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C3G Plus
OPERATIONS AND
MAINTENANCE MANUAL
3UM - C3G Plus 06/040000757045/GB
CELL CONTROLLER REL. 1.x e REL. 2.x
The information provided in this manual is the property of COMAU S.p.A.
Any form of reproduction, even partial, is forbidden without the prior written authorization of COMAU S.p.A.
COMAU reserves the right to modify the characteristics of the product described in this manual without prior
notice.
PRINTED IN ITALY -05/2000
Copyright © 1999 by COMAU
UPDATING LIST
In this issue of the manual, with respect to the previous one, changes to technical contents have been per-
formed due to the product updating. The modified sections are listed below.
TITLE: C3G Plus CELL CONTROLLER
UPDATING CHAPT. SUBJECT PAG. No. ACTION
01/0498 - Cover - Substituted
01/0498 - Back - Substituted
01/0498 - Summary all Substituted
01/0498 - Chapter divider 2-4-5-6-7 - Substituted
01/0498 2 Installation all Substituted
01/0498 3 Operator interface 1-2-11-13-16
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Main operations for system use 4 Added
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01/0498 6 Emergency procedure 1-2-3 Substituted
01/0498 7
Maintenance 14 � 24
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02/1198 - Summary all Substituted
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02/1198 3 Operator interface 1, 24 � 30,
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02/1198 4 Integration guide 1-3-4-33 Substituted
02/1198 5 Main operations for system use 1¸ 12
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02/1198 7 Maintenance 68-69 Substituted
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03/0499 - Back - Substituted
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03/0499 4 Integration guide 19 - 33 Substituted
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C3G Plus UPDATING LIST
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04/0799 1 Safety regulations 4-6 Substituted
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05/1199 5 Main operations for system use 19, 20 Substituted
06/0400 - Cover - Substituted
06/0400 - Back - Substituted
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06/0400 4 Integration guide 5-34-35
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C3G Plus PREFACE
05/1199 i
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C3G Plus VERSIONS SDLP-SDMP-SDHP
C3G Plus VERSIONS DDMP-DDHP
This manual refers to the COMAU robot system consisting of:
C3G Plus cell control unit Rel. 1.X Rel. 2.X
SDLP 3,8 KVA
7 KVA
16,5 KVA
Power installed SDMP
SDHP
Internal lighting � –
230 Vac 6 A, SCHUKO-type service socket � –
Emergency terminal function � –
RPT Resolver Position Tracker (on board robot) (1) (1)
System software version 5.2X / 5.3X / 5.4x
(1) RPT module is not available on robots identified by a release similar/higher to that indicated in the
following table:
Manufacture release is printed on robot identification plate.
Where necessary, this manual also gives information about RPT, as documentation concerning robots man-
ufactured in previous releases not specified in table or equipped with RPT module for special applications.
PREFACE C3G Plus
ii 06/0400
SMART RELEASE RPT
S2; S3; S4 3.0 -
S5 1.0 -
M 4.0 -
H1/H2/H3/H5 4.0 -
H4 3.0 -
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SYMBOLS USED IN THIS MANUAL
The symbols used to indicate: CAUTION, WARNING and NOTES are explained below:
Symbol used to identify operating procedures, technical information and precautions, which,
if not complied with and/or carried out correctly may cause injury to personnel.
Symbol used to identify operating procedures, technical information and precautions, which, if
not complied with and/or carried out correctly may cause damage to the equipment.
Symbol used to identify operating procedures, technical information and precautions to
which attention must be drawn.
The symbols below, which appear inside the operating procedures, mean that the operator should pay partic-
ular attention or carry out the instructions:
Dangerous electrical voltage
Components that are damaged by electrostatic charges
Earth connection point or pin.
TRAINING COURSES
� COMAU Robotics organises special training courses for robot system operating, programming and
maintenance personnel.
� Further courses can be organised to cater for any particular requirements and to provide the technical
and practical information required for independent operation of the COMAU robot system, depending on
the level of knowledge of the participants.
REFERENCE DOCUMENTS
For further information on the C3G Plus cell controller, consult the following documents:
� C3G Plus Technical Specifications (supplied with this manual);
� EZ Programming Environment;
� PDL2 Programming Language Manual;
� C3G Programming Guide;
� Manuals for the dedicated application programmes;
� Robot Operation and Maintenance Manuals.
� Manual for communication through field bus and Ethernet network.
C3G Plus PREFACE
06/0400 iii
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SUMMARY
This manual contains:
Page
CHAPTER 1 - SAFETY REGULATIONS
Responsibility .............................................................................................................................................1-1
Safety regulations.......................................................................................................................................1-1
CHAPTER 2 - INSTALLATION
Installation summary table..........................................................................................................................2-i
Provisions for installation............................................................................................................................2-1
Check packing list.......................................................................................................................................2-1
Acquaintance with operator interface .........................................................................................................2-1
Connection to power mains ........................................................................................................................2-2
C3G Plus - robot connections .....................................................................................................................2-5
Application Box connections.......................................................................................................................2-6
Connection of safety devices and cutting off commands leading from the transfer....................................2-6
Activation of C3G Plus ................................................................................................................................2-11
RPT buffer battery connection (optional) ....................................................................................................2-12
C3G Plus - robot off line functional check...................................................................................................2-13with different functions which are strictly correlated with the cell operating mode.
The PTU4 is capable of operating with any version of the system software without requiring particular set-
tings and it has:
� 16 line display, 40 backlit columns;
� 19 LEDs;
� keypad;
� display contrast and brightness adjustment through keys.
The following figures show the front, top and bottom views of the PTU4.
PTU4 - Front view
1. Three-position enabling button (right hand grip)
2. Three-position enabling button (left hand grip)
3. Mushroom-head emergency stop button
4. Auto/Manual selector (AUTO-T)
PTU4 - Top view
C3G Plus OPERATOR INTERFACE
04/0799 3-3
F2F1 F4F3 F6F5 F8F7
- +
U1 U2
U3 U4
ALARM
STEP
DISB
A2 EZA1
PREV
TOP
DRIVE
OFF
ON
HOLD
START
1
%
SCRN
ENTER
BACK
T2
RUN
T1
REC MODFLY
XTND JNTP POS
CIRC LIN JNT
ARM TYPEXCL
CHAR SCRL X
^C SEL
CUT COPY /
7 8 9
S.NXT SRCH PASTE
4 5 6
MODE UNDEL DEL
1 2 3
PAGE MARK HELP
0 -
SHIFT
.
X X
8
2Y Y
3Z Z
4X X
5Y Y
6Z Z
7
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1
4
2
3
1. “Terminal on control unit” button
2. Output of the connection cable to the control unit
PTU4 - Bottom view
NAME and SYMBOL DESCRIPTION
Function keys The Command Menu keys (F1 - F8) located below the liquid crystal dis-
play send the corresponding command, displayed on the menu line to the
control unit. For example the F1 key enters the CONF command from
main menu.
Teach/Test keys The BACK key moves back to the start position of the current movement
during step-by-step checking of a programme.
The RUN key starts running of programmes during step-by-step checking
of a programme created with the editor.
Keys T1 and T2 control tools 1 and 2 switching between OPEN and
CLOSE. The tool is correlated to the arm selected. The Leds are on when
the tool position is CLOSE.
The REC key inserts a move instruction and the position variable state-
ment and records the current position of the arm in the case of editing in
DATA or MEMORY DEBUG mode.
The MOD key modifies the value of the co-ordinates of an existing posi-
tion.
Tasti Controllo Keys from U1 to U4 are user-programmable keys. Their functions and
leds depend on the programme being run.
The DRIVE ON key powers the drives for all the arms. The LED indicates
that the function is active.
The DRIVE OFF key cuts off the power to the drives for all arms. The LED
indicates that the function is active.
The START key runs all programmes in the ready status and activates
movement during step-by-step checking of a programme or immediate ex-
ecution of a programme until it is released. The green LED indicates that
the function is active.
The HOLD key stops all holdable programmes and movement of all the
arms. The yellow LED indicates that the function is active.
The EXCL key allows overriding of the flange and electric limit switch
alarms of the robot for 60 seconds. If it is pressed a second time (before
60 seconds have passed) it allows immediate alarm activation. This key is
active only with the controller in programming status .
OPERATOR INTERFACE C3G Plus
3-4 00/1097
F1 F8......
BACK
T2
RUN
T1
REC MOD
U1 U2
U3 U4
DRIVE
OFF
ON
HOLD
START
EXCL
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NAME and SYMBOL DESCRIPTION
Video Control Keys The ALARM key, easily distinguished by the red LED on a yellow back-
ground, resets the alarm status when activated. The LED turns on when
alarm occurs.
The SHIFT key calls the secondary function of the double function keys, it
has no effect if pressed on its own.
The TOP key restores the top command menu while PREV returns the
previous command menu.
The CHAR/^C key displays the character menu. The character menu is
formed of two levels: the first level allows selection of a set of characters
whereas the second level is used to select the actual character. The char-
acter menu is active when data is being entered in the window selected. If
pressed together with the SHIFT key, it aborts the command being exe-
cuted.
The SCRL/SEL key interrupts and restores scrolling of information on the
display. If pressed together with the SHIFT key, the cursor is moved to the
window where the programme is waiting for entry from keyboard (case of
READ instruction).
The cancel key erases one character at a time to the left of the
cursor.
The arrow keys are used for moving the cursor up and down and to the
right and left of the display. If pressed in reply to a prompt, the up arrow
key calls the last ten answers entered from keyboard in reverse se-
quence.
The SCRN key toggles between the system and user screens. When the
editor is active, it switches between system, user and editor screens.
The ENTER key confirms entry of a command or data input.
Numeric/Edit Keys The 7/CUT key enters the numeric value 7. If it is pressed together with
the SHIFT key, it is used in the editor to erase programme lines selected
previously with the MARK key.
The 8/COPY key enters the numeric value 8. If pressed together with the
SHIFT key, it is used in the editor to memorise programme lines selected
previously with the MARK key in a buffer.
The 9/(Option) key enters the numeric value 9. If it is pressed together
with the SHIFT key, the command options menus are displayed.
The 4/S.NXT key enters the numeric value 4. If it is pressed together with
the SHIFT key, the editor SEARCH NEXT command is called.
The 5/SRCH key enters the numeric value 5. If it is pressed together with
the SHIFT key, the programme editor SEARCH command is called.
C3G Plus OPERATOR INTERFACE
00/1097 3-5
ALARM
PREV
TOP
SCRN
ENTER
CHAR SCRL X
^C SEL
SHIFT
CUT COPY /
7 8 9
S.NXT SRCH PASTE
4 5 6
MODE UNDEL DEL
1 2 3
PAGE MARK HELP
0 -.
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X
NAME and SYMBOL DESCRIPTION
Numeric/Edit Keys
(cont.)
The 6/PASTE key enters the numeric value 6. If it is pressed together with
the SHIFT key, it is used in the editor to insert the programme lines se-
lected with the MARK and /COPY keys in the correct position of the cur-
sor.
The 1/MODE key enters the numeric value 1. If it is pressed together with
the SHIFT key, it switches between the programme editor CODE and
DATA modes.
The 2/UNDEL key enters the numeric value 2. If it is pressed together
with the SHIFT key, it calls the programme editor UNDELETE LINE com-
mand.
The 3/DEL key enters the numeric value 3. If it is pressed together with
the SHIFT key, it calls the programme editor DELETE LINE command.
The 0/PAGE key enters the numeric value 0. If it is pressed together with
the SHIFT key, it calls the programme editor PAGE command.
The ./MARK key enters a full stop (.). If it is pressed together with the
SHIFT key, it is used in the editor to select programme lines.
The -/HELP key enters the minus sign (-). If it is pressed together with the
SHIFT key, it calls the programme editor HELP command in the EDITING
environment, or shows the list of possible input data for a command in the
case of a prompt (file; programmes; I/O points, etc.).
Single Axis Movement Keys The speed selection keys (%- and %+) reduce or increase the movement
speed percentage by the amount defined in $TP_GEN_INCR. For further
information, refer to the PDL2 Programming Language manual. If it is
pressed together with the SHIFT key, it selects speed at 100% (SHIFT
and %+) or 25% (SHIFT and %-). These are rocker type keys.
The TYP key selects the reference system as follows:
Jnt - joints mode. The keys are associated with each axis of
the arm selected; the auxiliary axes, if any, follow those of the arm (typi-
cally and keys). Pressing one of the keys moves
the corresponding axis in the positive or negative direction according to
the directions shown on the labels on the arm.
Bas - linear movement mode according to the x, y, z reference tern of the
world (workshop reference tern) The first three keys allow lin-
ear movements in the direction of the three axes of the world reference
system; the next three keys allow rotations of the tool around
the same axes keeping the position of the TCP unchanged.You are re-
minded that the world tern is not defined directly by any system variable;
in fact the robot base is represented with respect to the world through the
variable $BASE.
Tol - linear movement mode according to the x, y, z reference tern of the
tool (or TCP tern). The first three keys allow linear move-
ments in the direction of the three axes of the tool reference system (de-
fined by the variable $TOOL); the next three keys allow
rotations of the tool around the same axes keeping the TCP position un-
changed (tool work point).
OPERATOR INTERFACE C3G Plus
3-6 00/1097
CUT COPY /
7 8 9
S.NXT SRCH PASTE
4 5 6
MODE UNDEL DEL
1 2 3
PAGE MARK HELP
0 -.
1
%
ARM TYP
X X
8
2Y Y
3Z Z
4X X
5Y Y
6Z Z
7
- +
- +
- +
- +
- +
7
- +
8
- +
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NAME and SYMBOL DESCRIPTION
Single Axis Movement
Keys (cont.)
Usr - linear movement mode according to the user x, y, z reference tern
(for example the tern that describes the piece being machined). The first
three keys allow linear movements in the direction of the three
axes of the user reference system (defined by the variable $UFRAME);
the next three keys allow rotations of the tool around the
same axes keeping the TCP position unchanged.
Bwr, Twr, Uwr,: when pressed together with the SHIFT key, the TYP key
will toggle the mode between Cartesian movement (BASE, TOOL, USER)
and Wrist JNT (X, Y, Z and axis 4,5,6 joints). For further information, refer
to chapter 5 of this manual.
For movements according to Cartesian co-ordinates, keys 1, 2 and 3 cor-
respond to the movement along axes x, y and z of the Cartesian co-ordi-
nate system selected, while keys 4, 5 and 6 correspond to movement
around axes x, y and z (rotations).
When the axis jog keys (from 1- to 8- and from 1+ to 8+) are held down,
they move each axis of the arm selected according to the type of move-
ment chosen. These are rocker type keys.
The ARM key selects an arm (robot) and can be used to select the arms
to be jogged. When pressed together with the SHIFT key, it selects the
synchronised arm in a multi-arm system.
The Brightness and Contrast keys are used to adjust display brightness
and contrast.
The Step Disb key is used in EZ and system editor environment to switch
from the current step mode to Disabled and vice versa. For example, if the
step mode in EZ environment is Statement, this mode is disabled pressing
the Step Disb key. Pressing Step Disb again the Statement mode is re-en-
abled.
The function of the EZ key differs depending on the status in which it is
pressed:
- In stand-by status (loaded in memory but not active) pressing the EZ key
activates the related status if the EZ package is present and loaded on
the RAM disk. It has the same effect as the Utility Application (UA)
command.
- If the EZ status is active (after entry of the UA command or pressing the
EZ key), but the screen page is different from the EZ screen page
currently displayed on the programming terminal screen, the EZ screen
page is displayed.
- With EZ status active and the screen page currently displayed on the
programming terminal screen corresponding to the EZ screen page, this
is suspended and it is possible to access the edit environment again, if
necessary. It has the same effect as entering the EZ Change
Environment command.
Keys A1 and A2 are reserved for future use in application packages.
Pressing the FLY key in the Editor and EZ environments enables or dis-
ables association of the FLY mode to the MOVE learnt with the REC key.
C3G Plus OPERATOR INTERFACE
00/1097 3-7
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%
ARM TYP
X X
8
2Y Y
3Z Z
4X X
5Y Y
6Z Z
7
- +
STEP
DISB
EZ
A2A1
FLY
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- +
NAME and SYMBOL DESCRIPTION
The XTND, JNTP and POS keys make it possible to modify the type of
variable inserted on pressing the REC key in the Editor and EZ environ-
ments. Variables of the XTNDPOS, JNTPOS or POSITION type can be
selected according to the key that is pressed.
The CIRC, LIN and JNT keys make it possible to modify the type of trajec-
tory in the ProgramEdit/Memory Debug and EZ environments for setting
the REC key. The next time the REC key is pressed, a CIRCULAR,
LINEAR or JOINT clause is inserted in the MOVE instruction.
Mushroom-head emergency
stop button
Pressing this mushroom-head (red) button immediately stops all the arms
cutting off the power to the drives and activating the brakes.
It is connected to the safety chain and is not under software control.
To release, pull outwards.
AUTO/MANUAL selector This selector (optional) has two positions:
- Automatic movement during programme development; it is possible to
run test cycles at operating speed.
- Jogging of the axes, immediate execution and step-by-step checking of a
programme at reduced speed.
Some terminals do not have this selector. In this case the programming
terminal operates as if manual mode is always selected and when the
drives are on (Dr:ON), the enabling button must be held down to jog the
robot.
Three-position enabling button
(ENABLING DEVICE)
This is a safety switch that must be held down in the intermediate position;
to allow manual or automatic movement when the system is in program-
ming status, pressing this button the drives are automatically activated
(DRIVE ON) in programming status.
Releasing/completely pressing the button causes opening of the power
contactors and sets the robot to DRIVE OFF.
Terminal on Control
System button
This button acts as a safety device. On exiting programming mode, before
being able to operate automatically, it is necessary to put the programming
terminal in its housing on the control unit cabinet. Completely releasing the
button causes opening of the power contactors and sets the robot to
DRIVE OFF.
OPERATOR INTERFACE C3G Plus
3-8 00/1097
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XTND JNTP POS
CIRC LIN JNT
C3G-PTU4 DISPLAY
The programming terminal display is in the form shown below and it is split into three windows: status win-
dow, scroll window, command window. Substantially the display gives the same information displayed on the
video emulator of the C3G Plus. Owing to reasons of space, the commands and information are abbreviated.
� STATUS WINDOW: displays the following information about system status:
The First Field shows the status set by the key selector on the control panel and the AUTO/MAN key on
the programming terminal:
LOCAL + (automatic local)
REMOTE + (automatic remote)
AUTO-T + (automatic operation controlled by the operator through PTU4, for testing
programmes at normal speed)
PROGR + (programming)
The Second Field in the display shows the status of the system, of the Holdable programmes and of the
movement being programmed.
With the selectors in positions LOCAL, REMOTE, AUTO-T it has the following meanings:
**** + means that no holdable programme is being run
RUN + means that at least one holdable programme is being run.
With the selector in the PROGR position it has the following meanings:
**** + means that no movement is in progress
JOG + means that a jog movement is in progress
FORW + means that a FORWARD movement is in progress
BACK + means that a BACKWARD movement is in progress.
The meaning of HOLD and ALARM remains unchanged in any status of the selectors:
HOLD + means that the HOLD button is pressed, thus execution of the holdable
programmes and the movement of all arms are stopped.
ALARM + means that the system is under alarm.
% indicates the movement percentage speed and it may vary 1 to 100.
C3G Plus OPERATOR INTERFACE
00/1097 3-9
Arm
Conf
Cntl
Displ
Iocf
Exec
Load
Filr
Save
Mem Prog Set Util
PROGR HOLD % 100 Arm: 1 * * * * Typ: Jnt E
LOCAL
REMOTE
AUTO-T
ALARM
* * * *
RUN
JOG
FORW
BACK
Bas
Tol
Usr
Uwr
Twr
Bwr
DIS
CAL
TURN
SIMU
LOCK
RES
COOP
STBY
P
Command window
Scrolling window
Status window
Possible fields of
the Status window
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Arm: The First Field may have the following values:
1 1 � 2
2 Number of arm selected 1 � 2 Synchronised movements for more arms
3 2 � 1
42 � 1
1a C3G MMux device
1b
For further information about the meaning of the indication displayed, refer to the specific literature con-
cerning the device installed.
The Second Field shows the status of the Arm selected:
**** + means that the Arm is not calibrated
DIS + means that the Arm selected is disabled
CAL + means that the Arm selected is calibrated
TURN + means that the Turn_set operation must be performed (setting the resolver
turn count)
SIMU + means that the cell controller is in the simulation status in which a programme
can be run with the drives off
LOCK + means that the movement of the Arm specified or of all the arms is locked (see
LOCK/UNLOCK instruction)
RES + means that the movement of the Arm specified or of all the arms still has to be
reset (see RESUME instruction)
COOP + means that cooperative motion is activated
STBY + means that the Arm is in Stand-by status.
Typ: shows the type of manual movement that can be selected:
Jnt + joint movement
Bas + movement according to the Cartesian tern x,y,z referring to the robot base
Tol + movement according to the Cartesian tern x,y,z referring to the robot tool
Usr + movement according to the Cartesian tern x,y,z set by the user
Uwr + transfer according to the Cartesian tern x,y,z set by the user and changing
geometry according to the robot wrist axes
Twr + transfer according to the Cartesian tern x,y,z of the robot equipment and changing
geometry according to the robot wrist axes
Bwr + transfer according to the Cartesian tern x,y,z of the robot base and changing
geometry according to the robot wrist axes.
E shows that the Enabling Device button on the programming terminal is pressed
P shows that the programming terminal is in its housing on the cabin.
The above information is displayed on the first line of the status window. The second line shows the error
and system information messages.
� SCROLLING WINDOW: this window displays the messages that the system sends to the operator and
the user programmes.
� COMMAND WINDOW: displays the menu of the system commands described in the specific paragraph.
Some letters with special accents (for example: ã; õ; Ó; Á; Ú; Â) are not provided therefore
they appear without accent in the messages.
OPERATOR INTERFACE C3G Plus
3-10 00/1097
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PROVISION FOR ACTIVATING THE EMERGENCY TERMINAL
(Only for Rel. 1.x)
NAME and SYMBOL DESCRIPTION
CAP FOR CLOSING
CONNECTORS X201 (ON),
X200 (MACHINE 1 EMC) and
X199 (MACHINE 2 EMC,
only for C3G Plus versions
DDMP-DDHP)
Closing cap for the definition of the PTU4 operating modes. If inserted in
connector X201, the PTU4 is enabled as programming terminal. If inserted
in connector X200-X199, the PTU4 is enabled as emergency terminal. In-
serting/removing is allowed only with the control unit off.
The connector is inside the cabin (for further information see chapter 6 of
this manual).
EMERGENCY TERMINAL ACTIVE KEYS (Only for Rel. 1.x)
Substantially the emergency terminal active keys have the function described for the programming terminal.
The axis movement keys only work in JOINT mode.
The table below shows the active keys of the terminal.
SYMBOL DESCRIPTION
Enabling button
Mushroom-head emergency stop button
DRIVE ON and DRIVE OFF keys
Axis Movement Keys
Alarm key
After releasing the enabling button, the emergency terminal may display error messages.
Press the ALARM key on the emergency terminal to cancel the alarms.
C3G Plus OPERATOR INTERFACE
04/0799 3-11
EM
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G
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C
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TE
R
M
IN
A
L
DRIVE
OFF
ON
1
%
X X
8
2Y Y
3Z Z
4X X
5Y Y
6Z Z
7
ALARM
EMERGENCY CONTROL C3G-EMC2 (Only Rel. 2.x)
This is an hand-held device which, when interfacing with the controller unit C3G Plus Rel. 2.x, permits the
implementation of the emergency terminal function by following the same active modes as described under
the paragraphs “Programming and Emergency Terminal” and “Active keys on the emergency terminal” of
this chapter.
C3G-EMC2 CONNECTING PROCEDURE
The steps required to actuate the emergency terminal function are the following:
- Take X110/SDB3 off (the PTU4 connections are broken);
- Remove X111/SDB3 (closing plug);
- Disengage the connector X140/PDP (cut-off of 110 V a.c. supply to the electronics rack);
The non-disconnection of this connector during the emergency terminal function could cause
the system malfunctioning.
- Connect the cable X110/EMC2 to X110/SDB3 in the box C3G-EMC2;
- Connect the cable X111/EMC2 running out from the box C3G-EMC2 to the connector X111/SDB3 ;
- Connect the cable X7/EMC2 running out from the box C3G-EMC2 to the connector X7/SAU2;
- Connect the cable X110/SDB3 running out from the box C3G-EMC2 to the connector X110/EMC2.
All the above mentioned operations have to be carried out with great caution
After carrying out the machine handling operation through the emergency terminal, discon-
nect the hand-held device C3G-EMC2 and reset the original connections.
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SAMPLE CONNECTION OF C3G-EMC2
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CONNECTOR FOR ENABLING DEVICE ADDITIONAL BUTTON
NAME and SYMBOL DESCRIPTION
Connector X80 Connector (present on request) for connecting an additional three-position
safety switch (Enabling Device) with the same functions as the one on the
PTU4 programming terminal.
The connector is at the bottom left, cabin front view (below connectors X10
and X30).
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C3G Plus INTERFACE ON PERSONAL COMPUTER
CONNECTION CABLE FOR COMP: - PC CONNECTORS
The COMP: port of the control unit is used to manage information between the control unit and the PC on
which the C3G Plus video emulator is installed. If the user has purchased the portable PC from COMAU, it is
provided with the connection cable to be used. If not, the circuit is as shown in the following diagram:
A. 25-pin SUB-D - male - connector (to be connected to port COMP: of the control unit)
B. 9-pin SUB-D - female - connector (to be connected to the serial output of portable PC)
Maximum cable length: 15 m.
CABLE FOR CONNECTING SERIAL PORT CONNECTORS COM0: AND COM1:
Connectors: 9 PIN SUB-D (FEMALE)
Maximum cable length: 15 m.
Use a standard PC-PC cable.
PARALLEL PORT PAR: CONNECTION CABLE
Connector: 25 pin SUB-D (MALE)
Maximum cable length: 1.5 m.
Use a standard PC-PC cable.
PCINT PROGRAMME
The PCINT programme is contained on a floppy disk supplied with the C3G Plus. The language in which the
programme is written is specified on the floppy disk.
SET UP
� The PC on which it is decided to install the programme must have MS DOS 5.x or higher.
� Create a PC subdirectory and copy the contents of the disk
ACTIVATION
� Go to the subdirectory on which the contents of the floppy disk have been copied.
� At the PC prompt type: PCINT
� The main menu is shown with four possible options:
- - - > C3G VIDEO/KEYBOARD EMULATOR
CAUSE/REMEDY LOOKUP
CREATE CAUSE/REMEDY FILE
DOWNLOAD SYSTEM SOFTWARE
EXIT
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COMMANDS FOR SELECTING AND ISSUING DATA
Using the arrow keys on the PC keyboard it is possible to move on the data to be issued (the highlighter
moves - - - >). To issue the datum selected press ENTER.
E.G.: - - - > CAUSE/REMEDY LOOKUP
Type: ENTER
C3G VIDEO/KEYBOARD EMULATOR
Using the C3G video/keyboard emulator option it is possible to activate emulation of the C3G Plus video and
keyboard.
� Connect the serial port COMP: of the C3G Plus with the serial port of the PC (e.g. COM1). The connec-
tion cable must be the one specified in this chapter.
� On the PC select the C3G VIDEO/KEYBOARD EMULATOR option.
� The possibility is given to choose the serial port on the PC on which to install emulation:
Select PC communicationport:
- - - > COM1
COM2
Previous window
After selecting the port a wait for connection with controller message is shown; if the previous window is se-
lected the procedure returns to the previous screen page.
Normally it is not necessary to install the video/keyboard emulator working on PTU4. If the
emulator is not activated, carry out this step of the procedure as described below, if not,
carry out the following step of the procedure.
� Install the emulator working on the PTU4 as follows:
- Type the commands UCMC. You will be asked on which C3G Plus port to install.
- Type COMP: and confirm with ENTER.
� The C3G Plus screen is displayed on the PC. As the normal PC keyboard does not have all the neces-
sary function keys, some keys of the C3G Plus keyboard have been re-mapped to give them new func-
tions on the video emulation protocol. Consulting the help provided, it is possible to see the table with
the corresponding mappings.
ACTIVATING HELP
The help function is active only when video/keyboard emulator has been installed. With the ALT-F1
keys of the PC keyboard it is possible to display the table with the correspondences between the PC key-
board and the C3G Plus keyboard and an explanation of some dedicated functions.
EXITING THE EMULATOR
To exit the emulator protocol, de-install it from the controller typing the UCD commands on the PTU4, then
press the ALT-X keys on the PC to exit the protocol, select EXIT from the main menu.
CAUSE/REMEDY LOOKUP
Through the Cause/Remedy Lookup option it is possible to obtain a cause and remedy explanation of the er-
ror message displayed on the PTU4 or video emulator (for further information about error messages refer to
the DIAGNOSTICS paragraph in the maintenance chapter of this manual).
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For displaying special characters on the PC contained in the text of error messages, in
the AUTOEXEC.BAT file it is necessary to define the commands “MODE CON CODEPAGE
PREPARE=((850)C:\DOS\EGA.CPI)” and “MODE CON CODEPAGE SELECT=850”.
In the CONFIG:SYS file define the commands “COUNTRY=039, 850, C:\DOS\COUN-
TRY.SYS” and “DEVICEHIGH=C:\DOS\DISPLAY.SYS CON=(EGA,,1)”
� On the PC select the CAUSE/REMEDY LOOKUP option
� The PC screen displays a window in which to enter the number of the error message about which infor-
mation is required.
E.G.: error number: � 28707
CREATION OF CAUSE/REMEDY FILE
Through the Create Cause/Remedy File option it is possible to create and copy the ASCII file (approx.
600KB) of the list of all the controller error messages with the cause and remedy explanation in a specified
drive/directory. Then, using a simple editor programme, it will be possible to print the list.
To print the special characters contained in the error message text using printers with PCL
(HP or HP compatible) language, send the following sequence to the printer:
(12U”027-040-049-050-085”. To reset the printer send the following sequence:
E”027-069”.
� On the PC select the CREATE CAUSE/REMEDY FILE option
� The PC screen displays a window in which it is possible to specify where the file has to be addressed.
E.G.: Drive/Directory: � c:\save
The name of the file created is MESSAGE.TXT. We recommend to open this file from an MS-DOS session;
in fact, should it be opened with Word under Windows, the special characters held in the text of the error
messages could be not be correctly displayed
DOWNLOADING SYSTEM SOFTWARE
Through the Download System Software option it is possible to download the system software rapidly using
the parallel ports of the C3G Plus and PC.
If the system software is to be downloaded, after turning on the controller the programming
terminal displays a message with the request to download the software. Proceed as de-
scribed below.
� Connect to the parallel port PAR: of the C3G Plus and to the parallel port of the PC a standard cable
(PC-PC) for parallel ports.
If requiring to display software downloading messages on the PC, it is necessary to connect the serial
port COMP: of the C3G Plus with the serial port of the PC (e.g.: COM1). The connection cable should be
the one specified in this chapter.
� On the PC select the DOWNLOAD SYSTEM SOFTWARE option
The PC screen displays a window in which it is possible to specify the drive/directory where the system files
to be downloaded reside. Then you are requested to select the PC serial port to display software download.
E.G.: Change Directory: � a:\
Select the PC communication port:
- - - > COM1
COM2
Previous window
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If the serial port COMP: of the C3G Plus and the serial port of the PC (e.g. COM1) have not
been connected, the software download messages are displayed on the display of the PTU4
programming terminal.
� Specify the Drive/directory in which the files to be downloaded reside (e.g.: A:\); select the required PC
communication port and confirm with ENTER
After issuing ENTER the wait for connection with the controller message is displayed.
� Insert floppy disk 1/3 of the system software in the drive (for example A). The system links up automati-
cally and begins downloading.
If the software downloading procedure fails (for example when a wrong floppy disk is in-
serted), the programming terminal display shows the Bootmon environment. Activate the
character menu on the PTU4 and type RESET/INIT, confirm with ENTER. The downloading
procedure starts again automatically from the beginning.
� Disks 2/3 and 3/3 will then be requested in sequence. Insert the disks and confirm with ENTER.
� At the end of downloading, entry of the time and date will be requested. Enter the time/date and confirm
with ENTER.
At the end of downloading the PTU4 displays the system menu. If the PC is connected on the COMP: serial
port of the C3G Plus (e.g. COM1 of the PC with COMP:) the system video is also automatically displayed on
the PC.
C3G Plus VIDEO ON PC
The C3G Plus video displayed on the Personal Computer through the PCINT programme is shown in the
form given in the figure below and it is split into three windows: status window, scroll window, command win-
dow.
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Arm
Configure
F1
Cntrler
Display
F2
Io-conf
Execute
F3
Load
Filer
F4
Save
Memory
F5
Prog
F6
Set
F7
Util
F8
State: PROGR HOLD % 100 Arm: 1 * * * *
LOCAL
REMOTE
AUTO-T
ALARM
* * * * *
RUNNING
JOGGING
FORWARD
BACKWARD
DIS
CAL
TURN
SIMU
LOCK
RES
COOP
STBY
Command window
Scrolling window
Status window
Possible fields
of the Status
window
Drive: OFF Ax: * * * 4 5 6 - -
1 2 3 4 5 6 - -
T T T 4 5 6 - -
Pa: 00
1
PLC P
- - - -
� STATUS WINDOW: displays the following information about system status:
Drive: OFF/ON indicates that the robot motors are on or off.
State: The First Field indicates the status set by the key selector on the control panel and of the
AUTO/MAN key on the programming terminal:
LOCAL + (local automatic operation)
REMOTE + (remote automatic operation)
AUTO-T + (automatic operation controlled by the operator through PTU4, for testing
programmes at normal speed)
PROGR + (programming)
The Second Field indicates the status of the system, of Holdable programmes and of the
movement being programmed.
With the selectors in the local automatic , remote automatic , positions, AUTO-T has the
following meanings::
***** + means that no holdable programme is being run
RUNNING + means that at least one holdable programme is being run.
With the selector in the programming position it has the following meanings:
***** + means that no movement is in progress
JOGGING + means that a jog movement is in progress
FORWARD + means that a FORWARD movement is in progress
BACKWARD + means that a BACKWARD movement is in progress.
