COMAU Arc-Tin Kem en Manual

SMART NS - Manuals list
Comau Robotics
Instruction Handbook
Continuous wire welding system

(Custom - KGR with Generator
Kemppi KempArc)
Integration, Transport and Installation for the system

Kemppi KempArc Fieldbus connection with Robot
SMART5 Arc4
CR00757930-en_00/2014.11
The information contained in this manual is the property of COMAU S.p.A.
The reproduction, even partial, without prior written authorisation by COMAU S.p.A. is forbidden.
COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation in this
manual.
Copyright 2011 - 2014 by COMAU - Published on 03/2015

Summary
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Documents preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Limits on the manual content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. WIRE WELDING SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Information regarding the process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Protection of the eyes and the body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Protections against gas, fumes and fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2. INSTALLATION SUMMARIZING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...15
3. INSTALLATION SUGGESTIONS, LIFTING AND HANDLING PROCEDURE . . . . . ...17

Staff in charge for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Equipment necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation environment requirements and suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Network power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
C5G Installation dimensions and spaces (without air conditioner). . . . . . . . . . . . . . . . . . . . . 20
Installation dimensions and spaces C5G (with Air conditioner) . . . . . . . . . . . . . . . . . . . . . . . 21
Control Unit handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Robot support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Torch cleaning assembly and lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4. INSTALLATION OF THE CONTINUOUS WIRE WELDING SYSTEM COMPONENTS . .

..26
Control Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Summary
Robot installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Generator installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation of the outfitting on the Robot SMART5 Arc4 ......................... 28
Preparation of the Robot wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Collision avoidance kit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Torch installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Wire feeder installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Superior cable package installation (from torch to wire feeder) . . . . . . . . . . . . . . . . . . . . . . . 32
Installation of the cable connection kit from the wire feeder to the robot base. . . . . . . . . . . . 33
Mechanical milled torch cleaning assembly installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Tool Master installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Balancer installation (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TCP Check installation (optional) for alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TCP Check installation (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Location point Installation (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5. CONTINUOUS WIRE WELDING SYSTEM CONNECTIONS. . . . . . . . . . . . . . . . . . . ..45

Cables installation hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Connection between Control Unit and Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Connection between Control Unit and generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
C5G Fieldbus cable - welding generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Ground cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Seam Track cable: connection between the LEM current sensor and the C5G Control Unit . . 51
Connection between the generator and the torch cleaning unit. . . . . . . . . . . . . . . . . . . . . . . . . 52
Connection between the generator and wire feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Connection of the torch kit cable to the wire feeder unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Connection between Control Unit and safeties, line Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connection between C5G and TCP Check (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connections to the power supply networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Control Unit connection to the electric power supply line. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Generator connection to the mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Robot and torch cleaning assembly connection to the compressed air distribution line . . . . 67
Robot connection to the welding gas distribution network . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6. CONTINUOUS WIRE WELDING SYSTEM ACTIVATION . . . . . . . . . . . . . . . . . . . . . ..71

Precautions to be taken before activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connectors pin-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Power-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Welding wire installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Marathon Pac and cover positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Wire insertion in the wire feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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Summary
Bleeding the water circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

SMART-ARC and optional software modules activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Robot motions programming hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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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 application Continuous wire welding system.
The complete set of Continuous wire welding system manuals consists of:
Comau Continuous wire Technical specifications

welding system Integration, Transport and installation
Maintenance
Programming, spe- Software application of the SmartArc
cific for welding Continuous wire welding system
Wiring diagram of Continuous wire welding system
These manual must be integrated with the following documents:
Comau C5G Control Unit Technical specifications

Transport and installation
Maintenance
Use of C5G Control Unit
Wiring diagram
Robot Technical Specifications
Transport and installation
Maintenance
Wiring diagram
Programming PDL2 Programming Language Manual
VP2 - Visual PDL2
Motion Programming
Kemppi Service manual KempArc Pulse
Abirob Binzel User manual - BRS-CC Cleaning assembly with cutter
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.
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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.
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Preface
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 ignored and/or performed incorrectly could cause injuries.
if ignored and/or incorrectly performed 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.
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Wire welding safety precautions
1. WIRE WELDING SAFETY PRECAUTIONS

In this chapter are shown the following topics:
Responsibilities.
Information regarding the process.
Protection of the eyes and the body.
Protections against gas, fumes and fire.
Safety precautions.
The safety precautions that follow integrate those for the robotic system, contained in
the Chapter SAFETY PRECAUTIONS of the Control Unit or Robot manuals.
1.1 Responsibilities
Persons wearing a pace-maker are not allowed in any case to operate on arc welding.
Danger: high voltage!
Entry is forbidden to persons wearing a pace-maker.

Danger of death!
All the activities (installation, start-up, 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.
The Continuous wire welding system is not to be started up before the machine where
it is incorporated has been declared in conformity with the provisions of the applicable
directives.
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During welding operations an accident hazard exists caused by rubbing against the
metal edges of the parts to be welded or burns from contact with metal parts heated
by the welding. Wear protective gloves.
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.
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 infra-red rays,
but ionised rays have never been detected.
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1.3 Protection of the eyes and the body

The main danger present during the arc welding process is the emission of electromag-
netic waves, caused by the electric arc, having wave lengths that range from infra-red
to ultraviolet.
These rays, if they hit the eye, can cause various pathologies: conjunctivitis, burning of
the retina, glass-blower 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 12 indicates the tones of the
glass (always indicated on the glass conforming to relevant standards) to be used ac-
cording to the different types of welding executed; mirrored types are indicated to reduce
the action of the infra-red 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 protec-
tion.
The welded piece and the parts nearby (included the welding torch) can reach high tem-
perature that must be indicated in the appropriate sign (by the integrator).
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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
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
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 lim-
its of 10 mg/cu m of air. The welding of galvanised or painted parts is particularly haz-
ardous.
During welding, vapours are also formed by microscopic particles produced by the com-
bustion and in part by metal volatilization. At a certain distance from the arc these va-
pours 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 sil-
ica, 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 PNEUMOCO-
NIOSIS.
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.
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Make sure that in the immediate vicinity of the welding station there are no bins contain-
ing petrol, diesel, solvents, rags or other inflammable materials.
1.5 Safety precautions
1.5.1 Applicability
These precautions are to be applied when carrying out the following activities:
Installation and Start-up on page 13.
Operation in programming mode on page 14.
Maintenance and Repairs on page 14.
Putting out of service and dismantling on page 14.
1.5.2 Operating modes

