LB RC RACER999 Tin Plus en

Robot Racer 999
Plus
Rel. 2.0
Transport and installation

Information on preparations and needed
prearrangements for the Robot installation
Dimensions and weights, Robot transport and lifting
methods
Procedures for Robot installation
Procedures for the Robot options installation
Procedures for connection of the Robot with C5G
control unit
CR00758096-en_00/2015.10
The information contained in this handbook is the property of COMAU S.p.A.
Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A.
COMAU reserves the right to modify, without notice, the features of the product presented in this handbook.
Copyright 2008-2015 by COMAU - Published on 10/2015

Comau Robotics Product Instruction
SUMMARY
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Documents storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Limits on the handbook contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Symbols used in the handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. GENERAL SAFETY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Fundamental Requirements Applied and Respected . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. INSTALLATION SUMMARIZING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16
3. PREPARATION FOR ROBOT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...17

Staff in charge for installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Working environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Requirements for the installation environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Environment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operating space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operating environment prearrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Foundations preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Stresses on the supporting structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4. ROBOT TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...20

Robot weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Robot overall dimensions and transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Robot motion methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Robot lifting by means of crane or overhead crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Robot lifting by means of forklift truck (footpeg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5. ROBOT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25

Suggestions for Robot Installations on ceiling / wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3
SUMMARY
Preliminary requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Drilling on plate diagram not provided by Comau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Levelling plate fastening (CR82222600) on the floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fixing of the supporting stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Robot fixing on the backing plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6. ROBOT INSTALLATION COMPLETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..40

Installation Axis 1 Adjustable Mechanical Limit Switch Unit (CR82226900) . . . . . . . . . . . . . . . 41
7. ROBOT CONNECTION WITH CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..47

Preliminary precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Connection with the Control Unit (main motors and encoder cables) . . . . . . . . . . . . . . . . . . . . 49
Connection of digital I/O signals cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
I/O signals cables connection on Field Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8. OPERATIONS RELATED WITH THE FIRST STARTUP . . . . . . . . . . . . . . . . . . . . . . ..55

Precautions before the first power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Control Unit power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Ceiling / inclined plane installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Auto-Determination of Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Safety functional inspections of the Robotic system integrated in the production cell. . . . . . . . 57
4
PREFACE
PREFACE
This chapter contains:
Reference documents
Documents storage
Limits on the handbook contents
Symbols used in the handbook.
Reference documents
This document refers to the Robots with standards outfitting listed below:
Racer 999 Plus Rel. 2.0
The structure of the complete set of handbooks describing the Robot and Control Unit
is detailed in the following table:
Manufacturer Robot Set of Handbooks

Technical Specifications
Robot Racer 999 Plus Transport and installation
Comau
Rel. 2.0 Maintenance
Wiring diagram
These handbooks must be integrated with the following documents:
Manufacturer Description Set of Handbooks

C5G Control Unit / C5Compact Technical Specifications
Transport and installation
Comau Maintenance
Use of the Control Unit
Wiring diagram
Programming PDL2 Programming
Language Manual
Comau
Motion Programming
VP2 Visual PDL2
5
PREFACE
Documents storage
All the provided documents must be placed in close proximity to the area where is
installed the robotic system, maintained available for all people that work on it, and
preserved intact for the entire operational life of the robotic system.
Limits on the handbook contents

The figures included in the handbook have the purpose to represent the product
and can differ from what is actually visible on the robotic system.
Symbols used in the handbook

Here are the symbols that represent: WARNING, CAUTION and NOTES and their
meaning.
The symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed could cause injuries to the personnel.
The symbol indicates operating procedures, technical information and precautions, that
if are not observed and/or correctly performed may cause damages to the equipment.
The symbol indicates operating procedures, technical information and precautions that
must be underlined.
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.
6
GENERAL SAFETY REQUIREMENTS
1. GENERAL SAFETY REQUIREMENTS
This chapter deals with general specifications that apply to the whole Robot System.
Considering its significance, this chapter is referred unreservedly in each system
instructions handbook.
This chapter deals with the following topics:

Responsibilities
Safety requirements.
1.1 Responsibilities
The system integrator is responsible for ensuring that the Robotic system (Robot
and Control Unit) is installed and handled in accordance with the Safety Standards
in force in the country where the installation takes place. The application and use
of the necessary protection and safety devices, the issuing of declaration of
conformity and any EC marking of the system are the responsibility of the
Integrator.
COMAU Robotics denies any responsibility for accidents caused by incorrect or

improper use of the Robotic system (Robot and Control Unit), by tampering with
circuits, components or software, or the use of spare parts that are not included in
the spare parts list.
The application of these Safety Requirements is the responsibility of the persons
assigned to direct / supervise the activities indicated in the section Applicability,
which should make sure that the Authorised Personnel is aware of and
scrupulously follow the requirements contained in this document in addition to the
general Safety Standards applicable to Robotic system (Robot and Control Unit) in
force in the Country where the system is installed.
The non-observance of the Safety Standards may cause to the operators
permanent injuries or death and can damage the Robotic system (Robot and
Control Unit).
The installation shall be carried out by qualified Personnel and must conform to all
National and Local standards.
1.1.1 Safety Fundamental Requirements Applied and

Respected
The Robotic system composed by Control Unit and SMART 5 Robot series considers
as applied and respected the following Safety Fundamental Requirements, Annex I of
Machinery Directive 2006/42/CE: 1.1.3 1.1.5 1.2.1 1.2.2 1.2.3 1.2.4.3 1.2.5
1.2.6 1.3.2 1.3.4 1.3.8.1 1.5.1 1.5.2 1.5.4 1.5.6 1.5.8 1.5.9 1.5.10
1.5.11 1.5.13 1.6.3 1.6.4 1.6.5 1.7.1 1.7.1.1 1.7.2 1.7.4.
7
1.2 Safety requirements
1.2.1 Purpose
These safety requirements are aimed to define the behaviour and obligations to be
observed when performing the activities listed in the Applicabilitysection.
1.2.2 Definitions
Robotic system (Robot and Control Unit)
Robotic system is the workable assembly composed of: Robot, Control Unit, Teach
Pendant and other possible options.
Protected Area
The protected area is the zone confined by the protection barriers and intended to be
used for the installation and operation of the Robot.
Authorised Personnel
Authorised personnel defines the group of persons who have been appropriately trained
and assigned to carry out the activities listed in the section Applicability.
Staff in Charge
The staff in charge defines the personnel who manage or supervise the activities of the
employed persons defined in the preceding point.
Installation and Startup