The meaning of HOLD and ALARM remains unchanged in any status of the selectors:
HOLD + means that the HOLD buttonis pressed, thus execution of the holdable
programmes and the movement of all arms are stopped.
ALARM + means that the system is under alarm.
% indicates the movement percentage speed and it may vary 1 to 100.
Arm: The First Field may have the following values:
1 1 � 2
2 Number of arm selected 1 � 2 Synchronised movements for more Arms
3 2 � 1
4 2 � 1
1a C3G-MMux device
1b
For further information about the meaning of the indication displayed in the first field, refer to the
specific literature of the device installed.
The Second Field shows the status of the Arm selected:
***** + means that the Arm is not calibrated
DIS + means that the Arm selected is disabled
CAL + means that the Arm selected is calibrated
TURN + means that the Turn_set operation must be performed (setting the resolver turn
count).
SIMU + means that the cell controller is in the simulation status in which a programme can
be run with the drives off
LOCK + means that the movement of the Arm specified or of all the arms is locked (see
LOCK/UNLOCK instruction)
RES + means that the movement of the Arm specified or of all the arms has to be reset
(see RESUME instruction)
COOP + means that cooperative motion is activated
STBY + means that the Arm is in Stand-by status.
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Ax: indicates the status of the axis selected:
***456— + means that axes 1-2-3 are to be calibrated, axes 4-5-6 are calibrated, axes 7-8
are not present
123456— + means that axes 1,2,3,4,5,6 are calibrated, axes 7-8 are not present.
TTT456— + means that the Turn_set operation is to be carried out for axes 1-2-3, axes
4-5-6 are calibrated, axes 7-8 are not present.
Pa: The First Field shows the number of active programmes, the Second Field indicates if there is
a PLC programme active: word PLC or no PLC programme active: word —
P + indicates that the programming terminal is placed in the special housing on the
cabin.
- + indicates that the programming terminal is not placed in the special housing on
the cabin.
The above information is shown on the first line of the status window, the second line shows the error and
system information messages.
� SCROLLING WINDOW: this window displays the messages that the system sends to the operator and
the user programmes.
� COMMAND WINDOW: this displays the system command menu described in the specific paragraph.
Some letters with special accents (for example: ã; õ; Ó; Á; Ú; Â) are not provided therefore
they appear without accent in the messages.
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SYSTEM COMMANDS
This paragraph describes how to enter the different commands and includes a description of each of them.
The figure below shows the system command windows on the PC screen and on the programming terminal
display. At the end of the paragraph there is a list which summarises the commands.
ENTERING COMMANDS
Commands may be entered using one of the following methods:
� Highlight the command using the arrow keys. Select the command using the ENTER key. Selecting a
command displays either another command menu or a brief description of the command itself above the
original menu.
The highlighted command is executed only after the ENTER key has been pressed. For example, high-
lighting the EXECUTE command with the arrow keys displays a description of the command. Pressing
the ENTER key the command is executed.
On the PC screen and programming terminal any disabled or protected commands on the menu have a
lower case first letter while all available commands have an upper case first letter. On the PC screen an
available command will be highlighted in bold in addition to having an upper case first letter.
� Press the function keys (F1 - F8) on the PC or programming terminal keyboard to execute the corre-
sponding command. For example, pressing F2 executes the DISPLAY command from the main menu.
� Press the key corresponding to the first letter of the command. For example, pressing D executes the
DISPLAY command from the main menu.
In some cases, after entering a command, prompts are displayed which ask for additional information known
as parameters. For example, the PROGRAM GO command displays a prompt asking for a programme
name. To enter parameters in response to a prompt, use the alphanumerical keys of the PC keyboard or the
character menu of the programming terminal.
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Arm
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F1
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Display
F2
Io-conf
Execute
F3
Load
Filer
F4
Save
Memory
F5
Prog
F6
Set
F7
Util
F8
Arm
Conf
Cntl
Displ
Iocf
Exec
Load
Filr
Save
Mem Prog Set Util
F1 F2 F3 F4 F5 F6 F7 F8
Command window on PC screen
Command window on PTU4
Function keys on PTU4
For many commands including those that require user entry of a parameter, this can be selected using the
arrow keys and the ENTER key. Press the HELP key (if the word HELP is present on the line of the com-
mand highlighted) in reply to the prompt requiring entry of a parameter (file, programme, I/O point etc.). A list
of possible parameters to be used for that command will be displayed. Scrolling the list with the arrow keys,
select the item required, then press the ENTER key. In this way, the name of the item selected is displayed
as response to the prompt. If the right parameter has been selected, press the ENTER key to confirm the
prompt. To exit the HELP window without selecting a parameter, press PREV on the programming terminal,
or ESC on the keyboard with the PCINT programme active. To return to the command prompt, press TOP on
the programming terminal or SHIFT ESC on the keyboard with the PCINT programme active to return to the
main menu.
For some commands, pressing the HELP key after entering one or more characters after the prompt, only
the parameters whose initials correspond to the characters entered are displayed.
In the case of files, it is also possible to select the name of the device to be specified together with the name
of the file; this is possible pressing ENTER on the item which is displayed as first element in the list
of possible files.
The response to a parameter prompt must be typed before pressing the ENTER key. The left and right arrow
keys can be used to move the cursor on the response line. The delete (DEL) key will delete the character
immediately before the cursor, while the left and right arrow keys pressed together with the SHIFT key move
the cursor to the beginning and end of the response respectively.
Character menu
On the programming terminal, a character menu is available to enter alphanumeric and symbolic characters.
To access this menu, press the CHAR key. The character menu overlays the command menu in the com-
mand window.
Character menu on PTU4
Use the command menu keys (F1 - F8) to select a character and press the ENTER key after entering the
data.
The delete (DEL) key erases one character at a time to the left of the cursor. Pressing the CHAR key again
returns to the command menu.
Asterisk
The asterisk (*) can be used in a parameter to replace the beginning, ending, or all of the parameter. It al-
lows a single command to act on multiple items. For example, the MEMORY LOAD command requires a
programme name parameter, which can be replaced with an asterisk as follows:
ML * loads all programmes
ML arc* loads all programmes beginning with arc
Only one asterisk is allowed per parameter. This character cannot appear in the middle of the parameter. Not
all commands allow the asterisk to be used. Refer to individual command descriptions.
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File name (OPT):
EFGH IJKL MNOP QRST UVWX YZ$ symb
PROGR HOLD % 100 Arm: 1 **** Typ: Jnt - -
ABCD
Command Recall
The up arrow key recalls the last ten parameters that have been entered. This dispenses with the need to
enter the same parameter for a series of commands.
Command OptionsCommand options are available for some commands. If a command has options, (OPT) appears after the
prompt for the last parameter. The slash (/) character separates the option from the command. For example:
FC/C —FILER COPY with CONFIRM option
Pressing the / key displays the option menu for the current command. Options are selected and entered in
the same way as commands. Entering an option that is already displayed removes that option. Refer to indi-
vidual command descriptions for more information on options.
NOPAGE Option
The /NOPAGE option is available for all commands that display more than a single screen of information.
Normally, a single screen is displayed with a prompt to press any key to scroll the next pages. To display one
new line of information instead of scrolling through the whole page, press the spacebar key. Otherwise,
press any key and a new page will be displayed. Selecting the /NOPAGE option, the information continues to
scroll without waiting for a key to be pressed.
/4 option
The /4 option is used to format displays so that the information contained in them does not exceed 40 col-
umns in width. This is useful when View commands are issued from PDL2 via the SYS-CALL internal rou-
tine, in which displays are generally directed on a file or on the PC screen. This option is only available from
SYS_CALL and only for those commands that, if not issued from the programming terminal, display data be-
yond 40 columns.
Executing Commands from Programmes
The PDL2 SYS_CALL built-in routine can be used to execute commands from within a PDL2 programme.
(Refer to the PDL2 Programming Language manual).
COMMAND DESCRIPTION
This section describes each command, beginning with the top level down to each sub-command. A summary
list of commands is included at the end of the chapter.
Command items are given in their longest form, which is how they appear on the PC screen. On the PTU4
display they are shown in the abbreviated form of 4 characters per command.
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CONFIGURE COMMAND
Arm Cntrler Io_conf Load Save
Configure Display Execute Filer Memory Program Set Utility
The CONFIGURE command displays a command menu to configure the system to match user requirements.
Arm
Calibrate Reten_Mem Turn_set View_cal
Arm Cntrler Io_conf Load Save
The ARM command displays a command menu to configure the arm to match user requirements.
� Calibrate performs a calibration procedure on an entire arm or on specific axes of an arm. The arm
must be put in the calibration position before the command is issued. If an arm number is not specified,
the default arm shown by the prompt is used. An axis number should always be specified. To indicate an
entire arm, use the asterisk (*).
This command cannot be used when the system is in a FATAL or AUTOMATIC status, drive power is off
or if the system or programme protection is active. The access is bound to the use of a password, which
however is not required if it was already entered from the command Configure Controller Password.
The system must be in PROG status with drives on. The calibration data are saved automatically in:
Flash Eprom (SAU2)/RPT (optional); the C3G.SYS file and the ASCII calibration file (the name of which
is memorised in $CAL_FILE).
Options: /Learn learns the current position as the user calibration position.
/Nosave disables automatic saving of the calibration file in the Flash Eprom (SAU2)/RPT
(optional); the C3G.SYS file and the ASCII calibration file
/User uses the pre-learned user calibration position ($CAL_USER) instead of the system
position ($CAL_SYS).
Syntax: CAC axis_num
CAC/L
CAC/U axis_num
� Reten_Mem displays the commands for downloading from and saving in the Flash Eprom retentive
memory (in SAU2) or RPT module (optional). This makes it possible to read specific data relating to the
axes directly from the emergency manual control and keep specific Arm data. For both commands the
number of the servo board can be specified. The default number will be used if no number is specified.
The LOAD command downloads the data contained in the Flash Eprom (SAU2)/RPT (optional) in the
controller memory and automatically updates the C3G.SYS file and the ASCII calibration file (the name
of which is specified in the predefined variable $CAL_FILE).
Options: /Loadfile loads the data concerning the axes directly from the calibration file and saves
them automatically in the C3G.SYS file and in the Flash Eprom/RPT.
/Nofile disables automatic updating of the calibration file and of the C3G.SYS file.
Syntax: CARL/L
CARL/N
CARL
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The SAVE command saves the data relating to the axes from the controller memory in the Flash Eprom
(SAU2)/RPT (optional) and automatically updates the C3G.SYS file and the ASCII calibration file.
Options: /Nofile disables automatic updating of the calibration file and of the C3G.SYS file.
Syntax: CARS/N
CARS
� Turn_set sets the resolver turn counting at movement software level (and RPT level if present). Before
the command is issued, the arm must be taken to the calibration position (within half a resolver turn).
This command is useful when the pre-setting has been lost, for example following a resolver reading er-
ror.
If an arm number is not specified, the default arm is used. An axis number should always be specified.
To indicate an entire arm, use the asterisk (*).
To execute this command the system must be in PROG status and the drive power must be on. This
command cannot be used if the system is in the FATAL or automatic status, drive power is off or if sys-
tem protection is active.
Options: /Current uses the current arm position. Use this option only if the robot is still currently
calibrated (the controller has not been powered off since the RPT data was lost).
/User uses the pre-learned user calibration position.
Syntax: CAT axes_num
CAT/C axes_num
CAT/U axes_num
� View_cal displays the calibration constants.
Options: /4
Syntax: CAV
Cntrler
Password Restart Startup Time View
Arm Cntrler Io_conf Load Save
The CNTRLER command displays a command menu used to set the controller to match user requirements.
� Password establishes a system password needed for password protected commands and for access to
the Dmon feature for software maintenance (restricted to Comau).
Syntax: CCP password
� Restart displays a command menu for re-starting the controller without powering off. These commands
are disabled when the controller is in the AUTO-REMOTE mode.
Bootmon Cold Reboot Warm
Password Restart Startup Time View
� Bootmon restarts the system software and invokes the boot monitor mode, in which it is possible to per-
form system software maintenance operations. Access is restricted by password. A confirmation is re-
quired.
Syntax: CCRB
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� Cold restarts the system software and clears the memory. This is particularly useful when the system
has been corrupted by some user action. A confirmation is required. Following execution of a command
the system I/O ($SDIN [n]/ $SDOUT [n]) are updated to the current system situation. For the user I/O
($DIN [n]/$DOUT [n]), the status of the outputs is reset and the inputs are updated to the current system
situation. The PDL2 holdable/no-holdable programmes are deactivated and erased from the execution
memory. The PLC programme is deactivated and erased from the memory being run.
Syntax: CCRC
� Reboot restarts and reloads the system software. This is particularly useful to upgrade the system soft-
ware to a new release. Access is restricted by password. A confirmation is required.
Activation of the command involves erasing the contents of the RAM DISK. Be sure to make
a backup copy beforeproceeding with this command.
Syntax: CCRR
� Warm restarts the system software without clearing the memory. With this method of restarting the sys-
tem skips the tests that are normally performed when the controller is powered off and on again. A con-
firmation is required.
Following execution of this command the system I/O ($SDIN [n]/ $SDOUT [n]) are updated to the current
system situation. For the user I/O ($DIN [n]/ $DOUT [n]), the status of the outputs is reset and the inputs
are updated to the current system situation. The PDL2 holdable/no-holdable programmes are deacti-
vated and erased from the execution memory.
The PLC programme starts again automatically (RUN) from cycle start.
Syntax: CCRW
� Startup sets the name of the startup programme which is run at each system restart. This programme
can be holdable or non-holdable, but a holdable programme will not begin running until the START but-
ton is pressed. The name of the startup programme is kept in the $STARTUP variable. If no programme
name is issued with this command, the contents of the $STARTUP variable are cleared. This command
cannot be used if system, memory or programme protection is on.
Syntax: CCS
� Time sets the time (HH:MM:SS) and the date (DD-MM-YY) to the specified parameters. The month is
specified as a numeric value (1-12). This command cannot be used if system, memory or programme
protection is on.
Syntax: CCT
Example: CCT 13:00:00 01-01-97 —1.00 pm on 1-JAN-1997
� View displays:
- the system software version
- hardware board layout and other hardware-related information
- presence of RPT or flash Eprom
- total number of arms
- machine type and number of joints for each arm
- compensation model flag enabled
- whether or not an integrated disk drive is present (FD)
- whether or not a floating point co-processor is present (FPU)
- flag of PFDP and RIO boards
- flag of EIM - IBS SL/IBS MA/Ethernet boards,only if present in the controller rack
- flag of SINEC (CP1471(H1)), INTEC, IBS, SL2, EDN, SWIM boards, only if present in the controller
rack
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- configuration file name
- name of the electric gripper, if any, and of its related arm/axis
- RAM DISK status (RD has nnn bytes free)
- date and time.
The screen shown is the one that appears when the controller is switched on.
Options: /4
Syntax: CCV
Io_conf
The IO_CONF command activates a PDL2 utility programme used to map the user-defined I/O for the con-
troller to match user requirements. The RAM disk must contain the appropriate CL_INST programme other-
wise an error occurs.
This utility programme uses prompts and menus similar to those of the command language to guide the op-
erator through the configuration process.
Load
The LOAD command initialises predefined variables with the values stored in the configuration file. A confir-
mation is required.
A configuration file name can be included. If not specified file C3G.SYS is loaded.
The system must be in the PROG status and the drives off for this command to be executed. This command
cannot be used if the system is in automatic status, drive power is on or system, memory or programme pro-
tection is on.
A warm restart (WARM) is required to make the values operational.
As options, the LOAD command supports all of the single categories that can be loaded separately.
Options: /Arm
/Cntrler
/Data_comm
/Io
/Servo
Syntax: CL
Save
The SAVE command creates a new configuration file containing the current configuration data. The file name
and extension are always C3G.SYS.
The system must be in PROG status. This command is not active if the system, memory or programme pro-
tection is on.
To save different configuration files, make a copy of the current C3G.SYS file using FILER COPY before ac-
tivating SAVE. The SAVE command creates a backup (.BKS) file from the original C3G.SYS before creating
the new file.
Syntax: CS
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DISPLAY COMMAND
Arm Close Fieldbus Input Output Program Rll Vars
Configure Display Execute Filer Memory Program Set Utility
The DISPLAY command displays a command menu for opening display windows in the scroll window. These
windows show continuously updated information until they are closed with the CLOSE command. Multiple
windows can be opened at the same time. Display commands are always available.
When issuing a SYS_CALL instruction from inside a PDL2 programme, the DISPLAY command includes the
/T option which can redirect the output to the programming terminal display. Without this option the DISPLAY
commands, in the case of SYS_CALL, are sent to the PC screen (if the PCINT programme is active).
Arm
Currents Data Following Joint Position Resolver Status Temp
Arm Close Fieldbus Input Output Program Rll Set
The ARM command displays a command menu to display information related to an arm.
For systems equipped with multiple arms, an arm number parameter can be specified. A maximum of four
arms can be displayed at the same time. In the case of systems with the C3G-MMUX (Motor Multiplex 8/10)
device, some commands belonging to the DISPLAY ARM category display information regarding the active
set of auxiliary axes.
� Currents displays the motor currents of the axes in amperes.
Syntax: DAC
� Data displays arm interpolator data.
Syntax: DAD
� Following displays following errors of the axes in bit units.
Syntax: DAF
� Joint displays the current position target of each axis in degrees.
Syntax: DAJ
� Position displays the current Cartesian position target as an x,y,z location, Eular angle and configura-
tion string; the values of the joints (in mm, in the case of translating axes, or in degrees, in the case of
rotating axes) of the auxiliary component in a system fitted with auxiliary axes.
Syntax: DAP
� Resolver displays the current resolver position of each axis in bit units, read from the resolvers and
added to the calculated resolver turn.
Option: /Hex displays the data in hexadecimal format
Syntax: DAR
� Status displays the current status of the arm, including calibration and LOCK. If the system is equipped
with the C3G-MMUX device, this command displays the active set of auxiliary axes, its status, the servo
board to which the auxiliary axes belong and correspondence between the logic axis and the physical
axis, the cooperative motion and auxiliary axes disabled.
Syntax: DAS
� Temp displays the motor temperatures of the axes as a percentage of the maximum allowable tempera-
ture for the motor.
Syntax: DAT
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Close
Arm Input Output Program Rll Select Total Vars
Arm Close Fieldbus Input Output Program Rll Vars
The CLOSE command displays a command menu for removing displayed windows from the screen.
� Arm closes all ARM windows.
Syntax: DCA
� Input closes all input windows.
Syntax: DCI
� Output closes all output windows.
Syntax: DCO
� Program closes the window concerning active PDL2 programmes.
Syntax: DCP
� Rll closes the Rll programme window.
Syntax: DCR
� Select closes individual windows selected by the operator.
Syntax: DCS
� Total closes all windows opened by the DISPLAY command.
Syntax: DCT
� Vars closes all variable windows.
Syntax: DCV
Fieldbus
Master Slave
Arm Close Fieldbus Input Output Rll Vars
The FIELDBUS command contains a menu of commands in order to display the status of the Fieldbus Mas-
ter and Slave cards.
In particular, the following information can be displayed for each card:
NOCNFG indicates that the card is not configured;
RUNNING indicates that the communication is active;
STOPPED indicates that the communication is not active.
If no Fieldbus card is present no display is open.
� Master displays the information on the IBS-MASTER card.
Syntax: DFM
� Slave displaysthe information on the IBS-SLAVE, PROFIBUS-DP and RIO cards.
Syntax: DFS
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Input
AIN DIN GIN System
Arm Close Fieldbus Input Output Program Rll Vars
The INPUT command displays a command menu for displaying the status of user-defined and system inputs.
It is possible to associate the command with a HELP string using the HELP10 and HELP102 programmes
contained on Floppy disk “2/2 Configuration Tools”; to activate HELP display, press the SEL key and move
the cursor to right and left along the values of the variables.
� AIN displays user-defined analogue input values ($SAIN) as decimal values. If the value is forced, it is
displayed in red instead of blue on the screen, while on the programming terminal it is displayed in re-
verse. A string of numbers can be used to specify the indexes of individual inputs. The numbers are sep-
arated by hyphens (-).
A set of numbers is separated by two dots (..). If no parameter is used all analogue inputs are displayed for base 0.
Syntax: DIA
Example: DIA 1
DIA 1- 2 - 4..7
� DIN displays user-defined digital input values ($DIN), where 1 = TRUE and 0 = FALSE. If one of these
values is forced, an “F” (forced to false) or “T” (forced to true) will be displayed instead of 0 or 1.
Typing an input number, a set of digital inputs is displayed.
Syntax: DID
Example: DID 1
� GIN displays the user-defined groups of inputs ($GIN) as decimal values. If the value is forced, it is dis-
played in red instead of blue on the screen, while on the programming terminal it is displayed in reverse.
Syntax: DIG
� System displays system-defined digital inputs related to the boards present: SIM ($SDIN), IOS (from bit 65
to bit 80) and RIO. Pressing the SELECT key it is possible to access the display window directly, obtaining a
help associated to each individual bit. Use the LH and RH arrow keys to move the cursor along the bits, use
the UP and DOWN arrow keys to change module. Different notations are used for indicating if the RIO
board, if present, is communicating correctly with the PLC. On the screen display line the flashing message
“COM:RUNNING” or “COM:STOPPED” is shown, on the programming terminal a flashing up arrow indicates
correct connection. The bits in the range 129-160 are used for the NIO feature and show if the SINEC board
is present. In this case, the message “NIO board” will be shown at the end of the display line. Information as
to whether communication is active or not is not available. To move the cursor on the bits relating to inputs,
use the left, right arrow keys; to change module use the up and down arrow keys. Pressing the SELECT key
on a highlighted input, it is possible to obtain a help that describes the meaning of the bit.
Syntax: DIS
Output
AOUT DOUT GOUT System
Arm Close Fieldbus Input Output Program Rll Vars
The OUTPUT command displays a command menu for displaying the status of user-defined and system outputs.
It is possible to associate the command with a HELP string using the HELP10 and HELP102 programmes
contained on Floppy disk “2/2 Configuration Tools”; to activate HELP display, press the SEL key and move
the cursor to right and left along the values of the variables.
� AOUT displays the values of user-defined analogue outputs ($AOUT) as decimal values. Forced values
are displayed in red on the screen, while on the programming terminal they are displayed in reverse.
A string of numbers can be used to specify the indexes of individual outputs. The numbers are sepa-
rated by hyphens (-). A set of numbers is separated by two dots (..). If no parameter is used all analogue
outputs are displayed for base 0.
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Syntax: DOA
Example: DOA 17
DOA 17-18-25..27
� DOUT displays user-defined digital output values ($DOUT), where 1 = TRUE and 0 = FALSE. If one of
these values is forced, an “F” (forced to false) or “T” (forced to true) will be displayed instead of 0 or 1.
Typing an output number, a set of digital outputs is displayed.
Syntax: DOD
Example: DOD 17
� GOUT displays the user-defined groups of outputs ($GOUT) as decimal values. Forced values are dis-
played in red on the screen, while on the programming terminal they are displayed in reverse.
Syntax: DOG
� System displays system-defined digital outputs related to the boards present: SIM ($SDOUT), IOS and RIO.
Pressing the SELECT key it is possible to access the display window directly, obtaining a help associated to
each individual bit. Use the LH and RH arrow keys to move the cursor along the bits, use the UP and DOWN ar-
row keys to change module. Different notations are used for indicating if the RIO board, if present, is communi-
cating correctly with the PLC. On the screen display line the flashing message “COM:RUNNING” or
“COM:STOPPED” is shown, on the programming terminal a flashing up arrow indicates correct connection. The
bits in the range 129-160 are used for the NIO feature and show if the SINEC board is present. In this case, the
message “NIO board” will be shown at the end of the display line. Information as to whether communication is
active or not is not available. To move the cursor on the bits relating to outputs, use the left, right arrow keys; to
change module use the up and down arrow keys. Pressing the SELECT key on a highlighted output it is possible
to obtain a help that describes the meaning of the bit.
Syntax: DOS
Program
The PROGRAM command displays information about active PDL2 programmes.
It is possible to specify a particular programme name.It is also possible to add an asterisk to the name of the
program. If no parameter is used, information for all active programmes is displayed.
Options: /Full will also display the programmes with protected code not normally shown.
Syntax: DP
Rll
The RLL command displays information related to the PLC executing environment.
Syntax: DR
Vars
Bit Word
Arm Close Fieldbus Input Output Program Rll Vars
The VARS command contains a menu of commands for displaying the current values of shared memory ar-
rays used by PLC and PDL2 programmes to communicate with one another.
It is possible to associate the command with a HELP string using the HELP10 and HELP102 programmes
contained on Floppy disk “2/2 Configuration Tools”; to activate HELP display, press the SEL key and move
the cursor to right and left along the values of the variables.
� Bit displays $BIT, where 1 = TRUE and 0 = FALSE, according to 2 different displays:
- with single bits. It is necessary to separate the bits in the prompt that requests them with a dash ‘-’. For exam-
ple: “DISPLAY VAR BIT” “1-35-100" displays the value of $BIT[1], $BIT[35] and $BIT[100]. The maximum
number of $BITs that can be displayed at the same time is 4 (for the teach pendant) and 8 (for the PCINT).
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- with sets of bits. The $BIT interval required should be specified giving the first and last bits separated by
“..”. For example, “DISPLAY VAR BIT” “1..15" displays all the $BITs with an index between 1 and 15. A
maximum of 16 bits (on the teach pendant) and 32 bits (for the PCINT) can be displayed at the same time.
Syntax: DVB
� Word displays $WORD, in decimal format, hexadecimal or optionally in binary format.
A string of numbers can be used to specify the index of individual items of an array (1-512). The num-
bers are separated by hyphens (-). A set of numbers is separated by two dots (..).
Option: /Hex displays data in hexadecimal format
/Binary displays the data in binary format.
Syntax: DVW
EXECUTE COMMAND
Immediate execution of a PDL2 statement
Configure Display Execute Filer Memory Program Set Utility
The EXECUTE command executes a subset of PDL2 programme instructions from the command level. This
is sometimes referred to as immediate mode execution, as it mustbe used for the execution of short instruc-
tions with immediate effect (for example setting a predefined variable to a certain value).
An instruction is required as parameter. If the instruction involves references to variables, it is necessary to
specify the programme name as second parameter of the EXECUTE command. The option for the EXE-
CUTE command is available in the second parameter.
Options: /Context causes association of all references to predefined variables with the
programme
specified. If this option is not used, default values will be used for the predefined
variables and assignments to them will be ineffectual. An error occurs if this option is
used and the programme is not currently active.
Syntax: E instruction
Example: E ‘WRITE($ERROR,NL)’ ‘pippo’ — output = 0
E/C ‘WRITE($ERROR, NL)’ ‘pippo’ — output = pippo’s $ERROR
The following instructions cannot be used with the EXECUTE command:
� WAIT
� CONDITION
� ENABLE CONDITION
� DISABLE CONDITION
� PURGE CONDITION
Programme variables cannot be created with immediate mode execution.
The control must not be in FATAL status for this command to be valid and system, memory and programme
protection must be disabled. Pressing ^C deactivates execution.
The following conditions concern instructions that cause motion:
� the key status selector on the control panel must be in the programming position
� the Auto/Manual selector of the programming terminal must be set to Manual
� all motion is at a limited safety speed
� the enable button must be pressed and held during motion
� START must be pressed and held to maintain motion
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� pressing HOLD suspends motion (which can be restarted with START followed by RUN).
FILER COMMAND
Copy Delete Edit Print Rename Translate Utility View
Configure Display Execute Filer Memory Program Set Utility
The FILER command displays a menu of file management commands.
Most of the FILER commands require file names for parameters. A file name consists of the device, name
and extension.
dv:file_name.ext
A device name can consist of one to four characters followed by a colon (:). Some commands work only with
particular devices. Refer to each command for details.
FILER commands do not support subdirectories.
A file name can consist of one to eight characters, including letters, digits and the underscore (_).
A file extension begins with a period (.) and can consist of three characters, including letters, digits, and the
underscore (_). Some commands work only with a particular extension. Refer to each command for details.
Only the following FILER commands can be executed when memory or system protection is on:
UTILITY BACKUP
PRINT
VIEW
Copy
The COPY command creates duplicate copies of files. The original files are not affected.
At the FROM prompt specify the source file; at TO specify the destination file. Use of the asterisk is allowed
for file names and extensions.
It is advisable to use the FILER UTILITY BACKUP and FILER UTILITY RESTORE commands (instead of
FILER COPY) when copying all the files of the default backup device (for example FD:) to the default device
(ram disk) and vice versa.
Both system and memory protection must be off for this command to be active.
Options: /Confirm prompts for confirmation before each file is copied.
/Overwrite overwrites existing files without prompting for confirmation.
Syntax: FC source_file dest_file
Delete
The DELETE command removes files from the device.
A file specification is requested. The asterisk can be used for file names and extensions. If no device is spec-
ified the default device is used.
The DELETE command will prompt for confirmation before each file is deleted. Both system and memory
protection must be off for this command to be active.
Options: /Noconfirm eliminates the confirmation prompt.
Syntax: FD file_name
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Edit
The EDIT command invokes the file editor. The file editor can be used to create or modify ASCII files on the
RAM DISK.
A file name parameter is needed. The asterisk cannot be used. Only the RD (RAM DISK) can be used. If a
file extension is not included, the .PDL extension is used.
This command cannot be used if the editor, the MEMORY DEBUG and PROGRAM EDIT functions or the EZ
environment are active. Also, the controller cannot be in a FATAL status and system, memory and
programme protection must be off.
Syntax: FE file_name
Print
The PRINT command sends files from a storage device to a display device or printer.
A file specification parameter is required. The asterisk can be used for the file name and extension. If a de-
vice is not specified the default device is used.
PDL2 programme (.COD or .BKC) and variable (.VAR or .BKV) files are converted into ASCII format before
printing. All other files are assumed to be in ASCII format.
The destination device can be the programming terminal display or the PC screen, a file, communication port
or a user-defined window. If no destination device is specified, the device from which the command was is-
sued is used. Printers must be properly connected to one of the communication ports using the UTILITY
COMMUNICN MOUNT command issued beforehand.
In the case of a Filer Print command specifying a .VAR file and a destination file .LSV a back-up file is cre-
ated with .BKL for that .LSV file. If no destination device is specified, the .VAR file is printed on the screen.
If a .COD file contains checksum errors or other damaged data and it is not possible to recover a backup
copy of the file, use the FILER PRINT command to convert the programme into an ASCII file and send it to
the RAM DISK. The ASCII file can then be edited to correct the corrupted instructions and identifiers, which
will be identified by three question marks (“???”). Then use the FILER TRANSLATE command to convert the
file back into a .COD file.
Options: /Full prints a variable file without truncating the names of variables, programmes, rou-
tines
and data classes.
/List generates a listing file (.LIS) from a .COD or .BKC file.
Listing files contain the programme name and the line number at the side of each
PDL2
instruction.
/Overwrite overwrites existing files in the Ram Disk without prompting for confirmation.
/Nopage
/Range allows printing of the lines of the file included between the serial line and the
end
line specified as additional parameters.
Syntax: FP file_name
FP/L file_name
FP/N file_name
FP/R file_name start_line end_line
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Rename
The RENAME command changes the file name and/or extension of an existing file.
The original (source) and a new (destination) file specification are required as parameters. It is possible to
use the asterisk for extensions. If no device is specified for the original file, the default device is used. Differ-
ent devices cannot be specified for the source and destination files.
If the new file exists already, before the original file is renamed a prompt for confirmation will be displayed.
Renaming a programme file (.COD or .BKC) will not be allowed if the new name is already referenced inside
the file. This type of error is only detected when the programme is loaded.
Both system and memory protection must be off for use of this command.
Options: /Confirm prompts for confirmation before each file is renamed.
/Overwrite overwrites existing files without prompting for confirmation.
Syntax: FR source_file dest_file
Translate
The TRANSLATE command converts a source code file (.PDL) into a runnable code file (.COD).
The source code file name is required. It is possible to use the asterisk. The only device that can be specified
is RD:. If no file extension is specified, the extension will be .PDL.
If the .COD file already exists, the extension is changed to .BKCbefore creating the new .COD file.
If warnings or errors are detected during translation, they are displayed in the scroll window and logged in a
file called TRANS.ERR.
Both system and memory protection must be off for use of this command.
Options: /Back converts a .COD file into a .PDL file. It is the same as the Filer Print command of
a
.COD to a .PDL file.
/Confirm prompts for confirmation before converting each file.
/List produces a listing (.LIS) file and can only be used in conjunction with the /BACK option.
/Variables converts a .LSV ASCII file of variables into a .VAR file. It is used with
the
/BACK option to convert a .VAR file of variables into the corresponding .LSV file in
ASCII format.
Syntax: FT file_name
Utility
Attribute Backup Compress FD_format Install Restore Search
Copy Delete Edit Print Rename Translate Utility View
The UTILITY command displays a menu of file management utility commands.
� Attribute modifies file attributes. Access is restricted by password.
Hidden Readonly System
Attribute Backup Compress FD_format Install Restore Search
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� Hidden sets the “hidden” attribute for a file. When this attribute is set, the file cannot be accessed by
any command except LOAD. Access is restricted by password. This file is not displayed in the Ram
Disk.
Options: /Reset clears the hidden attribute.
Syntax: FUAH file_name
FUAH/R file_name
� Readonly sets the “readonly” attribute for a file. When this attribute is set, the file cannot be modified or
deleted and access is restricted by password.
Options: /Reset clears the readonly attribute.
Syntax: FUAR file_name
FUAR/R file_name
� System sets the system attribute for a file. When this attribute is set, the file cannot be deleted. Access
is restricted by password.
Options: /Reset clears the system attribute.
Syntax: FUAS file_name
FUAS/R file_name
� Backup copies files from the default device to the default backup device. Both default devices are ele-
ments in the predefined variable $DFT_DV and can be set using PDL2 assignment instructions. Where
necessary, the Kermit protocol is installed automatically.
If no file is specified, all the files are copied.
Syntax: FUB
� Compress recovers files from a compressed archive file and allows them to be viewed.
Extract View
Attribute Backup Compress FD_format Install Restore Search
� Extract extracts files from a compressed archive file. Both system and memory protection must be off to
use this command. The files extracted from the archive will have the same attributes as the source file
used to create the archive file.
Syntax: FUCE archive_name file_name
� View lists the files that are compressed in an archive. Both system and memory protection must be off
to use this command.