Installation and Start-up
When foreseen, connect the robot pneumatic system to the air distribution line and
carefully check that the setting of the system is the specified pressure value: a
wrong setting of the system pressure influences the correct robot motion.
Install filters on the pneumatic system to collect any condensation.
The automated welding system is to be installed in the specific areas prepared for
this purpose.
Electrical connections are to be made on the system with power cut-out, after the
connection has been made, restore all the protective coverings against accidental
contacts.
The welding system supply voltage and cable cross sections are to be those
specified in the technical documentation of the product.
Electrical connections to the welding system are to be performed 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.
The welding system components are not to be modified during installation.
Unforeseen drilling or cutting operations on the system components could deteri-
orate the safety level foreseen by the manufacturer.
Before starting welding activities, make sure that there is no inflammable material
close to the welding protection.
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The system is only to be used for ARC WELDING. Improper use of the system
could cause damage to persons, the user, the fixtures or an environment hazard
risk.
Operation 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 precautions regarding robot
handling in the different machine states. These are contained in the chapter
GENERAL SAFETY PRECAUTIONS" of the Robot.
Maintenance and Repairs

Only qualified and authorised persons are allowed to carry out maintenance opera-
tions.
Maintenance operations on the welding system are only to be carried out with the
system power off. Always check that any interconnected voltages have been
deactivated and if necessary wait before starting to operate 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 terminal blocks and the wiring elements up to the input terminals of the main
switch remain live when the main switch is open.
If the protections are removed to replace components, they are to be carefully

reinstalled so as to ensure the safety level foreseen 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 the disposal, abide by the current laws in force.
Putting out of service 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.
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Installation summarizing table
2. INSTALLATION SUMMARIZING TABLE

The table below summarises the installation sequence for the Continuous wire welding
system.
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. 2.1 - Installation summarizing table
Step Operation Done

Installation environment requirements and suggestions
1 Staff in charge for the installation
2 Equipment necessary
3 Installation environment requirements and sugges-
tions
4 Network power supply
Handling and transport procedures
5 Control Unit
6 Robot
7 Robot support
8 Generator
9 Torch cleaning assembly and lubricator
Installation procedure
10 Control Unit Installation
11 Robot holder (optional) installation
12 Robot installation
13 Generator installation
14 Outfitting installation on Robot SMART5 Arc4
15 Mechanical milled torch cleaning assembly installa-
tion
16 Tool Master installation
17 Balancer installation (optional)
18 TCP Check installation (optional) for alignment
check
19 Location point Installation (optional)
Components connection
20 Connection between Control Unit and Robot
21 Connection between Control Unit and generator
22 Seam Track cable: connection between the LEM
current sensor and the C5G Control Unit
23 Connection between the generator and the torch
cleaning unit
24 Connection between the generator and wire feeder
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Installation summarizing table
Tab. 2.1 - Installation summarizing table (Continued)
Step Operation Done

25 Connection between Control Unit and safeties, line
Ethernet
26 Connection between C5G and TCP Check (optional)
27 Connections to the power supply networks
28 Generator connection to the mains power supply
29 Robot and torch cleaning assembly connection to
the compressed air distribution line
30 Robot connection to the welding gas distribution net-
work
Activation procedure
31 Precautions to be taken before activation
32 Power-on
33 Welding wire installation
34 Bleeding the water circuit
35 SMART-ARC and optional software modules activa-
tion
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Installation suggestions, lifting and handling procedure
3. INSTALLATION SUGGESTIONS, LIFTING

AND HANDLING PROCEDURE
This chapter contains:
Staff in charge for the installation.

Equipment necessary.
Installation environment requirements and suggestions.
Network power supply.
Control Unit.
Robot.
Robot support.
Generator.
Torch cleaning assembly and lubricator.
3.1 Staff in charge for the installation

Staff assigned to the installation must be trained to correctly operate hoisting equipment.
Furthermore the staff must be a person educated (in electrical, mechanical and fluidic
fields) and therefore must know the dangers deriving from electric power and the pre-
caution to be adopted to perform connection on the power supply and the interconnec-
tion signals (security signals and control signals).
3.2 Equipment necessary

The following equipment is required for the installation of the Continuous wire welding
system:
Lifting system (crane).
Forklift.
Standard workshop equipment such as screwdrivers, wrenches, etc.
00/0312 17
3.3 Installation environment requirements and

suggestions
The integrator is to provide and install the following systems and structures:
welding fumes exhaust system;
install perimeter protections, access doors;
install protective shields for the eyes (see Tab. 1.1 - DIN classes of standard adiac-
tinic glass on page 12) and against sparks caused by the welding process.
Furthermore, the integrator shall comply to the requirements of current directives and
standards so as to install the Continuous wire welding system correctly and safely in a
cell.
The Continuous wire welding system is not to be started up before the machine where
it is incorporated has been declared in conformity with the provisions of the applicable
directives.
According to the configuration, the power supply cable connection on the main switch of
the C5G Control Unit can be upstream or downstream.
18 00/0312
3.4 Network power supply
Tab. 3.1 - Summary of network power supply required for Arc

application
Device Electric power Compressed air Gas Notes

See Control Unit
C5G Control
3 kVA / 4.5 A --- --- Transport and Installa-
Unit
tion" manual.
See details in Tab. 5.1 -
15.3 kVA [Pulse 350]
Generator Wire gauge and safe-
17.8 kVA [Pulse 450]
ties on page 65.
Torch Cleaning See details in Tab. 5.2 -
assembly and --- 7 l / second --- Compressed air supply
lubricator characteristics on page.
Welding torch --- 1800 Nl / minute --- 68.
production pro-
cedure --- --- According to need ---
3.5 Control Unit

The Robot and Control Unit customising for theContinuous wire welding system does
not change the standard lifting procedure.
The Robot and Control Unit lifting and handling procedures are contained in the related
manuals. The instruction manuals are indicated in paragraph Reference documents.
In the following chapter are described:

C5G Installation dimensions and spaces (without air conditioner).
Installation dimensions and spaces C5G (with Air conditioner).
Control Unit handling.
00/0312 19
3.5.1 C5G Installation dimensions and spaces

(without air conditioner)
Tab. 3.2 - Overall dimensions
C5G + rising
Quote standard C5G Notes
socket
A 800 mm (31.49 in) ---
B 1110 mm (43.70 in) --- ---
B --- 1210 mm (47.63 in) ---
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) Minimum dimension to guarantee the ventilation.
F 200 mm (7.87 in) Minimum dimension to guarantee the ventilation.
Tab. 3.3 - Weight

Weight
In closed container 240 kg (529 lb)
On pallet 195 kg (430 lb)
Without packaging 175 kg (386 lb)
20 00/0312
3.5.2 Installation dimensions and spaces C5G

(with Air conditioner)
Tab. 3.4 - Overall dimensions
C5G + rising
Quote standard C5G Notes
socket
A 800 mm (31.49 in) ---
B 1450 mm (57.09 in) --- ---
B --- 1550 mm (61.02 in) ---
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) Minimum dimension to guarantee the ventilation.
F 200 mm (7.87 in) Minimum dimension to guarantee the ventilation.
Tab. 3.5 - Weight

Weight
In closed container 275 kg (606 lb)
On pallet 230 kg (507 lb)
Without packaging 210 kg (463 lb)
00/0312 21
3.5.3 Control Unit handling

In order to move the system packed on a pallet use a forklift or a crane.
Arrange ropes with breaking loading and slope adequate to the weight to be lifted. The
forklift track and the crane must be adequate to the weight to be lifted.
In order to guarantee the correct balance during the operation, use only the suggested
anchor points.
Different lifting methods are described:

C5G lifting overview with packing in closed container.
Lifting overview C5G without packaging, on pallet (europallet 1200 x 800 mm).
Lifting overview C5G without packaging.
3.5.3.1 C5G lifting overview with packing in closed container
Information for lifting

Weight to be lifted: 240 kg (529 lb) / 275 kg (606 lb)
Lifting with crane (A)

Ropes quantity: 2
Ropes length (approximate): 6000 mm
Lifting with forklift (B)

Forks length: >1000 mm
Pitch forks: 530 mm
Operating procedure
See the operations detail on the specific
manual of the Control Unit.
22 00/0312
3.5.3.2 Lifting overview C5G without packaging, on pallet

(europallet 1200 x 800 mm)

Ropes quantity: 4
Eyebolts on C5G: 4 x M12 female

Pitch forks: 530 mm
Operating procedure
3.5.3.3 Lifting overview C5G without packaging


Ropes quantity: 4
Eyebolts on C5G: 4 x M12 female

Pitch forks: 620 mm
Forks inlet holes: 175 mm
Danger: Do not use the transpallet because it gener-
ates overturning risk and damage the cabinet.
Operating procedure
00/0312 23
3.6 Robot
Dimensions and Robot weight outfitted with the Continuous wire welding system differ
from the standard robot as shown in the following Tab. 3.6.
The motion procedures do not change from the not outfitted model. Pay attention not to
damage the outfitting with the lifting ropes.
The overall dimensions, the motion procedures and robot transport are described in the
Robot installation manual (see paragraph Reference documents).
Tab. 3.6 - Dimensions and weight increase
Outfitting dimension increase 0 mm.

Weight increase + 20 kg (44.01 lb) with reel
+ 5 kg (11.02 lb) without reel
24 00/0312
3.7 Robot support
Robot support bench lifting and handling procedures are contained in the Robot manual.
The instruction manuals are indicated in paragraph Reference documents.
3.8 Generator
Generator lifting and handling procedures are contained in the related manuals. The in-
struction manuals are indicated in paragraph Reference documents.
3.9 Torch cleaning assembly and lubricator
The torch cleaning assembly and lubricator lifting and handling procedures are con-
tained in the related manuals. The instruction manuals are indicated in paragraph Ref-
erence documents.
00/0312 25
Installation of the Continuous wire welding system components
4. INSTALLATION OF THE CONTINUOUS WIRE

WELDING SYSTEM COMPONENTS
Control Unit Installation.
Robot holder (optional) installation.
Robot installation.
Generator installation.
Outfitting installation on Robot SMART5 Arc4.
Mechanical milled torch cleaning assembly installation.
Tool Master installation.
Balancer installation (optional).
TCP Check installation (optional) for alignment check.
4.1 Control Unit Installation
Information for the proper installation of the Control Unit (type of fastening to perform,
material to be used, clamping couples, ...), are described in the C5G Control Unit man-
ual. See the relevant instruction Handbook indicated in Reference documents.
4.2 Robot holder (optional) installation
Information for the proper installation of the Robot holder (type of fastening to perform,
material to be used, clamping couples, ...), are described in the Robot SMART5 Arc4
manual. See the relevant instruction Handbook indicated in Reference documents.
4.3 Robot installation
Information for the proper installation of the Control Unit (type of fastening to perform,
material to be used, clamping couples, ...), are described in the in the Robot SMART5
Arc4 manual. See the relevant instruction Handbook indicated in Reference documents.
AP-AW-C5E-TIN_03_g_K.fm
26 00/0312
4.4 Generator installation
Operating procedure
a. The bearing surface where the generator is to be installed is to be able to support
the weight and must not be sloped.
The generator weighs approximately 36 kg (79.36 lb) and should be han-

dled with caution.
b. The generator may be supplied

with the optional trolley.
In this case the generator is
already positioned on the trolley.
c. If the generator does not have

the trolley, place the generator
directly on the floor.
Be sure that the power generator
is electrically insulated from the
welding ground.
d. Check the level of the coolant in the pump.
The information for the checking and topping up of the coolant level is contained in the
Generator manual. See the relevant instruction Handbook indicated in Reference doc-
uments.
00/0312 27
4.5 Outfitting installation on Robot SMART5 Arc4