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

Operating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual movement of Robot axes and programming
of work cycles at low speed, programmed cycle testing at low speed and, when allowed,
at working speed.
Functioning in Auto / Remote Mode

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

Maintenance and repair are activities that involve periodical checking and / or
replacement of Robot and Control System (mechanical, electrical, software) parts or
components, and trouble shooting, that ends when the Robot and Control System has
been reset to its original project functional conditions.
8
Decommissioning and Dismantling

Decommissioning defines the activities involved in the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.
Integrator
The integrator is the professional expert responsible for the Robot and Control System
installation and startup.
Misuse
Misuse is defined as the use of the system outside the limits specified in the Technical
Documentation.
Action Area
The Robot action area is the enveloping volume of the area occupied by the Robot and
its equipment during movement in the area.
1.2.3 Applicability
These requirements must be applied when carrying out the following activities:
Robot axes brake release
Decommissioning and Dismantling.
9
1.2.4 Operating modes

The startup is only possible when the Robot and Control System has been correctly
and completely installed.
The system installation and startup is exclusively the task of the authorised
personnel.
The system installation and startup is only permitted exclusively inside a protected
area of an adequate size to house the Robot and the equipment it is outfitted with,
without passing beyond the protection barriers. It is also necessary to check that in
normal Robot movement conditions there is no collision with parts inside the
protected area ( e.g structural columns, power supply lines, etc.) or with the
barriers. If necessary, limit the Robot work area using mechanical hard stop (see
optional units).
Any fixed Robot control stations must be located outside the protected area and in
a point such as to permit a full view of the Robot movements.
The Robot installation area must be as free as possible from materials that could
impede or limit the visibility.
During installation the Robot and the Control Unit must be handled as described in
the product Technical Documentation; if lifting is necessary, check that the
eye-bolts are fixed securely and use only adequate slings and equipment.
Fix the Robot to mount holder, with all the provided bolts and pins, tightened to the
tightening torque indicated in the product Technical Documentation.
If present, remove the fixing brackets of the axes and verify the proper fixing of the
equipment the Robot is outfitted with.
Check that the Robot guards are correctly fixed and that there are no moving or
loose parts. Check that the Control Unit components are intact.
Install the Control Unit outside the protected area: the Control Unit should not be
used as part of the fencing.
Check that the voltage value of the power mains is consistent with that indicated
on the nameplate of the Control Unit.
Before electrically connect the Control Unit, check that the circuit breaker on the
power mains is locked in open position.
Connection between the Control Unit and the three-phase supply mains at the
works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned
appropriately for the power installed on the Control Unit. See the product Technical
Documentation.
The power supply cable is to enter the Control Unit through the specific cable entry
and be properly clamped.
Connect the ground cable (PE) then connect the power conductors to the main
switch.
Connect the power supply cable, first connecting the ground cable to the circuit
breaker on the power mains line, after checking with a tester that the circuit breaker
terminals are not powered. It is recommended to connect the cable armouring to
the earth.
10
Connect the signals and power cables between the Control Unit and the Robot.
Connect the Robot to earth or to the Control Unit or to a nearby earth socket.
Check that the Control Unit door (or doors) is/are locked with the key.
A wrong connection of the connectors may cause permanent damage to the
Control Unit components.
The Control Unit manages internally the main safety interlocks (gates, enabling
push-buttons, etc.). Connect the Control Unit safety interlocks to the line safety
circuits, taking care to connect them as required by the Safety Standards. The
safety of the interlock signals coming from the transfer line (emergency stop, gates
safety devices etc.) i.e. the realisation of correct and safe circuits, is the
responsibility of the Robot and Control System integrator.
In the cell/line emergency stop circuit it is necessary to include the contacts of the
Control Unit emergency stop push-buttons, available on X30. The push-buttons are not
interlocked inside the emergency stop circuit of the Control Unit.
The safety of the system cannot be guaranteed in case of interlocks erroneous,

incomplete or missing execution.
The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic mode; in Programming mode the power is disabled
immediately. The procedure for the selection of the controlled stop time (that can
be set on SDM module) is indicated in the Transport and Installation Handbook of
the Control Unit.
When preparing protection barriers, especially light curtains and access doors,
take into consideration the Robot stopping times and distances according to the
stop category (0 or 1) and the weight of the Robot.
Check that the controlled stop time is consistent with the type of Robot connected to the
Control Unit. The stop time is selected using selector switches SW1 and SW2 on the
SDM module.
Check that the environmental and operating conditions do not exceed the limits
specified in the Technical Documentation of the specific product.
The calibration operations must be carried out with great care, as indicated in the
Technical Documentation of the specific product, and should be concluded by
checking the correct position of the machine.
11
To load or update the system software (for example after replacing boards), use
only the original software handed over by COMAU Robotics. Scrupulously follow
the system software loading procedure described in the Technical Documentation
supplied with the specific product. After loading, always make some Robot moving
tests at low speed remaining outside the protected area.
Check that the barriers of the protected area are correctly positioned.

The programming of the Robot is exclusively the task of the authorized personnel.
Before starting to program, the operator must check the Robotic system (Robot
and Control Unit) to make sure that there are no potentially dangerous irregular
conditions, and that there is nobody inside the protected area.
The programming should be controlled from outside the protected area whenever
possible.
Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the Teach Pendant is working properly (low
speed, emergency stop device, enabling device, etc.).
During the programming phases, only the operator with the Teach Pendant is
allowed inside the Protected Area.
If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
Activation of the motors (DRIVE ON) always must be controlled from a position
outside the operating range of the Robot, after checking that there is nobody in the
area involved. The Drive On operation is considered complete when the relevant
machine status indication is shown.
When programming, the operator must remain at an appropriate distance from the
Robot to be able to avoid any irregular machine movements, and in any case in a
suitable position to avoid the risk of being trapped between the Robot and
structural parts (columns, barriers, etc.), or between movable parts of the Robot.
When programming, the operator must avoid to remain in a position where parts of
the Robot, pulled by gravity, could move downwards, upwards or sideways (when
installed on a inclined plane).
Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at low speed has been carried out. The
test must be controlled from a safe distance.
Special attention is to be paid when programming using the Teach Pendant: in this
situation, although all the hardware and software safety devices are active, the
Robot movement depends on the operator.
During the first running of a new program, the Robot may move along a path that
is not the one expected.
The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the Robot position
out of the path that links two steps of the program), could give rise to movements
not envisaged by the operator when testing the program.
12
In both cases operate cautiously, always remaining out of the Robot range of action
and test the cycle at low speed.