Syntax: FUCV archive_name file_name
� FD_format is used to format a diskette in the floppy disk drive. Both system and memory protection
must be off to use this command.
High Low
Attribute Backup Compress FD_format Install Restore Search
� High causes a high density format of the disk (1440 Kbytes).
Syntax: FUFH
� Low causes a low density format of the disk (720 Kbytes).
Syntax: FUFL
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� Install makes it possible to install a certain application programme performing all the operations re-
quired automatically: identification of the backup device from which to copy the files, installation of the
Kermit protocol (if necessary), copy of the installation file of the application programme on the RAM disk
and its activation.
As parameter, it requests the name of the application programme installation file (for example
EZ_INST.COD for the EZ application) which can also be selected pressing the HELP key in response to
the prompt asking for the name of the installation file.
Syntax: FUI installation_file
If you want to install the applications through the Ethernet network, first configure the vari-
ables, which have the prefix $NET_ and hold the HOST references storing the files of the
required application.For further details about the configuration of the Ethernet network,
please refer to the “Manual for communications through field bus and Ethernet network”.
� Restore makes it possible to copy files from the default backup device to the default device. Both de-
vices form part of the predefined variable $DFT_DV and can be set using PDL2 assignment instruction.
Where necessary, the Kermit protocol is installed automatically.In order to copy all the files (this copying
operation is carried out even if no file is specified as a parameter), the file C3G.SYS present on the
backup device is copied and given the new name C3G.OLD.
Option: /Configure loads the old configuration file C3G.OLD and saves it as C3G.SYS. It is wise
to follow this command with Restart Cold to make the data file operational.
Syntax: FUR
� Search allows the user to find a string in a file on the RAM DISK.
A file specification and a string must be given. The file specification can contain the asterisk.
Syntax: FUS file_name search_string
View
The VIEW command displays the directory of a secondary storage device. The directory is a list of the files
stored on the device. For each file, the name, extension, byte size and creation date are given. If this file has
the Readonly or the System attribute, such condition is pointed out by the letter ‘r’ or ‘s’ respectively.This in-
formation is not given in case the command is sent from SYS.CALL.From the program PDL2 , use the
pre-set routine FL_STATE in order to know the attributes of a file. The number of unused bytes for the de-
vice is also displayed.
A file specification parameter can be used to specify a particular file or group of files. The asterisk is allowed
for the file name and extension. If no parameter is specified, all files are listed.
Options: /Nopage
Syntax: FV
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MEMORY COMMAND
Debug Erase Load Rll Save Teach View
Configure Display Execute Filer Memory Program Set Utility
The MEMORY command displays a menu of commands to manage programmes and variables in the main
memory (RAM).
Only the MEMORY VIEW command is available when memory or system protection is on.
Debug
The DEBUG command invokes the editor in a display and debug mode only. If the programme was loaded
with the /FULL option it is also possible to check the text. Programmes loaded with the /PERMANENT op-
tion, which is available only from SYS_CALL, cannot be used in MEMORY DEBUG. This function allows the
programmer to:
� change the current instruction
� modify position variables
� view programme execution
� view interaction between programmes
� modify the parameters that control execution, such as type of interrupt step, insertion of points
� change a programme if loaded with the /FULL option.
A programme name parameter is required which must already be loaded in the memory.
To use this command the controller must not be in a FATAL status and the system, memory and programme
protection must be off. The DEBUG command cannot be used when the FILER EDIT, PROGRAM EDIT or
MEMORY TEACH commands are active or while the EZ environment is active.
Syntax: MD programme_name
Erase
All Program Variable
Debug Erase Load Rll Save Teach View
The ERASE command displays a menu of commands to erase data and programmes from the memory. The
asterisk can be used with these commands for programme and variable names. All the programmes prompt
for confirmation before erasing.
� All erases both code and variables for the specified programme. To use this command, system, memory
and programme protection must be off.
Options: /Noconfirm eliminates the confirmation prompt.
Syntax: MEA programme_name
� Program erases the programme code for the specified programme. To use this command, system,
memory and programme protection must be off. Also, if the PROGRAMTurn_Set operation.....................................................................................................................................2-17
Deactivating the C3G Plus..........................................................................................................................2-17
Robot system integration............................................................................................................................2-17
Functional check of the installed robot system...........................................................................................2-18
CHAPTER 3 - OPERATOR INTERFACE
Control panel and serial and parallel interfaces..........................................................................................3-1
Programming and emergency terminal (C3G-PTU4) .................................................................................3-3
C3G-PTU4 display......................................................................................................................................3-9
Provision for activating the emergency terminal .........................................................................................3-11
Emergency terminal active keys.................................................................................................................3-11
Emergency control C3G-EMC2 ..................................................................................................................3-12
Connector for enabling device additional button ........................................................................................3-14
C3G Plus interface on personal computer ..................................................................................................3-15
Connection cable for COMP: - PC connectors ......................................................................................3-15
Cable for connecting serial port connectors COM0: and COM1: ..........................................................3-15
Parallel port PAR: connection cable ......................................................................................................3-15
SUMMARY C3G Plus
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PCINT programme ................................................................................................................................3-15
C3G Plus video on PC...........................................................................................................................3-18
System commands .....................................................................................................................................3-21
Stand-By function .......................................................................................................................................3-68
Brake Release Device (C3G-BRD).............................................................................................................3-69
CHAPTER 4 - INTEGRATION GUIDE
Safety signals to remote .............................................................................................................................4-1
System inputs/outputs ................................................................................................................................4-4
Input signals from external logic (machine line) ....................................................................................4-6
Output signals towards external logic (machine line) ............................................................................4-7
24 Vcc power supplies...........................................................................................................................4-8
Procedures for command activation with the controlloer in automatic remote status............................4-8
Examples of use of system signals dedicated to transfer interface............................................................4-11
Parallel inputs/outputs ................................................................................................................................4-14
Serial inputs/outputs ...................................................................................................................................4-33
Programmes contained in floppy disk “1/2 C3G CONFIGURATION TOOL” ..............................................4-33
CHAPTER 5 - MAIN OPERATIONS FOR SYSTEM USE
System operating modes............................................................................................................................5-1
System statuses .........................................................................................................................................5-1
System status in multimachine - multiarm configuration.............................................................................5-4
Robot movement in programming status....................................................................................................5-5
File management between PC and cell controller ......................................................................................5-10
Use of the Floppy Disk ...............................................................................................................................5-11
Examples of the use of digital I/O’s and analogue outputs.........................................................................5-12
Calibration ..................................................................................................................................................5-13
Kinematic compensation algorithm.............................................................................................................5-19
CHAPTER 6 - EMERGENCY PROCEDURES
Cutting off alarms using the EXCL key on PTU4........................................................................................6-1
Use of the PTU4 as emergency terminal....................................................................................................6-1
Use of the BRAKE RELEASE DEVICE ......................................................................................................6-3
C3G Plus SUMMARY
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CHAPTER 7 - MAINTENANCE
General rules for maintenance ...................................................................................................................7-i
Preventive maintenance .............................................................................................................................7-1
Extraordinary maintenance.........................................................................................................................7-3
Main C3G Plus versions SDLP - SDMP - SDHP connections...............................................................7-5
Main C3G Plus versions DDMP - DDHP connections ...........................................................................7-14
Diagnostics ............................................................................................................................................7-25
Problems during normal operation ........................................................................................................7-38
Fuses and protections ...........................................................................................................................7-39
Circuit diagrams.....................................................................................................................................7-41
Control Unit............................................................................................................................................7-43
C3G-DBU3 module................................................................................................................................7-49
C3G-BKM module .................................................................................................................................7-50VIEW command is active, MEP
cannot be used.
Options: /Noconfirm eliminates the confirmation prompt.
Syntax: MEP programme_name
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� Variable erases one or more variables belonging to the specified programme, which are not linked to a
loaded programme. The variable name is required as parameter. To use this command, memory, sys-
tem and programme protection must be off.
Options: /Noconfirm eliminates the confirmation prompt.
Syntax: MEV programme_name variable_name
Load
The LOAD command is used to load stored programme and data files into memory for execution.
The name of the programme to be loaded is specified as a parameter. The asterisk may be used for the
programme name. The programme is loaded from the default device.
Programmes are loaded first, followed by their data files. If a data file does not exist for a programme, the
variables are created in memory during loading.
It is not possible to load a programme while it is in the ready, paused or running status or if system or mem-
ory protection is on.
If the programme will not load because the .COD file has been corrupted, either recover a backup copy or
use the FILER PRINT command to output the programme to an ASCII file. Once the ASCII file has been ob-
tained, it must be edited to repair all corrupted statements and identifiers which are identified by three ques-
tion marks (“???”). Once the necessary corrections have been made, use the FILER TRANSLATE command
to re-convert into a .COD file.
To be able to use this command the controller must not be in a FATAL status and both system and memory
protection must be off.
Options: /As allows programmes to be loaded with a different data file, specified as a parameter.
The asterisk cannot be used with this option.
/Convert converts various kinds of mismatches between the data file and the programme.
/Depend automatically loads the code and variables of those programmes that are referred
to in the code of the programme specified as parameter to the MEMORY LOAD command.
/Full loads programmes with the associated comments, error notes and blank lines. A
programme that has been loaded with the /FULL option can be edited in the MEMORY
DEBUG environment and saved. Programmes with the EZ attribute in their header are
automatically loaded with the /FULL option.
/Nosavevars disables the saving of the variables (or VAR) when the MEMORY SAVE
function is run in this program. This option is available only if it’s used in conjunction with
the inside routine SYS_CALL.
/Variables loads only the data file.
/Permanent loads a programme’s code permanently into memory, preventing it from being
erased accidentally. The code uses less memory due to optimisation of the load process. To
retrieve the memory it is necessary to restart the controller. This option is only available when
used together with the built-in SYS_CALL routine.
Syntax: ML programme_name
ML/A programme_name data_file
ML/F programme_name
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Rll
Load Save
Debug Erase Load Rll Save Teach View
The RLL command displays a menu of commands to load and store a PLC programme code.
� Load loads the specified RLL programme from RAM disk to the PLC memory. The asterisk cannot be
used. A file extension cannot be specified (.RLL files are loaded). Programmes cannot be loaded while
memory or system protection is on or with the controller in a FATAL status.
Options: /PDL2source converts a PLC programme written in PDL2 into RLL format and then loads
it into the PLC. A file extension cannot be specified (a .COD extension is used automatically).
If a PDL2 programme will not load because the file has been corrupted, either recover a
backup copy or use the FILER PRINT command to convert the file into an ASCII file. For
further information about this procedure, refer to the section concerning the FILER PRINT
command.
Syntax: MRL programme_name
� Save saves the specified RLL programme from the PLC memory to a RAM disk file. The asterisk cannot
be used. The file created will have the same prog_name and a .RLL extension. Programmes cannot be
saved with memory or system protection on. Different versions of the same .RLL programme can be
saved using different prog_name specifications. The prog_name is not related to the name specified in
the PDL2 PROGRAM instruction of a PLC programme. Programmes cannot be saved with system or
memory protection on.
Syntax: MRS programme_name
Save
The SAVE command saves programme data or code from memory to a file on the default device.
The programme name is specified as parameter. A wildcard can be used for the programme name. The file
created will have the same name as the programme and a .VAR or .COD extension. If a data file by the
same name already exists, it will be renamed to have a .BKV or .BKC extension.
If the data were loaded with the /AS option, a message is displayed informing the operator and prompting for
confirmation to overwrite the existing data file.
In case data have been loaded with /Nosavevar, the variables of this program will not be saved
The programme data or code cannot be saved with memory or system protection on.
Options: /As allows programme data to be saved with a different file name, specified as a parameter.
The asterisk cannot be used with this option.
/Code saves the code of a programme loaded with the /FULL option if it has been modified
since it was loaded.
/Overwrite overwrites an already existing file without prompting for confirmation.
Syntax: MS programme_name
MS/A programme_name save_file
Teach
The TEACH command invokes the teach environment on the programming terminal. The teach environment
cannot be invoked on the PC screen and keyboard. The teach environment allows the operator to:
� assign the physical arm position to a position variable
� modify position variables
� create, delete and modify path data
A programme name must be specified to indicate for which programme the variables are to be taught. The
specified programme cannot be activated but it must be loaded in the memory.
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The TEACH command cannot be used at the same time as the PROGRAM EDIT (DATA mode) or MEMORY
DEBUG commands when memory, system or programme protection is on or if the controller is in FATAL sta-
tus.
Syntax: MT programme_name
View
Program Type Variable
Debug Erase Load Rll Save Teach View
The VIEW command displays a menu of commands to display the contents of the memory.
All MEMORY VIEW commands support the /NOPAGE option.
� Program displays information about loaded programmes and memory statistics, as follows:
- programme name
- programme attributes (H=hold, N=nohold, A=attach, D=detach)
- name of data file used in load (-= not loaded from a file)
- size of programme code (0 = not loaded)
- size of data (0 = not loaded)
- creation date and time of the .COD file and .VAR file that were initially loaded in the memory for this
programme. It is necessary to issue the /Full option to obtain this information.
� a symbol indicating if the loaded instructions or variables have been modified in memory but not saved
on the RAM disk. Issuing this command from the CRT/keyboard or from SYS_CALL, this symbol is dis-
played next to the code and variable sizes. If the command is issued from the programming terminal, the
/Full option must also be issued. The symbols used are the following:
“S” indicates that the program code or the variables have been saved
“*” indicates that the program code or variables have been modified but not saved
“-” indicates that the program code or variables have not been loaded in memory
“p” indicates that the program code has been loaded from SYS.CALL with the /Nosavevars option
If the programme name is not specified as parameter, information for all loaded programmes is dis-
played. The asterisk can be used.
Options: /Full displays informationon the programme.
/Nopage
/4
Syntax: MVP
� Type displays types of user-defined data, as follows:
- data type name
- byte size
- reference counter (number of programmes and variables referring to the data type)
- number of fields
- structure type (record or node)
- description of fields (name and data type information for each field)
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User-defined data types are global to the entire system. However, they only exist in memory as long as a
programme or programme variables referencing the type are loaded.
If a type name is not specified as a parameter, information for all loaded types is displayed. The asterisk can
be used.
Options: /Nopage
Syntax: MVT
� Variable displays information about loaded variables, as follows:
- variable name
- variable type
- reference counter (number of loaded programmes referencing the variable)
- status (private, exported, local to routine)
- value
If a programme or variable name is not specified as a parameter, information for all loaded variables is dis-
played. The asterisk can be used for the programme or variable name.
Options: /Nopage
/Full displays the names of the variables in full
Syntax: MVV
Variables of STRING or ARRAY data which were declared with an asterisk and have not been declared with
an actual size will be shown with a size of 0.
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PROGRAM COMMAND
Activate Deactiv Edit Go Rll State Test View
Configure Display Execute Filer Memory Program Set Utility
The PROGRAM command displays a menu of commands to develop and execute programmes.
Activate
The effect of the ACTIVATE command depends on the holdable/non-holdable programme attribute of the
programme specified as parameter:
� Activating a holdable programme places it in a ready state. The START button must be pressed to place
the programme in a running state.
� Activating a non-holdable programme places it in a running state directly.
If a holdable programme is already active on an arm and one of the programmes has the DETACH attribute
specified, a prompt is shown asking whether two or more programmes should stay active on the same arm. If
a holdable programme is still active and the DETACH attribute is not specified, a message is displayed say-
ing that the arm is already “DETACHed”.
The programme must be loaded into the memory before it can be activated. The asterisk cannot be used.
This command can be used with the memory protection on, but not when system or programme protection is
on. The controller must not be in a FATAL status.
The following options can be used to activate the programme with a different step mode than the default
mode. Refer to PROGRAM TEST STEP command for the meaning of each step.
Options: /Cycle
/Disable
/Fly
/Move
/Routine
/Statement
Syntax: PA programme_name
Deactiv
The DEACTIV command deactivates programmes that are in running, ready, paused or unpaused states.
Deactivated programmes remain loaded, but cannot be resumed. They can be reactivated using the PRO-
GRAM ACTIVATE command.
The programme to be deactivated is specified as a parameter. The asterisk can be used in the parameter to
deactivate more than one programme. This command can be used when memory protection is on, but not
when system or programme protection is on. The controller must not be in a FATAL status.
Options: /Confirm prompts for confirmation before deactivating a programme.
Syntax: PD programme_name
All active programmes can be deactivated using PD * or CTRL Y (^Y). CTRL Y can be issued from any ac-
tive menu level and it is only valid while in PROG mode and with no protection active.
Protected programmes cannot be deactivated using this command. To deactivate protected programmes, it
is necessary to use the PDL2 DEACTIVATE instruction or action.
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Edit
The EDIT command invokes the programme editor: this is an integrated programming environment which al-
lows the programmer to edit, teach points and verify PDL2 programmes.
(Refer to the C3G Programming Guide manual).
The programme editor works with PDL2 programme code files (.COD) stored on the RAM disk (RD:). A
programme name parameter is required and the asterisk cannot be used.
By default, the editor will be in DATA mode when it is invoked. Programmes can be edited in DATA mode
only when the PROGR/AUTO selector is set to PROGR and the specified programme is not being taught or
is not activated.
If the programme will not load because of a file data corruption error, recover a backup copy or use the
FILER PRINT command to convert the file into an ASCII file. For further information about this procedure, re-
fer to the FILER PRINT command.
The EDIT command cannot be used with memory, system or programme protection on or when the control-
ler is in FATAL status, nor when the FILER EDIT, MEMORY DEBUG or PROGRAM EDIT (DATA or CODE
mode) are active or when the EZ utility programme is enabled. Use of the PROGRAM EDIT command with
the MEMORY TEACH command active is possible in CODE mode but not DATA.
Options: /Code invokes CODE mode editing, allowing the programmer to modify the programme
instructions but not to teach or debug. The CODE mode must be used to modify the
statement section of a programme.
In the CODE mode any activated or loaded programme can be edited.
Syntax: PE programme_name
Go
The GO command loads and activates the specified programme. It is a combination of the MEMORY LOAD
and PROGRAM ACTIVATE commands.
If a holdable programme is already active on an arm and one of the programmes has the DETACH attribute
specified, a prompt is shown asking whether two or more programmes should stay active on the same arm. If
a holdable programme is still active and the DETACH attribute is not specified, a message is displayed say-
ing that the arm is already “ATTACHed”.
If the programme is already active a prompt will ask if deactivation is required.
If the programme is already loaded and the .COD file is newer than the loaded version, a warning message
will be displayed along with a question asking the operator if the newer version is to be loaded. If the answer
is no, the programme will not be loaded again before activation. The asterisk cannot be used. The command
cannot be used when memory, system or programme protection is on or if the controller is in FATAL status.
The first motion of a programme is executed at reduced speed if the programme was activated by the user or
by a holdable programme issuing the PROGRAM GO command. Also the motion executed after pressing
CTRL C (^C) or moving the cursor in MEMORY DEBUG will be executed at reduced speed. The reduced
speed for safety feature can be disabled by setting flags in the $PROG_CNFG predefined variable. To de-
termine if a motion is running at reduced speed use the $SAFE_ENBL predefined variable.
If the programme will not load because of a file data corruption error, recover a backup copy or use the
FILER PRINT command to convert the file into an ASCII file. For further information about this procedure, re-
fer to the FILER PRINT command.
The following options, with the exception of Update, can be used to activate the programme with a different step
mode than the default mode. Refer to the PROGRAM TEST STEP command.
The UPDATE option disables the question to the user, if the programme to be activated is already loaded
and/or active in the memory. The programme will be deactivated automatically and the newer version will be
loaded in the memory and activated.
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Options: /Cycle
/Disable
/Fly
/Move
/Routine
/Statement
/Update: replaces or activates a programme in memory
Syntax: PG programme_name
Rll
Activate Clear_plc Deactiv Go Restart Sing_scan View
Activate Deactive Edit Go Rll State TestView
The RLL command displays a menu of commands to handle PLC programme execution.
� Activate executes the PLC programme loaded in the PLC memory. This command cannot be used
when the controller is in a FATAL status or when system, memory or programme protection is on.
Syntax: PRA
� Clear_plc performs the following operations:
- sets the scan time variable
- clears the PLC programme from memory
- clears the $WORD variable contents
- clears the contents of $DIN, $DOUT and $BIT variables (including the forced elements)
Before clearing confirmation is required. This programme cannot be used when system, memory or
programme protection is active, when a PLC programme is running or when the controller is in the FA-
TAL status.
Syntax: PRC
� Deactiv stops execution of the PLC programme. The programme remains loaded in the PLC memory. A
prompt for confirmation is displayed before the programme is deactivated. This command can be used
when system, memory or programme protection is active or when the controller is in the FATAL status.
Syntax: PRD
� Go loads the specified PLC programme into the PLC memory and starts execution. It is a combination of
the MEMORY RLL LOAD and PROGRAM RLL ACTIVATE commands. This command cannot be used
when system, memory or programme protection is active or when the controller is in the FATAL status.
Options: /PDL2source converts a PLC programme written in PDL2 (prog_name.cod) into RLL format
and then loads it into the PLC memory.
If the PDL2 programme will not load because of a file data corruption error, recover a
backup
copy or use the FILER PRINT command to convert it into an ASCII file. For further informa-
tion
about this procedure, refer to the FILER PRINT command.
Syntax: PRG programme_name
� Restart causes a cold restart of the PLC. All the $DIN, $DOUT, $AIN, $AOUT, $GIN, $GOUT and $BIT
variables are cleared including retentive entries. The variables that are currently forced are not cleared.
In addition, the scan time variable is set. RESTART cannot be used when system, memory or
programme protection is active or when the controller is in the FATAL status. Before restarting, confir-
mation is required.
Syntax: PRR
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� Sing_scan executes the PLC programme loaded in the PLC memory for a single scan. For all timing
events, the single scan simulates a 50 msec interval and executes all the ladder rungs as if the above
time has elapsed.
The PLC programme must be deactivated before using this command. This command is mainly used for
debugging PLC programmes and cannot be used with memory, system or programme protection on or
when the controller is in FATAL status.
Syntax: PRS
� View displays information concerning the PLC programme currently loaded including the following val-
ues:
- programme name
- programme status
- estimated scan time (time estimated to scan RLL logic)
- previous scan time (time it took for the previous logic scan)
- cycle scan time (time between cycles of the programme loop).
This command can be used regardless of the type of protection level.
Syntax: PRV
State
Bypass Pause Unpause
Activate Deactiv Edit Go Rll State Test View
The STATE command displays a menu of commands to change the state of an active programme.
� Bypass allows the programmer to bypass the current statement when debugging the programme. This
command is helpful when the programme is suspended, for example waiting for a determinate condition
to occur. BYPASS cannot be used when memory, system or programme protection is on or when the
controller is in the FATAL status.
Syntax: PSB
� Pause sets the specified programme from a running to a paused state. Both holdable and non-holdable
programmes are placed in a paused state.
The asterisk can be used in the programme name. This command cannot be used when memory, sys-
tem or programme protection is on or when the controller is in the FATAL status.
Options: /Confirm prompts for confirmation before pausing programmes.
Syntax: PSP programme_name
� Unpause resumes the specified paused programme. Holdable programmes are set in a ready state and
START must be pressed to resume execution. Non-holdable programmes are placed in a running state.
The asterisk can be used in the programme name. This command cannot be used when memory, sys-
tem or programme protection is on or when the controller is in the FATAL status.
Syntax: PSU programme_name
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Test
Break Profile Step
Activate Deactiv Edit Go Rll State Test View
The TEST command displays a menu of commands to test any loaded PDL2 programme from outside the
programme editor. This is particularly effective for testing multiple programmes. The TEST command cannot
be used when memory, system or programme protection is on or when the controller is in the FATAL status.
� Break displays a menu of commands to set up and use break points in a programme.
Insert Purge View
Break Profile Step
A break point is a point in the programme at which programme execution will break, placing the system
in the ready state. To resume the programme, press the RUN key. Holdable programmes also require a
START.
BREAK commands can be used for any programme loaded, including the currently activated ones. The
system automatically numbers break points.
The Insert command inserts a break point. Inserted break points take effect immediately.
A programme name and a line number parameter are required; the line number must correspond to an
executable code. The break occurs at the specified line number before the statement is executed. If a
line number is not specified an error message is displayed.
Options: /Label allows a label to be specified instead of a line number.
/Routine allows a routine name to be specified instead of a line number.
It is also necessary to use both /LABEL and /ROUTINE options to specify a label inside a
routine.
Syntax: PTBI programme_name
PTBI/L programme_name
PTBI/R programme_name
PTBI/LR programme_name
PTBI/RL programme_name
� Purge removes break points from a programme. A break point number can be specified or an asterisk
can be used to purge all break points.
Syntax: PTBP
� View displays a list of break points. A programme name can be specified also using the asterisk. If not,
all the break points referring to all programmes are shown.
Options: /Nopage
Syntax: /PTBV
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� Profile displays a menu of commands to monitor performance in terms of CPU time of active
programmes. This information is useful when debugging programmes that execute simultaneously.
Disable Enable Reset View
Break Profile Step
� Disable disables the performance calculation. A warning is given if PROFILE is already disabled.
Syntax: PTPD
� Enable enables the performance calculation. CPU time calculation begins when PROFILE is enabled. A
warning is given if PROFILE is already enabled.
Syntax: PTPE
� Reset clears the information concerning performance calculation. A warning is given if PROFILE has al-
ready been reset.
Syntax: PTPR
� View displays the following information concerning performance:
- PROFILE starting time
- PROFILE duration (time elapsed since being enabled)
- PROFILE state (enabled or disabled)
- the following information for each active programme:
� programme name
� CPU time used
� percentage of CPU time used.
If an EXECUTE command has been issued while PROFILE is enabled, performance calculations related
to its execution are also displayed.
The performance calculations listed next to the programme named “Free” represent the CPU time not
used by the programmes or by the EXECUTE function.
Options: /4
Syntax: PTPV
� Step allows the programmer to define the type of step for a certainprogramme. A step defines how
many statements can be executed at a time. Upon completion of each step, the programme is placed in
a ready status. START is required to resume execution for holdable programmes or RUN for
non-holdable programmes.
Steps refer to individual programmes. The programmer associates a particular step with a particu-
lar programme. An asterisk can be used with the programme name parameter. The specified
programme must be loaded.
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When the step of a programme being executed is changed, the new step takes effect after execution of
the current statement.
Cycle Disable Fly Move Routine Statement View
Break Profile Step
� Cycle defines the step as a single cycle within the programme. The CYCLE or BEGIN CYCLE state-
ment must be present in the programme.
Syntax: PTSC
� Disable ends programme step execution. A programme can be specified also using asterisks.
Syntax: PTSD
� Fly defines the step as a single movement: it is similar to the /MOVE option, but execution does not stop
after the MOVEFLY instruction. It is not allowed on non-holdable programmes.
Syntax: PTSF
� Move defines the step as a single movement. It is not allowed on non-holdable programmes.
Syntax: PTSM
� Routine defines the step as one statement at a time, except that routines are executed as a single
statement.
Syntax: PTSR
� Statement defines the step as a single statement.
Syntax: PTSS
� View displays the step associated with a programme. The asterisk may be used to specify the
programme name. If not, all the steps related to all programmes will be displayed.
Syntax: PTSV
View
The VIEW command displays information related to the activated programmes together with the following
values:
� programme name;
� programme attributes;
� arm number;
� priority;
� primary state (running, held, suspended);
� current line number being executed and programme to which that line belongs;
� error number;
� CPU time;
� number of cycles.
An asterisk can be used for the programme name. This command can be used regardless of the level of pro-
tection but it cannot be used when the controller is in FATAL status or when the MEMORY ERASE PRO-
GRAM command is active.
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Options: /Chain displays the chain of calls to routines
- routine name
- programme to which the routine belongs
- line number
- frame type reference (main programme, break routine,
private, exported)
- state
/Full displays further information including:
- programme attributes
- arm number
- priority
- stack size
- stack currently used
- maximum percentage of stack used by the programme till now
- current programme state (running, held, suspended)
- reason for suspension
- current line number being executed and the programme to which it belongs
- activation time
- break points set
- step mode
- number of condition handlers defined and the list of them (those enabled, locally
or globally, are marked with an asterisk)
- number of errors on which ERR_TRAP_ON has been applied
- list of predefined variables linked with the programme stack
- call chain
- date of activation
- CPU time
/Nopage
/4
Syntax: PV programme_name
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SET COMMAND
Arm Cntrler Input Output Total_unf Update_io View_io
Configure Display Execute Filer Memory Program Set Utility
The SET command displays a menu of commands to change system characteristics. All SET commands
are allowed when memory protection is on, but only VIEW can be used also with system protection on.
Arm
Disable Enable Gen_ovr Nostroke Simulate Tp_main Unsimul
Arm Cntrler Input Output Total_unf Update_io View_io
The ARM command displays a menu of commands to set a particular state for an arm.
� Disable disables the DRIVE ON function of an arm. This command can only be issued when the system
is in the PROG or ALARM states, the drive power is off and memory protection is off. This command
also disables errors generated when the resolver cables are not connected to the robot.
The arm remains disabled until a SetArmEnable command is issued on that arm, regardless of any re-
starts that may be performed. In addition, both DRIVE and RPT module failure indications are disabled.
The SetArmDisable command is generally used when repairs are necessary on a certain arm. Once the
necessary repairs have been carried out, the system may still report errors due to the presence of some
latched hardware.
A cold restart should be performed to remove these errors.
For systems with multiple arms, an arm number parameter is required. An asterisk may be used to indi-
cate all arms.
Syntax: SAD
� Enable enables the DRIVE ON function of an arm. This command can only be issued when the system
is in the PROGRAMMING state, the drive power is off and memory protection is off.
For systems with multiple arms, an arm number parameter is required. An asterisk may be used to indi-
cate all arms.
Sintassi: SAE
� Gen_ovr sets $GEN_OVR to the value specified as a parameter. This command can be used while sys-
tem or programme protection is on, but cannot be used when memory protection is on. If the PTU4 is
housed in the support on the cabinet, this command can be used to increase or decrease the value of
$GEN_OVR. On the contrary, if PTU4 is not in the cabinet, the only decrement of the value is allowed
when the command is sent from PCINT or from SYS_CALL.
Option: /Increment sets the default increment/decrement unit used to update the current value of
$GEN_OVR when the %+ and %- keys of the programming terminal are used to
change
the value. The normal default is 5.
Syntax: SAG
SAG/I
� Nostroke allows the stroke ends for a specified arm to be disabled temporarily. The system must be in
the PROGRAMMING state. The stroke ends are automatically restored when the system enters an
AUTO or HOLD state, when drives are turned off, or when changing the PTU4 arm. To use this com-
mand the controller must not be in a FATAL state, but must be in the automatic mode. In addition, the
controller must not be in an ALARM state and system, memory and programme protection must be off.
While the stroke ends are disabled, only jog motion is allowed.
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For systems with multiple arms, an arm number parameter is required. An asterisk can be used to indi-
cate all arms.
Syntax: SAN
� Simulate allows programmes to be run simulating the movements without actually moving the arm. All
motion calculations are still performed. This command can only be issued with DRIVES OFF. However,
also with the arm simulating, it is possible to switch the status selector to programming and power
the drives to jog the robot. This command requires an arm parameter and can be used for:
- testing programmes without moving the arm;
- determining approximate cycle times;
- debugging programme logic.
Syntax: SAS
� Tp_main sets the default arm (normally set to 1) for movement from the programming terminal. An arm
parameter is required. To use this command, system and memory protection must be off and the drives
must be off.This command is not enabled if the command is sent from PCINT or from SYS_CALL and
the PTU4 is not present in the cabinet.Moreover, if EZ is active the command is disabled
Syntax: SAT arm_num
� Unsimul turns off arm simulation. All holdable programmes will be deactivated. This command requires
an arm parameter and must be issued with drives off.
Syntax: SAU
Cntrler
Key_lock Protect View Win_clear
Arm Cntrler Input Output Total_unf Update_io View_io
The CNTRLER command displays a menu of commands to set controller characteristics.
� Key_lock prevents unauthoriseduse of the keyboard or programming terminal. A password is required
for this command. The screen remains fixed asking for a password to unlock it and re-enable access to
the command menu.
Syntax: SCK password
� Protect displays a menu of commands to set the controller protection level. A password is required for
this command and it cannot be used if any of the following commands are already active: FILER EDIT,
MEMORY DEBUG or PROGRAM EDIT (DATA or CODE mode).
Clear Memory Program System
Key_lock Protect View Win_clear
� Clear removes the previous protection setting.
Syntax: SCPC
� Memory sets memory protection (commands affecting the memory cannot be issued).
Syntax: SCPM
� Program sets memory and programme protection (commands affecting execution memory and
programme activation and deactivation).
Syntax: SCPP
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� System sets system protection (commands affecting the system cannot be used).
Syntax: SCPS
� View displays the current default values for the following:
- default arm
- default communication port
- default system device
- current protection level
- current time and date
- default backup device
- default PDL2 device
- current $GEN_OVR increment
- startup file
Options: /4
Syntaxi: SCV
� Win_clear clears the information shown on a window.
Syntax: SCW
Input
Force Unforce View
Arm Cntrler Input Output Total_unf Update_io View_io
The INPUT command displays a menu of commands to control the user inputs. The subcommands can be
used while memory protection is on, but not when system or programme protection is on or when the control-
ler is in a FATAL state. This is true of all commands except VIEW which can be used in all system states.
Also, the SET INPUT and SET TOTAL_UNF commands must not be active to use this command. If the pro-
gramming terminal is connected, but not on the cabinet, the FORCE and UNFORCE commands are disabled
from the keyboard of the Screen-keyboard unit.
Each INPUT command displays a submenu to select the type of input as follows:
AIN DIN GIN
Force Unforce View
� Force simulates the inputs. The physical input is bypassed and the forced value is used. The operator
can choose from the submenu to force analogue (AIN), digital (DIN) or group (GIN) inputs. A particular
input can be specified by its index number. The asterisk cannot be used. A forced value can be speci-
fied. If no value is specified, the input is forced to its current physical state.
When digital inputs are forced, the forced value can be either C meaning its current physical state, T
meaning TRUE (ON) or F, meaning FALSE (OFF). These options are displayed after the prompt for the
forced value. Select the appropriate value and press the ENTER key.