In the following paragraphs are shown the installation procedures:
Preparation of the Robot wrench.
Collision avoidance kit installation.
Torch installation.
Wire feeder installation.
Superior cable package installation (from torch to wire feeder).
Installation of the cable connection kit from the wire feeder to the robot base.
4.5.1 Preparation of the Robot wrench
Operating procedure
a. Attach the ring (A) on the rear
part of the robot wrist (C) using
the 2 provided screws.
28 00/0312
Operating procedure (Continued)

b. Position the adapter D on the
flange C of the robot wrist
observing the reference pin.
c. Secure the adaptor D by tight-

ening the 4 supplied screws E
and using a weak thread-locker
Loctite 242.
00/0312 29
4.5.2 Collision avoidance kit installation
Operating procedure
a. Position manually the collision
avoidance assembly (A) on the
flange adaptor (B).
b. Fasten the collision avoidance

assembly (C) using the supplied
screws.
30 00/0312
4.5.3 Torch installation
Operating procedure
a. Position the Torch (A) on the
collision avoidance (B).
b. Manually tighten fixing bushing

C.
00/0312 31
4.5.4 Wire feeder installation

Operating procedure
a. Position the support A near the
fixing holes on the robot body.
b. Support by hand the support

and tighten the 3 fixing screws
B using a weak thread-lock
Loctite 242.
c. Position the wire feeder unit C

on the work bench with the
bottom facing upwards.
d. Position the insulating plate D

on the wire feeder unit.
e. Tighten the 4 fixing screws E.
32 00/0312

f. Insert the 4 fixing screws F in
the plate D.
g. Position the wire feeder unit C

on the support A, passing the
head of the fixing screws inside
the slots.
h. Tighten the 4 rear fixing screws

F.
i. Position the X92 connector G of

the robot, in the appropriate
seat of the bracket A.
j. Tighten the 4 fixing screws H of

the connector.
00/0312 33
4.5.5 Superior cable package installation (from torch to wire feeder)
Operating procedure
a. Position the sheathing A
passing it in sequence inside:
a.1 the hole B at the rear of the

robot;
a.2 guide ring (C) on the robot wrist.
b. Assemble the plastic flange D

(comprising two half flanges)
onto the corrugation of the
sheathing A; position the fixing
screw E towards the end of the
corrugation.
34 00/0312

c. Remove the rubber cap F of the
collision avoidance unit.
d. Loosen the locking screw G.
e. Insert the special tool H inside

the hole J.
f. Screw the tool on the sleeve K

at the end of the sheathing.
g. Pull the sheathing towards the

robot wrist, until it is against
collision avoidance unit.
h. Tighten the locking screw G: the

screw must tighten without any
resistance, indicating the
incorrect positioning of the
sheathing inside the collision
avoidance unit.
i. Unscrew and remove the

wrench H.
00/0312 35

j. Secure the flange D on the back
of the robot's wrist, by tight-
ening the two fixing screws L.
k. Reposition the rubber cap F on

the collision avoidance unit.
36 00/0312
4.5.6 Installation of the cable connection kit from the wire feed-
er to the robot base
Operating procedure
a. Remove the left plate on the
base of the robot and gain
access A for the passage of the
sheathing inside the robot itself.
b. Remove the plate C unscrewing

the 4 screws D.
c. Pass the sheathing B inside the

V
base of the robot using access

A and out of the robot using
access E. Apply the half collar F
to the base of the robot in corre-
spondence with the threaded
holes.
d. Position the sheathing H on the

half-collar F, apply the second
half-collar I on the sheathing
and secure the wiring to the
structure of the robot using the
screws G.
00/0312 37

Before proceeding with the attachment of the sheathing to the robot arm,
check that the length available is such that it can cover the distance
between the fixed support and the wire feeder unit without placing the
sheathing under tension. Otherwise, loosen the screws G and slide the
sheathing further as described above.
e. Attach the bracket J to the
underside of the support K
using the threaded holes.
f. Apply the half-collar L to the

bracket.
g. Place the sheathing M on the

half-collar L. Apply the second
half-collar N to the sheathing
and fasten all with the two
screws O.
38 00/0312

h. Fix the sheathing M to the arm
of the robot (underside of the
arm), using the support P.
i. Fix the sheathing M to the arm

of the robot (underside of the
arm), using the two half-collars
Q and related fixing screws.
j. Secure the sheathing M to the

upper side of the robot with the
two ties R.
Before definitively fixing the sheathing M with the ties R, check that the
connectors and fittings are correctly connected to the wire feeder unit.
Check that the arrangement of the sheathing is not under tensions due to
hindrances or incorrect fastening.
00/0312 39

k. Position the two plates V and W
on the base of the robot.
l. Tighten the 4 fixing screws S

using a weak thread-lock Loctite
242.
m. Insert the sheathing X inside the

two half-collars U.
n. Unite the two half-collars to the

bracket W.
o. Fix the two half-collars U to the

bracket W with screws T.
p. Position the cover Y.
q. Tighten the 4 fixing screws Z

using a weak thread-lock Loctite
242.
40 00/0312
4.6 Mechanical milled torch cleaning assembly

installation
Fig. 4.1 - Overall dimensions (view from below and front view)
00/0312 41
Operating procedure
a. If the column is present, secure
it to the ground with the appro-
priate anchor plugs using the
through holes A, as indicated in
the figure.
For the type of blocks to

be used and the tighten-
ing torque values, see the
manual of the manufactur-
er.
b. Fix the torch cleaning unit on the column.
If there is no column it is necessary to fix the torch cleaning and lubricator

assembly on an adequate holder.
c. Unscrew the ring nut (B) and fill

the tank (B) with the electrolytic
liquid provided with the option.
Consult the manufactur-

er's material for the type of
electrolytic liquid.
d. Re-screw the ring nut (B).
Make sure that the cutter on the torch cleaning unit is consistent with the type of torch
installed on the Robot.
42 00/0312
4.7 Tool Master installation
Operating procedure
a. Insert the Tool Master 2 in the appropriate threaded hole 1 on axis 6 of the robot.
b. Perform the TPC (Tool Centre Point) calculation / check procedure.
To calculate the user TCP see SmartArc manual.
c. Once the check / calibration operations has been carried out, remove the Tool
Master from the robot wrist.
If the robot is SMART5 Arc4, the Tool Master values to assign for the
Tool calculation are:
X = 154 Y=0 Z=7
00/0312 43
4.8 Balancer installation (optional)
Operating procedure
a. Fasten the cradle in an intermediate point of the bundle to allow the robot
maximum freedom of movement.
b. The balancer is to be fastened
to a stable point, sufficiently
robust to support the weight of
the balancer and the bundle,
and higher than the cradle
coupling point.
Maximum reach: 4-6 kg
44 00/0312
4.9 TCP Check installation (optional) for alignment