The activation of the automatic operation (AUTO and REMOTE states) is permitted
only with the Robotic system (Robot and Control Unit) integrated inside an area
with protection barriers properly interlocked, as required by the Safety Standards
currently in force in the Country where the installation takes place.
Before starting the automatic mode the operator must check the Robot and Control
System and the protected area to make sure there are no potentially dangerous
irregular conditions.
The operator can activate automatic operation only after having checked:
that the Robot and Control System is not in maintenance or repair status;
that the protection barriers are correctly positioned;
that there is nobody inside the protected area;
that the Control Unit doors are closed and locked with the appropriate key;
that the safety devices (emergency stop, protection barrier safety devices)
are functioning;
Special attention is to be paid when selecting the remote mode, in which the line
PLC can perform automatic operations of motors power up and program starting.
Robot axes brake release

In absence of motive power, the Robot axes repositioning is possible by means of
optional brake release devices and suitable lifting devices. Such devices only allow
the brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enabling push-button) are disabled; also the
Robot axes can move upwards or downwards because of the forces generated by
the balancing system or by the gravity force.
Before using the manual brake release devices, it is recommended to sling the Robot,
or hook it to an overhead travelling crane.
The use of brake releasing device may cause the axes falling due to gravity, as well
as possible impacts due to an incorrect reset, after applying the brake releasing
module. The procedure for the correct usage of the brake releasing device (both
for the integrated one and module one) is to be found in the maintenance
handbooks.
13
When after the interruption of an unfinished MOVE the motion is enabled again, the
typical function of trajectory recuperation may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next restart of the
automatic cycle. Avoid moving the Robot in positions that are distant from the ones
required for the motion restarting; alternatively disable the outstanding MOVE
programmes and/or instructions.

At the COMAU works all Robots are lubricated using products that do not contain
any harmful substances. However, in some cases, repeated and prolonged
exposure to such products may cause irritation of the skin and they may be harmful
if swallowed.
First Aid Measures. In case of contact with the eyes or skin: rinse the affected
areas with copious amounts of water; should irritation persist, seek medical advice.
If swallowed, do not induce vomiting or administer anything by mouth; consult a
doctor as soon as possible.
Maintenance, trouble-shooting and repair are only to be carried out by authorised
personnel.
When carrying out maintenance and repair operations, the specific warning sign
stating the maintenance status must be placed on the control panel of the Control
Unit, until the end of the operation, even if it should be temporarily suspended.
Maintenance and components or Control Unit replacement operations must be
carried out with the main switch in open position and locked with a padlock.
Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages deriving from connection to peripheral units or external
power sources (e.g. 24 Vdc input/output). Power off the external sources when
operating on involved system parts.
Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
Faulty components are to be replaced with others having the same Part number,
or equivalent components defined by COMAU Robotics.
After replacement of the SDM module, check on the new module that the setting of the
stop time on selector switches SW1 and SW2 is consistent with the type of Robot
connected to the Control Unit.
Trouble-shooting and maintenance activities must be carried out, whenever

possible, outside the protected area.
Trouble-shooting executed on the control is to be carried out, whenever possible
without power supply.
Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards must be observed
when operating in presence of dangerous voltages.
Trouble-shooting on the Robot must be carried out with the power supply turned
off (DRIVE OFF).
At the end of the maintenance and trouble-shooting operations, all the deactivated
safeties must be reset (panels, protection shields, interlocks, etc.).
14
Maintenance, repair and trouble-shooting operations must be concluded with the

check of the correct functioning of the Robotic system (Robot and Control Unit) and
all the safety devices, executed from outside the protected area.
When loading the software (for example after replacing electronic boards) the
original software handed over by COMAU Robotics is to be used. Scrupulously
follow the system software loading procedure described in the specific product
Technical Documentation; after loading, to be sure, always run a test cycle,
remaining outside the protected area
Disassembly of Robot components (e.g. motors, balancing cylinders, etc.) may
cause uncontrolled movements of the axes in any direction: before starting a
disassembly procedure, consult the warning plates applied on the Robot and the
Technical Documentation supplied.
It is strictly forbidden to remove the protective covering of the Robot springs.
Decommissioning and Dismantling

The decommissioning and removal of the Robot and Control System is exclusively
the task of Authorised Personnel.
Move the Robot in transport position and assemble the axes locking brackets
(when required) following the instructions on the plate on the Robot and its
Technical Documents.
Before decommissioning initiation, the mains voltage at the Control Unit inlet must
be powered off (switch off the circuit breaker on the power mains and lock it in open
position).
After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the power mains,
first disconnecting the power conductors, then the earth one. Disconnect the power
supply cable from the Control Unit and remove it.
First disconnect the connection cables between the Robot and the Control Unit,
then the ground cable.
If present, disconnect the Robot pneumatic system from the air distribution mains.
Check that the Robot is properly balanced and if necessary sling it correctly, then
remove the Robot securing bolts from the mount holder.
Remove the Robot and Control Unit from the work area, following all the
requirements indicated in the products Technical Documents; if lifting is necessary,
check the eyebolts proper fixing and use only suitable slinging devices and
equipment.
Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU Robotics & Service,
or one of its branches, who will indicate, according to the type of Robot and Control
Unit, the operating methods in accordance with safety principles and safeguarding
the environment.
The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.
15
INSTALLATION SUMMARIZING TABLE
2. INSTALLATION SUMMARIZING TABLE

The table below summarises the Robot installation sequence.
The table can be used as a check list for the installation activities progress. In this case
it is recommended to copy the table below and fill in the appropriate box Done at the
end of each operation.
Tab. 2.1 - Installation summarizing table
Step Operation Done

Preparation for Robot installation
1 Working environmental conditions
2 Operating environment prearrangements
3 Foundations preparations
4 Stresses on the supporting structure
Robot transport
5 Robot overall dimensions and transport position
6 Robot lifting by means of crane or overhead
crane
Robot lifting by means of forklift truck (footpeg)
Robot Installation
7 Robot Installation
Levelling plate fastening (CR82222600) on the
floor
Fixing of the supporting stand
Robot fixing on the backing plan
Robot Installation Completion
8 Installation Axis 1 Adjustable Mechanical Limit
Switch Unit (CR82226900)
Robot connection with Control Unit
11 Connection with the Control Unit (main motors and
encoder cables)
16
PREPARATION FOR ROBOT INSTALLATION
3. PREPARATION FOR ROBOT INSTALLATION