A digital input that is part of a group of inputs must be forced as a group and not as a digital input. This
command is not allowed in case the command is sent from PCINT or from SYS_CALL and the PTU4
has not been placed in the cabinet.
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Syntax: SIFA — analogue
SIFD — digital
SIFG — group
� Unforce remaps a forced logical input back to its original physical configuration. The operator can
choose from the submenu to unforce analogue (AIN), digital (DIN) or group (GIN) inputs.
A particular input can be specified by its index number. The asterisk cannot be used.
Syntax: SIUA — analogue
SIUD — digital
SIUG — group
� View displays the forced inputs. The operator can choose from the submenu to display forced analogue
(AIN), digital (DIN) or group (GIN) inputs.
If a group of inputs is forced, all the corresponding digital inputs will be displayed as forced when using
the SIVD command.
Syntax: SIVA — analogue
SIVD — digital
SIVG — group
Output
Force Unforce View
Arm Cntrler Input Output Total_unf Update_io View_io
The OUTPUT command displays a menu of commands to control the user outputs. The subcommands can
be used while memory protection is on, but not when system or memory protection is on. This is true of all
commands except the VIEW command which can be used in all system states. Also, in order to use the
OUTPUT command, the controller must not be in a FATAL state and the commands SET OUTPUT and SET
TOTAL_UNF must not already be active. If the programming terminal is connected, but not on the cabinet,
the FORCE and UNFORCE commands are disabled from the keyboard of the Screen-keyboard unit.
Each OUTPUT command displays a submenu to select the type of output, as follows:
AOUT DOUT GOUT
Force Unforce View
� Force simulates outputs. The forced value is used by the programme and allocated to the physical out-
put. Any allocation to forced outputs will in no way affect the physical outputs or execution of the
programme. It is not possible to change the value of forced outputs until the forced state has been re-
moved by the UNFORCE command. The operator can choose from the submenu to force analogue
(AOUT), digital (DOUT) or group (GOUT) outputs.
A particular output can be specified by its index number. The asterisk cannot be used. If no value is
specified, the output is forced to its current physical state.
When digital outputs are forced, the forced value can be either C meaning its current physical state, T
meaning TRUE (ON) or F, meaning FALSE (OFF). These options are displayed after the prompt for the
forced value. Select the appropriate value and press the ENTER key.
A digital output that is part of a group must be forced as a group and not as a digital output.
Syntax: SOFA — analogue
SOFD — digital
SOFG — group
� Unforce removes the forced value from an output. The state of the physical output remains unchanged.
The operator can choose from the submenu to remap analogue (AOUT), digital (DOUT) or group
(GOUT) outputs.
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� A particular output can be specified by its index number. The asterisk cannot be used.
Syntax: SOUA —analogue
SOUD —digital
SOUG —group
� View displays the forced outputs. The operator can choose from the submenu to display analogue
(AOUT), digital (DOUT) or group (GOUT) outputs.
If a group of outputs is forced, all the corresponding digital outputs will be displayed as forced when us-
ing the SOVD command.
Syntax: SOVA —analogue
SOVD —digital
SOVG —group
Total_unf
The TOTAL_UNF command unforces all forced inputs and outputs. A confirmation prompt is displayed be-
fore the command is executed. This command can be used with memory protection on but not while system
of programme protection is on. The controller must not be in a FATAL state and the SET INPUT and SET
OUTPUT commands must not already be active.
Syntax: ST
Update_io
Disable Enable View
Arm Cntrler Input Output Total_unf Update_io View_io
The UPDATE_IO command controls the user I/O refresh feature.
� Disable separates the internal I/O image from the physical image. The input internal values and the out-
put physical values remain unchanged until an ENABLE command is issued. A confirmation is required.
To use this command, system and programme protection must be off, the controller must not be in a FA-
TAL state and the SET UPDATE_IO ENABLE command must not already be active.
Syntax: SUD
� Enable re-establishes the link between the internal I/O image and the physical image after a disable
command has been issued. A confirmation is required. To use this command, system and programme
protection must be off, the controller must not be in a FATAL state and the SET UPDATE_IO DISABLE
command must not already be active.
Syntax: SUE
� View displays the current state of I/O updating (enabled or disabled).
Syntax: SUV
View_io
The VIEW_IO command displays the current I/O configuration.
Options:/Nopage
Syntax: SV
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UTILITY COMMAND
Applicatn Communicn
Configure Display Execute Filer Memory Program Set Utility
The UTILITY command displays a menu of commands that handle special purpose features of the system.
Applicatn
The APPLICATN command allows the user to start an application programme. The application programme
must be running before this command is issued and must be programmed to handle a call for application aid.
This command activates the EZ application if this has been installed previously. To use this command, sys-
tem and memory protection must both be off.
Syntax: UA
Communicn
Dismount Mount Port_char Set_def View
Applicatn Communicn
The COMMUNICN command displays a menu of commands that handle data communication devices for the
controller. These devices include serial ports and network devices.
� Dismount disconnects the protocol currently activated on a communication device.
Syntax: UCD
� Mount displays a menu of communication protocols to be activated on a certain communication device.
If a device is not specified, the default one will be used.
Crt_emu Ddcmp Kermit Tisoft 3964 R
Dismount Mount Port_char Set_def View
� Crt_emu activates the video emulation protocol. Before entering this command, make sure that the
video emulation programme is running on the PC and that the serial line cable is connected to the speci-
fied port. Use the UTILITY COMMUNICN DISMOUNT command to exit the video emulation environ-
ment.
Syntax: UCMC
� Ddcmp activates the DDCMP protocol on a serial port. A port name is required as parameter. While
DDCMP is mounted on a port, that port must be referenced as DCMn: instead of COMn:. When DDCMP
is dismounted, the port is accessed using COMn:.
Options: /Maint activates the maintenance mode of the DDCMP protocol.
Syntax: UCMD
UCMD/M
� Kermit activates the Kermit protocol of a serial port. This protocol is mainly used for file transfers be-
tween the controller RAM disk and the serial port. It can handle packages up to a maximum of 2000
bytes in length.
Options: /Speed changes the default baud rate for the protocol. A speed parameter is required
to
specify the new baud rate.
Syntax: UCMK
UCMK/S speed
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� Tisoft installs the TISOFT protocol on a serial port. This protocol is mainly used to interface with the
TISOFT package for PLC that is running on a PC or to link with the TI VPU unit.
Syntax: UCMT
� 3964 R installs protocol 3964 R on the port specified as parameter.
Syntax: UCM3
Option: /APPL reserved for starting up the protocol for specific applications.
� Port_char is used to set the characteristics of a communication device. For example, on a serial port
the following characteristics can be set:
- Speed: 110, 300, 1200, 2400, 4800, 9600, 19200, 38400 baud
- Bit/character: 7, 8 bit
- Stop bit: 1, 1.5 or 2 bit
- Parity: none, odd, even
- Readahead buffer present
- Ahd Size: (readahead buffer size) 0 to 4096 with 128 steps (e.g. 0-128-256-...). Present only if buffer
is present.
- Protocol: none, XON/XOFF
- Character handling: none, ASCII, passall, ASCII + passall
This command displays a window listing the current characteristics. The left and right arrow keys can be
used to select the different characteristics. The ENTER key or the right and left arrow keys will move to
the next characteristic, while the up and down arrow keys can be used to select different values for the
characteristic selected. When the desired values for the characteristics are set, press the PREV/TOP
key.
To use this command, both system and memory protection must be off and the UTILITY COMMUNICN
PORT_CHAR command must not already be active.
Syntax: UCP
The CTRL C (^C) key aborts the UTILITY COMMUNICN PORT_CHAR command. If changes are made,
the user is asked whether the parameters are to be saved.
� Set_def allocates the port specified as parameter to the predefined variable $DFT_DV [5]. It will be used
as default communication port.
Memory and system protection must be off to be able to use this command.
Syntax: UCS
� View displays the characteristics of a communication device.
Options: /Nopage
/4
Syntax: UCV
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COMMAND SUMMARY LIST
Example for reading the list:
EXECUTE (/CONTEXT) E F3
VIEW SIV* F7,F2,F3,*
In the first example the command is EXECUTE and it has an option indicated by /CONTEXT. The sequence
of keys for issuing the command is E and the sequence of function keys to be used is F3.
The example referring to the VIEW command is actually a selection of a submenu of the SET INPUT com-
mand and it has no options. The sequence of keys for issuing the command is SIV and the sequence of
function keys is F7, F2 and F3. The asterisk (*) which follows the two sequences of keys means that the SET
INPUT VIEW command has a submenu, therefore it is not a final command request.
(Main commands)
Level 1 Level 2 Level 3 Level 4 Level 5
Character
keys
Function
keys
Configure
Arm
Calibrate (/Learn, /Nosave /User)
Reten_Mem
Load (/Loadfile, /Nofile)
Save (/Nofile)
C*
CA*
CAC
CAR*
CARL
CARS
F1*
F1,F1,*
F1,F1,F1
F1,F1,F2,*
F1,F1,F2,F1
F1,F1,F2,F2
Turn_set (/Current, /USer)
View_cal (/4)
CAT
CAV
F1,F1,F3
F1,F1,F4
Cntrler
Password
Restart
Bootmon
Cold
Reboot
Warm
CC*
CCP
CCR*
CCRB
CCRC
CCRR
CCRW
F1,F2,*
F1,F2,F1
F1,F2,F2,*
F1,F2,F2,F1
F1,F2,F2,F2
F1,F2,F2,F3
F1,F2,F2,F4
Startup
Time
View (/4)
CCS
CCT
CCV
F1,F2,F3
F1,F2,F4
F1,F2,F5
Io_conf
Load (/Arm, /Cntrler,
/Data_comm, /Io, /Servo)
Save
CI
CL
CS
F1,F3
F1,F4
F1,F5
Display
Arm
Currents
Data
Following
Joint
Position
Resolver (/Hex)
Status
Temp
D*
DA*
DAC
DAD
DAF
DAJ
DAP
DAR
DAS
DAT
F2,*
F2,F1,*
F2,F1,F1
F2,F1,F2
F2,F1,F3
F2,F1,F4
F2,F1,F5
F2,F1,F6
F2,F1,F7
F2,F1,F8
Close
Arm
Input
Output
Program
DC*
DCA
DCI
DCO
DCP
F2,F2,*
F2,F2,F1
F2,F2,F2
F2,F2,F3
F2,F2,F4
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Level 1 Level 2 Level 3 Level 4 Level 5
Character
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Function
keys
Rll
Select
Total
Vars
DCR
DCS
DCT
DCV
F2,F2,F5
F2,F2,F6
F2,F2,F7
F2,F2,F8
Fieldbus
Master
Slave
DF*
DFM
DFS
F2,F3,*
F2,F3,F1
F2,F3,F2
Input
AIN
DIN
GIN
System
DI*
DIA
DID
DIG
DIS
F2,F4,*
F2,F4,F1
F2,F4,F2
F2,F4,F3
F2,F4,F4
Output
AOUT
DOUT
GOUT
System
DO*
DOA
DOD
DOG
DOS
F2,F5,*
F2,F5,F1
F2,F5,F2
F2,F5,F3
F2,F5,F4
Program
Rll
Vars
Bit
Word (/Hex)
DP
DR
DV*
DVB
DVW
F2,F6
F2,F7
F2,F8,*
F2,F8,F1
F2,F8,F2
Execute (/Context) E F3
Filer
Copy (/Confirm,/Overwrite)
Delete (/Noconfirm)
Edit
Print (/Full, /List, /Overwrite, /Nopage, /Range)
Rename (/Confirm, /Overwrite)
Translate (/Back, /Confirm, /List, /Variables)
Utility
F*
FC
FD
FE
FP
FR
FT
FU*
F4,*
F4,F1
F4,F2
F4,F3
F4,F4
F4,F5
F4,F6
F4,F7,*
Attribute
Hidden (/Reset)
Readonly (/Reset)
System (/Reset)
FUA*
FUAH
FUAR
FUAS
F4,F7,F1,*
F4,F7,F1,F1
F4,F7,F1,F2
F4,F7,F1,F3
Backup
Compress
Extract
View
FUB
FUC*
FUCE
FUCV
F4,F7,F2
F4,F7,F3,*
F4,F7,F3,F1
F4,F7,F3,F2
FD_format
High
Low
FUF*
FUFH
FUFL
F4,F7,F4,*
F4,F7,F4,F1
F4,F7,F4,F2
Install
Restore (/Configure)
Search
FUI
FUR
FUS
F4,F7,F5
F4,F7,F6
F4,F7,F7
View (/Nopage) FV F4,F8
Memory
Debug
Erase
All (/Noconfirm)
Program (/Noconfirm)
Variable (/Noconfirm)
M*
MD
ME*
MEA
MEP
MEV
F5,*
F5,F1
F5,F2,*
F5,F2,F1
F5,F2,F2
F5,F2,F3
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(Main commands)
Level 1 Level 2 Level 3 Level 4 Level 5
Character
keys
Function
keys
Load (/As, /Convert, /Full, /Depend,Nosavevars,
/Permanent, /Variables)
Rll
Load (/PDL2source)
Save
ML
MR*
MRL
MRS
F5,F3
F5,F4,*
F5,F4,F1
F5,F4,F2
Save (/As, /Code, /Overwrite)
Teach
View
Program (/Nopage, /4)
Type (/Nopage)
Variable (/Nopage)
MS
MT
MV*
MVP
MVT
MVVF5,F5
F5,F6
F5,F7,*
F5,F7,F1
F5,F7,F2
F5,F7,F3
Program P* F6,*
Activate (/Cycle, /Disable, /Fly, /Move,
/Routine, /Statement)
Deactiv (/Confirm)
Edit (/Code)
Go (/Cycle, /Disable, /Fly,/Move, /Routine, /Statement, /Update)
Rll
Activate
Clear_plc
Deactiv
Go (/PDL2source)
Restart
Sing_scan
View
PA
PD
PE
PG
PR*
PRA
PRC
PRD
PRG
PRR
PRS
PRV
F6,F1
F6,F2
F6,F3
F6,F4
F6,F5,*
F6,F5,F1
F6,F5,F2
F6,F5,F3
F6,F5,F4
F6,F5,F5
F6,F5,F6
F6,F5,F7
State
Bypass
Pause (/Confirm)
Unpause
PS*
PSB
PSP
PSU
F6,F6,*
F6,F6,F1
F6,F6,F2
F6,F6,F3
Test
Break
Insert (/Label,, /Routine)
Purge
View (/Nopage)
PT*
PTB*
PTBI
PTBP
PTBV
F6,F7,*
F6,F7,F1,*
F6,F7,F1,F1
F6,F7,F1,F2
F6,F7,F1,F3
Profile
Disable
Enable
Reset
View (/4)
PTP*
PTPD
PTPE
PTPR
PTPV
F6,F7,F2,*
F6,F7,F2,F1
F6,F7,F2,F2
F6,F7,F2,F3
F6,F7,F2,F4
Step
Cycle
Disable
Fly
Move
Routine
Statement
View (/Nopage)
PTS*
PTSC
PTSD
PTSF
PTSM
PTSR
PTSS
PTSV
F6,F7,F3,*
F6,F7,F3,F1
F6,F7,F3,F2
F6,F7,F3,F3
F6,F7,F3,F4
F6,F7,F3,F5
F6,F7,F3,F6
F6,F7,F3,F7
View (/Chain, /Full,/Nopage, /4) PV F6,F8
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(Main commands)
Level 1 Level 2 Level 3 Level 4 Level 5
Character
keys
Function
keys
Set
Arm
Disable
Enable
Gen_Ovr
(/Increment)
Nostroke
Simulate
Tp_main
Unsimul
S*
SA*
SAD
SAE
SAG
SAN
SAS
SAT
SAU
F7,*
F7,F1,*
F7,F1,F1
F7,F1,F2
F7,F1,F3
F7,F1,F4
F7,F1,F5
F7,F1,F6
F7,F1,F7
Cntrler
Key_lock
Protect
Clear
Memory
Program
System
SC*
SCK
SCP*
SCPC
SCPM
SCPP
SCPS
F7,F2,*
F7,F2,F1
F7,F2,F2,*
F7,F2,F2,F1
F7,F2,F2,F2
F7,F2,F2,F3
F7,F2,F2,F4
View (/4)
Win_clear
SCV
SCW
F7,F2,F3
F7,F2,F4
Input
Force
AIN
DIN
GIN
SI*
SIF*
SIFA
SIFD
SIFG
F7,F3,*
F7,F3,F1,*
F7,F3,F1,F1
F7,F3,F1,F2
F7,F3,F1,F3
Unforce
AIN
DIN
GIN
SIU*
SIUA
SIUD
SIUG
F7,F3,F2,*
F7,F3,F2,F1
F7,F3,F2,F2
F7,F3,F2,F3
View
AIN
DIN
GIN
SIV*
SIVA
SIVD
SIVG
F7,F3,F3,*
F7,F3,F3,F1
F7,F3,F3,F2
F7,F3,F3,F3
Output
Force
AOUT
DOUT
GOUT
SO*
SOF*
SOFA
SOFD
SOFG
F7,F4,*
F7,F4,F1,*
F7,F4,F1,F1
F7,F4,F1,F2
F7,F4,F1,F3
Unforce
AOUT
DOUT
GOUT
SOU*
SOUA
SOUD
SOUG
F7,F4,F2,*
F7,F4,F2,F1
F7,F4,F2,F2
F7,F4,F2,F3
View
AOUT
DOUT
GOUT
SOV*
SOVA
SOVD
SOVG
F7,F4,F3,*
F7,F4,F3,F1
F7,F4,F3,F2
F7,F4,F3,F3
Total_unf
Update_io
Disable
Enable
View
ST
SU*
SUD
SUE
SUV
F7,F5
F7,F6,*
F7,F6,F1
F7,F6,F2
F7,F6,F3
View_io (/Nopage) SV F7,F7
C3G Plus OPERATOR INTERFACE
03/0499 3-61
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(Main commands)
Level 1 Level 2 Level 3 Level 4 Level 5
Character
keys
Function
keys
Utility
Applicatn
Communicn
Dismount
Mount
Crt_emu
Ddcmp
(/Maint)
Kermit
(/Speed)
Tisoft
U*
UA
UC*
UCD
UCM*
UCMC
UCMD
UCMK
UCMT
F8,*
F8,F1
F8,F2,*
F8,F2,F1
F8,F2,F2,*
F8,F2,F2,F1
F8,F2,F2,F2
F8,F2,F2,F3
F8,F2,F2,F4
UCP
UCS
UCV
F8,F2,F3
F8,F2,F4
F8,F2,F5
OPERATOR INTERFACE C3G Plus
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COMMAND ANALYTICAL INDEX
Commands
Character
keys
Function
keys
Activate PA F6,F1
Activate PRA F6,F5,F1
AIN DIA F2,F4,F1
AIN SIFA F7,F3,F1,F1
AIN SIUA F7,F3,F2,F1
AIN SIVA F7,F3,F3,F1
All MEA F5,F2,F1
AOUT DOA F2,F5,F1
AOUT SOFA F7,F4,F1,F1
AOUT SOUA F7,F4,F2,F1
AOUT SOVA F7,F4,F3,F1
Applicatn UA F8,F1
Arm CA* F1,F1,*
Arm DA* F2,F1,*
Arm DCA F2,F2,F1
Arm SA* F7,F1,*
Attribute FUA* F4,F7,F1,*
Backup FUB F4,F7,F2
Bit DVB F2,F8,F1
Bootmon CCRB F1,F2,F2,F1
Break PTB* F6,F7,F1,*
Bypass PSB F6,F6,F1
Calibrate CAC F1,F1,F1
Clear SCPC F7,F2,F2,F1
Clear_plc PRC F6,F5,F2
Close DC* F2,F2,*
Cntrler CC* F1,F2,*
Cntrler SC* F7,F2,*
Cold CCRC F1,F2,F2,F2
Communicn UC* F8,F2,*
Compress FUC* F4,F7,F3,*
Configure C* F1,*
Copy FC F4,F1
Crt_emu UCMC F8,F2,F2,F1
Currents DAC F2,F1,F1
Cycle PTSC F6,F7,F3,F1
Data DAD F2,F1,F2
Ddcmp UCMD F8,F2,F2,F2
C3G Plus OPERATOR INTERFACE
03/0499 3-63
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Commands
Character
keys
Function
keys
Deactiv PD F6,F2
Deactiv PRD F6,F5,F3
Debug MD F5,F1
Delete FD F4,F2
DIN DID F2,F4,F2
DIN SIFD F7,F3,F1,F2
DIN SIUD F7,F3,F2,F2
DIN SIVD F7,F3,F3,F2
Disable PTPD F6,F7,F2,F1
Disable PTSD F6,F7,F3,F2
Disable SAD F7,F1,F1
Disable SUD F7,F6,F1
Dismount UCD F8,F2,F1
Display D* F2,*
DOUT DOD F2,F5,F2
DOUT SOFD F7,F4,F1,F2
DOUT SOUD F7,F4,F2,F2
DOUT SOVD F7,F4,F3,F2
Edit FE F4,F3
Edit PE F6,F3
Enable PTPE F6,F7,F2,F2
Enable SAE F7,F1,F2
Enable SUE F7,F6,F2
Erase ME* F5,F2,*
Execute E F3
Extract FUCE F4,F7,F3,F1
FD_format FUF* F4,F7,F4,*
Fieldbus DF* F2,F3,*
Filer F* F4,*
Fly PTSF F6,F7,F3,F3
Following DAF F2,F1,F3
Force SIF* F7,F3,F1,*
Force SOF* F7,F4,F1,*
Gen_ovr SAG F7,F1,F3
GIN DIG F2,F4,F3
GIN SIFG F7,F3,F1,F3
GIN SIUG F7,F3,F2,F3
GIN SIVG F7,F3,F3,F3
Go PG F6,F4
OPERATOR INTERFACE C3G Plus
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Commands
Character
keys
Function
keys
Go PRG F6,F5,F4
GOUT DOG F2,F5,F3
GOUT SOFG F7,F4,F1,F3
GOUT SOUG F7,F4,F2,F3
GOUT SOVG F7,F4,F3,F3
Hidden FUAH F4,F7,F1,F1
High FUFH F4,F7,F4,F1
Input DCI F2,F2,F2
Input DI* F2,F4,*
Input SI* F7,F3,*
Insert PTBI F6,F7,F1,F1
Io_conf CI F1,F3
Joint DAJ F2,F1,F4
Kermit UCMK F8,F2,F2,F3
Key_lock SCK F7,F2,F1
Load CARL F1,F1,F2,F1
Low FUFL F4,F7,F4,F2
Load CL F1,F4
Load ML F5,F3
Load MRL F5,F4,F1
Master DFM F2,F3,F1
Memory M* F5,*
Memory SCPM F7,F2,F2,F2
Mount UCM* F8,F2,F2,*
Move PTSM F6,F7,F3,F4
Nostroke SAN F7,F1,F4
Output DCO F2,F2,F3
Output DO* F2,F5,*
Output SO* F7,F4,*
Password CCP F1,F2,F1
Pause PSP F6,F6,F2
Port_char UCP F8,F2,F3
Position DAP F2,F1,F5
Print FP F4,F4
Profile PTP* F6,F7,F2,*
Program DCP F2,F2,F4
Program DP F2,F6
Program MEP F5,F2,F2
Program MVP F5,F7,F1
C3G Plus OPERATOR INTERFACE
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Commands
Character
keys
Function
keys
Program P* F6,*
Program SCPP F7,F2,F2,F3
Protect SCP* F7,F2,F2,*
Purge PTBP F6,F7,F1,F2
Readonly FUAR F4,F7,F1,F2
Reboot CCRR F1,F2,F2,F3
Rename FR F4,F5
Reset PTPR F6,F7,F2,F3
Resolver DAR F2,F1,F6
Restart CCR* F1,F2,F2,*
Restart PRR F6,F5,F5
Rll DCR F2,F2,F5
Rll DR F2,F7
Rll MR* F5,F4,*
Rll PR* F6,F5,*
Routine PTSR F6,F7,F3,F5
Reten_Mem CAR* F1,F1,F2,*
Save CARS F1,F1,F2,F2
Save CS F1,F5
Save MRS F5,F4,F2
Save MS F5,F5
Search FUS F4,F7,F5
Select DCS F2,F2,F6
Set S* F7,*
Set_def UCS F8,F2,F4
Sing_scan PRS F6,F5,F6
Simulate SAS F7,F1,F5
Slave DFS F2,F3,F2
Startup CCS F1,F2,F3
State PS* F6,F6,*
Statement PTSS F6,F7,F3,F6
Status DAS F2,F1,F7
Step PTS* F6,F7,F3,*
System DIS F2,F4,F4
System DOS F2,F5,F4
System FUAS F4,F7,F1,F3
System SCPS F7,F2,F2,F4
Teach MT F5,F6
Temp DAT F2,F1,F8
OPERATOR INTERFACE C3G Plus
3-66 03/0499
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Commands
Character
keys
Function
keys
Test PT* F6,F7,*
Time CCT F1,F2,F4
Tisoft UCMT F8,F2,F2,F4
Total DCT F2,F2,F7
Total_unf ST F7,F5
Tp_main SAT F7,F1,F6
Translate FT F4,F6
Turn_set CAT F1,F1,F3
Type MVT F5,F7,F2
Unforce SIU* F7,F3,F2,*
Unforce SOU* F7,F4,F2,*
Unpause PSU F6,F6,F3
Unsimul SAU F7,F1,F7
Update_io SU* F7,F6,*
Utility FU* F4,F7,*
Utility U* F8,*
Variable MEV F5,F2,F3
Variable MVV F5,F7,F3
Vars DCV F2,F2,F8
Vars DV* F2,F8,*
View CCV F1,F2,F5
View FUCV F4,F7,F3,F2
View FV F4,F8
View MV* F5,F7,*
View PRV F6,F5,F7
View PTBV F6,F7,F1,F3
View PTPV F6,F7,F2,F4
View PTSV F6,F7,F3,F7
View PV F6,F8
View SCV F7,F2,F3
View SIV* F7,F3,F3,*
View SOV* F7,F4,F3,*
View SUV F7,F6,F3
View UCV F8,F2,F5
View_cal CAV F1,F1,F4
View_io SV F7,F7
Warm CCRW F1,F2,F2,F4
Win_clear SCW F7,F2,F4
Word DVW F2,F8,F2
C3G Plus OPERATOR INTERFACE
03/0499 3-67
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STAND-BY FUNCTION
With the Stand-by function it is possible to save current consumption when the robot is stationary. This func-
tion is activated automatically when the controller is in the local automatic or remote automatic
state and when the robot has been stationary since a length of time that can be defined in the $TUNE [27]
variable; the effect is that of activating the motor brakes to maintain the static positionof the robot. The value
of the $TUNE [27] variable set by COMAU is 10 seconds; setting this variable to 0, the function is deacti-
vated.
The Stand-by function is automatically deactivated at the first system request to resume motion (START, RE-
SUME).
The Stand-by function can be displayed only with the Display Arm Status (DAS) command which shows the
state of the Arm drives as “STB” instead of “ON” or “OFF”.
When the Stand-by function is active the controller motors are on DRIVE ON and the control-
ler state is local automatic or remote automatic . Strictly follow the safety rules
concerning this controller operating condition (see chapter 1).
OPERATOR INTERFACE C3G Plus
3-68 03/0499
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BRAKE RELEASE DEVICE (C3G-BRD)
This portable device makes it possible to deactivate one robot axis brake at a time. It is connected to:
� the 220 Vac mains supply (standard provision)
� the motor connector on the X2 (X2EXT) robot base after removing the cable leading from the control
system.
This device is intended for use by trained personnel as it is potentially dangerous (dropping of the axes due
to the effect of gravity).
REF. DESCRIPTION
1 Selector used to select the axis whose brake is to be released.
If the Harting connector is connected to connector X2 it is possible to release the brakes of
axes 1 to 6; if it is connected to connector X2EXT it is possible to release the brakes of
axes 7 and 8.
2 Button used to release the brakes: when activated, the brake is released; if the lever is re-
leased the brake stops receiving power again and the axis is locked.
3 Socket for connection to a power source.
4 Harting connector.
C3G Plus OPERATOR INTERFACE
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C3G Plus KIT IVECO
Blinker unit and main switch tripping
ITEM DESCRIPTION
1 Main switch with tripping coil
2 Blinker
3 Microswitch for blinker
4 Microswitch for tripping coil
5 Keylock selector switch with return spring on the control board
OPERATOR INTERFACE C3G Plus
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Wiring diagram
GENERAL
The kit for the IVECO option includes a blinker, a microswitch and a keylock selector switch.
The function of the blinker (H120) is to display the power supply state of the electric equipment within the
controller.
Therefore it must be connected just after the main isolator switch and placed in such a position as to be
clearly visible when the controller doors are open.
The blinker is connected to the three-phase line, without neutral earth wire, to signal for the harmful condition
which is actual when the main voltage is applied; such condition is signalled by means of three red blinking
lamps of the discharge type.
The blinker, connected as above mentioned, signals the mesh connection of three or two
phases by lighting up the corresponding lamp.
The mesh connection of one phase only is not signalled (all the lamps are off).
The blinker is installed together with a limit switch (S110) with three normally closed (N.C.) contacts, which
makes the blinker turn on when the cabinet doors are opened
When the door of the controller is opened, the single-throw limit switch (S111), having one normally-closed
(N.C.) contact, makes the main switch trip automatically by powering up the coil (D1, D2).
The keylock selector switch (S112), installed on the controller door, permits to cut out the automatic tripping
of the switch.
C3G Plus OPERATOR INTERFACE
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OPERATOR INTERFACE C3G Plus
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SAFETY REGULATIONS 1-1
INSTALLATION 2-1
OPERATOR INTERFACE 3-1
INTEGRATION GUIDE 4-1
MAIN OPERATIONS FOR SYSTEM USE 5-1
EMERGENCY PROCEDURES 6-1
MAINTENANCE 7-1
SUMMARY
Paragraph Page
Safety signals to remote 4-1
System inputs/outputs 4-4
Input signals from external logic (machine line) 4-6
Output signals towards external logic (machine line) 4-7
24 Vdc power supplies 4-8
Procedures for command activation with the controller in automatic remote status 4-8
Examples of use of system signals dedicated to transfer interface 4-11
Parallel inputs/outputs 4-14
Serial inputs/outputs 4-33
Programmes contained in Floppy Disk “1/2 C3G CONFIGURATION TOOL” 4-33
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Operations and
Maintenance Manual
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Operations and
Maintenance Manual C3G Plus
SAFETY SIGNALS TO REMOTE
Connection to safety interlocks is described in chapter 2, step 7 of the installation procedure. To simplify inte-
gration operations and have a complete picture of the signals available to the machine, the connection cir-
cuitry of the safety signals and the summary tables are repeated.
SAFETY SIGNALS TOWARDS EXTERNAL EQUIPMENT
C3G Plus INTEGRATION GUIDE
02/1198 4-1
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If the C3G-CSM (Controlled Stop Module) is installed on the controller, in AUTO LOCAL and
AUTO REMOTE states, an emergency stop and/or opening of the safety gates causes con-
trolled stopping of the robot (EN 60204-1), category 1 stop). In this way, power is cut off
(opening of the power contactor) after 1 second. In PROGR. programming status, the power
is cut off immediately (EN 60204-1, category 0 stop). These times must be taken into account
when installing the protective barriers in particular if light curtains are used.
1
For safety purposes, the interface connectors to the outside must be fitted with a suitable ca-
ble clamp, the cables must be screened and the screening appropriately connected to the
ground, in order to guarantee electromagnetic compatibility of the system as per directive
89/392.
INTEGRATION GUIDE C3G Plus
4-2 01/0498
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X30 SIGNALS DESCRIPTION
15
16
EXTERNAL SAFETY GATES CH1 INPUT
EXTERNAL SAFETY GATES CH1 OUTPUT
Safety signals to external equipment that must be used
to connect the safety gates and all devices that assure
operator safety during the work cycle.
17
18
EXTERNAL SAFETY GATES CH2 INPUT
EXTERNAL SAFETY GATES CH2 OUTPUT
33
34
EXTERNAL EMERG. STOP CH1 INPUT
EXTERNAL EMERG. STOP CH1 OUTPUT
Safety signals to external equipment that must be used
to connect a mushroom-head emergency button to in-
terrupt the work cycle.
35
36
EXTERNAL EMERG. STOP CH2 INPUT
EXTERNAL EMERG. STOP CH2 OUTPUT
58
46
EXTERNAL SAFETY STOP CH1 OUTPUT
EXTERNAL SAFETY STOP CH1 INPUT
Safety signals to external equipment that can be used
for category 1 controlled stopping according to EN
60204-1 (if the C3G-SSM device is present on request)
59
47
EXTERNAL SAFETY STOP CH2 OUTPUT
EXTERNAL SAFETY STOP CH2 INPUT
52
53
POWER CONTACTOR 1 INPUT
POWER CONTACTOR 1 OUTPUT
Auxiliary contacts of power contactors K101 and K102.
These are made available externally for connecting the
power supply to equipment or for detecting the status
of the power contactors.55
56
POWER CONTACTOR 2 INPUT
POWER CONTACTOR 2 OUTPUT
6
24
SAFETY RELAY LOGIC CH1 INPUT
SAFETY RELAY LOGIC CH1 OUTPUT
Equipment supply contacts (Safety Relay Logic). Used
to connect the supply to the equipment through safety
relays.
66
68
SAFETY RELAY LOGIC CH2 INPUT
SAFETY RELAY LOGIC CH2 OUTPUT
48
50
INTERNAL +24 Vdc OUTPUT (x)
INTERNAL +24 Vdc INPUT (x)
Power connection to the safety circuits. Bridge (x) +24
Vdc, bridge (y) 0 V (+24 Vdc).
49
51
INTERNAL 0 V (+24 Vdc) OUTPUT (y)
INTERNAL 0 V (+24 Vdc) INPUT (y)
If the C3G-CSM (Controlled Stop Module) is installed on the controller, in AUTO LOCAL
and AUTO REMOTE states, an emergency stop and/or opening of the safety gates causes
controlled stopping of the robot (EN 60204-1), category 1 stop). In this way, power is cut off
(opening of the power contactor) after 1 second. In PROGR. programming status, the
power is cut off immediately (EN 60204-1, category 0 stop). These times must be taken into
account when installing the protective barriers in particularif light curtains are used.