check
The functioning of the TCP Check could be impaired if the support it is secured to is elec-
trically connected with the welding ground. If necessary, install commercial isolators be-
tween the TCP Check plate and the support column.
The following paragraphs describe the TCP Check system (optional) installation proce-
dures to perform the alignment check.
Depending on the adopted solution, perform one of the following procedures:
TCP Check installation (optional).
Location point Installation (optional).
4.9.1 TCP Check installation (optional)
Operating procedure
a. To attach the TCP Check there
are 4 holes for TCEI M8x25
screws.
P1 P2
Plan view
00/0312 45

b. If the holder column is present
the TCP Check can be directly
attached on the available plate
with 4 M8 threaded holes.
Plan view
a. To attach the column on the
pavement there are 4 passing
holes with diameter 13 mm.
For the type of blocks to

er.
Plan view
46 00/0312

b. In the figure the maximum
dimensions of the column.
If the column is not pre-

sent, it is necessary to at-
tach the TCP Check on
the appropriate holder.
Frontal view
c. Attach the TCP check on the
column. Screw the fixing
screws clamping them to the
right tightening torque.
For the type of screws to

er.
00/0312 47
4.9.2 Location point Installation (optional)
Operating procedure
a. Fasten the location point in an
appropriate place (on fixture or
on column).
48 00/0312
Continuous wire welding system connections
5. CONTINUOUS WIRE WELDING SYSTEM

CONNECTIONS
Cables installation hints.
Connection between Control Unit and Robot.
Connection between Control Unit and generator:
C5G Fieldbus cable - welding generator.
Ground cable.
Seam Track cable: connection between the LEM current sensor and the C5G
Control Unit.
Connection between the generator and the torch cleaning unit.
Connection between the generator and wire feeder.
Connection of the torch kit cable to the wire feeder unit.
Connection between Control Unit and safeties, line Ethernet.
Connection between C5G and TCP Check (optional).
Connections to the power supply networks:
Control Unit connection to the electric power supply line.
Generator connection to the mains power supply.
Robot and torch cleaning assembly connection to the compressed air distribution
line.
Robot connection to the welding gas distribution network.
5.1 Cables installation hints

The connection cables used in the Arc application are to be installed with special care,
paying attention to the following advice:
protect the cables with appropriate coverings (standard IEC 60204-1);
arrange the cables in a tidy manner and do not make coils to recover the excessive
length;
avoid power cables and communication cables being too close to each
other;
do not use cables that are not foreseen in the Arc application.
00/0312 45
5.2 Connection between Control Unit and Robot
Status: Power off

Material: Motor cable
Encoder cable
Ground cable
Equipment: 8 mm (0.314 in)spark plug wrench
Medium / big flat-head screwdriver
Preliminary procedures / notes

Details of the connections are contained in the relevant Control Unit and
Robot Installation manuals.
Operating procedure
Connections overview (representative image)
C5G ROBOT CONTROLLER CIP ROBOT PANEL

X93 X124
Ax1
X60
X10
X30
X62
X90
Ax2
X1
X2
Ax3
Ax4
AIR
Ax5
Ax6
X90
ENCODER/BRAKE CABLE
GROUND CABLE
MOTOR CABLE
Follow-up procedure
Not necessary.
46 00/0312
5.3 Connection between Control Unit and generator
Status: Power off

Material: Ground cable
The described cables are provided
with the application kit.
Equipment: Wrench, depending on the screw type
used for the locking of the ground
cable eyelet.

The cables indicated are supplied in the application kit, with different lengths
according to the choice made at the time of purchase.
The following procedures and connections are required:
C5G Fieldbus cable - welding generator.
Ground cable.
00/0312 47
5.3.1 C5G Fieldbus cable - welding generator
Operating procedure - Fieldbus cable
a. Connect the Fieldbus cable to the connector X93 of the CIP panel of the C5G
Control Unit.
b. Connect the other end of the
Fieldbus cable to connector A,
called the ROBOT CONTROL,
on the generator's interface
panel.
Pay attention to the coupling
phase between the cable
connectors and the one on the
generator: mechanically, the
two connectors have a unique
coupling position.
Turn the ring nut on the cable
connector clockwise to secure it
to connector A.
48 00/0312
5.3.2 Ground cable
Operative procedure - Welding ground cable
A: Ground connector
B: Ground cable
C: Hall-effect current sensor (LEM)
D: Ground cable terminal. To be connected close to the equipment that supports the
parts to be welded.
E: Seam Track cable
F: X35 connector of the Control Unit, CIP interface panel
a. Connect the TCP Check cable on connector (A) of the splitter.

Position the ground cable avoiding overlaying of spires.
b. Remove the cover F of the

Hall-effect sensor LEM,
unscrewing the 6 fixing screws.
00/0312 49
Operative procedure - Welding ground cable (Continued)

c. Check the direction of the arrow
stamped on the Hall-effect
current sensor H.
The yellow arrow shown in the
figure determines the flow
direction of the current.
d. Taking the "yellow arrow"

shown in the figure as
reference, insert the cable
coming from the generator into
the cable gland G.
e. Pass the cable in the sensor H

and exit from the cable gland J.
f. Connect the terminal of the

ground cable K to the metal
structure of the equipment that
supports the parts to be welded.
The cable must be connected to
the nearest metallic point in the
welding area.
g. Carry on the system impedance calibration.