Staff in charge for installation
Working environmental conditions
Operating environment prearrangements
Foundations preparations
Stresses on the supporting structure.
Before carrying out any type of installation operation carefully read the Cap.1. - General
Safety Requirements on pag. 7.
The Robot has to be matched with Comau Control Unit. Any other use is prohibited.
Possible exceptions must be expressly authorised by COMAU Robotics & Service.
In this chapter are described the instructions to carry out properly the Robot installation.
The installation operating is described in Chapter Robot Installation.
17
3.1 Staff in charge for installation

Staff in charge for installation must be trained to handle correctly the lifting devices.
Moreover, the staff must be warned or trained in mechanics and therefore be aware of
the dangers deriving from the installation operations.
3.2 Working environmental conditions

This paragraph contains:
Requirements for the installation environment
Environment data
Operating space.
3.2.1 Requirements for the installation environment

The environment of the Robot use is the normal factory environment and therefore
repaired from atmospheric agents such as rain, hail, snow, fog, airborne dusts, etc.
Of course it is advisable that it does not involve corrosive vapours or exceeding heat
sources.
The Robot shall be placed in an equipped environment with all the predispositions
deriving from the laws in force in the user country.
The work environment where the Robot will be installed shall comply with the following
aspects:
The environmental conditions (clime, vibrations, etc.) shall comply with the
information given in the Technical specifications chapter. Moreover it is forbidden
to install the Control Unit and the Robot in environments:
with deflagration risk
with temperature higher than the maximum admissible
subjected to nuclear radiations.
The backing plan where the Robot will be installed must be able to support its
weight, ensure the stable support and shall not be sloped.
3.2.2 Environment data

Operating environment temperature: 0C 45C
Relative humidity: 5% 95% without condensate.
Storage environment temperature: -25 C 60 C.
Store only in closed, dry, protected from weather conditions environments
Maximum temperature gradient: 1,5 C/min.
For further information see the Robot "Technical Specifications" handbook.
18
3.2.3 Operating space
The maximum overall dimension of the Robot operating area is described in the Robot
"Technical Specifications" handbook.
3.3 Operating environment prearrangements

The area chosen for the Robot installation must have the needed connections for:
Robot and Control Unit functioning (electrical system)
application functioning foreseen for the Robot (pneumatic system, Gas supply,
etc.).
3.4 Foundations preparations

In case of Robot floor installation, the Customer must appropriately prepare the
foundations on which the Robot shall be installed.
The foundations shall be made in order to properly bear the weight and stresses
generated by the Robot.
Find below the recommendations for the foundations preparation:
Type of concrete: non-slatted cement
Concrete thickness: block dimension + 50 mm (minimum)
Concrete resistance: Fck,cube = 25 N/mm
The floor shall be regular, levelled and perfectly plain.

Any possible vibrations transmitted by machines installed nearby the Robot installation
area, can reduce the precision and repeatability of the Robot motion.
It is recommended to prepare a suitable foundation in order to reduce at minimum level
the transmitted vibrations.
Because of the considerable stresses discharged to the ground by the Robot and the
need to have appropriate backing plans, the direct fixing on the floor is not foreseen.
The Robot must be fixed to a horizontal flat surface with the following flatness tolerance:
0,2 .
3.5 Stresses on the supporting structure
The graphs and the values of the stresses generated by the Robot are listed in the Robot
"Technical Specifications" handbook.
19
ROBOT TRANSPORT
4. ROBOT TRANSPORT
Robot weight
Robot overall dimensions and transport position.
Robot motion methods.
4.1 Robot weight

In the following table are listed the Robot weights depending on the type of packaging
used for transport.
Packaging type Weight

173 kg
Robot without packaging
(382 lb)
183 kg
Robot on pallet
(404 lb)
In certain special configurations, the Robot can be packed in a closed crate with the
C5Compact Control Unit. For the lifting mode of the Robot packed in such way, see the
Transport and Installation handbook of the C5Compact Control Unit.
4.2 Robot overall dimensions and transport position

The proper Robot transport position is represented in the following Fig. 4.1 - Robot
transport position and overall dimensions diagram.
In addition are listed the maximum dimensions of the Robot on the platform and the
value of the angle position of the single Robot axes.
The Robot is stable only in transport position and without the installed equipment.
Any movement of the Robot axes made when the Robot is not fixed to the floor can
cause overturning.
20
ROBOT TRANSPORT
Fig. 4.1 - Robot transport position and overall dimensions diagram
Dimensions in millimetres
Racer 999 Plus AXES 1 AXES 2 AXES 3 AXES 4 AXES 5 AXES 6
Joint position ( 0.5) 0 -60 -150 -90 +90 0
21
ROBOT TRANSPORT
4.3 Robot motion methods

In the following section are described the possible Robot lifting methods:
Robot lifting by means of crane or overhead crane
Robot lifting by means of forklift truck (footpeg)
In case of need to lift the Robot after installation (lifting from fixing plate), the lifting shall
always be carried out by means of upward translation, perpendicular to the fixing plate
until reaching the dowel pins extraction from the seats on the Robot base, in order to
avoid damages to centering pins.
22
ROBOT TRANSPORT
4.3.1 Robot lifting by means of crane or overhead crane
Lifting device: Crane or overhead crane with adequate load to be lifted

capacity, taking into consideration the safety limits
Equipment: Q.ty 2 eyebolts A M12 mm
Q.ty 1 lifting belts B with rings on the ends L = 1000 mm
(39.36 in)
Q.ty 1 lifting belts C with rings on the ends L = 1300 mm
(51.18 in)
Lifting diagram:
Operative notes: Screw the eyebolts A on the holes on the base and on the
column axis 1 of the Robot.
Connect the lifting ropes B and C to the eyebolts A.
Slightly lift the Robot by checking the balance and the
balancing.
Lift the Robot keeping it in balanced.position.
Move the Robot carefully.
At the end of the procedure, remove the eyebolts A used for the Robot lifting.
23
ROBOT TRANSPORT
4.3.2 Robot lifting by means of forklift truck (footpeg)
Lifting device: Forklift truck with adequate load to be lifted capacity,

taking into consideration the safety limits
Equipment Forks A Forklift truck Length about 1400 mm (39.37 in)
Lifting diagram:
Operative notes: Prepare the inter-axis of the forks A at a distance of about