PIN
X30-2 SIGNALS DESCRIPTION
52
53
POWER CONTACTOR 1 INPUT
POWER CONTACTOR 1 OUTPUT
Auxiliary contacts of power contactors K121 and K122.
These are made available externally for connecting the
power supply to equipment or for detecting the status
of the power contactors of machine 2.55
56
POWER CONTACTOR 2 INPUT
POWER CONTACTOR 2 OUTPUT
6
24
MACHINE EXCLUSION 1 INPUT
MACHINE EXCLUSION 1 OUTPUT
Auxiliary contacts of relays K123 and K124. They are
made available externally for detecting the status of the
excluded machine.
66
68
MACHINE EXCLUSION 2 INPUT
MACHINE EXCLUSION 2 OUTPUT
C3G Plus INTEGRATION GUIDE
02/1198 4-3
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X80 SIGNALS DESCRIPTION
1
2
ENABLING DEVICE 2 CH1 INPUT
ENABLING DEVICE 2 CH1 OUTPUT
Connector for connecting to a second three-position
enable device (Enabling Device 2), present on request.
3
4
ENABLING DEVICE 2 CH2 INPUT
ENABLING DEVICE 2 CH2 OUTPUT
SAFETY SIGNALS ON THE ROBOT
PIN X91 ALL COMAU
ROBOTS (EXCEPT
SMART S FAMILY)
SIGNALS DESCRIPTION
G
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SAFETY FLANGE OUT
SAFETY FLANGE INP
ROBOT ALARM OUT.
ROBOT ALARM INP.
Emergency signals towards the robot that
must be used for connection of the safety
flange and/or other devices.
PIN X92
SMART S2/S3/S4
SIGNALS
1
3
SAFETY FLANGE OUT.
SAFETY FLANGE INP.
SYSTEM INPUTS/OUTPUTS
The C3G Plus cell controller is pre-engineered for connection with control devices of the machine line
through a specific interface. The diagrams and summary tables are given on the following pages.
The system I/O signals available on connector X30 (X30-2) are described below.
INTEGRATION GUIDE C3G Plus
4-4 02/1198
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INPUT SIGNALS FROM EXTERNAL LOGIC (MACHINE LINE)
These are controller input signals used to communicate with external equipment (e.g. a PLC).
PIN
X30 SIGNALS DESCRIPTION
1 DRIVE ON (LED A1 SIM, $SDIN[9]) When the system is in Remote status, this is a request
from a remote device to activate the motor start-up cycle.
(normally deactivated, is activated at high logic level)
19 DRIVE OFF (LED A2 SIM, $SDIN[10]) When the system is in Remote status, this is a request
from a remote device to activate the motor shutdown cy-
cle.
(normally active, is active at low logic level)
2 START (LED A3 SIM, $SDIN[11]) When the system is in Remote status, this is a request to
enable the work cycle.
(normally deactivated, is activated at high logic level)
20 HOLD (LED A4 SIM, $SDIN[12]) When the system is in Remote status, this is a request to
disable the work cycle.
(normally active, is active at low logic level)
3
21
4
22
U1 (LED A5 SIM, $SDIN[13])
U2 (LED A6 SIM, $SDIN[14])
U3 (LED A7 SIM, $SDIN[15])
U4 (LED A8 SIM, $SDIN[16])
Undefined input signals whose function can be
customised through user programming.
7 USER INP. COMMON RETURN Common return reference for input signals.
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OUTPUT SIGNALS TOWARDS EXTERNAL LOGIC (MACHINE LINE)
These are controller output signals used to communicate with external equipment (e.g. a PLC).
PIN
X30 SIGNALS DESCRIPTION
8 DRIVE ON/OFF
(LED C1 SIM, $SDOUT[9])
When closed indicates that the control unit has received the
Drive ON command from the machine line, has carried out
the motor start-up procedure and is in Drive ON status.
(Drive ON = true, Drive OFF = false)
26 START/HOLD
(LED C2 SIM, $SDOUT[10])
When closed, it means that control unit has received
START signal with at least one "HODABLE" program pre-
viously activated and ready to start.
9
27
10
28
U1 (LED C3 SIM, $SDOUT[13])
U2 (LED C4 SIM, $SDOUT[14])
U3 (LED C5 SIM, $SDOUT[15])
U4 (LED C6 SIM, $SDOUT[16])
Undefined output signals whose function can be
customised through user programming.
11 LOCAL/REMOTE
(LED C7 SIM, $SDOUT[11])
When closed indicates that the remote operating mode
has been selected using the status selector on the front
panel and that the system is in Remote status.
(Local = false, Remote = true)
29 ALARM (LED D1 SIM, $SDOUT[4]) When open indicates that an alarm has occurred and has
been detected by the control unit.
(no alarm = true, alarm = false)
12 TEACH EN/DIS
(LED C8 SIM, $SDOUT[12])
When closed indicates that the system is in Programming
status (through selection on front panel) and has enabled
the relevant safety devices (reduced speed, servo alarm
threshold restriction).
13 AUTO/MAN PTU ($SDOUT[17]) When closed indicates that the AUTO/MAN selector on
the programming terminal is in the AUTO position, i.e. pro-
gramming operations involving robot movement are per-
formed at machine working speed.
(Auto = true, Man = false)
30 EMERG. STOP TO REMOTE Emergency signal to remote which is opened when one of
the emergency buttons on the programming terminal or
operator panel is pressed (normally closed).
14
32
COMMON OUTPUT +24 Vdc + 24 Vdc common return reference for output signals.
25 OUTPUT COMMON RETURN 0 Vdc 0 Vdc common return reference for output signals.
71 COMMON (STATUS SELECTOR) Common wire for auxiliary contacts.
54 PROGRAMMING
Status selector in programming position
42 AUTO-LOCAL
Status selector in automatic-local position
40 AUTO-REMOTE Status selector in automatic-remote position
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24 Vdc POWER SUPPLIES
PIN
X30
X30-2
SIGNALS DESCRIPTION
45
81
INT. +24V TO EXT. EQUIP.
INT. 0 V (+24 Vdc) TO EX. E.
+ 24 Vdc continuous power supply from the controller.
107
108
+24 Vdc EXTERNAL EQUIPMENT
0 Vdc
Provision for connection of the continuous +24 Vdc
supply from the transfer.
PROCEDURES FOR COMMAND ACTIVATION WITH THE CONTROLLER IN
AUTOMATIC REMOTE STATUS
The controller manages motor start/stop and cycle start/stop commands with the DRIVE ON/OFF and
START/HOLD commands coming from the external equipment after checking congruence and safety condi-
tions.
DRIVE ON PROCEDURE
Remote activation of the DRIVE ON procedure makes it possible to activate the motors when the DRIVE ON
signal is active if all the system checks have been passed. This procedure is activated only if the status se-
lector on the operator panel is in the Automatic Remote position .
The DRIVE ON request to the system must be performed at least 4 seconds after the
last DRIVE OFF because of hardware behaviour of the dynamic braking device
(C3G-DBU3) installed on the control unit.
1. On the controller:
- the main power switch must be in the ON position;
- the status selector must be in the Remote position .
- relays K16/SIM (LOCAL/REMOTE pin 11 on X30) and K17/SIM (ALARM pin 29 on X30) are closed.
In the case of an error, all the output relay contacts of the SIM module remain open.
2. On the remote control panel if the timeout counter has not expired:
- if the status of relay K10 of the SIM module (pin 8 on X30) is OFF (DRIVE ON/OFF);
- if the power contactors are open (POWER CONTACTOR 1 Pin 52-53 X30, POWER CONTACTOR 2
Pin 55-56 X30) (if the second machine is present POWER CONTACTOR 1 PIN 52-53/X30-2, POWER
CONTACTOR 2 PIN 55-56/X30-2);
- if no alarm is present (ALARM pin 29 on X30 closed);
the DRIVE ON COMMAND is activated (pin 1 on X30).
3. On the controller, if the following conditions are found:
- DRIVE ON (pin 1 on X30) active (true);
- DRIVE OFF (pin 19 on X30) active (true);
- START (pin 2 on X30) not active (false);
- HOLD (pin 20 on X30) active (true);
the DRIVE ON procedure is performed; otherwise relay K17/SIM is opened which generates an alarm
signal (pin 29 on X30).
At the end of the DRIVE ON procedure, relay K10/SIM (DRIVE ON/OFF pin 8 on X30) is closed with ro-
bot powered.
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START PROCEDURE
The START procedure from remote permits activation of the robot cycle after making all the system checks
and checking the DRIVE ON status. This procedure is active only if the status selectoron the operator panel
is in the Automatic Remote position . The control unit does not switch to Start status if the DRIVE ON
command has not been removed.
1. On the remote panel:
- if there is an alarm signal (ALARM at low logic level pin 29 on X30) the DRIVE OFF signal is sent pre-
venting activation of the cycle;
- if the robot is in DRIVE ON status (pin 8 on X30), and the power contactor is not closed, an alarm is
generated;
- if the robot is in DRIVE ON status and the power contactor is closed;
the DRIVE ON command is deactivated (pin 1 on X30) and the START command is activated (pin 2 on
X30).
2. On the controller, if the following conditions are found:
- DRIVE ON (pin 1 on X30) not active (false);
- DRIVE OFF (pin 19 on X30) active (true);
- START (pin 2 on X30) active (true);
- HOLD (pin 20 on X30) active (true);
the START signal (pin 26 on X30) is activated which causes activation of the “holdable” programmes in-
stalled. For the programme installation procedures refer to the Programming manuals.
HOLD PROCEDURE
This procedure is activated if the machine is in the START status (active cycle).
1. On the remote panel:
- it activates the HOLD command (low logic level pin 20 on X30);
- a timer is initialised.
2. On the controller:
- the cycle is interrupted;
- the START/HOLD output is deactivated (low logic level pin 26 on X30).
3. On the remote panel, if the following conditions are found:
- START/HOLD output not active (false);
- ALARM output active (true);
- DRIVE ON/OFF output active (true);
the timer initialised in step 1 is reset.
HOLD PROCEDURE FROM LOCAL
The stop commands (DRIVE OFF and HOLD) are always active regardless of the position of the PRO-
GRAMMING, , Automatic LOCAL, , Automatic REMOTE . status selector. It is therefore possi-
ble that a HOLD command be activated from the PTU4 while the control unit is in Remote status and,
consequently all “holdable” programmes being run are stopped.
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The transfer is informed of the Hold status of the control unit through deactivation of the START/HOLD out-
put, i.e. with opening of the contact of the corresponding relay. Also, the LOCAL/REMOTE output is deacti-
vated indicating that the system is operating following a local command.
The output that indicates hold to the transfer is kept open (HOLD) even when the HOLD command from the
operator panel is removed.
The LOCAL/REMOTE output is active when the HOLD command from the operator panel is removed indicat-
ing that the system is once again under the control of the remote PLC.
DRIVE OFF PROCEDURE
This procedure is activated if the robot is in Drive ON status.
1. On the remote panel:
- the DRIVE OFF command is activated;
- a timer is initialised.
2. The controller:
- stops the robot in controlled mode;
- deactivates the START/HOLD output (pin 26 on X30);
- switches off power to the motors;
- deactivates the DRIVE ON/OFF output (pin 8 on X30).
3. On the remote panel if the following conditions are found:
- DRIVE ON/OFF output not active (false);
- power contactor open;
- ALARM output active (true);
- START/HOLD output not active (false);
the timer initialised in step 1 is disabled.
INTEGRATION GUIDE C3G Plus
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EXAMPLES OF USE OF SYSTEM SIGNALS DEDICATED TO TRANSFER
INTERFACE
EXAMPLE OF PROGRAMME NUMBER SELECTION FROM REMOTE THROUGH
USER-PROGRAMMABLE I/O’s
(1) User-programmable I/O’s (IOM). The signals described are for example purposes and
may be used within a programme for work cycle management.
(2) Control unit initial status: status selector in the Automatic remote position .
(3) If there are no activated programs, START control is not effective and this OUTPUT
remains FALSE.
(5) Another solution for checking the PROGR. CODE consists in sending the C3G a parity
signal which will be checked by the PDL2. In this way, the outputs that provide echo of
the programme code are saved (REC. PROGR. CODE).
C3G Plus INTEGRATION GUIDE
04/0799 4-11
C 3G-CONTR OL SYSTEM
X30/1
X30/19
X30/2
DRIV E ON I NP UT
DRIVE OFF INPUT
START INPUT
X30/20 HOLD INPUT
(1) P RO GR. CO DE I NPUT
(1) PROG R. S TRO BE I NPUT
(1) PROGR. START INPUT
X30/B DRIVE ON/OFF OUTPUT
X30/26 START/HOLD OUTPUT
X30/11 L O CA L/ RE MO TE O UTPUT
X30/29 ALARM OUTPUT
X30/53 DRI V E O N O UTP UT
(PO W E R CO NT ACTO R)
(1) RE C. PRO G. CO DE INP UT (5)
(5)
(1) P RO G R. REC. O UTPUT
(A CK NO W LE DG E )
(1) E ND O F P RO GRA M /
P RO G RA M RUNNI NG
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(2)
S TA R T U P DRI V E ON
P RO GR. S E LE CT.
& S T A RT CHA NG E O F PRO G RA M
(3)
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R U N N I N G
P R O G R . X
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EXAMPLE OF STOPPING AND RE-STARTING THE WORK CYCLE FROM REMOTE
(3) Control unit initial status: drive power on and status selector in Automatic Remote
position (PROGRAM EXECUT.).
(4) No indication to the outside that HOLD status has been removed is provided.
INTEGRATION GUIDE C3G Plus
4-12 01/0498
C3G-CONTROL SYSTEM
X30/1
X30/19
X30/2
DRIVE ON INPUT
DRIVE OFF INPUT
START INPUT
X30/20 HOLD INPUT
X30/8 DRIVE ON/OFF OUTPUT
X30/26 START/HOLD OUTPUT
X30/11 LO CAL /REMOTE OUTP UT
X30/29 ALARM OUTPUT
X30/12 TEACH EN./DIS OUTPUT
X30 (X30-2)/
52-53 55-56
DRIVE ON OUTPUT
(POWER CONTACTOR) 1/2
X30/54
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(3)
(4)
LO CAL HOLD PUSHBUTTON
ON THE O PERATOR PANEL
(4)
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R EM O TE
H O L D
R EM O TE
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R ES TO RE
R EM O T E
(RE) START
LO CAL HO LD
(O PERATO R
PANEL)
L O C AL
H O L D
R EST O R E
R EM O T E
(RE) START
(3)
PROG RAM M ING
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EXAMPLE OF CHANGING STATUS FROM REMOTE TO LOCAL AND FROM REMOTE
TO PROGRAMMING
(3) Control unit initial status: drive power on and status selector in Automatic Remote
position (PROGRAM EXECUT.).
(6) The DRIVE OFF and HOLD INPUT signals must be restored on change of status.
(7) The outputs towards the transfer are managed in all statuses.
(8) Uncertainty due to the response of the status selector.
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X30/1
X30/19
X30/2
DRIVE ON INPUT
DRIVE OFF INPUT
START INPUT
X30/20 HOLD INPUT
X30/8 DRIVE ON/OFF OUTPUT
X30/26 START/HOLD OUTPUT
X30/11 LO CAL /REMOTE OUTP UT
X30/29 ALARM OUTPUT
X30/12 TEACH EN./DIS OUTPUT
X30 (X30-2)/
52-53 55-56
DRIVE ON OUTPUT
(POWER CONTACTOR) 1/2
X30/54
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(6)
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HOL D
(7)
(7)
X30/13 AUTO/MAN ON T.P. OUT.
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SC3G-MPI module...................................................................................................................................7-51
C3G-RPT module (optional) ..................................................................................................................7-52
Servo Amplifiers Unit SAU2...................................................................................................................7-54
System software loading .......................................................................................................................7-59
List of spare parts ..................................................................................................................................7-67
SUMMARY C3G Plus
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SAFETY REGULATIONS 1-1
INSTALLATION 2-1
OPERATOR INTERFACE 3-1
INTEGRATION GUIDE 4-1
MAIN OPERATIONS FOR SYSTEM USE 5-1
EMERGENCY PROCEDURES 6-1
MAINTENANCE 7-1
SUMMARY
Paragraph Page
Responsibility 1-1
Safety regulations 1-1
C3G Plus
Operations and
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Operations and
Maintenance Manual C3G Plus
RESPONSIBILITY
� The “integrator” is responsible for incorporating the robot system in a manufacturing or re-
search environment, for issuing the declaration of conformity and applying the EC label to the
system in compliance with the safety principles of the Machine Directive.
� COMAU S.p.A. shall not be held responsible for injury or damage resulting from incorrect or im-
proper use of the robot system, use of unspecified spare parts and tampering with circuits, com-
ponents and system software.
� The foremen who manage / supervise the operations specified in point 3 are responsible for en-
suring that these safety rules are enforced. They must make sure that all authorized personnel
have been instructed as regards the rules contained in this document and the general safety
rules applicable to the robot system and that the aforesaid personnel comply with all these rules.
� Failure to comply with safety regulations may result in injury to personnel and damage to con-
troller components.
SAFETY REGULATIONS
1. PURPOSE
1.1 The purpose of these safety regulations is to define a series of behaviour rules and duties to be
observed when performing the activities listed in point 3, to ensure the safety of personnel, equip-
ment and the surrounding environment.
2. DEFINITIONS
2.1 Robot System
The term Robot System refers to the functional assembly consisting of: control unit, robot, porta-
ble programming and/or emergency terminal and any options.
2.2 Protected Area
Protected Area is the area that is enclosed by protective barriers, in which the robot is to be in-
stalled and operated.
2.3 Authorized Personnel
Authorised Personnel is the group of persons that have been appropriately trained and delegated
to perform the activities listed in point 3.
2.4 Foremen
Foremen are personnel who direct or supervise the activities assigned to subordinate workers as
defined in the previous paragraph.
2.5 Installation and Commissioning
The term installation refers to the integration of the robot system mechanics and electrics into a
manufacturing situation or research environment in accordance with the safety requirements laid
down in the Machines Directive.
The term commissioning refers to the operations involved in verifying system operation once the
system has been installed.
2.6 Operation during Programming
Operating mode under operator control. This mode excludes automatic operation and permits the
following activities: manual movement in the various different modes, programming of work cycles
at reduced speed, programmed cycle testing at reduced speed and when permitted, at working
speed.
2.7 Automatic Operation
Operating mode in which the robot performs the programmed cycle autonomously at working
speed inside the protected area, with protective barriers closed and interlocked with the emer-
gency stop circuit, and with local (situated outside the protected area)or remote start/stop.
2.8 Emergency Manual Operation
Operating mode that permits movement of the robot with downgraded safety system in the case
of a fault, under operator control and with protective barriers closed.
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DEFINITIONS - Continued
2.9 Maintenance and Repairs
Maintenance and repair operations refer to periodic checking and/or replacement of parts (me-
chanical, electrical, software) or of robot system components and tracing of the causes of any
faults and ends with resetting of the robot system to original operating conditions.
2.10 Removal from Service and Dismantling
Removal from Service refers to the removal of the robot system (mechanical and electrical) from
the manufacturing situation or research environment.Dismantling involves the demolition and dis-
posal of the components that make up the robot system.
2.11 Integrator
The integrator is the qualified person responsible for application of the robot system.
2.12 Incorrect Use
The integrator is the qualified person responsible for the application of the robot system.
2.13 Work Envelope
The robot work envelope is the area in which the robot, including fixtures, operates.
3. FIELD OF APPLICATION
3.1 These regulations must be complied with when performing the following activities:
� installation and commissioning;
� operation during programming;
� automatic operation;
� emergency manual operation;
� maintenance and repairs;
� removal from service and dismantling;
4. OPERATING MODES
4.1 Installation and Commissioning
4.1.1 Commissioning is allowed only when the robot system is incorporated in a manufacturing system
or in a research environment that guarantees the use of safety conditions.
4.1.2 Installation and commissioning of the system must be performed by authorized personnel only.
4.1.3 The system must only be installed and commissioned inside a protected area of a suitable size to
house the robot and its relative dressing, without any part of these being outside the safety
guards. Also, make sure that during normal robot movements this does not collide with other parts
inside the protected area (for instance, structural pillars, mains, etc.). If necessary, restrict the ro-
bot work area by means of mechanical stops.
4.1.4 The robot installation area must be kept free, as far as possible, from any materials that may ob-
struct or limit visibility.
4.1.5 During installation, handle the robot and control unit as specified in the Product User Manual; if
they must be lifted, check that the eyebolts are secured correctly and use only suitable slings and
equipment.
4.1.6 Secure the robot to the support with all the bolts provided.
4.1.7 Remove any anchoring brackets from the axes and check that the robot fixtures are secured cor-
rectly.
4.1.8 Check that the robot guards are fixed correctly and that there are no loose or loosened parts,
check also that the control unit components are in good condition.
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Installation and Commissioning - Continued
4.1.9 When required, connect the robot's pneumatic system to the air distribution network and check
carefully to make sure that the pressure is set correctly. If the pressure of the balancing system is
not correct it will affect the robot's movements.Also install filters to collect any condensate in the
system.
4.1.10 Install the control unit so that the control panel can only be operated from outside the protected
area.
4.1.11 Check that the pre-engineered voltage on the power supply transformers indicated on the specific
rating plate corresponds to the power mains voltage.
4.1.12 Before making the electrical connections to the control unit, make sure that the power mains cir-
cuit breaker is locked in the open position.
4.1.13 The connection between the control unit and theP
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STATUS CHANGE
REMOTE TO
LOCAL ON
THE OPER. PANEL
(6)
REMOTE
DRI VE
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STATUS CHANGE
REMOTE TO
PROGRAMM. ON
THE OPER. PANEL
PROGRAMMING
LOCAL
DRIVE ON
PROGRAMMING
AUTO SELECT
ON P.T.
PROG RAM M ING
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EXAMPLE OF ALARM RESET
The DRIVE ON and START signals are active on the positive rising edge. They require a minimum 50 ms
pulse but their status may also be cancelled when the status of the C3G changes as required.
The DRIVE OFF and HOLD signals are active on the level and are low active signals that must be high dur-
ing normal functioning. For these signals, it is also possible to use negative pulses with a minimum duration
of 50 ms.
In the case of a remote emergency stop, the alarm can be reset simply by sending the DRIVE ON request.
The C3G makes the checks, cancels the alarm and performs DRIVE ON. If recovery is not possible the
alarm condition is restored.
C3G-PLC Example of Remote Alarm Reset
PARALLEL INPUTS/OUTPUTS
This paragraph provides information about the parallel I/O’s.
IOM MODULE I/O CONNECTION (BASIC CONFIGURATION) SLOT 4 FOR C3G Plus
VERSIONS SDLP - SDMP - SDHP AND SLOT 4-6 FOR C3G Plus VERSIONS DDMP - DDHP
With the C3G Plus double cabin versions DDMP - DDHP two IOM modules are present at
the same time. The IOM module of Slot 4 will be dedicated to MACHINE 1 and available ex-
ternally on connector X30; the IOM module of Slot 6 will be dedicated to MACHINE 2 and
available externally on connector X30-2.
The IOM module which handles 16 inputs and 16 outputs at 24 Vdc, of which 16 inputs and 15 outputs avail-
able to the user, is inserted in the Control Unit rack inside the controller. EACH AVAILABLE I/O CHANNEL
IS CONNECTED BOTH TO THE ROBOT AND TRANSFER AT THE SAME TIME. The I/O signals may be
directed:
� towards the TRANSFER for any external equipment (through connector X30 and/or X30-2 for C3G Plus
versions DDMP - DDHP only);
� towards the ROBOT to handle fixtures installed on this (through the specific connector);
� towards TRANSFER and ROBOT at the same time.
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4-14 01/0498
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X30/1 DRIVE-ON
C3G (commands)PLC
X30/19 DRIVE-OFF
X30/2 START
X30/20 HOLD
PLC (statuses)C3G
X30/8 DRIVE-ON/OFF
X30/26 START/HOLD
X30/29 ALARM
INITIAL
STATUS
DRIVE
ON
START HOLD START
EMER.
STOP
ALARM
RECOVERY
START
When connecting the I/O channels, do not exceed the values indicated in the technical data
given below:
� INPUT
- Input voltage for channel activation: 14 to 35 Vdc;
- Input voltage for channel deactivation: 0 to 15 Vdc;
- Input current with channel activated: 2 to 15 mA;
- Maximum input current with channel not activated: 0.5 mA.
� OUTPUT
- Operating voltage: 4.5 to 36 Vdc;
- Maximum output current with channel not activated: 0.25 mA;
- Maximum voltage drop with channel active: 1.8 Vdc;
- Maximum output current with all channels active: 0.5 A @ ta = 25°C;
- Maximum output current with all channels active: 0.5 A @ ta = 45°C.
The IOM module can be powered using the 24 Vdc voltage generated by the control unit or by an external
power supply connected to connector X30. THE MODULE IS USUALLY POWERED BY THE 24 VDC GEN-
ERATED BY THE CONTROLLER.
If the user decides to power the IOM module with an external power supply, jumpers JP 200 and JP 201 on
the SDB3 module for IOM slot 4 and/or SDB3-2 for IOM slot 6 must be set as shown in the following figures.
The I/O’s may be powered in sets of eight. These groups may be powered with a 24 Vdc
power supply inside or outside the control unit. Usually, the entire module (8+8 outputs and
8+8 inputs) is powered using one or the other type of power supply. However, it is possible
to power the IOM module with two power supplies at the same time dividing the I/O’s as fol-
lows:
� INTERNAL POWER SUPPLY: inputs 1-8 / outputs 1-8;
� EXTERNAL POWER SUPPLY: inputs 9-16 / outputs 9-16;
or vice versa.
In the PDL2 programming language, the I/O’s of the IOM module are identified as follows:
IOM SLOT 4
� input 1 to 16 � $din[1] to $din[16];
� output 1 to 16 � &dout[17] to $dout[32].
� Output 16 $dout[32] is not available.
IOM SLOT 6 (ONLY FOR C3G Plus VERSIONS DDMP - DDHP)
� input 1 to 16 � $din[33] to $din[48];
� output 1 to 16 � $dout[49] to $dout[64].
Output 16 $dout[64] is not available.
C3G Plus INTEGRATION GUIDE
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INTEGRATION GUIDE C3G Plus
4-16 01/0498
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1 2 3
JP 200
1 2 3
JP 201
24 Vdc SUPPLY OUTSIDE the C3G Plus
24 Vdc SUPPLY INSIDE the C3G Plus OUT 1 to 8
+24 Vcc
EXTERNAL
+
-
X30
1 2 3
JP 200
1 2 3
JP 201
107
108
24 Vdc SUPPLY OUTSIDE THE C3G Plus OUT 1 to 8
24 Vdc SUPPLY INSIDE the C3G Plus
24 Vdc SUPPLY INSIDE the C3G Plus OUT 9 to 16
24 Vdc SUPPLY OUTSIDE THE C3G Plus OUT 9 to 16
The I/O signals are available connecting to the pins indicated in the following table.
Signal allocation for the IOM module is the same both when it is inserted in slot 4 and in slot
6. The IOM module signals of slot 4 are available externally on connector X30, those of the
IOM module of slot 6 on connector X30-2. These are respectively on machine 1 and/or 2.
BASIC IOM MODULE SIGNAL ALLOCATION
ROBOT BASIC IOM MODULE (SLOT 4-6) TRANSFER
SMART S FAMILY
X91
PIN
ALL COMAU ROBOTS
EXCEPT SMART S FAMILY SW. ALLOCATION X30 (X30-2)
PINX90
PIN
X91
PIN INP/OUT IOM SLOT 4 IOM SLOT 6
C T — INP 1 ($DIN[1]) ($DIN[33]) 91
D U — INP 2 ($DIN[2]) ($DIN[34]) 92
E V — INP 3 ($DIN[3]) ($DIN[35]) 93
F W — INP 4 ($DIN[4]) ($DIN[36]) 94
— X — INP 5 ($DIN[5]) ($DIN[37]) 95
— — C INP 6 ($DIN[6]) ($DIN[38]) 96
— — N INP 7 ($DIN[7]) ($DIN[39]) 97
— — S INP 8 ($DIN[8]) ($DIN[40]) 98
G C — INP 9 ($DIN[9]) ($DIN[41]) 73
H D — INP 10 ($DIN[10]) ($DIN[42]) 74
R E — INP 11 ($DIN[11]) ($DIN[43]) 75
S F — INP 12 ($DIN[12]) ($DIN[44]) 76
— G — INP 13 ($DIN[13]) ($DIN[45]) 77
— — D INP 14 ($DIN[14]) ($DIN[46]) 78
— — P INP 15 ($DIN[15]) ($DIN[47]) 79
— — T INP 16 ($DIN[16]) ($DIN[48]) 80
L H — OUT 1 ($DOUT[17]) ($DOUT[49]) 99
M c — OUT 2 ($DOUT[18]) ($DOUT[50]) 100
N J — OUT 3 ($DOUT[19]) ($DOUT[51]) 101
P Y — OUT 4 ($DOUT[20]) ($DOUT[52]) 102
— Z — OUT 5 ($DOUT[21]) ($DOUT[53]) 103
— — F OUT 6 ($DOUT[22]) ($DOUT[54]) 104
— a — OUT 7 ($DOUT[23]) ($DOUT[55]) 105
— b — OUT 8 ($DOUT[24]) ($DOUT[56]) 106
— M — OUT 9 ($DOUT[25]) ($DOUT[57]) 82
— N — OUT 10 ($DOUT[26]) ($DOUT[58]) 83
— P — OUT 11 ($DOUT[27]) ($DOUT[59]) 84
— R — OUT 12 ($DOUT[28]) ($DOUT[60]) 85
— S — OUT 13 ($DOUT[29]) ($DOUT[61]) 86
— K — OUT 14 ($DOUT[30]) ($DOUT[62]) 87
— L — OUT 15 ($DOUT[31]) ($DOUT[63]) 88
BASIC CONF. IOM POWER SUPPLY (SLOT 4 - SLOT 6)
24 VDC POWER SUPPLY OUTSIDE THE C3G Plus 24 VDC POWER SUPPLY INSIDE THE C3G Plus
POSITION:
JP200/SDB3 (SDB3-2) PIN 2-3 - (OUT 1 � OUT 8)
JP201/SDB3 (SDB3-2) PIN 2-3 - (OUT 9 � OUT 16) JP 200/SDB3 (SDB3-2) PIN 1-2 (OUT 1 � 8)
JP 201/SDB3 (SDB3-2) PIN 1-2 (OUT 9 � 16)
CONNECT EXTERNAL POWER SUPPLY:
X30 (X30-2) PIN 107 -> +24 Vdc
PIN 108 -> 0 V (24 Vdc)
C3G Plus INTEGRATION GUIDE
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CONNECTOR X91
Pin Signal
A Internal + 24 Vdc
B Internal 0 Vdc
C User available wire n° 26 twist./pair 3
D User available wire n° 27 twist./pair 3
E Twist./pair 3 shield
F User available wire n° 25
G Safety flange OUT
H Safety flange INP
J ROBOT alarm OUT
K ROBOT alarm INP
L HIGH SPEED INPUT +
M HIGH SPEED INPUT -
N User available wire n° 28 twist./pair 1
P User available wire n° 29 twist./pair 1
R Twist./pair 1 shield
S User available wire n° 30 twist./pair 2
T User available wire n° 31 twist./pair 2
U Twist./pair 2 shield
Connectors X90 and X91 for all COMAU Robots except the SMART S family
CONNECTOR X91
PIN SIGNALA +24 VDC
B 0 V (+24 VDC)
C USER AVAILABLE WIRE 15
D USER AVAILABLE WIRE 16
E USER AVAILABLE WIRE 17
F USER AVAILABLE WIRE 18
G USER AVAILABLE WIRE 1
H USER AVAILABLE WIRE 2
J HIGH SPEED INPUT +
K HIGH SPEED INPUT -
L USER AVAILABLE WIRE 6
M USER AVAILABLE WIRE 24
N USER AVAILABLE WIRE 7
P USER AVAILABLE WIRE 20
R USER AVAILABLE WIRE 3
S USER AVAILABLE WIRE 4
Connectors X91 and X92 for SMART S2-S3-S4
INTEGRATION GUIDE C3G Plus
4-18 01/0498
CONNECTOR X92
PIN SIGNAL
1 SAFETY FLANGE
3 SAFETY FLANGE
2 INTERNAL 0 VDC
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CONNECTOR X90
PIN SIGNAL
A + 24 Vcc interno
B 0 Vcc interno
C User available wire 1
D User available wire 2
E User available wire 3
F User available wire 4
G User available wire 5
H User available wire 6
J User available wire 7
K User available wire 8
L User available wire 9
M User available wire 10
N User available wire 11
P User available wire 12
R User available wire 13
S User available wire 14
T User available wire 15
U User available wire 16
V User available wire 17
W User available wire 18
X User available wire 19
Y User available wire 20
Z User available wire 21
a User available wire 22
b User available wire 23
c User available wire 24
Connectors X200 and X201 for robot SMART H4
Connectors X200 and X201 are installed on robot flange distribution unit. If safety flange is
mounted, remove jumpers X9 - X10 on terminal boards X8 and X9 located inside robot arm
sectioning units.
C3G Plus INTEGRATION GUIDE
04/0799 4-19
CONNECTOR X200
PIN SIGNAL
A +24 Vdc
B 0V (+24Vdc)
C $DIN [9]
D $DIN [10]
E $DIN [11]
F $DIN [12]
G $DIN [13]
H $DOUT [17]
J $DOUT [18]
K $DOUT [19]
L SAFETY FLANGE M1 OUT
M +24 Vdc
N NOT CONNECTED
P $DOUT [27]
R $DOUT [28]
S $DOUT [29]
T SAFETY FLANGE M1 INP
U $DIN [2]
V $DIN [3]
W $DIN [4]
X $DIN [5]
Y $DOUT [20]
Z GROUND
a SHIELD
b KSR 1
c KSR 2
CONNECTOR X201
PIN SIGNAL
A +24 Vdc
B 0V (+24Vdc)
C $DIN [6]
D $DIN [14]
E AVAILABLE
F $DOUT [22]
G $DOUT [23]
H $DOUT [24]
J $DOUT [21]
K $DIN [1]
L $DOUT [25]
M $DOUT [26]
N $DIN [7]
P $DIN [15]
R AVAILABLE
S $DIN [8]
T HSI -
U AVAILABLE
V AVAILABLE
W AVAILABLE
X AVAILABLE
Y AVAILABLE
Z GROUND
a AVAILABLE
b AVAILABLE
c HSI +
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Example of I/O Connection with External 24 Vdc Power Supply
MACHINE LINE - ROBOT SIGNALS
For the connection of signals from the machine line to the robot it is possible to use the input channels con-
nected directly from connector X30 (X30-2) to the connector on the robot and shown in the previous table.