The procedure is described in the Power generator manual. See the rele-
vant instruction Handbook indicated in Reference documents.
50 00/0312
5.4 Seam Track cable: connection between the LEM

current sensor and the C5G Control Unit
Status: Power off

Material: Seam Track cable and LEM current
sensor
Equipment: Not necessary.
Operating procedure - Seam Track cable
a. The Seam Track cable A is

supplied with the LEM current
sensor and already connected
to the sensor B.
b. Connect the other end of the

Seam Track cable to the X35
connector C of the C5G Control
Unit (CIP panel).
00/0312 51
5.5 Connection between the generator and the torch

cleaning unit
Status: Power off

Material: The indicated cable is included in the
application kit.
Equipment: None

The indicated cable is supplied in the application kit: cables of different length are
available in order to meet different arrangements of the generator and the torch
cleaning unit in the cell.
Operating procedure- Fieldbus Cable between the Generator and the Torch
Cleaning Kit
a. Connect the end of the Fieldbus cable C to connector A of the generator.
b. Connect the other end of the cable C to the connector B on the Fieldbus module
D on the torch cleaning unit.
Pay attention during the coupling phase between the cable connectors
and those on the generator and the Fieldbus module: mechanically, the
two male-female connectors have a unique coupling position. Turn the
ring nut on the cable connector clockwise to secure it to connector A/B.
52 00/0312
5.6 Connection between the generator and wire feeder
Status: Power off

Material: Cables pack 95 mm (AWG 3/0)
Equipment: Pincer.

The connection between the generator and wire feeder unit is made by the
"Connection Pack Kit" cable with a length of 10 meters (Comau code
CR19078059).
The section of the cables pack that is not overhead is to be positioned in-
side metal cable trays to protect against impacts and crushing. Position the
cable pack avoiding overlaying of spires.
00/0312 53
Operating procedure
Generator side Wire feeder unit side
Connection pack kit cable
A: Hoses and Connection Kit cable
1 Signals cable connector. To connect to the 24-pole connector of the generator, called the WIRE FEEDER
2 Welding torch power supply cable connector
3 Water pipe for cooling the torch (delivery pipe with blue collar)
4 Gas delivery pipe for welding
5 Compressed air delivery pipe for weld cleaning (slag removal)
6 Water pipe for cooling the torch (return pipe with red collar)
7 Water pipe fitting for cooling the torch (return pipe with red collar)
8 Signals cable connector. To connect to the wire feeder unit connector, called the CONTROL
9 Water pipe fitting for cooling the torch (delivery pipe with blue collar)
10 Compressed air delivery pipe fitting for weld cleaning (slag removal)
11 Gas delivery pipe fitting for welding (pipe with yellow collar)
12 Welding torch power supply cable connector
54 00/0312
Operating procedure (Wire feeder unit connections)

a. Connect the cable bundle to the Rear view of the Wire feeder unit
wire feeder unit installed on the
robot.
The following connectors and fittings

are present on the rear of the wire
feeder unit:
A= signal cable 24-pin connector

B= connection for sheath coupling
C= compressed air passage
D= gas pipe connection
E= torch power supply connector
b. Connect the gas pipe H with

yellow collar, to fitting D.
c. Connect the signals cable G to

the connector A.
d. Connect the compressed air

pipe F to the fitting C.
The following connectors and fittings Front view of the Wire feeder unit
are present on the front of the wire
feeder unit:
I= compressed air fitting

J= signal cable 10-pin connector
(torch cable side - for the manage-
ment of the collision avoidance sen-
sor and to power the switch
controlling the feed of the welding
wire)
K= water pipe inlet/outlet fitting
(open circuit)
L= EURO connector of the torch
sheathing
Finally, switch M is located on the
front to manually handle the
advancement of the wire for welding.
00/0312 55
Operating procedure (Wire feeder unit connections)

e. Connect the water pipes N and
O, with blue and red collars, to
the connectors on the bracket
P.
f. Connect fittings Q and R, of the

water pipes coming from the
torch unit, to the fittings on the
bracket applied to the wire
feeder unit, respecting the
coupling colours of the collars
(red and blue).
56 00/0312
Operating procedure (generator connections)

The following connectors and fittings Generator front view
are present on the front of the gener-
ator:
S= connector to update/configure
the generator software (not used by
Comau)
T= ground cable connector
U= torch power supply connector
The following connectors and fittings

are present on the rear of the gener- Generator rear view
ator:
S= connector to update/configure
the generator software (not used)
U= torch power supply connector
V= Fieldbus connector (input and
output)
X= signal cable connector (24-pin)
W= water cooling pipe inlet/outlet fit-
tings (blue delivery pipe fitting, red
return pipe fitting)
a. Connect the signals cable

connector 1 to connector X of
the generator.
b. Connect the power cable

connector 2 to the connector U
on the front or back of the
generator, depending on the
arrangement of the generator
and the robot inside the cell.
The choice of the con-

nector must permit to
position the power cable
on the floor of the factory
without overlapping other cables and
coiling of the cable itself.
00/0312 57

c. Connect the water pipes 3 and
6 to fittings W of the generator,
respecting the pairing of colours
(red and blue) on the pipes
(collars) and on the generator
connectors.
Connect the gas and the

compressed air delivery
pipes (references 4 and
5), respectively to the gas
cylinder and to the compressed air
of the factory.
58 00/0312
5.6.1 Connection of the torch kit cable to the wire feeder unit
a. Connect the wire holder sheath
B to fitting A.
b. Connect the torch cable fitting C

to the "EURO" connector D of D
the wire feeder unit.
Having inserted the fitting C to
the connector D, paying
particular attention to the
coupling of the two parts, turn
the outer ring nut to fasten.
00/0312 59
5.7 Connection between Control Unit and safeties, line

Ethernet
Status: Power off

Material: Depending on the type of installation
required
Equipment: Standard maintenance equipment.

Not necessary.
Operating procedure
C5G ROBOT CONTROLLER CIP

X93 X124
X60
X10
X30
X62
X90
ETHERNET
PLC Interface
SAFETY
a. Safety signals:
connect the safety signals through connector X30 on the CIP panel at the cabinet
base.
Details of the connections are contained in the Guide to Control Unit inte-
gration manual.
60 00/0312

b. Ethernet network:
updating though the Ethernet
network, connect the Control
Unit to the line Ethernet. The
connection is to be performed
on ETH2 connector of the
AMS-APC820 module.
Ethernet network connection details are contained in the Guide to Control

Unit integration manual.
Follow-up procedure
Not necessary.
00/0312 61
5.8 Connection between C5G and TCP Check (optional)
Status: Power off

