the base of the cabinet through the X90
cable gland connector; the other end is connected via a special connector to the welding
generator.
Tab. 5.2 - Order part numbers of the RS422 serial cable

Serial cable, length 7 m (23 ft) CR16041460
Serial cable, length 12 m (39.4 ft) CR16041461
Serial cable, length 32 m (105 ft) CR16041465
46
WELDING GENERATOR
RS422 serial cable composition detail
For more functional details regarding RS422 communication, see the par. 3.4 “Serial
port RS422 COM1 on module AMS-APC820/830”
47
WELDING GENERATOR
5.9 Welding ground connection cable

The ground cable connects the generator to the equipment holding the item to be
welded.
The cable must be fixed to the equipment using an eyelet (12 mm diameter) and an
appropriate screw.
Tab. 5.3 - Ground cable order Part No.

Welding ground 95 mm², 10 m (32.8 ft) 19060484
48
WELDING GENERATOR
5.10 Transport trolley

The transport trolley permits easy handling of the generator.
It can sustain the generator models indicated in this manual, including, if required,
a3x500V autotransformer (optional).
Tab. 5.4 - Transport trolley order Part No.

Transport trolley with cylinder holder CR16657580
49
WELDING GENERATOR
5.11 3x500V autotransformer (optional)

The autotransformer is used to supply the generator in cases of a 500 Vac +/- 10%
power supply from the mains. The module is installed in the lower zone of the generator.
The generator base profile is not changed.
When the autotransformer is installed, the generator power supply cable comes out
directly from the autotransformer module and the main switch to power off electric power
is on the new autotransformer module.
Tab. 5.5 - 3x500V autotransformer order Part No.

3x500V autotransformer CR19061436
50
WELDING GENERATOR
5.12 RCU 5000i remote control unit

The RCU 5000i remote control unit allows to create and manage directly on the
component to be welded all the characteristic curves and workings, as well as to monitor
all welding data.
Tab. 5.6 - RCU 5000i remote control unit order part numbers

RCU 5000i remote control unit CR16657680
Connection cable extension 5 m (16.4 ft) (optional) CR19076016
51
TORCH CLEANING UNIT AND LUBRICATOR
6. TORCH CLEANING UNIT AND LUBRICATOR

This chapter contains:
– Mechanical milled torch cleaning unit
– Digital I/Os cable from Torch cleaning unit towards Control Unit
– Wire cutter (optional)
52
6.1 Mechanical milled torch cleaning unit

The mechanical torch cleaning unit is a device that removes the accumulation of splatter
by milling Since this is a mechanical operation, this device can be applied to all wire
welding processes.
The mechanical milled torch cleaning unit includes:
– cleaning unit
– lubricator
– holder column.
The unit can be used with the Wire cutter (optional)
The installation requires the Plate for arc outfitting.
The unit is electrically connected to the Control Unit through a multipolar cable and uses
the I/Os of the C5G-SDM module.
The unit is electrically connected to the generator.
To operate it requires (not included in the cleaning unit):
– Digital I/Os cable from Torch cleaning unit towards Control Unit
– compressed air supply: dry air must be provided with a supply pressure of 0.4 - 0.6
MPa (4 - 6 bar).
Torch cleaning unit and lubricator Torch cleaning unit and lubricator
(rear view) (frontal view)
53
Tab. 6.1 - Mechanical milled torch cleaning unit orderpart numbers

Torch cleaning unit
Mechanical milled torch cleaning unit Robacta REAMER, with
lubricator and supporting column, height 700 mm (27.56 in). 16689494
Match the appropriate mill to the welding torch type chosen.
Mill for torch
Mill for RA280/RA400 Torch with nozzle diam. 12 mm CR19074019
54
6.2 Digital I/Os cable from Torch cleaning unit towards

Control Unit
This multipolar cable must be used to connect the mechanical torch cleaning unit to the
Control Unit and uses the I/Os of the C5G-SDM module.
The torch cleaner connection kit includes the cabinet internal connectors and cables that
converge to the X8 connector and the digital I/Os cable from Mechanical torch cleaning
unit towards the Control Unit.
There are 2 different solutions for each Control Unit model (only one between those
available can be installed), characterized by the length of the cable from the cabinet
base towards the torch cleaner.
For detailed information on connectors and cabinets internal cables, refer to par. 3.1
Torch cleaner connection kit (in the Control Unit) on page 23.
Tab. 6.2 - Torch cleaner connection kit order part numbers

Torch cleaner connection kit, including Control Unit internal
CR16654180
cables and external cable length 8 m (26.25 ft)
CR16654280
CR16504680
CR16504780
55
6.3 Wire cutter (optional)

The wire cutter is of mechanical type controlled by a pneumatic switch. The wire cutter
is installed on Torch cleaning unit and lubricator.
The wire cutter matched with Mechanical milled torch cleaning unit shares the
compressed air supply.
Tab. 6.3 - Wire cutter order Part No.