The current/voltage limits of the inputs must never be exceeded.
CONNECTION OF ADDITIONAL I/O MODULES
The additional I/O modules inserted in the Control Unit (CU) rack have a front connector usually identified as
J3 which is connected by a harness and a 64-PIN HARTING connector located on the front panel of the con-
troller, in the provisions reserved for additional connectors identified as X31 for the first module, X32 for the
second and so on in rising order.
INTEGRATION GUIDE C3G Plus
4-20 03/0499
INP1
X3/IOM X30
A1
F1
AR
CC
C1
OUT1
CR
91
+-
24 Vcc EXT
X90/ROBOT
T
B
C
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0 V (+24 Vcc INT)
(IOM)
73
107
99
108
JP 200/SDB3
0 V +24 Vcc
1 2 3
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Additional I/O modules
C3G Plus INTEGRATION GUIDE
01/0498 4-21
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Refer to the tables given below for connection of the power supplies and signals present on the HARTING
connectors (X3x).
Conductors
For connection, use COMAU cable code 00420859 with the following characteristics:
Composition 40 x 18 AWG black conductors
8 x 14 AWG black conductors
3 x 20 AWG twisted pairs individually shielded
Operating voltage 300/550 V
Test voltage 1500 V
Operating temperature 80 °C
Outside diameter 29 mm max.
Outer sheath RAL 7035 grey PVC
Shielding 85% cover-copper plait
It should be remembered that for installations in Italy the conductors must comply with CEI 20-22 standards
second part; if the COMAU cable is not used, conductors with equivalent electrical characteristics and com-
plying with UL 758 VW1 standards must be used.
Failure to comply with the above instructions results in non-compliance with the UL approval
standard of the module to which the cable is connected.
The maximum permissible distances for connections are given in the following figure.
The connection cables of connectors X3x leading from the remote unit must be shielded and
the shielding must be earthed appropriately.
Maximum Permissible Distances for Connections
INTEGRATION GUIDE C3G Plus
4-22 01/0498
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C3G-IOM (16 INPUT/16 OUTPUT MODULE)
This is a slave module of the VME bus.
The module can be configured for C3G IOM user or C3G IOMs system I/O’s (special version); in this case it is recognised by the RBC
module and mapped in the area of I/O’s not available to the user and the function of each channel is pre-defined univocally.
It handles up to 16 Inputs and 16 Outputs. The outputs are protected by fuse with, in the event of breakage, specific monitoring indica-
tion. When an input or output is activated the corresponding LED on the front panel lights up.
It may be added on the Control Unit rack starting from the first external slot at the right of the base configuration modules.
TECHNICAL CHARACTERISTICS
INPUT
Number of inputs
16
Number of common returns (0 V)
2
Type of input
IEC Type 1
Input voltage for channel activation
14 to 36 Vdc
Input voltage for channel deactivation
0 to 5 Vdc
Input current with channel activated
2 to 15 mA
Input current with channel not activated
0.5 mA
OUTPUT
Number of outputs
16
Number of common returns (24 Vdc)
2
Fuses (one for each common return)
5 A/250 V Normal Blow
Type of output
transistor
Operating voltage
4.5 to 36 Vdc
Maximum output current with all channels active
0.5 A @ ta = 25°C
0.4 A @ ta = 45°C
SIGNAL ALLOCATION
SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE) SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE)
IOM MOD.
SYSTEM CONFIG.
– AC – OUTPUT 1 C1 C1 C1
IOM MOD.
SYSTEM CONFIG.
– BC – OUTPUT 2 C2 C2 C2
INPUT 1 A1 A1 A1 OUTPUT 3 C3 C3 C3
INPUT 2 A2 A2 A2 OUTPUT 4 C4 C4 C4
INPUT 3 A3 A3 A3 OUTPUT 5 C5 C5 C5
INPUT 4 A4 A4 A4 OUTPUT 6 C6 C6 C6
INPUT 5 A5 A5 A5 OUTPUT 7 C7 C7 C7
INPUT 6 A6 A6 A6 OUTPUT 8 C8 C8 C8
INPUT 7 A7 A7 A7 OUTPUT 9 D1 D1 D1
INPUT 8 A8 A8 A8 OUTPUT 10 D2 D2 D2
INPUT 9 B1 B1 B1 OUTPUT 11 D3 D3 D3
INPUT 10 B2 B2 B2 OUTPUT 12 D4 D4 D4
INPUT 11 B3 B3 B3 OUTPUT 13 D5 D5 D5
INPUT 12 B4 B4 B4 OUTPUT 14 D6 D6 D6
INPUT 13 B5 B5 B5 OUTPUT 15 D7 D7 D7
INPUT 14 B6 B6 B6 OUTPUT 16 D8 D8 D8
INPUT 15 B7 B7 B7 OUT 1 � 8 COM. – CC C10
INPUT 16 B8 B8 B8 OUT 9 � 16 COM. – DC D10
INPUT 1 � 8 RET. – AR A12 OUT 1 � 8 RIT. – CR C12
INPUT 9 � 16 RET. – BR B12 OUT 9 � 16 RIT. – DR D12
OUT FUSES FUSE – –
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EXAMPLE OF CONNECTION
EXAMPLE OF USE OF THE IOMs MODULE IN
HANDLING A MULTI-MACHINE SYSTEM
INTEGRATION GUIDE C3G Plus
4-24 01/0498
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C3G-ACI 32 AC INPUT MODULE
VME Input module compatible with 110 Vac 32 channel slave type interface, with signalling through activation of LEDs on front panel
when an input is present.
It may be added on the Control Unit rack starting from the first free slot at the right of the basic configuration modules.
TECHNICAL CHARACTERISTICS
INPUT
Number of inputs
32
Number of common returns (0 V)
4
Input voltage for channel activation
79.0 to 132.0 Vac
Input voltage for channel deactivation
0.0 to 20.0 Vac
Input current with channel activated
4.0 to 15.0 mA
Maximum input current with channel not activated
1.5 mA
Operating frequency
47 to 63 Hz
SIGNAL ALLOCATION
SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE)SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE)
INPUT 1 A1 A1 A1 INPUT 17 C1 C1 C1
INPUT 2 A2 A2 A2 INPUT 18 C2 C2 C2
INPUT 3 A3 A3 A3 INPUT 19 C3 C3 C3
INPUT 4 A4 A4 A4 INPUT 20 C4 C4 C4
INPUT 5 A5 A5 A5 INPUT 21 C5 C5 C5
INPUT 6 A6 A6 A6 INPUT 22 C6 C6 C6
INPUT 7 A7 A7 A7 INPUT 23 C7 C7 C7
INPUT 8 A8 A8 A8 INPUT 24 C8 C8 C8
INPUT 9 B1 B1 B1 INPUT 25 D1 D1 D1
INPUT 10 B2 B2 B2 INPUT 26 D2 D2 D2
INPUT 11 B3 B3 B3 INPUT 27 D3 D3 D3
INPUT 12 B4 B4 B4 INPUT 28 D4 D4 D4
INPUT 13 B5 B5 B5 INPUT 29 D5 D5 D5
INPUT 14 B6 B6 B6 INPUT 30 D6 D6 D6
INPUT 15 B7 B7 B7 INPUT 31 D7 D7 D7
INPUT 16 B8 B8 B8 INPUT 32 D8 D8 D8
INPUT 1 � 8 RET. – AR A12 INP. 17 � 24 RET. – CR C12
INPUT 9 � 16 RET. – BR B12 INP. 25 � 32 RET. – DR D12
FUSE (NOT USED) FUSE – –
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C3G-DCI 32 DC INPUT MODULE
VME Input module compatible with 24 Vdc 32 channel slave type interface, with signalling through activation of LEDs on front panel
when an input is present.
It may be added on the Control Unit rack starting from the first free slot at the right of the basic configuration modules.
All the channels are protected against polarity inversion through double diode.
TECHNICAL CHARACTERISTICS
INPUT
Number of inputs
32
Number of common returns
4
Type of input
IEC type 1
Input voltage for channel activation
14.0 to 36.0 Vdc
Input voltage for channel deactivation
0.0 to 5.0 Vdc
Input current with channel activated
2.0 to 15.0 mA
Maximum input current with channel not activated
0.5 mA
Protection against polarity inversion
Through diode
SIGNAL ALLOCATION
SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE) SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE)
INPUT 1 A1 A1 A1 INPUT 17 C1 C1 C1
INPUT 2 A2 A2 A2 INPUT 18 C2 C2 C2
INPUT 3 A3 A3 A3 INPUT 19 C3 C3 C3
INPUT 4 A4 A4 A4 INPUT 20 C4 C4 C4
INPUT 5 A5 A5 A5 INPUT 21 C5 C5 C5
INPUT 6 A6 A6 A6 INPUT 22 C6 C6 C6
INPUT 7 A7 A7 A7 INPUT 23 C7 C7 C7
INPUT 8 A8 A8 A8 INPUT 24 C8 C8 C8
INPUT 9 B1 B1 B1 INPUT 25 D1 D1 D1
INPUT 10 B2 B2 B2 INPUT 26 D2 D2 D2
INPUT 11 B3 B3 B3 INPUT 27 D3 D3 D3
INPUT 12 B4 B4 B4 INPUT 28 D4 D4 D4
INPUT 13 B5 B5 B5 INPUT 29 D5 D5 D5
INPUT 14 B6 B6 B6 INPUT 30 D6 D6 D6
INPUT 15 B7 B7 B7 INPUT 31 D7 D7 D7
INPUT 16 B8 B8 B8 INPUT 32 D8 D8 D8
INPUT 1 � 8 RET. – AR A12 INP. 17 � 24 RET. – CR C12
INPUT 9 �16 RET. – BR B12 INP. 25 � 32 RET. – DR D12
FUSE (NOT USED) FUSE – –
INTEGRATION GUIDE C3G Plus
4-26 00/1097
EXAMPLE OF CONNECTION
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C3G-DLO 32 DC 0,5 A OUTPUT MODULE
VME output module compatible with slave type interface capable of supporting 32 dc Outputs (0.5 A) with signalling through activation
of LEDs on the front panel when the outputs are active.
It may be added on the Control Unit rack starting from the first free slot at the right of the basic configuration modules.
The outputs are protected by fuse with specific indication on the monitoring system if it is tripped.
TECHNICAL CHARACTERISTICS
OUTPUT
Number of outputs
32
Number of common returns
4
Fuses (one for each common return)
5 A 125 V “Normal Blow” 5 x 20
Type of output
Transistor
Operating voltage
4.5 to 36.0 Vdc
Maximum output current with channel not activated
0.2 mA
Maximum voltage drop with channel active
1.8 Vdc
Maximum output current with all channels active
0.5 A @ ta = 25°C
0.4 A @ ta = 45°C
Protection against transients
Through diode
SIGNAL ALLOCATION
SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE) SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE)
OUTPUT 1 A1 A1 A1 OUTPUT 17 C1 C1 C1
OUTPUT 2 A2 A2 A2 OUTPUT 18 C2 C2 C2
OUTPUT 3 A3 A3 A3 OUTPUT 19 C3 C3 C3
OUTPUT 4 A4 A4 A4 OUTPUT 20 C4 C4 C4
OUTPUT 5 A5 A5 A5 OUTPUT 21 C5 C5 C5
OUTPUT 6 A6 A6 A6 OUTPUT 22 C6 C6 C6
OUTPUT 7 A7 A7 A7 OUTPUT 23 C7 C7 C7
OUTPUT 8 A8 A8 A8 OUTPUT 24 C8 C8 C8
OUTPUT 9 B1 B1 B1 OUTPUT 25 D1 D1 D1
OUTPUT 10 B2 B2 B2 OUTPUT 26 D2 D2 D2
OUTPUT 11 B3 B3 B3 OUTPUT 27 D3 D3 D3
OUTPUT 12 B4 B4 B4 OUTPUT 28 D4 D4 D4
OUTPUT 13 B5 B5 B5 OUTPUT 29 D5 D5 D5
OUTPUT 14 B6 B6 B6 OUTPUT 30 D6 D6 D6
OUTPUT 15 B7 B7 B7 OUTPUT 31 D7 D7 D7
OUTPUT 16 B8 B8 B8 OUTPUT 32 D8 D8 D8
OUT 1 � 8 COM. – AC A10 OUT. 17 � 24 COM. – CC C10
OUT 1 � 8 RET. – AR A12 OUT. 17 � 24 RET. – CR C12
OUT 9 � 16 COM. – BC B10 OUT. 25 � 32 COM. – DC D10
OUT 9 � 16 RET. – BR B12 OUT. 25 �32 RET. – DR D12
OUT. COM.
EARTH FUSE FUSE – –
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C3G-DHO 32 DC 2A OUTPUT MODULE
VME output module compatible with slave type interface capable of supporting 32 dc Outputs (2 A) with signalling through activation of
LEDs on the front panel when the outputs are active.
It may be added on the Control Unit rack starting from the first free slot at the right of the basic configuration modules.
The outputs are protected by fuse with specific indication on the monitoring system if it is tripped.
TECHNICAL CHARACTERISTICS
OUTPUT
Number of outputs
32
Number of common returns
4
Fuses (one for each common return)
8 A 125 V “Normal Blow” 5 x 20
Type of output
Transistor
Operating voltage
4.5 to 36.0 Vdc
Maximum output current with channel not activated
0.2 mA
Maximum output current
CHANNELS ACTIVE CURRENT CURRENT
SIMULTANEOUSLY @ ta = 25°C @ ta = 45°C
4 2A 1,5A
8 1,5A 1A
16 1A 0,7A
32 0,7A 0,4A
SIGNAL ALLOCATION
SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE) SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE)
OUTPUT 1 A1 A1 A1 OUTPUT 17 C1 C1 C1
OUTPUT 2 A2 A2 A2 OUTPUT 18 C2 C2 C2
OUTPUT 3 A3 A3 A3 OUTPUT 19 C3 C3 C3
OUTPUT 4 A4 A4 A4 OUTPUT 20 C4 C4 C4
OUTPUT 5 A5 A5 A5 OUTPUT 21 C5 C5 C5
OUTPUT 6 A6 A6 A6 OUTPUT 22 C6 C6 C6
OUTPUT 7 A7 A7 A7 OUTPUT 23 C7 C7 C7
OUTPUT 8 A8 A8 A8 OUTPUT 24 C8 C8 C8
OUTPUT 9 B1 B1 B1 OUTPUT 25 D1 D1 D1
OUTPUT 10 B2 B2 B2 OUTPUT 26 D2 D2 D2
OUTPUT 11 B3 B3 B3 OUTPUT 27 D3 D3 D3
OUTPUT 12 B4 B4 B4 OUTPUT 28 D4 D4 D4
OUTPUT 13 B5 B5 B5 OUTPUT 29 D5 D5 D5
OUTPUT 14 B6 B6 B6 OUTPUT 30 D6 D6 D6
OUTPUT 15 B7 B7 B7 OUTPUT 31 D7 D7 D7
OUTPUT 16 B8 B8 B8 OUTPUT 32 D8 D8 D8
OUT 1 � 8 COM. – AC A10 OUT. 17 � 24 COM. – CC C10
OUT 1 � 8 RET. – AR A12 OUT. 17 � 24 RET. – CR C12
OUT 9 � 16 COM. – BC B10 OUT. 25 � 32 COM. – DC D10
OUT 9 � 16 RET. – BR B12 OUT. 25 � 32 RET. – DR D12
OUT. COM.
EARTH FUSE FUSE – –
INTEGRATION GUIDE C3G Plus
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EXAMPLE OF CONNECTION
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C3G-ACO 16 AC 1A OUTPUT MODULE
VME output module compatible with slave type interface capable of supporting 16 ac Outputs (1 A) with signalling through activation of
LEDs on the front panel when the outputs are active.
It may be added on the Control Unit rack starting from the first free slot at the right of the basic configuration modules.
The outputs are protected by fuse with specific indication on the monitoring system if it is tripped.
TECHNICAL CHARACTERISTICS
OUTPUT
Number of outputs
16
Number of common returns
4
Fuses (one for each common return)
4 x 5 A 125 V “Normal Blow” 5 x 20
Type of output
Triac
Operating voltage
79.0 to 132.0 Vac
Maximum output current with channel not activated
6.0 mA at 60°C
Maximum voltage drop with 0.5 A load
1.8 Vac
Maximum output current
CHANNELS ACTIVE CURRENT CURRENT
SIMULTANEOUSLY @ ta = 25°C @ ta = 45°C
16 1 A 0,4 A
Supply frequency
47 to 63 Hz
SIGNAL ALLOCATION
SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE) SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE)
OUTPUT 1 A1 A1 A1 OUTPUT 9 C1 C1 C1
OUTPUT 2 A2 A2 A2 OUTPUT 10 C2 C2 C2
OUTPUT 3 A3 A3 A3 OUTPUT 11 C3 C3 C3
OUTPUT 4 A4 A4 A4 OUTPUT 12 C4 C4 C4
OUTPUT 5 B1 B1 B1 OUTPUT 13 D1 D1 D1
OUTPUT 6 B2 B2 B2 OUTPUT 14 D2 D2 D2
OUTPUT 7 B3 B3 B3 OUTPUT 15 D3 D3 D3
OUTPUT 8 B4 B4 B4 OUTPUT 16 D4 D4 D4
OUT 1 � 4 COM. – AC A10 OUT. 9 �12 COM. – CC C10
OUT 1 � 4 RET. – AR A12 OUT. 9 � 12 RET. – CR C12
OUT 5 � 8 COM. – BC B10 OUT. 13 � 16 COM. – DC D10
OUT 5 � 8 RET. – BR B12 OUT. 13 � 16 RET. – DR D12
OUT. COM.
EARTH FUSE FUSE – –
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C3G-RLO 16 AC 2A RELAY OUTPUT MODULE
VME output module compatible with slave type interface capable of supporting 16 dc or ac outputs (max 2 A), with signalling through ac-
tivation of LEDs on the front panel when the outputs are active.
It may be added on the Control Unit rack starting from the first free slot at the right of the base configuration modules.
Each output channel is protected individually by fuse. For this module fuse monitoring is not provided.
The coil of the relays must be supplied externally at 24 Vdc.
TECHNICAL CHARACTERISTICS
OUTPUT
Number of outputs 16
Number of common returns 4
Fuses (one for each common return)
4 x 3 A 250 V “Normal Blow” 5 x 20
Type of output Relay
Operating voltage
4.5 to 36.0 Vdc
20.0 to 265 Vac
Maximum output current with channel not activated 0.0 mA
Repetition frequency 6 Hz
Coil 24 Vdc ± 10%
Maximum contact resistance
With 0.5 to 2 A current
With 10 to 500 mA current
Maximum output current
CHANNELS ACTIVE RESISTIVE INDUCTIVE
SIMULTANEOUSLY LOAD LOAD
CURRENT CURRENT
@ ta = 45°C @ ta = 45°C
AC/DC AC DC
8 2A 1A 0,85A
16 1,5A
SIGNAL ALLOCATION
SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE) SIGNAL RED
LED
CONN. J3 PIN
(MOD. FRONT)
CONN. X3X PIN
(CABINET BASE)
OUTPUT 1 A1 A1 A1 OUTPUT 9 C1 C1 C1
OUTPUT 2 A2 A2 A2 OUTPUT 10 C2 C2 C2
OUTPUT 3 A3 A3 A3 OUTPUT 11 C3 C3 C3
OUTPUT 4 A4 A4 A4 OUTPUT 12 C4 C4 C4
OUTPUT 5 B1 B1 B1 OUTPUT 13 D1 D1 D1
OUTPUT 6 B2 B2 B2 OUTPUT 14 D2 D2 D2
OUTPUT 7 B3 B3 B3 OUTPUT 15 D3 D3 D3
OUTPUT 8 B4 B4 B4 OUTPUT 16 D4 D4 D4
OUT. 1 � 4 COM. – AC A10 OUT. 9 � 12 COM. – CC C10
OUT. 1 � 4 RET. – AR A12 OUT. 9 � 12 RET. – CR C12
OUT. 5 � 8 COM. – BC B10 OUT. 13 � 16 COM. – DC D10
OUT. 5 � 8 RET. – BR B12 OUT. 13 � 16 RET. – DR D12
USER POWER
+24 Vcc – C7 C7
USER POWER 0V
(+24 Vcc) – C8 C8
FUSE (NOT
USED) FUSE – –
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R =
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C3G-ADM 2 ANALOG OUT-8 DC INP - 8 DC OUT
VME Input/Output module compatible with slave type interface. It comprises 2 analogue output channels, 8 24 VDC digital input chan-
nels and 8 24 VDC digital output channels with signalling by LEDs on the front panel when the channels are active. It may be added on
the Control Unit rack starting from the first free slot on the right of the basic configuration modules.
POWER FAILURE ON OPTOISOLATED ANALOGUE OUTPUTS POWER SUPPLY VOLTAGE
On the ADM module, detection of the presence of the power supply voltage (24 Vdc) of the optoisolated analogue section is provided.
Suitably positioning a 3-position jumper block it is possible to choose one of the following indications:
� position NF/8 (Signalling level: NONE)
- The lack of external voltage is not detected.
� position F/8 (Signalling level: SYSTEM)
- The lack of external voltage causes activation (1) of the FAIL bit in the status register on the VME Bus and consequently a fatal
alarm that blocks the system.
� position NF/ST (Signalling level: USER)
- In this case input no. 8 is dedicated to signalling the power failure at user level and therefore subtracted from normal use; any
external use of channel 8 (connection on connector J3) is ignored. The system user can programme the effect of this alarm via
PDL2.
TECHNICAL SPECIFICATIONS
DIGITAL INPUTS DIGITAL OUTPUTS ANALOGUE OUTPUTS
Number of inputs
8
Number of common earths
1
Input voltages for channel activation
14.0 to 36.0 Vdc
Input voltage for channel deactivation
0.0 to 5.0 Vdc
Input current with channel activated
2.0 to 15 mA
Maximum input current with channel
not activated
0.5 mA
Protection against polarity inversion
Through diode
Number of outputs
8
Number of common outputs
1
Fuse (on common return)
8A 125 V Normal Blow 5x20
Type of output
Transistor
Operating voltage
4.5 to 36 Vdc
Maximum output current with channel not
activated
0.2 mA
Maximum voltage drop with channel active
2.2 Vdc
Maximum output current
CHANNELS ACTIVE CURRENT CURRENT
SIMULTANEOUSLY @ ta = 25°C @ ta =
45°C
4 2 A 1,5 A
8 1 A 0,5 A
Protection against transient through diode
Number of outputs
2
Type of output
Single-ended Optoisolated
Voltage
from 0 V to +10V
Load resistance
Output in voltage: minimum 2000 �
Resolution
11 bit
Precision
±0.5% full scale value at 25°C
±0.7% full scale value at 60°C
Reply time for all output channels
10 ms maximum
Settling time
1 ms max.
Short-circuit effects
No damage due to permanent short circuit
Insulation voltage
1500 Vms
The analogue outputs are not isolated from one another
Power supply voltage of the optoisolated section
External 24 Vdc ± 20% (absorption max. 0.05 A)
Fuse on power supply of the optoisolated section
1 A 125 V Normal Blow 5x20
“Power fail” signal on power supply of the
optoisolated section for external voltagewith the controller, and a short explanation of the purpose of each programme.
Some programmes have a file (*.DOC) which contains the explanations for use, available on floppy disk “2/2
C3G CONFIGURATION TOOL” with the exception of the TRI_PAR programme available on floppy disk “1/2
C3G CONFIGURATION TOOL”.
The explanation of the TRICAL programme is given in the manual concerning this subject.
Below is the list of programs together with the name of the explanatory document:
1) CICONF.CPK
CI_INST.COD
CI_INST.DOC
: This programme makes it possible to configure and display the I/O points
present on the local (Control Unit) and remote bases and makes it possible
to define sets of inputs ($GIN) and sets of outputs ($GOUT).
2) FAMCNFG.CPK
FA_INST.COD
FAMILY.DOC
: This programme makes it possible to configure machines of the MAST,
PMAST and SMART families. It also makes it possible to modify the pa-
rameters of the special axes of a robot.
3) FTPCNFG.CPK
FTP_INST.COD
FTP_INST.DOC
: This programme enables file transfer protocol (FTP) configuration.
4) IBSM.COD
IBSM1.COD
IBSM.DOC
: This programme makes it possible to configure and diagnose the IBS-M
board (INTERBUS-S MASTER).
5) RICNFG.CPK
RI_INST.COD
RI_INST.DOC
: This programme makes it possible to enter certain parameters concerning
the serial management protocols of remote I/O’s (IBS, L2, RIO) and define
the type of IOS module.
6) SHAND.CPK
SH_INST.COD
SH_INST.DOC
: This programme makes it possible to configure certain parameters of the
hand and also to modify its status.
7) TO_SET.CPK
TO_INST.COD
TO_SET.DOC
: This programme makes it possible to calculate the values of the tool (tool
tern) and frame (position of the piece to be machined in relation to the
world tern).
8) TRICAL.COD
TRICAL_M.COD
: Tricept robot calibration programme.
9) CRASH.COD : Saves the last three system crashes in the CRASH.DAT ascii file.
10) PRESSE.COD : Makes it possible to disable the acc./dec. modulation algorithm for Smart 3
robots which differ from SMART 6.75P models.
11) DRIVE.COD : Disables the “undefined drive full scale current value” and “incorrect drive
full scale current value” alarms.
12) TRI_PAR.COD
TRIPAR_I.DOC
: Makes it possible to choose the ILCO or PI part of the Tricept data file
13) CVCONV.CPK
CV_INST.COD
: This program permits the C3G.SYS data recovery from the release 5.3x to
the release 5.4x.
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14) HELPIO.COD
HELPIO.DOC
: It permits to configure the help of the command DISPLAY INPUT/OUT-
PUT.To this purpose, the program HELPIO.COD has to be modified (by
PROGRAM EDIT) and sent to execution (by PROGRAM GO), after loading
the program HELPIO2:COD to the memory (by MEMORY LOAD.
15) COMAFEAF.GSD : Makes it possible to configure the DP SLAVE Profibus on PLC.
16) COMAO4A1.GSD : Enables configuration of card PF-DP by means of the PLC
17) C3G_EDN.EDS : It permits to configure DeviceNet from PLC.
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INTEGRATION GUIDE C3G Plus
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SAFETY REGULATIONS 1-1
INSTALLATION 2-1
OPERATOR INTERFACE 3-1
INTEGRATION GUIDE 4-1
MAIN OPERATIONS FOR SYSTEM USE 5-1
EMERGENCY PROCEDURES 6-1
MAINTENANCE 7-1
SUMMARY
Paragraph Page
System operating modes 5-1
System statuses 5-1
System status in multimachine - multiarm configuration 5-4
Robot movement in programming status 5-5
File management between PC and cell controller 5-10
Use of the Floppy Disk unit 5-11
Examples of the use of digital I/O’s and analogue outputs 5-12
Calibration 5-13
Kinematic compensation algorithm5-19
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C3G Plus
Operations and
Maintenance Manual
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Operations and
Maintenance Manual C3G Plus
SYSTEM OPERATING MODES
The controller can work in three ways, which can be selected through the status selector on the control panel
of the controller: automatic local, automatic remote and programming.
The automatic local mode makes it possible to execute production programmes which, as they contain in-
structions for robot movement, can be started by pressing the START button on the PTU4 programming ter-
minal. The status selector should be set to the automatic local position .
The automatic remote mode is similar to automatic local, but the commands for example for starting are sent
from a remote device, such as PLC or work station. The status selector should be set to the automatic re-
mote position .
The programming mode is used when creating and checking the programmes. For safety reasons, robot
movements are performed at lower speed than in the automatic mode (the maximum speed of a robot al-
lowed during programming is 250 mm/sec on the centre of the flange).
The status selector should be set to the programming position . Programmes can be developed using
the editor environment (for further information see the C3G Programming Guide). The points can be learnt
by the programming terminal moving the robot manually with the movement buttons, the programmes can be
fine-tuned using the debug tools offered by the system. During programming, to execute a movement in-
struction, the operator must press the START button and the enable button on the programming terminal.
When the status selector is set to programming or automatic local , operation is in the local mode.
When the selector is at automatic remote , operation is remote.
Before being able to perform any operation requiring movement, the drives power has to be switched on.
This takes place pressing the DRIVE ON button on the programming terminal. If the status selector is at pro-
gramming , the enable button should also be kept pressed to power the drives. To turn the drives off
and activate the brakes for all the robots connected to the controller, simply release the enable button.
SYSTEM STATUSES
The status the system is in mainly depends on:
� the status selector on the control panel
� the optional AUTO/MAN selector on the programming terminal
� the DRIVE ON, DRIVE OFF and HOLD keys on the programming terminal
System transition from one status to the other is also affected by the enable button and the terminal on con-
trol unit button, both on the programming terminal.
The controller may be in one of the following four statuses:
� AUTO: this is the status generally used for executing production programmes which control robot move-
ment.
� PROG: in this status the robot can be moved manually using the jog keys or executing programme instruc-
tions (from editor environment or EXECUTE command). In the latter case, the START button and the enable
button must be kept pressed to be able to perform the movement.
If the C3G-CSM (Controlled Stop Module) is installed on the controller, in AUTO LOCAL and AUTO RE-
MOTE states, an emergency stop and/or opening of the safety gates causes controlled stopping of the robot
(EN 60204-1), category 1 stop). In this way, power is cut off (opening of the power contactor) after 1 second.
In PROGR. programming status, the power is cut off immediately (EN 60204-1, category 0 stop).
� HOLD: in this status the arm is gradually decelerated until reaching the stopping point; the movement is
suspended and also execution of the movement programmes (called holdable). When all the conditions
necessary to exit the HOLD status are fulfilled, the system returns to the previous status (programming
or automatic) but, it is necessary to press the START button to resume execution of the movement
programmes.
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� ALARM: this status is reached following a system alarm. The system starts different actions such as
suspending programme execution, deactivating drives, etc. depending on the seriousness of the error.
The system current status is displayedon the first status line of the programming terminal (or PC video, if the
PCINT tool is used with CRT emulation procedure).
The figure below shows a simplified layout of the actions that cause the system to pass from one status to
another.
Simplified layout of system statuses
HOLD status
The rules connected with safety in operating with the controller ensure that the system enters the HOLD status every
time a change is made in the operating mode, passing for example from automatic local to programming .
To exit the HOLD status to enable a certain operating mode, all the conditions connected with safety must be
fulfilled. A typical example is when the operator moves the status selector to the programming position
to work away from the control unit holding the programming terminal to carry out operations such as teaching
points.
The input in the HOLD status causes retaining of the HOLD button on the programming terminal. This button
must be pressed to exit the HOLD status.
If the HOLD status has been caused by pressing the DRIVE OFF button on the programming terminal, it will
be necessary to press the DRIVE OFF and HOLD buttons again to exit the HOLD status and the DRIVE ON
button to re-enable the drives.
AUTO status
For the system to be in the AUTO status, the status selector on the control panel must be in the automatic lo-
cal or automatic remote position.
In the AUTO status, to start programmes that are ready to be run it is necessary to press the START button
on the programming terminal or send the START input from remote.
MAIN OPERATIONS FOR SYSTEM USE C3G Plus
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PROG HOLD
Hold
ALARM
AUTO
TPOC
Key type status switch (CP)
to Automatic Remote or Local
Wait for
TPOC
Key type status switch
(CP) to PROGRAMMING,
Auto/Man switch (TP) to
MAN and HOLD unlatched
Key type status switch (CP) change
or Auto/Man switch (TP) change to
MAN or HOLD or DRIVES OFF
Auto/Man switch (TP)
change to AUTO or HOLD
or DRIVES OFF
Key type status (CP) to
PROG, Auto/Man switch
(TP) to AUTO and HOLD
unlatched
Key type status switch
(CP) to Automatic Remote
or Local and HOLD unlatched
(unlatched)
Key type status switch
(CP) to PROG, Auto/Man
switch (TP) to AUTO and
enable button unlatched
Key type status switch (CP)
to PROG, Auto/Man switch
(TP) to AUTO and enable
button unlatched
CP = Control Panel
TPOC = Teach Pendant on Cabinet (Programming Terminal housed on cabinet)
TP = Teach Pendant (Programming Terminal)
The conditions that may take the system status from AUTO to HOLD are the following:
� switching the control panel status selector on any other position;
� pressing the DRIVE OFF or HOLD button on the programming terminal;
� system alarm.
To return to AUTO, it is necessary to move the status selector back to automatic local or automatic re-
mote and press the buttons pressed previously again (DRIVE OFF and/or HOLD). To continue running
the movement programmes the START button must be pressed after making sure that the drives are pow-
ered (DRIVE ON button).
AUTO_T status (Automatic in programming mode)
This status can only be enabled if the AUTO/MAN key (optional) exists on the programming terminal. The
conditions for entering this status are the following:
� status selector at programming .
� programming terminal fitted with the optional AUTO/MAN selector and this selector at AUTO.
This status is similar to the normal AUTO status but it allows movement control at full speed from the pro-
gramming terminal when the START and enable button are both kept pressed by the operator to perform the
movement.
The system passes from AUTO_T to HOLD following:
� release of the enable button by the operator. This also causes the movement to be stopped which can
be reset keeping the enable button pressed again. The second line of the status window will request this
button to be pressed.
� switching of the AUTO/MAN on the programming terminal or of the status selector on the control panel.
It will then be necessary to press the HOLD button to return to the AUTO status.
� All the conditions that cause HOLD from AUTO, such as pressing the HOLD or DRIVE OFF buttons also
remain valid.
PROG status
The PROG status is obtained when:
� the status selector is set to programming .
� the optional AUTO/MAN selector, if present on the programming terminal, is set to MAN.
In this status it is possible to move the robot manually, pressing the movement buttons on the programming
terminal. It is also possible to run programmes from the editor environment (in DATA mode) to check
whether they are correct and make any changes if necessary. The movements are performed at reduced
speed.