Material: TCP Check cable
Equipment: Not necessary

This procedure is only required in the event of TCP Check installation (optional).
Operating procedure
a. Connect the TCP Check cable

on connector (A) of the splitter.
In the event of the multi
machine version, connect
the cable to one of the
connectors B of the split-
ter C.
b. Connectors D are the connec-

tions of the two optical sensors
used in the TCP Check.
62 00/0312

c. Connect the other end of the
TCP Check cable to the X82
connector of the CIP interface
panel of the C5G Control Unit
(reference E).
d. Make sure that the cable inside

the Control Unit F is connected
to the module G (connector
X136 HS1, X136/C5G HSK5).
Follow-up procedure
Not necessary.
00/0312 63
5.9 Connections to the power supply networks

The continuous wire welding system requires the following connections to the supplies
networks:
Control Unit connection to the electric power supply line.
Generator connection to the mains power supply.
Robot and torch cleaning assembly connection to the compressed air distribution
line.
Robot connection to the welding gas distribution network.
5.9.1 Control Unit connection to the electric power supply line
The information for connection to the electric power supply line is contained in the C5G
installation manual (see Reference documents).
5.9.2 Generator connection to the mains power supply

The power supply of the generator is provided through a loose cable with three phase
16A, 400V standard plug. If there is a transformer, power is supplied through a loop ca-
ble without end.
Depending on the socket installation type and the power supply provided, please con-
sider the need to install a differential circuit breaker.
Connect the generator power supply plug to an appropriate socket.
Upstream of the generator there may be a switch/protection fuse connection of the pow-
er supply cable with appropriate characteristics.
Tab. 5.1 contains the electrical connection characteristics.
Before connecting the power supply cable, verify the mains power supply voltage coher-
ence with those of the power generator / transformer (if present).
64 00/0312
Tab. 5.1 - Conductor section and protections
Power supply
Power supply Network protection
Type of generator Power conductor cross
voltage characteristics
section
Kemppi KempArc Primary continuous
3x400V - 15%
Pulse 350 power (100% of
+ 20%
insertion time):
3x500V +/- 10% *1
15.3 kVA
50 / 60 Hz
cos 0.99
Kemppi KempArc Primary continuous
3x400V - 15%
Pulse 450 power (100% of
+ 20%
insertion time):
3x500V +/- 10% *1
17.8 kVA
50 / 60 Hz
cos 0.99
*1: If the Autotransformer 3x500V (optional) is present
Status: Energy directly disconnected from the

mains
Material: Not necessary
Equipment: Not necessary

Not necessary.
Operating procedure
Before connecting, make
sure that there is no
power in the power sup-
ply line.
a. Before proceeding with the

connection of the plug to the
socket of the plant, make sure
the power switch A of the
generator is in the OFF (O)
position.
00/0312 65

b. Connect plug B to the power
socket of the plant.
If the introduction of a 500V transformer is required, before proceeding

with the connections between the generator and transformer, make sure
that the power switch of the transformer is in the OFF (O) position. In this
case the plug B of the generator must be connected to the socket on the
transformer. Connect the plug of the transformer, with ground connection,
to the socket of the plant. Before starting the transformer, adapt the con-
nections inside the transformer to match the voltage of the plant.
66 00/0312
5.9.3 Robot and torch cleaning assembly connection to the

compressed air distribution line
In Tab. 5.2 contains the pneumatic connection specifications.
Tab. 5.2 - Splitter Compressed air supply characteristics
Required air pressure

Device Supply fitting /tube
and flow rate
7 l / second
Torch cleaning assem- 1.53 gallon / second
1/4 G fitting
bly and lubricator 0.6 MPa
6 bar
1800 Nl / minute
395.94 gallon / minute
Robot 3/8 G fitting
0.6 MPa, 0.7 MPa (max)
6 bar, 7 bar (max)
Status: Water power supply powered off

directly from mains
Equipment: Standard maintenance equipment

The procedure gives information on the compressed air connection points.
The air is to be suitably filtered, adjusted to the pressure indicated and provided
with gate to cut out for maintenance purposes.
The connection is made directly on the inlet fitting of the devices.
00/0312 67
Operating procedure
a. Supply compressed air to the
fitting (A) installed at the robot
base.
b. Supply compressed air to the

fitting installed on the Torch
Cleaning Unit and lubricator.
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 devices until the installation
procedure has terminated.
68 00/0312
5.9.4 Robot connection to the welding gas distribution network

Tab. 5.3 contains the pneumatic connection characteristics.
Tab. 5.3 - Welding gas supply characteristics
Required air pressure

Device Supply fitting /tube
and flow rate
1800 Nl / minute
395.94 gallon / minute
Robot 3/8 G fitting
0.6 MPa, 0.7 MPa (max)
6 bar, 7 bar (max)
Status: Power off

Equipment: Standard maintenance equipment

The procedure provides information on the connection points of the welding gas.
The connection is made to the specific pipe A present on the sheathing.
Operating procedure
a. Connect the welding gas supply pipe 4 directly to the gas cylinder or to the distri-
bution network of the plant.
00/0312 69

1= signals cable connector
2 = welding torch power supply
cable connector
3 = water pipe for cooling the torch
(delivery pipe with blue collar)
4 = gas delivery pipe for welding
5= compressed air delivery pipe
6 = water pipe for cooling the torch
(return pipe with red collar)
70 00/0312
Continuous wire welding system activation
6. CONTINUOUS WIRE WELDING SYSTEM

ACTIVATION
Precautions to be taken before activation.

Connectors pin-out.
Power-on.
Welding wire installation.
Bleeding the water circuit.
SMART-ARC and optional software modules activation.
Robot motions programming hints.
6.1 Precautions to be taken before activation
a. Check presence and efficiency of the installation environment requirements as

described in par. 3.3 Installation environment requirements and suggestions
page 18.
b. Wear the individual protection devices as indicated in par. 1.3 Protection of the
eyes and the body page 11.
6.2 Connectors pin-out
For information regarding the arrangement and the pin-out of the connectors, see the
Robot manual (see Reference documents).
00/0312 71
6.3 Power-on
Proceed as follows:
If the Generator has been stored at a temperature different to that for use, power-on and
wait for it to acclimatise.
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 In-
structions for Use manual (see Reference documents).
b. Put the main switch on the Generator / Transformer to ON
c. Open the pneumatic system cut-out ball valve. Supply the robot and the Torch
Cleaning assembly and lubricator with compressed air.
d. Open the gas system flow regulator.
For information regarding faults that could occur on the generator, see the Instructions
for Use manual (see Reference documents).
6.4 Welding wire installation