900 mm (35.43 in)
Insert the forks A inside the pallet B, as describe in the
figure
Be sure that the forks ends A come out from the opposite
side of the pallet B
Lift and move the Robot near the installation position
proceeding carefully.
At the end of the installation / lifting operations, remove the previously installed eyebolts.
24
ROBOT INSTALLATION
5. ROBOT INSTALLATION
Suggestions for Robot Installations on ceiling / wall
Preliminary requirements
Drilling on plate diagram not provided by Comau
Levelling plate fastening (CR82222600) on the floor
Fixing of the supporting stand
Robot fixing on the backing plan.
This chapter describes the operations to be carried out in case of Robot installation on
the floor.
25
ROBOT INSTALLATION
5.1 Suggestions for Robot Installations on ceiling /

wall
The Robot is set to be lift and installed on ceiling / wall.
Installation must be carried out screwing the Robot to a fixing flange A that must be
provided of suitable closed compartments B to insert the forks in the forklift truck.
A: Fixing plate:
B: suitable closed
compartments
Principle diagram
This plate must be made by the integrator and must be set with suitable holes for
fastening, as described in the Fig. 5.1 - Drilling diagram for fixing on plate not provided
by Comau.
The fixing screws of the Robot to the plate, of the plate to the ceiling and the closed
boxes must be able to support the stresses listed in Fig. 8.7 - Stresses on the supporting
structure.
The forklift truck used for handling and the load must be provided with a mechanism that
allows a 180 rotation.
26
ROBOT INSTALLATION
5.2 Preliminary requirements
Because of the considerable stress discharged to the ground by the Robot, and the need
to have appropriate backing plans:
direct fixing to the floor is not foreseen.
the Robot must be secured to a horizontal flat surface with the following flatness
tolerance: 0,2 .
The Robot can be installed on the wall; in case of installation of this type, pay
particular attention to the programming and moving operations "Off line".
Remark that:
in order to carry out the required calibration operations on axes, it is necessary to
foresee that the Robot can be handled in calibration position (Fig. 12.1 - Robot
calibration position) without interfering with installation environment overall
dimensions (equipment, etc.).
in order to use the software option of load auto-determination it is necessary to
have some cubic meters of free space in order to allow the Robot axes motion
during operations.
The Robot can be fastened on:

to one plate with drillings for screws and dowel pins (for the main quotes of the
fixing points see Drilling on plate diagram not provided by Comau). The steel plate
can be carried out by the Robot integrator or it is available as optional plate for
installation purposes.
Leveling Plate Unit for Robot Fixing (CR82222600)
to one stand with drillings for screws and dowel pins (for the main dimensions of
the fixing points see Drilling on plate diagram not provided by Comau). The steel
stand can be made by the Robot integrator or it is available as optional bench for
installation purposes.
Bench for Robot Fixing (CR822218xx)
a supporting structure with bores suitable for screws and dowel pins. The
supporting structure in steel shall be carried out by the Robot integrator.
If a suitable supporting structure is used as an alternative to the steel plate, it is
necessary to:
foresee the availability of a worked plain surface which allows a planarity
among the Robot backing plans < 0,2 mm.
check that the supporting structure levelling error is 0,5/1000 mm (max.)
drill the appropriate drillings as shown in the Fig. 5.1
If the plate is set by the integrator the stresses discharged on ground by the Robot and
the resistance conditions of the fastening surface shall be checked.
Installation of the supporting structure is to be performed by the integrator.
27
ROBOT INSTALLATION
5.3 Drilling on plate diagram not provided by Comau

In the following Fig. 5.1 it is shown the drilling diagram to be made for Robot fixing using
a plate or structure not provided by Comau.
Fig. 5.1 - Drilling diagram for fixing on plate not provided by Comau
0.2
min
A
B B
min
B B
min
A: centring holes (details on Screws and Pins Kit for Robot Fixing (CR82226800))
B: Threaded holes for Robot fixing (details on Screws and Pins Kit for Robot Fixing (CR82226800))
Robot fixing operations are described on par. 5.6 Robot fixing on the backing plan on
pag. 38.
28
ROBOT INSTALLATION
5.4 Levelling plate fastening (CR82222600) on the floor
Status: ---
Material: Chemical sleeve anchors (Tab. 5.1)
Leveling Plate Unit for Robot Fixing
(CR82222600)
Leveling mortar for metal
Equipment: Drilling machine
Drilling tip for bores 9, 18
Angle grinder
Precision level gauge
Torque wrench with sockets and
inserts
Arc welding machine
Vacuum cleaner with filter suitable for
very thin powder collection
4 male M16 eyebolts
Fixing Chemical sleeve anchors (Tab. 5.1)
components:
Preliminary procedures / notes

Procedure required in case of option Leveling Plate Unit for Robot Fixing
(CR82222600); or as an alternative carry out the fixing procedure of the
option Bench for Robot Fixing (CR822218xx) or to a supporting structure
made by the Robot integrator.
To avoid any micro motion of the plate caused by repeated alternated stresses
generated by the Robot during normal working cycles, lay the plate on a layer of
aligning mortar specifically for metal on concrete applications.
Fixing the plate on the floor shall ensure the possibility to level the Robot with a
tolerance of: 0.5/1000 mm and is to be able to bear the stresses generated by the
Robot.
Use chemical sleeve anchors to fix the plate on the floor.

In the following Tab. 5.1 are listed the fixing components advised by Comau.
Tab. 5.1 - Recommended components for fixing the levelling plate on

the floor (not supplied)
Hole Depth
Component Reference Part No. Q.ty
Diameter
Chemical
HILTI HVU M16x125
capsule
18x 125 mm 8
HAS-E
Pin HILTI
M20x125/38
29
ROBOT INSTALLATION
Please read the instructions before using the recommended fixing components.
Operating procedure - Bores tracing

a. Trace on the pavement the two perpendicular axes in the position in which the
Robot is to be installed.
b. Trace the position of the bores A to place the chemical capsules.
A A
A
A
A
A
A A
Operating procedure - Floor Drilling

Be sure to carry out the drillings perpendicularly to the floor.
Do not use water: the bore shall be dry.
a. Pre-drill the floor surface using a drilling machine and an adequate drilling tip 9
(depth 125 mm).
b. Drill the floor surface using a drilling machine and an adequate drilling tip bore
18 (depth 125 mm).
c. Vacuum all the cement with a vacuum cleaner, clean carefully inside the bores.
30
ROBOT INSTALLATION
Operating procedure - Chemical sleeve anchors positioning

a. Insert inside the bores the chemical capsules.
b. Insert and screw the threaded holes and be sure that the threads are touched by
the chemical component.
c. Wait until the chemical capsule acts and grips with the pin, fixing it to the floor.
The waiting time is about 5 hours.
d. Clean the floor area on which the plate shall be leaned.
Operating procedure - Plate positioning
On the plate there are

three notches B, whose B
axial intersection defines
the Robot axis 1 position
(reference CL); in correspondence of
this position a dowel pin hole can be B
CL
found on the plate.
e. After having spread a layer of

leveling mortar for metal,
position the four base plates C
on the flour nearby the pins D.
D
E
f. Fix four base plates on the floor: C C
tighten the lock nuts E and
tighten to the torque of 100 Nm.
31
ROBOT INSTALLATION
Operating procedure - Plate positioning (Continue)

g. Insert four male M16 eyebolts in
the threaded holes K for the
Robot fastening.
K K
K K
h. Sling the plate by means of 4

lifting ropes F with minimum
length of 1 metre.
i. Lift the plate (about 106 kg / F