Moving the status selector from the programming position to the automatic one or to , the system
requires the programming terminal to be placed in the cabinet before enabling the automatic status.
ALARM status
The system enters the ALARM status when an alarm occurs. An error message is displayed on the second
status line of the system screen and the dedicated led next to the ALARM key on the programming terminal
lights up.
Different conditions can cause an alarm and the actions to be taken to exit the ALARM status and return the
system to its previous status (automatic/programming/remote) differ depending on the seriousness of the er-
ror.
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SYSTEM STATUS IN MULTIMACHINE - MULTIARM CONFIGURATION
Below is an example in which the controller handles two MACHINES and three ARMS. This example does
not cover all the possible configurations, but it shows the statuses of the controller in multi-machine -
multiarm handling.
� MACHINE 1: composed of two ARMS (ARM1 and ARM2)
� MACHINE 2: composed of one ARM (ARM3)
PROG Status
If movement of ARM1 has been selected using the ARM key on PTU4, when the DRIVE ON key on PTU4 is
pressed, the power contactor will close, thereby powering the drives concerning MACHINE 1. In this case it
will only be possible to move the axes which form ARM1, ARM2 is disabled.
The power contactor of MACHINE 2 (ARM3) is open.
AUTO Status (local-remote)
This is distinguished by two cases:
� Management without the IOMs module (inserted in the CONTROL UNIT rack):
when the DRIVE ON key on the PTU4 is pressed, the power contactors are closed which supply the
drives concerning MACHINES 1 and 2; all the axes which form the three ARMS are enabled (motors on).
� Management with the IOMs module (inserted in the CONTROL UNIT rack):
when the DRIVE ON key on the PTU4 is pressed, it is possible to activate both machines; or from the
remote panel (managed by the IOMs module) MACHINE 1 (MOTOR ON - MACHINE 1) or MACHINE 2
(MOTOR ON - MACHINE 2).
Then, depending on the case, both power contactors are closed which supply the drives of MACHINE 1 and 2;
or activating MACHINE 1 (MOTOR ON - MACHINE 1) or MACHINE 2 (MOTOR ON - MACHINE 2) from the
remote panel, the respective power contactor will be closed which supplies the drives of the machine selected.
The DRIVE ON, DRIVE OFF, START and HOLD commands (on PTU4) or MOTOR ON,
MOTOR OFF, RUN and STOP commands (on the remote panel) further decide the control-
ler status.
Examples:
� If the MOTOR OFF - MACHINE 1 key is pressed on the remote panel: when the DRIVE
ON key on PTU4 is pressed only MACHINE 2 will be activated.
� Vice versa, if the DRIVE OFF key on PTU4 is pressed: when the MOTOR ON -
MACHINE 1 or MOTOR ON MACHINE 2 keys are pressed both machines are not
activated.
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ROBOT MOVEMENT IN PROGRAMMING STATUS
REFERENCE TERNS
A Cartesian reference system, or reference tern, is a geometrical concept which makes it possible to repre-
sent an object in space. For example, the corner of a table can be chosen as reference system to represent
the table itself. The same may be done with a book rested on the table, just as for a weldinggun fitted on the
robot flange.
A transformation of co-ordinates describes the position of one reference system in relation to another. It is
described by a POSITION type variable. For example if a table is in a room, its position in relation to the
room is expressed by POSITION p_table, which describes the transformation of co-ordinates between the
two reference systems. Transformation of co-ordinates may also be used to calculate the position of an ob-
ject in relation to different reference systems. For example, a book whose position in relation to the table cor-
ner is p_book will have the position (p_table:p_book) in relation to the corner of the room. The (:) sign
represents the relative position operation, and makes it possible to compose the effect of different co-ordi-
nate transformations. For further information, refer to the PDL2 Programming Language Manual.
SYSTEM REFERENCE TERNS
The controller has three system variables ($BASE, $TOOL and $UFRAME) which make it possible to de-
scribe the main co-ordinate transformations. Before proceeding with the explanation of these transforma-
tions, definition of some reference terns is necessary.
World tern – Reference tern of the workshop with respect to which the
machines are positioned.
Base tern – Tern that indicates the robot base
User tern – Tern that indicates the piece to be machined
Flange tern – Tern that indicates the robot flange
TCP tern – Tern that indicates tool bit
The $TOOL variable describes the position of the TCP tern with respect to that of the flange tern; the $BASE
variable describes the position of the base tern with respect to the world tern; lastly the $UFRAME variable
describes the position of the piece to be machined with respect to the world tern. POS transformation indi-
cates the taught point P on which the TCP will position itself during programme execution. Remember that all
the taught POSITIONS are defined in relation to the user reference tern (defined by $UFRAME).
For better understanding, imagine the corner of the room indicated by the world tern and a robot positioned
near a table, as shown below.
Reference terns for system and movement of co-ordinates
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User Frame
Flange Frame
$TOOL
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Taught PointY
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P
Base Frame
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Tool Frame
Robot
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$UFRAME
Pos
Now imagine a pen fitted on the robot flange that must write the word COMAU on the table. $BASE transfor-
mation defines the point in which the robot base is, the $TOOL movement indicates the pen and the
$UFRAME movement indicates the position of the table in relation to the room.
MANUAL MOVEMENT
Manual movement of the arm (robot) is necessary under different circumstances including teaching positions
or maintenance of tools fitted on the arm. The ARM, TYP and keys on the right-hand part of the
programming terminal are dedicated to manual movement. The necessary conditions for performing the
movement are: Programming status, status selector on the control panel at the programming position
and the enable button on the programming terminal pressed.
Before starting the movement it is wise to choose the movement mode and speed. Using the TYP key it is
possible to select one of the following four modes, the abbreviation of which appears on the programming
terminal status window.
� Jnt - joints mode. The keys are associated with each axis of the arm selected: any auxil-
iary axes follow those of the arm (typically keys and ). Pressing one of the
keys causes movement of the corresponding axis in the plus or minus direction according to the direc-
tions given on the plates on the arm.
� Bas - linear movement mode according to the world x,y,z reference tern (the workshop reference tern).
The first three keys allow linear movements in the direction of the three world reference
system axes; the next three keys allow rotation of the tool around the same axes keeping
the position of the TCP unchanged. Remember that the world tern is not directly defined by any system
variable; in fact it is the robot base that is represented with respect to the world through the $BASE vari-
able.
� Tol - linear movement mode according to tool x, y, z reference tern (or TCP tern). The first three keys
allow linear movements in the direction of the three tool reference system axes (defined by
$TOOL variable); the next three keys allow rotation of the tool around the same axes keep-
ing the position of the TCP (tool work point) unchanged.
� Usr - linear movement mode according to the user x,y,z reference tern (for example the tern that de-
scribes the piece being machined). The first three keys allow linear movements in the di-
rection of the three user reference system axes (defined by $UFRAME variable); the next three keys
allow rotation of the tool around the same axes keeping the position of the TCP
unchanged.
The speed with which the manual movement will be carried out can be selected using the key
which acts on a percentage value that can be viewed on the status window. This percentage value is called
general override and does not only act on the manual movement speed but on all types of movement both in
the programming and automatic status.
The TCP movement speed during manual movement is always lower than the safety speed of 250 mm/s
also in the joints mode. In the Cartesian modes (Tol, Usr, Bas) the maximum speed that can be reached is
limited by the system variable $JOG_SPD_OVR which normally has a value of 50% (i.e. half the safety
speed). This value may be changed at will to adapt the normal manual movement speed to single program-
ming requirements.
Before performing a movement in the Cartesian modes (Tol, Usr, Bas) it is wise to check
the correct definition of the reference systems and in particular the statement of the tool tern
through the $TOOL variable. Incorrect tool description causes errors in point learning and
makes it impossible to keep the TCP position unchanged during movements for bearing rea-
sons only. A good method for checking that $TOOL is correct is to check that the TCP re-
mains fixed while changing the tool direction with the special keys .
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The procedure for manually moving the arms of a robotised cell differs slightly depending on the configura-
tion of the cell controller. The following paragraphs give further details for a few typical situations.
MANUAL MOVEMENT OF A SINGLE ARM SYSTEM
To perform manual movement of a single arm, simply set the status selector to the programming position
choose the most appropriate mode and press the keys keeping the enable button on the
programming terminal pressed.
MANUAL MOVEMENT OF AUXILIARY AXES, SLIDES AND REVOLVING UPRIGHTS
The auxiliary axes can be added to an arm to move positioners of different kinds, thereby increasing the
working space. Another example of auxiliary axis is the welding gun for powered spot welding.
Manual movement of an auxiliary axis is normally possible only in the joints mode (Jnt) using the corre-
sponding keys (typically and ). However, if the auxiliary axis moves a
slide, an upright or an integrated gun, it is possible to carry out the axis movement also in the Cartesian
modes (Tol, Usr, Bas) using the same Jnt mode keys. For the integrated slide and upright see further details
in the C3G Programming guide manual.
MANUAL MOVEMENT WITH CONTROLLER MULTI-ARM CONFIGURATION
In the case of controller multi-arm configuration, it is necessary to choose the arm intended to be moved
pressing the ARM key and checking the current value on the programming terminal status window. Selection
can be done in the programming status, if the Drives are active (DRIVE ON) when the key is pressed, the
system switchesto DRIVE OFF.
It is also possible to activate two arms belonging to two different machines at the same time. To do this it is
necessary to be in DRIVE OFF status and press the SHIFT key together with the ARM key. The program-
ming terminal status window will show the codes of the two arms separated by an arrow (for example 1�2).
At the next DRIVE ON both arms are activated. The movement keys will however be enabled to
move only the arm indicated by the arrow on the status line (arm 1 if 1� 2 and arm 2 if 1� 2). It is possible
to change the direction of the arrow pressing the ARM key in DRIVE ON status (it has this function only if the
arms were both in DRIVE ON).
For manual movement of integrated arms (a particular case of the multi-arm system), see the special chapter
in the C3G Programming guide manual.
MANUAL MOVEMENT IN WRIST_JNT MODE
In movement of certain types of arms in the Cartesian mode (Tol, Usr, Bas) it is easier to change the direc-
tion of the tool in a mode that does not produce rotation around a Cartesian axis but directly moves the robot
wrist axes (for a robot with 6 axes, the wrist axes are the last three). This is typically helpful for machines
with less than six axes as their capability to turn the tool is limited and it is not possible to obtain require-
ments exactly. This mode can be selected pressing the SHIFT key together with TYP key. This operation
changes the behaviour of the Tol, Usr, Bas modes and because of this, also the corresponding abbrevia-
tions change into Twr, Uwr, Bwr. The Jnt mode remains unchanged.
The difference in the movement of the robot more clearly involves the keys dedicated to changing the geom-
etry, i.e. the , and keys. In the Twr, Uwr and Bwr modes these keys
are associated directly with each axis of the wrist and pressing one of them moves the corresponding axis
leaving the position of the other wrist axes unchanged. However, this operation does not change the position
of the TCP as the first three axes move to compensate the change in direction. It should be noted that if the
robot possesses only two wrist axes (for example 4 and 5) it will only be possible to activate keys
and , while only will be usable for a robot with four axes. With regard
to keys , and the difference is less apparent: movement is linear in
the direction required but the tool geometry is not constant during the path as the wrist axes are not moved.
The only model of robot that is an exception to this is the SMART S3 robot for which the first three keys pro-
duce the same effect as the normal modes (Tol, Usr, Bas).
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MOVEMENT INSTRUCTION IN PROGRAMMING STATUS
Programming the movement of a robot requires a certain knowledge about the C3G system and PDL2 pro-
gramming language. However, before creating a true programme, it is possible to carry out a few simple
movements by the direct execution of an instruction. To do this, the system must be in the programming sta-
tus and the menu command EXECUTE must be called which makes it possible to execute an instruction
typed in manually.
In its simplest form the instruction comprises the key words MOVE TO followed by the destination position.
The most useful instruction during the first phases of use is:
MOVE TO $CAL_SYS
This produces a movement of each axis to its calibration position. In its most complete form, it is possible to
select the arm wanted to be moved, the type of trajectory and destination.
The arm is allocated by the key word ARM(arm_num) to be found immediately after the word MOVE. The
definition may be omitted if the system has only one arm or if intending to move the default arm pre-defined
by the system.
The type of trajectory can be of the joints, linear or circular type and it is described respectively by the
pre-defined constants JOINT, LINEAR and CIRCULAR (see C3G Programming guide manual for further
details). If the type of trajectory is not indicated, the value defined in the system variable $MOVE_TYPE is
valid which is normally set to JOINT.
The destination points are typically expressed inside a programme but it is also possible to allocate them di-
rectly in the instruction line of the EXECUTE command. Two ways of allocating the destination point which
are particularly useful for set up and maintenance are described below. A Cartesian destination point can be
allocated through the built-in POS which allows the three co-ordinates x, y, and z in which to take the TCP,
the three tool direction angles and a configuration string as parameters. All the positions of this type are
called POSITION and they always refer to the user reference system active at the time of execution of the in-
struction (current $UFRAME), the configuration string can generally be left blank. The following is a valid po-
sition which defines a point at 100 mm from the user reference in direction z: POS(0,0,100,0,0,0,”). See the
C3G Programming guide and PDL2 Programming Language Manual for further details. A destination
point can also directly define the position that must be reached by each axis of the arm (including auxiliary
axes). For this purpose it is sufficient to type the values separated by a comma (in the correct order) and en-
close the whole statement between curly brackets. A missing value leaves the position of the corresponding
axis unchanged. The following is a position of the joints type which requires axis 1 to move 10 degrees from
position zero, leaves axis 2 still, takes axis 3 to -30 degrees and leaves the wrist unchanged: {10, ,-30}.
Below are some examples of valid movement instructions (see the C3G Programming guide and PDL2
Programming Language Manual for further details).
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MOVE LINEAR TO POS(100,200,300,0,0,0,’’) linear movement of the arm pre-defined on a
Cartesian point of co-ordinates x=100, y=200
and z=300 and tool tern with the same direction
as the user tern.
MOVE JOINT TO POS(0,0,0,0,180,0,’’) joints type movement of the pre-defined arm on
a Cartesian point of co-ordinates x=0, y=0 and
z=0 and axis z of the tool tern facing the oppo-
site direction to z of the user reference.
MOVE JOINT TO {0,0,0,0,0,0} joints type movement of the first six axes of the
default arm on the zero positions.
MOVE JOINT TO {, , , , ,90} movement of only axis 6 of the default arm on
the 90 degrees position.
MOVE LINEAR TO {45} linear movement that takes the arm in a position
that differs from the initial one only for axis 1
which is taken to 45 degrees. During the linear
movement of the TCP all the arm axes can
move.
MOVE ARM[1] LINEAR TO POS(100,100,100,0,0,0,’’) linear movement of arm 1 that takes the TCP to
the given Cartesian position in relation to the
user tern.
MOVE ARM[2] JOINT TO POS(0,0,0,0,180,0,’’) joints movement of arm 2 which takes the TCP
to the given Cartesian position in relation to the
user tern.
MOVE ARM[1] LINEAR TO {0,0,0, , ,} linear movement that takes the first arm to a
Cartesian position in which the first three axes
have value nil while the wrist axes return to the
initial position. During the linear movement of the
TCP all the arm axes can move.
MOVE ARM[2] JOINT TO {-90} movement of the second arm which moves only
axis 1 to the 90 degrees position in the negative
direction.
MOVE CIRCULAR TO POS(100,100,0,0,0,0,’’) VIA
POS(0,200,0,0,0,0,’’)
pre-defined arm movement which joins the start-
ing point at POS(100,100,0,0,0,0,”) with a cir-
cumference that passes through
POS(0,200,0,0,0,0,”)
Before performing a movement it is wise to check the correct definition of the reference
systems and in particular the tool tern and user reference statement ($TOOL and
$UFRAME). These statements may be overlooked only in the case of joints type movements
on jointpoints such as for example MOVE JOINT TO $CAL_SYS. In all other cases the
consequences can be dangerous with risks to personnel and tooling. In particular if the
description of the tool is not correct ($TOOL wrong) the TCP will not reach the point re-
quired, nor will it perform a correct linear or circular trajectory. With regard to the description
of the user tern ($UFRAME) it is important to check that, when the movement is executed, it
is the same as the one active at the time of memorising the point. If not, positioning will take
place differently than memorised. Freedom is however left to re-execute the same trajecto-
ries with different $UFRAME values as this is indispensable for certain applications which
specifically require movement of the whole programme inside the working space (palletising
applications).
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FILE MANAGEMENT BETWEEN PC AND CELL CONTROLLER
Below is a description of the procedures for deleting, displaying and transferring files via PC. To do this it is
necessary to use the PCINT programme, which must be installed on the PC; for PCINT programme set up
and use, refer to the “PCINT PROGRAMME” paragraph in chapter 3 of the manual.
After installing the programme, select the VIDEO/C3G KEYBOARD EMULATOR option and from the sys-
tem/keyboard menu type the commands indicated by the procedures.
DELETING FILES PRESENT ON PC
� Typing the command ALT-D on the PC it is possible to see/change the directory selected.
� Type the command FD (Filer, Delete): and press ENTER on the PC.
TRANSFERRING FILES FROM PC TO CONTROLLER
� Typing the command ALT-D on the PC it is possible to see/change the directory selected.
� Type the command FC (Filer, Copy): and press ENTER on the PC; the follow-
ing message will be displayed:
Destination file name
� Type destination file name, and press ENTER on the PC; at the end of the opera-
tion the word:
Done
Items between round brackets may be omitted.
TRANSFERRING FILES FROM CONTROLLER TO PC
� Typing the command ALT-D on the PC it is possible to see/change the directory selected.
� Type the command FC (Filer, Copy): and press ENTER on the PC; the following
message will be displayed:
Destination file name
� Type the destination file name, and press ENTER on the PC; at the end of the
operation the word:
Done
Items between round brackets may be omitted.
DISPLAYING FILES PRESENT ON PC
� Typing the command ALT-D on the PC it is possible to see/change the directory selected.
� Type the command FV (Filer, View): and press ENTER on the PC. The file se-
lected will be displayed.
AUTOMATIC FILE TRANSFER FROM CONTROLLER TO PC
� Type the FUB command (Filer, Utility, Backup). This command saves the files specified on the backup
device (FD COMP: or COM0:) which is recognised automatically. In the case of COM0: Kermit commu-
nication protocol must be installed on the PC.
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AUTOMATIC FILE TRANSFER FROM PC TO CONTROLLER
� Type the FUR command (Filer, Utility, Restore). This command copies in the RAM Disk files coming
from the external device (FD COMP: or COM0:) which is recognised automatically. In the case of
COM0: Kermit communication protocol must be installed on the PC.
USE OF THE FLOPPY DISK UNIT
All cell controllers can be fitted with floppy disk unit (FDU) the use of which is described below.
FILE TRANSFER FROM RAM DISK TO FLOPPY DISK
� Press the programming terminal key TOP to return to the main menu, and type the command FC (Filer,
Copy).
� The programming terminal display shows the following message:
Source file name (OPT):
� After activating the characters menu, type in RD: followed by the name of the file to be copied.
� The programming terminal display shows the following message:
Destination file name
� After activating the characters menu, type in FD: followed by the name of the file to be copied.
FILE TRANSFER FROM FLOPPY DISK TO RAM DISK
� Press the programming terminal key TOP to return to the main menu, and type the command FC (Filer,
Copy).
� The programming terminal display shows the following message:
Source file name (OPT):
� After activating the characters menu, type in FD: followed by the name of the file to be copied.
� The programming terminal display shows the following message:
Destination file name:
� After activating the characters menu, type in RD: followed by the name of the file to be copied.
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EXAMPLES OF THE USE OF DIGITAL I/O’s AND ANALOGUE OUTPUTS
The examples below are written using PDL2 programming language and may be used in the context of a
programme.
� DIGITAL INPUTS (e.g. IOM module)
WAIT FOR $DIN[1] = ON -- The programme stops waiting for the condition
IF $DIN[1] = ON THEN -- If the condition is true the movement is
MOVE LINEAR TO PNT0001P executed on point PNT0001P.
ENDIF If the condition is false point PNT0001P
is skipped.
CONDITION[1] : -- Test in multitasking an input
WHEN $DIN[1] = ON DO
$BIT[1]: = ON
END CONDITION
� DIGITAL OUTPUTS (e.g. IOM module)
$DOUT[17]: = ON -- Output activation
$DOUT[17]: = OFF -- Output deactivation
� ANALOGUE OUTPUTS (e.g. ADM module)
Notes on ADM MODULE I/O MAP
If the ADM module is the first I/O module in the rack starting from the left, the digital inputs take on num-
bering from $DIN[33] to $DIN[40], the digital outputs from $DOUT[41] to $DOUT[48], the analogue out-
puts from $AOUT[49] and $AOUT[50].
The I/O module inserted in the following slot will take the number $DIN[57] or $DOUT[57] for the first
channel and following for all the others.
If the ADM module is not the first I/O module in the rack, the numbering follows the standard one of the
modules before it.
Notes on the Write Modes of ADM MODULE Analogue Outputs
The resolution of the analogue outputs is 11 bits (from 0 to +10 Vdc) justified at the left with 4 bits there-
fore the word writing mask is the following.
Where the WORD writing mask has value 7FF0 in hexadecimal and 32752 in decimal. Requiring, for exam-
ple, to write a voltage value it is necessary to allocate a decimal number to the analogue output required as
in the following example:
$AOUT[57]: = 32572 -- Output activated 10 Vdc
$AOUT[57]: = 0 -- Output deactivated 0 Vdc
$AOUT[57]: = 7800 -- Output activated 2.381 Vdc
A fall in the supply voltage of the system in which the ADM module is inserted causes ana-
logue output reset at hardware level. Repositioning the output to the value prior to the failure
is made by the software in the blackout restarting environment.
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bit considerati bit
non considerati
sign
considered bits not considered
bits
CALIBRATION
This paragraph describes the calibration and Turn-set procedures that can be carried out using the controller
and examines the subject of calibration in detail.
The basic concepts, the terminology used and the internal mechanisms for handling axis position information
are given below.
TERMINOLOGY
� AXIS POSITIONAL VALUE: the axis positional value contains all the information necessary to determine
the exact position of an axis in space; it is handled by the control unit using information contained in 32
bits.
� FLASH EPROM: is a memory used to save the characteristic information about the robot associated
with the controller, the calibration constant values and the length of the levers and other parameters for
use of the emergency terminal without the optional RPT module.
� RPT module: the RPT (Resolver Position Tracker) module is an optional microprocessor device housed
at the baseof the robot. Its main functions are:
- counting resolver revolutions for eight axes;
- containing the specifications of the robot to which it is associated, the calibration constants, the length
of the levers and other parameters for the emergency terminal;
This module makes the robot ABSOLUTE, as the data stored in it are retained even in the case of a power
failure. If this module is not operative when the controller is turned on, the revolution count cannot be re-
called.
The C3G controller handles a system without RPT. At system restart, the controller checks that the values
read from the resolver are the same as those read before switching off (either with a warm/cold restart or af-
ter a power failure). If the values correspond, the machine is considered calibrated. If they do not corre-
spond, a Turn_set procedure will be necessary.
Note that no check is performed on the resolver turn numbers. For this reason, the user is advised to put the
arm in the DRIVE OFF state before switching the system off.
� RECONSTRUCTION OF THE AXIS POSITIONAL VALUE: when the controller is turned on, the system
software reconstructs the axes positional values among the various initialisations.
The system software verifies this value checking that the difference between the reconstructed position
and the position before switching off is below a threshold. If the threshold is exceeded, the controller dis-
plays the 59411 SAX: motion after switchoff error and the operator is responsible for checking that the
physical position of the robot corresponds to the new value.
� CALIBRATION POSITION: the calibration position is the value that the positional value of the axis must
have. The calibration position is a “joint type” reference position in the robot working space.
� CALIBRATION CONSTANTS (or calibration error): a calibration constant is the difference between the
data read by the resolver and the theoretical position that the resolver should have in that particular ro-
bot position. In fact, as positioning of the resolver in relation to the robot joint is random, the real position
of the resolver must be corrected according to the theoretical position required for the joint. The calibra-
tion constant is contained inside the resolver revolution. It is described in the variable $CAL_DATA and
can be read using the command CAV (Configure, Arm, View_cal).
� NUMBER OF RESOLVER REVOLUTIONS: the number of revolutions is pre-set by the calibration oper-
ation.
� SYSTEM CALIBRATION: the purpose of this calibration procedure is to establish the position of the
axes of a robot comparing this to an ideal robot. This makes it possible to interchange robots of the
same type (if explicitly allowed) and assures universal applicability of the programmes they use.
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The system calibration procedure consists in moving the robot to a pre-established position checked
with suitable equipment (reference guards, dial gauges, supports, calibration equipment). Once this po-
sition has been reached, proceed as follows:
- fix the reference indexes of all the axes in the case of initial calibration or record the existing ones if
calibration is being performed after replacing a component in the kinematic chain;
- using the programming terminal enter the appropriate calibration command CAC (Configure Arm Cali-
brate) so that the control unit assumes the same axis positional value as the calibration position.
- Enter the Password, unless the command CCP (Configure Controller Password) has already been
sent
Once the indexes are aligned, the Turn-set and recalibration of a robot already installed in the workshop can
be carried out. Calibration performed by positioning each axis on the indexes is not as precise as that per-
formed by mechanical tools: there may be inaccurate positions in the application programmes.
Recovery of calibration, if necessary, (performed by COMAU) must be carried out when the robot is started
for the first time. Afterwards calibration should not be repeated, unless a component in the kinematic
chain has to be replaced due to a mechanical failure or unless a collision damages the structure of
the robot.
� USER CALIBRATION: allows the user to define and carry out calibration on a different position than the
system position. This type of calibration can be used when the system position can only be reached with
difficulty after the robot has been inserted in the final application. Calibration precision is the responsibil-
ity of the user who must provide the instruments to check the positioning of the robot for any subsequent
recalibration, in particular as regards the position of the reference indexes.
On some types of robot, calibration notches are used instead of reference indexes.
� TURN-SET: the Turn-set operation must be performed when the RPT module (optional) and/or the con-
trol unit lose the count of the resolver revolutions; some possible situations in which this count is lost are
described below. The operation consists in moving the axis on the reference indexes and giving the ap-
propriate command.
� ASCII CALIBRATION FILE: the calibration file CALIB1.TXT is an ASCII file with the syntax of a PDL2 file
inside which the calibration constants ($CAL_DATA[n]) and other typical robot data are stored. The file
name can be changed before performing calibration giving the predefined $CAL_FILE variable to the
name required (for further information refer to the PDL2 Programming Language Manual).
� FILE C3G.SYS: is a system file in which the current system status regarding the situation of I/O’s, the
predefined variables and other typical controller parameters are stored (for further information refer to
the PDL2 Programming Language Manual).
PROCEDURES
� CALIBRATION
Refer to the specific robot manuals for robots TRICEPT HP1 and robot SMART H4.
� In this procedure the operator must move the axis to the calibration position with the aid of special tools.
With the axis in the required position, the drives on (Dr:ON) and the control unit in programming status
(St:PROGR), the operator must invoke the CAC (Configure Arm Calibrate) command: the command
asks for the arm and the axis to be calibrated (* for all the axes).
The command carries out the operations required and also sends the number of resolver revolutions de-
fined to the RPT module.
MAIN OPERATIONS FOR SYSTEM USE C3G Plus
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The calibration constants are stored in the variable $ARM_DATA[arm_num].CAL_DATA, in the ASCII
calibration file, in the C3G.SYS file, in the Flash Eprom on SAU2 or RPT (optional).
For robots with particular mechanical structures (e.g. TRICEPT HP1) specific calibration programmes
are foreseen.
The calibration command also allows other options (which can be activated by pressing the
and keys on the programming terminal together).
Example:
a. /Learn
This option makes it possible to define a user calibration position. The operator must move the robot
to the required position and invoke the CAC/L command. At this point the calibration position is
stored in the system variable $ARM_DATA[arm_num].CAL_USER.
System calibration must be carried out prior to this operation.
b. /User
This option calibrates on the position stored in the system variable
$ARM_DATA[arm_num].CAL_USER.
Once this operation has been performed, the calibration error is stored in the same system variable
dedicated to the system calibration error.
� TURN-SET
This operation must be performed if the control unit knows the calibration constants but has lost the in-
formation about the number of resolver revolutions. The information is lost by the control unit if, at re-
start, the RPT module (if present) does not provide the number of resolver revolutions correctly, or due
to resolver errors, and/or due to slipping of the axes with the controller off without RPT.
The operator must move the robot onto the reference indexes as accuratelymains circuit breaker must be effected by means
of a shielded quadripole cable (3-phases + ground) of suitable dimensions for the control unit
power installed
4.1.14 The supply cable must enter the control unit through the appropriate raceway and locked cor-
rectly.
4.1.15 After connecting the ground conductor (PE), connect the power conductors of the power cable to
the main circuit breaker or to the terminals on the controller Assemble the protectiive cover on the
main circuit breaker or on the input terminals.
4.1.16 Connect the supply cable to the circuit breaker on the power mains after checking, with the use of
an appropriate instrument, that the circuit breaker terminals are disconnected.
4.1.17 The controller can be provided with an internal lighting circuit and service socket connected down-
stream of the main circuit breaker. Should it be necessary to power the circuits independently
from the main circuit breaker, it will be necessary to alter an internal connection by connecting a
shielded three-core cable (2 phases + ground) to the mains, scaled according to the protection
rating of the mains, in the same way and according to the same sequence of operations as speci-
fied for connection of the power supply.
4.1.18 Connect the earth wire and the signals and power cables between the control unit and the robot.
4.1.19 Check that the control unit door(s) is/are locked with the special key.
4.1.20 The components of the control unit may be permanently damaged if the connectors are con-
nected incorrectly.
4.1.21 The C3G Plus internally makes the main safety interlocks (gates, enable button, etc.). Should it be
necessary to connect to the signals provided to make additional external circuits, make sure that
these signals are used according to safety regulations. The safety of interlock signals leading from
the transfer line (emergency stop, gates safety, etc.), i.e. providing correct and safe circuits is the
task of the robot system integrator.
System safety cannot be guaranteed if these interlocks are missing, incomplete or incorrectly es-
tablished.
4.1.22 Stopping due to tripping of the protective barrier safety devices causes uncontrolled stopping of
the robot with possible loss of the trajectory programmed. To stop the robot with controlled
ramping down, it is advisable to connect the interlock signals so as to activate a Drive Off com-
mand before the emergency stop.
Example: opening of the protective barrier safety locks causes Remote Drive Off; opening of the
protective barriers causes an emergency stop..
4.1.23 If the C3G-CSM (Controlled Stop Module) is installed on the controller, in AUTO LOCAL and
AUTO REMOTE states, an emergency stop and/or opening of the safety gates causes controlled
stopping of the robot (EN 60204-1), category 1 stop). In this way, power is cut off (opening of the
power contactor) after 1 second. In PROGR. programming status, the power is cut off immediately
(EN 60204-1, category 0 stop). These times must be taken into account when installing the pro-
tective barriers in particular if light curtains are used.
4.1.24 Check that the environmental and operating conditions do not exceed the limits specified in the
product User Manual.
C3G Plus SAFETY REGULATIONS
02/1299 1-3
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Installation and Commissioning - Continued
4.1.25 Calibration operations must be carried out with extreme care as specified in the User Manual, and
must be completed by checking the correct machine position.
4.1.26 Only the original disks, supplied by COMAU S.p.A. with the robot, must be used to load or update
the system software (e.g. after replacing cards). After loading the software, always run a safety
test cycle from outside the protected area. When loading the system software, follow the proce-
dure described in the Product User Manual to the letter.
4.1.27 Make sure that the safety barrier around the protected area has been cerrectly fitted .
4.2 Operation during Programming
4.2.1 The robot must be programmed by authorized personnel only.
4.2.2 Before programming, the operator must check the robot system to ensure there are no potentially
dangerous anomalous conditions and (ensure) that there is nobody inside the protected area.
4.2.3 Whenever possible, programming must be carried out from outside the protected area.
4.2.4 Whenever work must be carried out inside the protected area, the operator outside the protected
area must make sure that all the necessary protections have been installed and are operational
and in particular that the portable programming unit functions correctly (reduced speed, enable
pushbutton, emergency stop, etc.).
4.2.5 The operator can enter the protected area during programming only if he has the programming
terminal.
4.2.6 During programming, only the operator with the programming terminal may remain within the pro-
tected area. If the presence of another operator is absolutely necessary, he must have a further
three-position safety device connected to the control system.
4.2.7 During programming, the operator must keep far enough away from the robot to be able to avoid
any unexpected movements from the robot, and in a position to avoid being caught between the
robot and parts of the surrounding structure( pillars, safety barrier, etc.), or between moving parts
of the robot.
4.2.8 During programming, the operator must not approach any parts of the robot that may drop or lift
due to the gravity.
4.2.9 The motors must always be activated (Drive On) from outside the robot's work envelope after
checking there is noone inside the area involved. The Drive On operation is concluded when the
relevant machine status message is displayed.
4.2.10 Programmed cycle testing at working speed (a function that is included only if specific request is
made), in situations which require close visual observation with the operator inside the protected
area, must only be carried out after a complete test cycle has been run at reduced speed. Testing
must be controlled from a safe distance.
4.2.11 Be extremely careful when programming from the portable programming terminal: the hardware
and software safety devices are in operation, but robot movement is under the operator's control.
4.2.12 The first time a new program is run, the robot may move along an unexpected path.The modifica-
tion of steps in the program (e.g. shifting one step from one part of the program to another, incor-
rect recording of a step, modification of the robot position outside the path that joins two steps in
the program), may give rise to movements that were not envisaged by the operator during pro-
gram testing.
In both cases, it is extremely important to proceed with caution, and remain outside the robot's
work envelope.
SAFETY REGULATIONS C3G Plus
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4.3 Automatic Operation
4.3.1 The robot system can only be activated for automatic operation by authorised personnel when the
protective barriers are closed and electrically interlocked as specified in the safety standards.
4.3.2 Prior to activating automatic operation, the operator must check the robot system and the pro-
tected area to make sure there are no potentially dangerous anomalous conditions.
4.3.3 The operator can only activate automatic operation after checking that:
� the robot system is not being maintenanced or repaired;
� the protective barriers have been positioned correctly;
� there is noone inside the protected area;
� the control unit doors are locked by properly key.