Wire cutter for Mechanical milled torch cleaning unit 19060447
56
COIL HOLDER SUPPORT AND WIRE UNIT
7. COIL HOLDER SUPPORT AND WIRE UNIT

The welding wire is normally available in 2 possible variants.
Depending on the welding wire variant used, can be installed one of the following
alternatives:
– Coil holder support on Wire feeder (for wire on coil), installed on the wire feeder unit
– Marathon pack kit, can be positioned according to installation requirements
(considering the maximum distance between the container and wire feeder unit).
It is recommended to support the welding wire with the appropriate Balancer unit
(optional).
57
7.1 Coil holder support on Wire feeder

Due to the coil holder support present inside the wire feeder is possible to install the
welding wire coil inside the wire feeder.
Such solution is typically adopted for small welding volumes and allows a limited
autonomy.
For further information, refer to par. 4.2 Wire feeder unit on page 33
58
7.2 Marathon pack kit

The Marathon pack kit consists of a cover and a wire guide sheath that is inserted into
the wire feeder unit and is installed to cover the welding wire container (Marathon Pack).
Such solution is typically adopted for large welding volumes and allows a high
autonomy, given the large size of the coil.
One of the following cover alternatives can be installed:
– Circular cover
– Octagonal cover
Circular cover Octagonal cover
Tab. 7.1 - Marathon pack kit order part numbers

Circular cover
Circular Marathon pack kit with 3.5 m (11.48 ft) sheath CR16100980
Circular Marathon pack kit with 5 m (16.4 ft) sheath CR16101480
Circular Marathon pack kit with 6.35 m (20.83 ft) sheath CR16101080
Circular Marathon pack kit with 8 m (26.24 ft) sheath CR16101180
Octagonal cover
Octagonal Marathon pack kit with 1.6 m (5.24 ft) sheath CR16100580
Octagonal Marathon pack kit with 5 m (16.4 ft) sheath CR16101380
Octagonal Marathon pack kit with 8 m (26.24 ft) sheath CR16100880
59
SMARTARC APPLICATION SOFTWARE
8. SMARTARC APPLICATION SOFTWARE

It is an application software, installed on the Control Unit, necessary to manage a Wire
welding system in a simple and homogeneous manner.
The software is only supplied together with the outfitted robot and is configured
according to the order of the Customer. The user interface is available on the teach
pendant.
The basic configuration consists of the SmartArc package, to which additional functions
can be added through optional packages.
For information, see the SMART-ARC software manual.
Tab. 8.2 - SmartArc software and optional packages Part No.
Comau Part
Description Notes
No.
Main software package for wire welding
SmartArc 13620060
applications (arc welding).
Requires SmartArc package.
SmartArc Spot 13620160 Software option to execute an intermittent
process without stopping the robot motion.
SmartArc OverLap 13620360 Software option to restart overlapping the
weld bead.
Is the software option that ensures the TCP
(Tool Center Point) control.
SmartArc TCP Check 13620460
To be used matched with the option TCP
Check (optional, as an alternative to the
reference tip) (see par. 4.5.3 on page 39).
60
Original instructions
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Wire welding

Technical specifications for

Copyright © 2016 by COMAU - Date of publication 12/2016

1. SAFETY REQUIREMENTS FOR CONTINUOUS WIRE WELDING . . . . . . . . . . . . . . ...9

2. WIRE WELDING SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16

3. C5G / C5COMPACT CONTROL UNIT CUSTOMIZATION . . . . . . . . . . . . . . . . . . . . ...21

4. ROBOT CUSTOMIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...30

5. WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43

6. TORCH CLEANING UNIT AND LUBRICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..52

7. COIL HOLDER SUPPORT AND WIRE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..57

8. SMARTARC APPLICATION SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..60

Comau Wire welding system – Technical specifications

These handbooks must be integrated with the following documents:

Comau Control Unit – Technical Specifications

Fronius – Transpulse Synergic 4000, 5000 (Generator use instruction)

Limits on the handbook contents

Symbols used in the handbook

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

SAFETY REQUIREMENTS FOR CONTINUOUS WIRE WELDING

1. SAFETY REQUIREMENTS FOR

SAFETY REQUIREMENTS FOR CONTINUOUS WIRE WELDING

Entry is forbidden to persons wearing a pace-maker.

SAFETY REQUIREMENTS FOR CONTINUOUS WIRE WELDING

1.2 Information regarding the process

1.3 Protection of the eyes and the body

Tab. 1.1 - DIN classes of standard adiactinic glass

CLASS FORESEEN USE CONDITIONS

SAFETY REQUIREMENTS FOR CONTINUOUS WIRE WELDING

Tab. 1.1 - DIN classes of standard adiactinic glass

CLASS FORESEEN USE CONDITIONS

SAFETY REQUIREMENTS FOR CONTINUOUS WIRE WELDING

1.4 Protections against gas, fumes and fire

SAFETY REQUIREMENTS FOR CONTINUOUS WIRE WELDING

1.5 Safety requirements

1.5.2 Operating modes

SAFETY REQUIREMENTS FOR CONTINUOUS WIRE WELDING

Functioning in Programming mode

Maintenance and Repair

– If protections are removed for replacement of components, they are to be carefully

Decommissioning and Dismantling

WIRE WELDING SYSTEM DESCRIPTION

2. WIRE WELDING SYSTEM DESCRIPTION

2.1 General overview

– C5G / C5Compact Control Unit customization *¹

WIRE WELDING SYSTEM DESCRIPTION

Fig. 2.1 - Control Unit connection principle

A C5G / C5Compact Control Unit customization

The Wire welding system is available in several configurations distinguished by:

Tab. 2.1 - Wire welding systemconfiguration

WIRE WELDING SYSTEM DESCRIPTION

WIRE WELDING SYSTEM DESCRIPTION

WIRE WELDING SYSTEM DESCRIPTION

Tab. 2.2 - Structure

*¹ mandatory component in the configuration

C5G / C5COMPACT CONTROL UNIT CUSTOMIZATION

3. C5G / C5COMPACT CONTROL UNIT

A C5G / C5Compact Control Unit

C5G / C5COMPACT CONTROL UNIT CUSTOMIZATION

Fig. 3.1 - Customization and services in the C5G Control Unit