233.7 lb) by using an
appropriate lifting device. K
j. Position the leveling plate G on

the 4 base-plates C fixed on the
floor.
k. Level the plate by means of the

adjusting screws H to obtain a
leveling error within 0.5/1000
mm (max.)
l. Once the proper levelling has

been obtained, screw the
H Z5
fastening nuts I. I C
G
m. Position the straight edges J.
n. Carry out the electric welding of

the straight edges J to the base
plates and to the levelling plate,
J
carrying out a weld bead along
the entire length of the straight
edges.
32
ROBOT INSTALLATION
Operating procedure - Plate positioning (Continue)

Make a corner weld bead adopting all the technical precautions needed to
ensure the best sealing joint.
Non accurate welding can cause improper Robot fixing as well as
malfunctioning during Robot motion, that can lead to dangerous situations
for the operators.
Follow-up procedures
Fix the Robot as described on par. 5.6 Robot fixing on the backing plan on pag. 38 and
the following ones.
33
ROBOT INSTALLATION
5.5 Fixing of the supporting stand
Status: ---
Material: Chemical sleeve anchors (Tab. 5.2)
Bench for Robot Fixing (CR822218xx)
Leveling mortar for metal
Equipment: Drilling machine
Drilling tip for bores 9, 18
Precision level gauge
Torque wrench with sockets and
inserts
Vacuum cleaner with filter suitable for
very thin powder collection
Fixing Chemical sleeve anchors (Tab. 5.2)
components:

Procedure required in case of option Bench for Robot Fixing
(CR822218xx); or as an alternative carry out the fixing procedure of the
option Leveling Plate Unit for Robot Fixing (CR82222600) or to a
supporting structure made by the Robot integrator.
To avoid any micro motion of the plate caused by repeated alternated stresses
generated by the Robot during normal working cycles, lay the plate on a layer of
aligning mortar specifically for metal on concrete applications.
The fixing of the supporting stand can be made:

directly on the floor, using chemical sleeve anchors; in the following Tab. 5.2 are
shown the fixing components suggested by Comau.
On a 25 mm tick steel plate with planarity tolerance 0,5 and using hex
head fixing screws - M16x40 (8.8).
During the moving of the Comau supporting stands, take into consideration the
following weights:
Bench CR82221809: About 39 kg (85.98 lb)
34
ROBOT INSTALLATION
Tab. 5.2 - Recommended components for fixing the Robot supporting

stand to the floor (not supplied)
Hole Depth
Component Reference Part No. Q.ty
Diameter
Chemical
HILTI HVU M16x125
capsule
18x 125 mm 8
HAS-E
Pin HILTI
M20x125/38
Please read the instructions before using the recommended fixing components.
Operating procedure - Bores tracing

a. Position the Robot supporting stand in the installation position, using a forklift
truck.
b. Trace the position of the bores A to place the chemical capsules.
1
350
B 190 B
A
350
190
A A
B A B
A: Through holes for fixing on the floor or plate 18
B: Threaded holes M16x20 for levelling screws
35
ROBOT INSTALLATION
Operating procedure - Bores tracing (Continue)

c. By using a forklift truck, remove the supporting stand from the installation position
in order to allow the following operations.
Operating procedure - Floor Drilling

Be sure to carry out the drillings perpendicularly to the floor.
Do not use water: the bore shall be dry.
a. Pre-drill the floor surface using a drilling machine and an adequate drilling tip 9
(depth 125 mm).
b. Drill the floor surface using a drilling machine and an adequate drilling tip bore
18 (depth 125 mm).
c. Vacuum all the cement with a vacuum cleaner, clean carefully inside the bores.
Operating procedure - Chemical sleeve anchors positioning

a. Insert inside the bores the chemical capsules.
b. Insert and screw the threaded holes and be sure that the the threads are touched
by the chemical component.
c. Wait until the chemical capsule acts and grips with the pin, fixing it to the floor.
The waiting time is about 5 hours.
d. Clean the floor area on which the plate shall be leaned.
Operating procedure - Supporting stand positioning

a. Spread a levelling mortar for
metal in the leaning area of the
base plates C. A
b. Position the Robot supporting
stand A on threaded holes B
installed on the floor, by using a C
forklift truck.
B
Note: the supporting stand must
be properly oriented depending
on the Robot installation
position.
36
ROBOT INSTALLATION
Operating procedure - Supporting stand positioning (Continue)

c. Level the supporting bench by
means of the 4 through holes D
(M16) by using 4 screws
M16x20 (not provided by
Comau).
d. Operate on the 4 screws in

order to obtain a levelling error
D D
of 0.5/1000 mm (max.).
e. Once the proper levelling has

been obtained, fix the four base
plates C of the stand on the
floor and screw the blocking
nuts E tightening to the 100 Nm.
torque.
C
E
Fix the Robot as described on par. 5.6 Robot fixing on the backing plan on pag. 38 and
the following ones.
37
ROBOT INSTALLATION
5.6 Robot fixing on the backing plan
Status: Power turned off

Material: Components of the Screws and Pins
Kit for Robot Fixing (CR82226800)
Equipment: Torque wrench with 5 and 14 mm
insert
Fixing Centring =16 mm L = 53 mm
components: Centring =16 mm L = 43mm
Socket hex head screw M16x50 (8.8)
ISO 4762
Self locking washer 16x25.4x3.4

None
Operating procedure
B1, C1
D D
D D
B2, C2
A = Drilling position diagram of the backing plan (Plate / Structure)
B1 = Centering =16 mm L = 43 mm
B2 = Centering =16 mm L = 53mm
C1 = socket hex head screw M6x60 (8.8)
C2 = socket hex head screw M6x50 (8.8)
D = socket hex head screw M16x50 (8.8) ISO 4762 + self-locking washer
16x25.4x3.4
38
ROBOT INSTALLATION
Operating procedure (Continue)

a. Clean the plate on which the
Robot must be placed.
C
b. Place the two centrings =30
mm B on the plate A and screw A B
the related fixing screws C to
the tightening torque of 50,1
Nm.
c. Lift the Robot as shown on