In the following paragraphs the welding wire installation procedures are described.
Depending on the adopted solution, perform one of the following procedures:
Set the main switch lever of the Generator and Transformer (if present) to 0 (OFF).
Installation of the support on-board the Robot (Reel) and coil introduction
(optional).
Marathon Pac and cover positioning.
Then continue the installation with the procedure of Wire insertion in the wire feeder.
72 00/0312
6.4.1 Installation of the support on-board the Robot (Reel) and

coil introduction (optional)
Operating procedure
a. Set the coil holder (A) (Reel) on the Robot installation base.
b. Fasten the coil holder screwing the fixing screws.
c. Insert manually the coil (B) on the coil holder (Reel) installed on the Robot. The
coil weight is 15-18 kg (33.07-39.68 lb).
If it is properly inserted the coil is automatically blocked on the support.
d. Insert the wire sheath (C) on the

holder (D) and screw the
locking knob (E).
e. Insert the wire on the sheath.
f. Push the wire until it comes out

from the opposite side of the
sheath.
g. Fix the end of the sheath to the

wire feeder (see Wire insertion
in the wire feeder).
Representative image
00/0312 73
6.4.2 Marathon Pac and cover positioning
Operating procedure
a. Set in the right position the
Marathon Pac containers
The Marathon Pac bulk
drum weight is about
250 kg and must be
handled with care,
using an adequate lift-
ing means.
b. Position and secure the

Marathon Pac Kit (cover) on the
container of the welding wire;
the circular cover can be
positioned.
c. Insert the welding wire in the

sheath (point A).
d. Push the wire until it comes out

from the opposite side of the
sheath (point B).
e. Fix the sheath end B to the wire

feeder (see Wire insertion in the
wire feeder).
74 00/0312
6.4.3 Wire insertion in the wire feeder
Operating procedure
a. Set the main switch lever of the
!
Generator and Transformer (if

present) to 0 (OFF).
b. Open the wire feeder cover.
c. Pull down the two small rolls

locking levers A (as the left
lever) in order to unlock the
rolls.
d. Set the sheath with the wire on

the taper hole B.
e. Push the wire in order to put it in

the exit zone C.
f. Pull up the two small rolls
locking levers B (as the right
lever) in order to free the rolls
and adjust the wire closing
pressure.
g. By turning the knobs of lever A

the pressure on the wire can be
adjusted based on its diameter.
The levers A have graduated
reference scales correlated to
the diameter of the wire to be
used.
a. Close the cover E of the wire

feeder unit.
b. Set the main switch lever of the

Generator and Transformer (if
present) to 1 (ON).
c. Use the impulse push-button

(D) i, until the wire does not
come out from the welding
torch.
00/0312 75
6.5 Bleeding the water circuit
For information regarding the water bleeding procedure, see the Generator manual (see
Reference documents).
6.6 SMART-ARC and optional software modules acti-

vation
For information regarding the activation and use of the software:

SMART-ARC *
SMART-ARC SCRATCH START
SMART-ARC OVERLAP
SMART-SEARCH
see the related manual (see Reference documents).
* Software provided with the application.
76 00/0312
6.7 Robot motions programming hints

During the welding cycle programming the maximum range of axis 1 has to be checked.
An amplitude of more than 140 could cause excessive wear and damage the outfitting
on board the robot.
Therefore the amplitude is to be limited within a range of 140.
If the robot axis 1 amplitude is excessive, it could cause damage to the outfitting. It is
recommended to limit the range of axis 1 to -70/+70 from a hypothetical central work
point (140 maximum range).
-70
+70
00/0312 77
78 00/0312
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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SMART NS - Manuals list

Continuous wire welding system

Integration, Transport and Installation for the system

Copyright 2011 - 2014 by COMAU - Published on 03/2015

1. WIRE WELDING SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

2. INSTALLATION SUMMARIZING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...15

3. INSTALLATION SUGGESTIONS, LIFTING AND HANDLING PROCEDURE . . . . . ...17

4. INSTALLATION OF THE CONTINUOUS WIRE WELDING SYSTEM COMPONENTS . .

5. CONTINUOUS WIRE WELDING SYSTEM CONNECTIONS. . . . . . . . . . . . . . . . . . . ..45

6. CONTINUOUS WIRE WELDING SYSTEM ACTIVATION . . . . . . . . . . . . . . . . . . . . . ..71

Bleeding the water circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Comau Continuous wire Technical specifications

These manual must be integrated with the following documents:

Comau C5G Control Unit Technical specifications

Limits on the manual content

Symbols used in the manual

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

1. WIRE WELDING SAFETY PRECAUTIONS

Entry is forbidden to persons wearing a pace-maker.

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

1.4 Protections against gas, fumes and fire

1.5 Safety precautions

1.5.2 Operating modes

Operation in programming mode

Maintenance and Repairs

If the protections are removed to replace components, they are to be carefully

Putting out of service and dismantling

2. INSTALLATION SUMMARIZING TABLE

Tab. 2.1 - Installation summarizing table

Step Operation Done

Tab. 2.1 - Installation summarizing table (Continued)

Step Operation Done

3. INSTALLATION SUGGESTIONS, LIFTING

Staff in charge for the installation.

3.1 Staff in charge for the installation

3.2 Equipment necessary

3.3 Installation environment requirements and

3.4 Network power supply

Tab. 3.1 - Summary of network power supply required for Arc

Device Electric power Compressed air Gas Notes

3.5 Control Unit

In the following chapter are described:

3.5.1 C5G Installation dimensions and spaces

Tab. 3.2 - Overall dimensions

Tab. 3.3 - Weight

3.5.2 Installation dimensions and spaces C5G

Tab. 3.4 - Overall dimensions

Tab. 3.5 - Weight

3.5.3 Control Unit handling

Different lifting methods are described:

3.5.3.1 C5G lifting overview with packing in closed container

Information for lifting

Lifting with crane (A)

Lifting with forklift (B)

3.5.3.2 Lifting overview C5G without packaging, on pallet

Lifting with crane (A)

Lifting with forklift (B)

3.5.3.3 Lifting overview C5G without packaging

Lifting with crane (A)

Lifting with forklift (B)