Cap.4. - Robot transport. B
D
d. Place the Robot E on the plate E
referring to the centrings B.
Place the Robot in the proper A
position with the frontal side as
shown on the picture of the
plate.
Carry out carefully the
procedure in order not to
damage the two centrings B.
e. Position the self-locking washer

and flat washer and screw the
four fixing screws D of the
Robot tightening them at a
torque of 205 Nm.
None
39
ROBOT INSTALLATION COMPLETION
6. ROBOT INSTALLATION COMPLETION

In this chapter are described the installation completion operations of some optional
assemblies, which can be installed on the Robot.
Installation Axis 1 Adjustable Mechanical Limit Switch Unit (CR82226900)
40
6.1 Installation Axis 1 Adjustable Mechanical Limit


Material: Axis 1 Adjustable Mechanical Limit
Equipment: Torque wrench with 8 mm inserts
Fixing Socket hex head screw M10x20 (12.9)
components: ISO 4762

The installation of the unit is the task of the integrator and is to be carried
out observing the safety precautions contained at the beginning of this
handbook.
The possible assembling positions are described in the diagram of this

manual of the Robot Technical Specifications.
Remember that the installation positions must be determined in
accordance with the safety criteria of the cell and depending on the Risk
Analysis.
After maintenance operations or mechanical impacts it is necessary

to check the correct functioning of the group and the lock of the
fastening screws.
Avoid to overhaul and/or replacement of some group items, it is advised to

replace the entire unit.
Remove any fixtures / piping installed on the Robot that interfere with the
fastening seats of the mechanical hard stops.
The Robot is equipped with a stop buffer to be fixed using the screws provided,
in the seats on the Robot column to limit the stroke of axis 1 in one direction only.
If is necessary limit the stroke in both directions, we will use a second buffer stop
installable as an option.
The installation position must be coherent with what has been required by the cell
projecting.
41
Operating procedure
a. Place the limit switch A in the
desired position in the seats on
the Robot base, in relation to
the stroke limitations to be
obtained.
b. Screw the 4 fixing screws B

(socket hex head screw
M10x20) tightening them at a
torque of 84.6 Nm.
After assembly installation of the assembly it is necessary to set the
software limit switch (positive and negative) with a value suitably
dimensioned with the mechanical limit switch.
In order to activate the software configuration, it is necessary to carry out
a CONFIGURE CONTROL RESTART COLD procedure.
42


Equipment: Torque wrench with 6 mm inserts

handbook.

Analysis.

fastening screws.

The unit allows to limit the axis 2 stroke in the two working directions, if necessary
to limit the stroke only in one direction, use only one of the two stops.
projecting.
43
Operating procedure
the Robot Axis 2, in relation to
obtained.

(socket hex head screw M8x45)
tightening them at a torque of
41.6 Nm.
44


Equipment: Torque wrench with 5 mm insert

handbook.

Analysis.

fastening screws..

The unit allows to limit the axis 3 stroke in the two working directions, if necessary
to limit the stroke only in one direction, use only one of the two stops.
projecting.
45
Operating procedure
the Robot Axis 2, in relation to
obtained.

(socket hex head screw M6x35)
tightening them at a torque of
17.5 Nm.
46
ROBOT CONNECTION WITH CONTROL UNIT
7. ROBOT CONNECTION WITH CONTROL UNIT

Preliminary precautions
Connection with the Control Unit (main motors and encoder cables).
Connection of digital I/O signals cables
I/O signals cables connection on Field Bus
7.1 Preliminary precautions

The Control Unit features must be consistent with the connected Robot.
For this reason, both the Robot and the Control Unit are provided with
approval documents where is highlighted the serial number of the related
Robot / Control Unit which it must match with.
Always respect this matching to allow in the Control Unit configuration file
to check the torques and the functions of the motors.
At the end of the installation procedure it will be possible to check the

proper matching between the Robot and Control Unit displaying the main
screen of the Teach Pendant.
Cable ducts arrangement:
Install the cable ducts respecting the minimum bending radiuses (Minimum is 10
times the cable diameter).
Do not carry out bends with angles of 90.
For Robots installed on the floor, do not place the cable duct near the Robot
distribution panel, but leave a sufficient space to properly connect and disconnect
the connectors.
When installing the cables avoid the contact of the cable sheaths with sharp
edges to avoid damaging the sheaths; protect the edges of the terminal section
of the cable ducts to avoid abrasion on the sheaths.
For Robots installed on raised supports, any cable supports used must not be placed
near the connectors, but at a minimum distance of approx. 600 mm from the
connectors cable glands.
47
Preliminary procedures / notes (Continue)

Connections on Robot:
When connecting, avoid tight bending radii on the cables. A bending radius of
approx. 10 times the cable diameter is recommended.
The cable must not be too stretched.
Do not wind the excess power cables (motors, weld cable, etc.) in hanks with
many overlapped coils (maximum 2 coils) to prevent over-temperature risks and
damage due to lack of dissipation in air.
The connection between Harting connectors (male and female) must be made
without forcing, to avoid the re-entry or the bending of the pins.
During the connection, keep the mating connector parallel to the panel connector
it must be connected to.
The connection between connectors is to be made avoiding axial and/or lateral
movements to avoid damaging the coding pins and contacts.
The coding pins on both connectors are to be used to guide the connector
coupling.
The two levers on the panel connector are only to be used to secure the
mechanical clamping of the connection and not to facilitate the connection.
In case of Robots installed on holders, it is advisable to support the cables so that
the weight does not force the connectors on Robot base.
48
7.2 Connection with the Control Unit (main motors and

encoder cables)

Material: Not required
Equipment: Standard maintenance equipment
Fixing ---
components:

Before connecting the Robot it is necessary to verify the correct matching
with the Control Unit. Further details in par. 7.1 Preliminary precautions
on pag. 47.
Operating procedure
a. Connect the ground conductor (Robot side) on the distribution panel on the
Robot base.
b. Connect the passing cables by means of connectors X1, X2 on the distribution

panel on the Robot base.
c. Clamp each connector with its clamping levers.

Model with C5Compact Control Unit
Robot base
C5Compact Motor Brake cable
Connector
X1 X2
Encoder cable
Ground cable
49

Model with C5G Control Unit
Follow-Up procedure
Pull softly the cables and ground conductor to check the proper connection.
50
7.3 Connection of digital I/O signals cables

Material: I/O signals cable: CR1724446x for
C5Compact Control Unit or
CR1743328x for C5G Control Unit
Fixing ---
components:

on pag. 47.
In the following procedure some examples are shown.

For further information refer to the specific application handbook.
Operating procedure
a. Insert the signals cable end (Control Unit side) through the X90 cable gland
connector on the Control Unit.
b. Connect the cable:
b.1 on the X2/CAB terminal block in case of C5Compact Control Unit
b.2 on the X3/CAB terminal block in case of C5G Control Unit
c. Connect the I/O signals cable by means of the X50 connector (Robot side) on the
distribution unit on the Robot base.
C5Compact X50
Interface Panel (CIP) Robot base
I/O service cable
51

C5G Connector X50

Interface Panel (CIP) Robot base
I/O service cable
Follow-Up procedure
Pull softly the cables to check the correct connection.
52
7.4 I/O signals cables connection on Field Bus

Material: Multibus cable
Fixing ---
components:

on pag. 47.
In the following procedure some examples are shown.

For further information refer to the specific application handbook.
Operating procedure
a. Connect one end of the Multibus cable to the X93 connector on Control Unit.
b. Connect the other end of the Multibus cable to the connector X50 on Robot base.
53

Follow-up procedure
Pull softly the cables to check the correct connection.
54
OPERATIONS RELATED WITH THE FIRST STARTUP
8. OPERATIONS RELATED WITH THE FIRST

STARTUP
Precautions before the first power up
Control Unit power up
Safety functional inspections of the Robotic system integrated in the production cell
8.1 Precautions before the first power up

The Robotic system (consisting of Robot and Control Unit) must be integrated in a
complex system and suitably interfaced. If the interfacing circuits of the safety
signals are not made, the Control Unit can be started but it will not be possible to
enable the Robot motors.
Refer to the principle diagrams described in the "Transport and Installation" instructions
handbook of the Control Unit for the proper interfacing.
The battery in the UPS module of the Control Unit must be recharged in advance
to guarantee controlled shutdowns. The first complete loading is obtained in about
3 hours. During this period, the Control Unit could not guarantee controlled
shutdowns in absence of electrical power supply.
55
8.2 Control Unit power up

To power up the Control Unit, close the main switch (position I on the knob).
During the first seconds after the power up, the system carries out the required
tests to check the functionality of the present modules. This activity is signalled by
the lighting on of the LED present on the modules.
After performing the tests and the following system loading, the Teach Pendant will
be the interface for any kind of activity required on the Robotic system (moving,
programming, diagnostics, etc.).
If any errors deriving from the not-closed safety and control circuits, consult the
"Transport and Installation" instruction handbook of the C5Compact Control Unit.
The vastness of the topics related to the Control Unit power up, motion and
programming and other necessary topics, requires the consultation of additional
handbooks.
Depending on requirements, the following documents are recommended:
for Robotic system power up, use: Use of the Control Unit
for special applications: (several handbooks of the applications).
8.2.1 Ceiling / inclined plane installation

In case of Robot ceiling / inclined plane installation, make sure there is a correct
configuration of the Robot ceiling installation position:
1. On the Teach Pendant enter the screen page "Assembly" accessible by selecting
Setup and Arm.
2. Select the option ceiling / sloped surface
3. Save the configuration using the key Save (F5) and exit from the screen page
"Assembly" using the key Close (F6).
8.2.2 Auto-Determination of Load

To carry out the auto-determination of the load (software option) it is necessary to have
some cubic metres of free space to allow the Robot axes to move during the execution
of the function.
For further information, see the "Motion Programming" handbook.
56
8.3 Safety functional inspections of the Robotic

system integrated in the production cell
Before the startup, carry out an accurate control on the safety aspects of the robotic
system related to the integration in the production cell.
Particularly, but not limited only to the items below, check:
the safety shutdowns commands functionality
safety circuits of the movable guards functionality, checking that after the guards
opening (access door) the Robot motion is allowed only in Programming mode
the operating areas deriving from installation of the options related to sectioning
the safety signals of interchange with the cell
that the operating spaces of the Robot are consistent with the perimeter fences.
57
58
Original instructions
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Robot Racer 999

Transport and installation

Copyright 2008-2015 by COMAU - Published on 10/2015

1. GENERAL SAFETY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

2. INSTALLATION SUMMARIZING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16

3. PREPARATION FOR ROBOT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...17

4. ROBOT TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...20

5. ROBOT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25

6. ROBOT INSTALLATION COMPLETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..40

7. ROBOT CONNECTION WITH CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..47

8. OPERATIONS RELATED WITH THE FIRST STARTUP . . . . . . . . . . . . . . . . . . . . . . ..55

Manufacturer Robot Set of Handbooks

These handbooks must be integrated with the following documents:

Manufacturer Description Set of Handbooks

Limits on the handbook contents

Symbols used in the handbook

GENERAL SAFETY REQUIREMENTS

1. GENERAL SAFETY REQUIREMENTS

This chapter deals with the following topics:

COMAU Robotics denies any responsibility for accidents caused by incorrect or

1.1.1 Safety Fundamental Requirements Applied and

GENERAL SAFETY REQUIREMENTS

1.2 Safety requirements

Installation and Startup

Functioning in Programming Mode

Functioning in Auto / Remote Mode

Maintenance and Repair

GENERAL SAFETY REQUIREMENTS

Decommissioning and Dismantling

GENERAL SAFETY REQUIREMENTS

1.2.4 Operating modes

GENERAL SAFETY REQUIREMENTS

The safety of the system cannot be guaranteed in case of interlocks erroneous,

GENERAL SAFETY REQUIREMENTS

Functioning in Programming Mode

GENERAL SAFETY REQUIREMENTS

Functioning in Auto / Remote Mode

Robot axes brake release

GENERAL SAFETY REQUIREMENTS

Maintenance and Repair

Trouble-shooting and maintenance activities must be carried out, whenever

GENERAL SAFETY REQUIREMENTS

Maintenance, repair and trouble-shooting operations must be concluded with the

Decommissioning and Dismantling

INSTALLATION SUMMARIZING TABLE

2. INSTALLATION SUMMARIZING TABLE

Tab. 2.1 - Installation summarizing table

Step Operation Done

PREPARATION FOR ROBOT INSTALLATION

3. PREPARATION FOR ROBOT INSTALLATION

PREPARATION FOR ROBOT INSTALLATION

3.1 Staff in charge for installation

3.2 Working environmental conditions

3.2.1 Requirements for the installation environment

3.2.2 Environment data

For further information see the Robot "Technical Specifications" handbook.

PREPARATION FOR ROBOT INSTALLATION

3.2.3 Operating space

3.3 Operating environment prearrangements

3.4 Foundations preparations

The floor shall be regular, levelled and perfectly plain.

3.5 Stresses on the supporting structure

4.1 Robot weight