� the safety devices (emergency stop, protective barrier safety devices) are working properly;
� the portable programming terminal has been placed in its housing (this condition is requested
by the controller in Auto-Remote status).
4.3.4 Special attention must be paid when selecting the automatic- remote status, in which the line PLC
may automatically switch on the motors and start the program.
4.4 Emergency Manual Operation
(In case the manual emergencyas possible: if the robot is
not positioned correctly, the system alerts the operator with the 59409 SAX: joint position not suffi-
ciently accurate error and then with the 59421 SAX: positive adjustment is required error and/or
with the 59422 SAX: negative adjustment is required error. Once the robot is positioned the operator
must invoke the CAT (Configure Arm Turn-set) command.
Following this command the system recalculates the correct number of resolver revolutions. This operation
must be performed only on the axis for which the count has been lost; if several axes are found to be in the
above situation, it is advisable to perform the turn-set operation on one axis at a time. In particular, if there
are axes that influence each other, operate first on the influencing axis and then on the influenced axis.
The Turn-set command has two options:
a. /Current
If the resolver revolution count has been lost with the controller on, it is possible to pre-set the
number of resolver revolutions using the current robot position, with the Configure Arm
Turn-set/Current (CAT/C) command.
If the RPT module is present, as soon as it is clear that the resolver revolution count has
been lost do not turn off the control unit until the Turn-set command is invoked.
b. /User
The User option allows recalculation of the number of resolver revolutions with reference to user
calibration.
C3G Plus MAIN OPERATIONS FOR SYSTEM USE
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SHIFT
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� LOSS OF CALIBRATION
Events may occur during use of the control unit which cause loss of the calibration constants or of the
number of resolver revolutions.
If there are no problems, the Ar:CAL message appears in the status window. If Ar:Turn is displayed, an
operation to restore resolver revolution is requested.
The Display Arm Status (DAS) command is used to trace the faulty axis.
Ar:—- which may be displayed in the status window of the programming terminal or PC
screen does not mean that a calibration procedure is necessary. It is usually sufficient to is-
sue the CARL (Configure, Arm, Reten_Mem, Load) command to recover the data from
RPT/Flash Eprom, or calibration data can also be recovered using the CARL/LOAD FILE
command.
� The 63511-13:SCC: RPT resolver primary shorted and 63521-13:SAX: RPT resolver secondary
shorted errors due, for example, to a break in a resolver cable or disconnection and reconnection of a
resolver connector, cause a count loss on the RPT module, if present, and the control unit must be
switched off; at the subsequent restart, the Turn-set operation must be performed with the robot posi-
tioned on the reference indexes.
The 61441 SAX: incorrect resolver reading error requires switching off the control unit. If the error has
also caused the RPT module, if present, to lose the count, at the subsequent restart, the Turn-set opera-
tion must be performed with the robot positioned on the reference indexes.
If the control unit has lost the calibration constants after loading a new software version, the CARL
(Configure Arm Reten_Mem Load) command must be invoked to read the previously stored calibration
constants from Flash Eprom or from the RPT module. If present, and if the RPT module has not been
disconnected, it will have retained the number of resolver revolutions; otherwise the robot must be posi-
tioned on the reference indexes and the Turn-set command must be invoked to restore the resolver rev-
olution count.
If all the information concerning calibration in the Flash Eprom or RPT module and on the C3G.SYS file
has been lost, use the CARL/F (Configure, Arm, Reten_Mem, Load/File) command to read the cali-
bration constants stored in the ASCII calibration file; a Turn-set operation is also needed to recover the
number of resolver revolutions.
MAIN OPERATIONS FOR SYSTEM USE C3G Plus
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Summary of Calibration and Turn-Set Operations
C3G Plus MAIN OPERATIONS FOR SYSTEM USE
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NCALIBRATION TU RN _SET
ROBOT ON INDICES
CAC CAT(2) (1)
GENERAT ES A
CALIBRAT ION ERROR
$CAL_DATA
S ET S T HE RES OLVER REVOLUT IONS
COUNT ER AND ES TABLIS HES AXES
POS IT ION
$CAL_DATA
SHARED MEMORY
RPT
(option)
CARS
CARL
C S
C L
FILE
C3G.SYS
RAM DISK
(4)
(5)
C3G Plus
RBC 2
(7)
PRINT ER
(1)
(2)
TURN_SET command
CALIBRATION command
Saving the CALIBRATION CONSTANTS:
(3)
(4)
(5)
(6)
(7)
in F lash Eprom (S AU2)
in RPT (option)
in RAM DIS K (C3G.S YS file)
in RAM DIS K (CALIB1.T XT calibration AS CII file)
printer hard copy
ROBOT ON INDICES
FLASH
EPROM
(SAU2)
(3)
CARL
CARS
CALIBRAT ION
AS CII F ILE
(CALIB1.T XT )
(6)
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RAM DISK
RPT
MEMORY
(option)
CALIBRATION COMMANDS (RETRIEVING/SAVING)
MEANING OF COMMANDS: CS (Configure, Save)
CAC (Configure, Arm, Calibrate)
CARS (Configure, Arm, Reten_Mem, Save)
CARL (Configure, Arm, Reten_Mem, Load)
CARL/LOADFILE (Configure, Arm, Reten_Mem, Load/Loadfile)
ROBOT CALIBRATION
The robots are calibrated by COMAU after assembly. Calibration reference indexes and/or notches are in-
stalled on the axes. In most applications, these indexes/notches make it possible to bring the robot to its
zero position with a sufficient degree of accuracy; however, should it be necessary to calibrate the robot, or
after mechanical disassembly operations that affect the robot geometry, special tools must be used.
The robot calibration procedure depends on the type of robot connected to the control unit (refer to the spe-
cific manual supplied with the robot).
MAIN OPERATIONS FOR SYSTEM USE C3G Plus
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RAM DISK
(RBC2)
FILE
C3G-SYS
calibration
ASCII FILE
(CALIB1.TXT)
FLASH
EPROM
(SAU2)
RPT
(Opz.)
CARL/LOADFILE CARL
CARS-CAC
CARL
CARL
CARL/LOADFILE
CARL/LOADFILE
MEMORY
KINEMATIC COMPENSATION ALGORITHM
GENERAL DESCRIPTION
From system software version C3G 5.11 a new software feature is available, integrated to the system soft-
ware, which improves precision in positioning the robot within the work area. The software compensates ki-
nematic errors due to inaccuracy of the length of the robot levers and errors due to incorrect coupling of the
axes (axis orthogonality) and also flexion errors caused by the weight of mechanical bodies.
NOTES FOR CORRECT USE
Below you will find a series of notes which define some particularities of the new feature and how to use it
correctly.
� To make it possible to activate kinematic error compensation on a robot such as, for example, the
SMART H4 or SMART H1, it is necessary to have the file that identifies the kinematic model. The exten-
sion of this file is .ROB. Each robot has its own specific file, which cannot be used by other robots.
� With the C3G Plus cell controller it is possible to have a maximum of 4 Arms per system, each of which
has a file which identifies its kinematic model.
� The files with .ROB extension are saved on floppy disk 1/3 of the system software. We suggest to:
� identify the arm to which the robot to be compensated belongs through the last character in the .ROB file
(particularly for multiarm systems). In this case, to enable the compensation algorithm, all you have to
do is load the .ROB file in the controller ram disk.
� insert the robot serial number in the .ROB file name.
E.g.: File PR103_1.ROB belongs to the robot with serial number 103, Arm 1.
� The possibility exists of personalising the .ROB file name through the system variable
$ARM_DATA[ARM].FL_COMP (maximum 8 characters excluding extension). If the user wants to call the
.ROB file in a particular way, he should set the above-mentioned variable and call the .ROB file in the cor-
responding arm ram disk in the same way. Then, re-start the controller using the CCRW command.
� To check whether dynamic compensation is active, use the controller Execute command with the in-
struction WRITE($A_ALONG1[1]::32::4,NL). The teach pendant or PC video will display a binary num-
ber; counting from the right, bit 23,if set at 1, indicates consent to enable the compensation software,
while bit 22, if set at 1, indicates active compensation. Moreover it is possible to check whether the off-
set has been activated using the “Configure Controller View” command; if the offset is activated “Y” will
be displayed in the last column for “arm”, otherwise “N”.
� The compensation of kinematic errors acts dynamically during execution of the programme on the final
points of the movement instructions. This means that at each NOMINAL point (point generated with the
CAD system) the compensation algorithm is applied which, in turn, generates a corresponding point called
COMPENSATED, on which the robot is taken in order to improve positioning on the nominal point.
� The compensation software is functioning only if the robot is out of the singularity areas; therefore it hin-
ders the user from moving the machine to the requested position. However, during the teaching of
points, the programmer must be allowed to move close to the point of singularity in order to look for an-
other point in the surrounds, which is available for the compensation. To this purpose, the command
SET ARM NOSTROKE may be used, which disables the compensation algorithm for 60 seconds. Dur-
ing this lapse of time, the user may reach the point and teach for a new position. In case a longer time is
required as the position to be compensated is rather complex to be reached, the routine COMPS_SET
may be called out from the command menu under the EZ environment in order to disable and enable
the compensation algorithm close to a MOVE instruction. The system command DISPLAY ARM POSI-
TION displays, next to the actual Cartesian position (POS) of the arm and the value of the joints (JNT),
an explicative character concerning the compensation at that point and having the following meaning:
- r : indicates that a movement is in progress or that the compensation has not been per-
formed at the current position;
- N : indicates that the compensation has been performed at the current position and therefore
the displayed position is nominal (ideal);
C3G Plus MAIN OPERATIONS FOR SYSTEM USE
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- D : indicates that the compensation algorithm has been temporarily disabled (e.g. through
Set Arm Nostroke).
� The values of the joints and of the Cartesian position shown on the display are the NOMINAL (ideal) val-
ues only with the robot stationary (interlocked on the final point). What the display shows during the exe-
cution of a movement refers to the kinematic compensation world.
� The variables learnt through the teach pendant (program edit environment) are of the NOMINAL type.
� The value obtained through the built-in features PDL2 ARM_PS and ARM_JNTP represents the position
of the NOMINAL robot only when the robot is stationary (interlocked on the final point).
� The value obtained through the built-in features PDL2 Hdinpos represents the position of the NOMINAL
robot.
� For correct robot programming, with active compensation, the system variable value $CNFG_CARE
should be kept at TRUE.
� As the wrist fitted on the H4 robot is not round, when compensation is applied, near the wrist singularity
after an instruction of the type: Move to {0, 25, -75, 0, 12, 0} the Joint Display shows: 0, 25, -75, 2, 12,
-2; this position of the joint corresponds correctly with the Cartesian position reached by the robot.
The approximation in the wrist axes (4 and 6) is due to the need to use inverse kinematic compensation
on the final point reached.
For further information regarding kinematic compensation please refer to the C3G Plus Pro-
gramming Rules and Notes about Working Area manual.
MAIN OPERATIONS FOR SYSTEM USE C3G Plus
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PRESCRIZIONI DI SICUREZZA 1-1
INSTALLATION 2-1
OPERATOR INTERFACE 3-1
INTEGRATION GUIDE 4-1
MAIN OPERATIONS FOR SYSTEM USE 5-1
EMERGENCY PROCEDURES 6-1
MAINTENANCE 7-1
SUMMARY
Paragraph Page
Cutting off alarms using the EXCL key on PTU4 6-1
Use of the PTU4 as emergency terminal 6-1
Use of the BRAKE RELEASE DEVICE 6-3
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C3G Plus
Operations and
Maintenance Manual
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Operations and
Maintenance Manual C3G Plus
CUTTING OFF ALARMS USING THE EXCL KEY ON PTU4
Through the EXCL key on the programming terminal it is possible to cut off flange and electric limit switch
alarms on the robot for 60 seconds, when the controller is in the programming status . The count of the
time elapsed since the EXCL key was pressed is displayed on the programming terminal.
This function is particularly useful in operating situations in which it is necessary to move the robot from an
abnormal position, without having to use the Emergency Terminal or the C3G-BRD device.
Activation of the EXCL key is allowed only with the controller in programming status and under the direct
responsibility of the operator. Normal safety conditions are at all events resumed with the following:
� 60 seconds from when the EXCL key is pressed
� If the EXCL key is pressed within 60 seconds
� At a change of status: Programming � Automatic or
DRIVE ON � DRIVE OFF
USE OF THE PTU4 AS EMERGENCY TERMINAL (Only for Rel. 1.x)
Through the use of the PTU4 and the insertion of a special connector it is possible to activate manual emer-
gency movement. In this mode the control electronics (CONTROL UNIT) is excluded and it is possible to
move the robot axes one by one at low speed.
Normally the cell controller is associated to a robot by COMAU; during installation this asso-
ciation must be adhered to (see chapter 2 INSTALLATION). If the controller is connected to
a different robot than the one foreseen, malfunctioning may occur in the emergency move-
ment such as for example inverted rotation around the axis or the failure of axis movement to
correspond with the movement key on the PTU4.
PROCEDURE
� Move the main switch to OFF.
� Open the left door of the controller and open the inner door on which the electromechanical components
are located.
C3G Plus EMERGENCY PROCEDURES
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� For single cabin controller versions (SDLP - SDMP - SDHP):
remove the closing cap from connector X201 (ON) and insert it in connector X200 (EMC).
� For double cabin controller versions (DDMP - DDHP):
remove the closing cap from connector X201 (ON) and insert it in connector X200 (EMC) when needing
to move MACHINE 1 or X199 (EMC) when intending to move MACHINE 2.
These operations make it possible to enable the PTU4 as emergency terminal. .
� Close the doors opened previously and move the main switch to ON. The emergency terminal will be in-
itialised.
� During emergency movement all the safety devices are cut off except the emergency
buttons (EMERGENCY STOP) on the PTU4 and control panel (any remote buttons).
� Be very careful when moving the robot, following the safety instructions given in chapter
1 of this manual.
� Robot motion in the Emergency status cannot be uniform.
� Move the robot axes in the most suitable direction to take it back to the normal position,
paying particular attention to the direction of movement (+/-).
If the robot has overstepped the limit switches, movement is only allowed in the opposite di-
rection to the tripped limit switch.
� Activate the robot motors (DRIVE ON). Move the robot one axis at a time using the PTU4 key for moving
the axis to be moved.
� After each emergency movement it is necessary to:
- Turn off the controller moving the main switch to OFF.
- Re-position the closing cap in connector X201(ON) to reset normal controller operation (PTU4 as pro-
gramming terminal).
- Turn on the controller moving the main switch to ON.
- Carry out the TURN_SET operation (see chapter 2, step 11 of the installation procedure).
- If the RPT module is present, the TURN_SEToperation must not be performed.
EMERGENCY PROCEDURES C3G Plus
6-2 04/0799
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USE OF THE BRAKE RELEASE DEVICE (C3G-BRD)
If the robot is positioned in such a way as not to allow its movement with the normal emergency procedures it
is possible to use device C3G-BRD. This device makes it possible to supply the brake of each single axis
(one at a time) allowing the movement of the axis itself. In this case, there is no connection between the con-
trol unit and the robot, therefore all the system safety devices are cut off.
The brake release operation through C3G-BRD must be performed only by skilled personnel.
Depending on the axes to be moved (they may fall due to the effect of gravity) slinging the
robot is recommended.
PROCEDURE
1. Deactivate the control unit setting the main switch to OFF.
2. Disconnect the motor cable from connector X2 (X2 EXT) at the base of the robot to be moved (DS).
3. Support the axes subject to gravity and secure them to a hoist (if necessary).
C3G Plus EMERGENCY PROCEDURES
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4. Connect the brake release device C3G-BRD in the following sequence:
a. connect the Harting connector of the device to connector X2 (X2 EXT) at the robot base;
b. connect the device socket to a 220 Vac power source outside the control unit.
Take the utmost care to work in the highest possible safety conditions in the operations we
are about to carry out.
5. Release the brakes using the device and selecting the chosen axis (letting go of the release lever the
axis stops because the 24 Vdc is cut off).
6. Free the axis from the abnormal position.
7. Remove the C3G-BRD device.
8. Restore any damage suffered by the axis.
9. Carry out the TURN_SET operation (see chapter 2, step 11 of the installation procedure).
10. Restore normal system working conditions.
EMERGENCY PROCEDURES C3G Plus
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C3G-BRD
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SELECTION OF AXIS TO
BE MOVED
BRAKE RELEASE
SAFETY REGULATIONS 1-1
INSTALLATION 2-1
OPERATOR INTERFACE 3-1
INTEGRATION GUIDE 4-1
MAIN OPERATIONS FOR SYSTEM USE 5-1
EMERGENCY PROCEDURES 6-1
MAINTENANCE 7-1
SUMMARY
Paragraph Page
General rules for maintenance 7-i
Preventive maintenance 7-1
Extraordinary maintenance 7-3
Main C3G Plus versions SDLP - SDMP - SDHP connections 7-5
Main C3G Plus versions DDMP - DDHP connections 7-14
Diagnostics 7-25
Problems during normal operation 7-38
Fuses and protections 7-39
Circuit diagrams 7-41
Control Unit 7-43
C3G-DBU3 module 7-49
C3G-BKM module 7-50
C3G-MPI module 7-51
C3G-RPT module (optional) 7-52
Servo Amplifiers Unit SAU2 7-54
System software loading 7-59
List of spare parts 7-67
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Operations and
Maintenance Manual
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Operations and
Maintenance Manual C3G Plus
GENERAL RULES FOR MAINTENANCE
� Before carrying out any maintenance operation, carefully read chapter 1 Safety
Specifications and in particular the instructions in the paragraph concerning
maintenance.
� Any maintenance operation on the controller may only be carried out by specialised and
suitably trained personnel.
� If the control panel is opened and then closed, make sure that the control and/or
extension spindle of the main switch Q100 is in the same position (ON/OFF) to prevent
damage to the control itself.
� The removal or installation of components of the electromechanical section, electronic
modules, connectors, cables and any other component may only be carried out with the
main switch open.
� Before doing any maintenance work whatsoever make sure that there are no external
current supplies interlinked to electronic modules and components of the controller.
� The electronic modules are sensitive to electrostatic discharge: handle the
modules only after wearing an antistatic bracelet connected to ground. The
modules should be touched only holding them by their fastening screws.
� All tripped protection fuses must be replaced only by equivalent ones specified by the
manufacturer. The use of unspecified fuses may cause danger for the operators and
faulty controller operation.
� In the event of cable replacement, restore the connections of any screens disconnected
previously.
� The replaced cable must bear the COMAU code corresponding to the removed one.
� Before connecting any cable, always refer to the controller wiring diagrams.
� When installing new cables avoid bending radii differing from the previous ones. Use the
same previous fastening points and specific routes.
� If the cable has a cable clamp check that it is in correct operating conditions.
� After any maintenance operation, re-install any protections removed previously.
� After any maintenance work, before restoring the normal working cycle, carry out the
controller functional tests, particularly on the replaced component.
� If the controller is partly or completely disposed of, the parts to be disposed of must be
differentiated. At all events disposal of the controller must meet the laws in force of the
country in which the controller is installed.
C3G Plus MAINTENANCE
01/0498 7-i
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MAINTENANCE C3G Plus
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PREVENTIVE MAINTENANCE
ROUTINE CHECKS
In order to ensure correct operation of the controller, the cabin doors must be kept closed.
Every six months you are advised to inspect and if necessary, clean the dissipater of the Servo Amplifiers
Unit rack SAU2, to be found in the rear controller compartment. Access to the compartment is gained by
backing off the screws fastening the controller rear door and opening it.
REPLACING THE BACK-UP BATTERY
The CONTROL UNIT buffer battery must be replaced every three years of operation proceeding as follows:
� Open the left cabin door
� Move the back-up battery switch above the Control Unit to OFF
� Slacken the knobs fastening the back-up battery support to the Control Unit, remove and disconnect the
connectors (A) of the buffer battery
� Connect the new back-up battery, close the support again and turn the switch ON.
� When replacing the battery avoid contacts between the metal parts of the controller and
the battery terminals
� When connecting the new battery take care to connect the terminals correctly.
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MAINTENANCE C3G Plus
7-2 00/1097
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EXTRAORDINARY MAINTENANCE
Extraordinary maintenance summary chart
C3G Plus FUNCTIONAL LAYOUTS
SDLP-SDMP-SDHP VERSIONS
Main C3G Plus connections
Power supply distribution
Axes control circuit
Serial and parallel line connections
Internal/external safety device layout
System Inputs/Outputs
User Inputs/Outputs
C3G Plus FUNCTIONAL LAYOUTS
DDMP - DDHP VERSIONS
Main C3G Plus connections
Power supply distribution
Axes control circuit
Serial and parallel line connections
Internal/external safety device layout
System Inputs/Outputs
User Inputs/Outputs
DIAGNOSTICS
Tests when system is switched on
Diagnostic levels
Safety circuit test device
OPERATING PROBLEMS
Help tables for solving operating problems
PROTECTIONS
Fuses and protections
Electromechanical warnings
Thermal probe S2 warnings
CIRCUIT DIAGRAMS
Circuit diagram explanations
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CONTROL UNIT C3G-PWR3
CONTROL UNIT C3G-RBC2
CONTROL UNIT C3G-SCC2
CONTROL UNIT I/O INT. ANNEX
CONTROL UNIT C3G-SIM
CONTROL UNIT I/O Modules
MODULO C3G-DBU3
MODULO C3G-BKM
MODULO C3G-MPI
MODULE C3G-RPT (When installed)
Function description
Front panel (layout and meaning)
Replacements
SERVO AMPLIFIERS UNIT 2
Function description
Configurations
Front panel (layout and meaning)
SAU2 main components layout
Additional axes
Soft start circuit enabling/disablingAxes electric limit switch enabling/disabling
Replacements
SYSTEM SOFTWARE
System software loading
Subsequent system software loading with same version or later versions
Software operations for robot replacement
Software operations for controller replacement
Software operations for updating characterisation file
C3G PTU4 software
SPARES
High consumption COMAU spares
COMAU spares
Commercial spares
MAINTENANCE C3G Plus
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Main C3G Plus Connections
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Power Supply Distribution (Page 1 of 2)
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Machine line Robot
Only for Rel. 1.x
Power Supply Distribution (Page 2 of 2)
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Axes Control Circuit
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Serial and Parallel Line Connections
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Only for Rel. 1.x
Internal/External Safety Device Layout (Page 1 of 2)
MAINTENANCE C3G Plus
7-10 06/0400
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Internal/External Safety Device Layout (Page 2 of 2)
C3G Plus MAINTENANCE
01/0498 7-11
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System Inputs/Outputs
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(*) excluded SMART H4
(**) X200 on SMART H4
(***) X8 H4 Spot
(****) X9 H4 Handling
User Inputs/Outputs
C3G Plus MAINTENANCE
04/0799 7-13
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Main C3G Plus Connections
DDMP - DDHP Versions
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Power Supply Distribution (Page 1 of 2)
C3G Plus MAINTENANCE
01/0498 7-15
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Power Supply Distribution (Page 2 of 2)
MAINTENANCE C3G Plus
7-16 01/0498
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Machine 1 Axes Control Circuit
C3G Plus MAINTENANCE
01/0498 7-17
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Machine 2 Axes Control Circuit
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7-18 04/0799
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Serial and Parallel Line Connections
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Internal/External Safety Device Layout (Page 1 of 2)
MAINTENANCE C3G Plus
7-20 06/0400
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Internal/External Safety Device Layout (Page 2 of 2)
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01/0498 7-21
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System Inputs/Outputs
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(*) X200 for SMART H4
(**) X8 H4 Spot
(***) X9 H4 Handling
User Input/Output IOM Slot 4
C3G Plus MAINTENANCE
04/0799 7-23
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User Input/Output IOM Slot 6
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DIAGNOSTICS
The system with active Control Unit possesses three different diagnostics levels which make it possible to lo-
cate any faults:
level 1 During system start-up the green RUN led of the module on which the fault occurs
(RBC2 or SCC2) flashes emitting a light code referring to the type of fault.
In general the Control Unit modules have special leds for showing correct operation or
faults and their meaning is described for each individual module in the CONTROL UNIT
paragraph of this chapter.
level 2 During system start-up, when the programming terminal display shows the system di-
agnostic tests a hexadecimal code is emitted which indicates the fault.
level 3 During normal system operation the programming terminal display shows an error mes-
sage (decimal number plus alarm meaning) which describes the type of fault.
Below is a description of the tests when the system is switched on and the diagnostic levels.
TESTS WHEN SYSTEM IS SWITCHED ON
Diagnostics at system switch on:
� GCSR test: before starting the tests on another board, it makes sure that the interprocessor communica-
tion registers are working properly.
� CPU test: checks the address modes and instructions of microprocessor 68020.
� ROM checksum: checks that the checksum on the BootROM is correct.
� RAM test: checks each single word of the local and shared RAM. It is not a destructive test as it stores
and recovers the original contents of the RAM. The shared RAM is checked from every board to verify
that it can be accessed by all boards.
� Timer test: checks the interval timers for accurate synchronisation.
� UART test: checks the UART’s (serial ports) in local loopback mode.
� Fence register: checks that the memory protection characteristic is working properly.
� Image register: applied to the PLC board or Robot CPU if the PLC board is not present. It checks the
special characteristics of the RAM region concerning the image of the shared RAM.
� DSP test: only on the Servo CPU boards, checks operation of the DSP chip and the relevant high speed
RAM.
DIAGNOSTIC LEVEL 1
LED CODES
If a diagnostic result is negative or if a fault occurs that inhibits the system start-up sequence, the green RUN
LED of the board on which the fault has occurred will begin to flash. The sequence of pauses and flashes
given below is always the same while the number of flashes of the LED varies according to the type of prob-
lem. The sequence is the following:
1. Long pause (3 seconds)
2. Primary code
3. Medium pause (1.5 seconds)
4. Secondary code
5. Code repetition, a long pause is repeated.
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Primary codes indicate a general type of fault:
Intermittence Type of fault
1 Fault at initialisation
2 Diagnostic error
3 Unforeseen asynchronous events
4 Others
INITIALISATION FAULT CODES
In this case secondary codes are not defined.
DIAGNOSTIC ERROR CODES
The secondary code represents the diagnostic number concerning the routine that has given a negative result.
The values are the following:
Intermittence Diagnostic
1 RAM test
2 UART test
3 CRT test
4 ROM checksum
5 CPU test
6 TOD clock
7 DSP test
8 Image register test
9 DS/WD image register test
10 JMP image register test
11 MCR image register test
12 FORCE image register test
13 Shadow image register test
14 GCSR test
15 Timer test
16 Data bus test
18 Address line test
20 Memory protection test
21 Floating point compressor test
UNFORESEEN ASYNCHRONOUS EVENT CODES
In this case the secondary code represents the number that identifies the event. The number may be fairly
high.
OTHER CODES
The following secondary codes are defined in this category:
Intermittence Diagnostic
1 There is another board on the bus that does not answer.
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Example: LED pause and flash cycle.
If the system start-up sequence is aborted, thus the RUN led of RBC2 or SCC2 flashes,to
remedy the fault it is necessary to replace the module with the RUN led that is flashing. The
code issued is used by COMAU to identify the fault and it may be mentioned for subsequent
module repair.
DIAGNOSTIC LEVEL 2
VALUES OF CODES
If one of the CPU’s fails to pass a diagnostic test, the programming terminal display will show a hexadecimal
fault code.
Indicate the display of the tests that are performed during system initialisation by modules
RBC2 (RBC0) and SCC2 (SCC0).
The tests of modules RBC2 and SCC2 are not displayed at the same time on the display of
the PTU4, but one at a time in the following order:
1. Local Diags on Board “RBC0"
2. Diagnostics on Board ”SCC0"
PTU4 Display during System Initialisation
C3G Plus MAINTENANCE
00/1097 7-27
CICLO
LED
ON
OFF
Pausa
Lunga
Codice
Primario
Pausa
Media
Codice
Secondario
TEMPO
Pausa
Lunga
1 2 1 2 3 4 5
Primary
Code
Secondary
Code
Long
Pause
Medium
Pause
Long
Pause
CYCLE
TIME
Boot Rom V. 5.x Phase: Diagnostics
C3G Firmware Version 5.x
Copyright (c) Comau Robotics
All right reserved
Local Diags on Board "RBC0"
Diagnostics on Board "SCC0"
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Code Meaning
0002 0000
0004 0000
0008 0000
0010 0000
0020 0000
0040 0000
0080 0000
0100 0000
0200 0000
0400 0000
0800 0000
1000 0000
1800 0000
2000 0000
2800 0000
3000 0000
3800 0000
4000 0000
4800 0000
5000 0000
5800 0000
6000 0000
6800 0000
7000 0000
7800 0000
8000 0000
8800 0000
9000 0000
9800 0000
A000 0000
A800 0000
B000 0000
B800 0000
C000 0000
C800 0000
D000 0000
D800 0000
E000 0000
E800 0000
F000 0000
F800 0001
F800 0002
F801 0002
F802 0102
F802 1002
F803 0002
F804 0102
F806 0102
F810 0102
F836 0102
F836 0802
F836 1002
F836 2002
F838 0102
F838 0202
F838 1002
F838 2002
F800 0004
F800 0008
F800 0010
F800 0020
F800 0040
OS RAM fault
Program RAM fault
IR RAM fault
Enable RAM fault
ROM fault
Simulated scan fault
Watchdog timer fault
Communication port 1 fault
CPU fault
BOARD (requested device) not found
RAM checksum not passed
Parity generator/checker fault
Timer CHIP fault
Watchdog expired unexpectedly
DMA/SCC Port 1 external fault
DMA/SCC Port 2 external fault
Communication port 2 fault
Wrong time
Battery fault
Fault due to high temperature
Timer 2 fault
Bus time out fault
Unexpected interrupt
Unexpected bus error
Diagnostics test being run
Bus interface fault
AC power fail test not passed
RESET register fault
I/O Base fault
Physical address register fault
Logical address register fault
Exception register fault
Output register fault
System fail generator fault
Cooperative test fault
Internal DMA/SCC fault
Unknown test type not passed
Internal DMA/SCC fault
Other error
Error register fault
GCSR error
DSP error
RAM initial error
D/A converter error with channel A channel B
D/A converter error with channel A 1.2 V
Timeout error with DSP
Internal DSP timer error
R/D axes mask error
Sine generator error
DSP internal ram error not alone
DSP internal ram error
DSP external ram error
DSP programme ram error
DSP interrupt error, interrupt fails to arrive from outside (or too slow or too fast)
DSP interrupt error, not arrived or incorrect timer interrupt
DSP interrupt error, timer interrupt occurred with interrupt disabled
DSP interrupt error, external interrupt occurred with interrupt disabled
G.A. MISC OUTPUT REG ERROR
ANNEX card fault
Data Bus fault
Fence register inoperative
FP coprocessor fault
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If the initialising tests are interrupted and an error code among those listed is displayed, e.g.
“LOCAL DIAGS ON BOARD “RBCO” 00080000, to reset the fault it is necessary to replace
the module that failed the test, in this case, RBC2. The code issued is used by COMAU to
identify the fault and can be mentioned for subsequent module repair.
DIAGNOSTIC LEVEL 3
The PC video emulator and programming terminal display show the controller error messages which differ
according to the fault detected. These error messages are on parallel stored in a file called ERROR.LOG,
resident in the controller memory which may be consulted if the message is erased from the display/PC
video emulator or if requiring to check which alarms have occurred previously. The error messages are in the
following form:
E.G: 28694 - 11 - DRIVE OFF Safety gates or Emergency stop
The meaning of the error message is the following:
28694 (consecutive alarm number); 11 (seriousness level); DRIVE OFF (effect on controller status) Safety
gates or Emergency stop (text of message with fault detected on the system)
Below is a list of the levels of seriousness of the system and their meaning:
Level of se-
riousness
Meaning Effect of Problem Reset Action
00: Informative message None
01: Informative message None
02: Warning No effect on control
status
03: Not used
04: PDL2 programme error Set the programme to
PAUSE or HOLD if it is
a holdable programme
Reset the programme
pressing the SHIFT and
SCRN keys
05: Not used
06: PDL2 programme error Set all the programmes
to PAUSE or HOLD if
they are holdable
programmes
Reset pressing the SHIFT
and SCRN keys
07: Not used
08: Hold HOLD Reset the programme
pressing the HOLD key
09: Not used
10: Drives off HOLD + DRIVE OFF Reset the programme
pressing the DRIVE OFF
and HOLD keys
11: Drives off DRIVE OFF due to
safety chain open +
HOLD
Reset the programme
pressing the DRIVE OFF
and HOLD keys
12: Drives off HOLD + DRIVE OFF,
DEACTIVATE
(programme deactiva-
tion)
Reset the programme
pressing the DRIVE OFF
and HOLD keys
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Level of se-
riousness
Meaning Effect of Problem Reset Action
13: Fatal Cuts off the supply to
the robot motors via
the safety relay on the
RBC2 board, deacti-
vates all programmes
(DEACTIVATE) and
leaves the system in
minimum configuration.
No active PLC
programme is inter-
rupted.
Reset re-supplying the
control system or using
the CONFIGURE
CNTRLER RESTART
WARM command
14: Fatal Cuts off the supply to
the robot motors via
the safety relay on the
RBC2 board, deacti-
vates all programmes
(DEACTIVATE) and
leaves the system in
minimum configuration.
All the outputs handled
by the PLC programme
are cancelled.
Reset re-supplying the
control system or using
the CONFIGURE
CNTRLER RESTART
WARM command
15: Fatal Cuts off the supply to
the robot motors via
the safety relay on the
RBC2 board, deacti-
vates all programmes
(DEACTIVATE) and in-
terrupts all system soft-
ware.
Reset re-supplying the
control system or using
the CONFIGURE
CNTRLER RESTART
WARM command
The message text between the higher and lower than symbols is replaced by specific error information.
Through the PCINT programme it is possible to display on the personal computer all the controller error mes-
sages with the explanation of the cause and remedy of the fault. To consult this, refer to the procedure de-
scribed in chapter 3, “PCINT programme” paragraph.
BOOTMON ENVIRONMENT
If the result of an initial diagnostic test is negative or the system software checksum does not give a valid re-
sult on a control module other than the RBC2 module, the system enters the BootMON environment.
a) at the BootMON environment prompt, type the following command:
CF C3G LOAD
and press the ENTER key;
b) load the operating software following the procedure given in the “SYSTEM SOFTWARE LOADING”
paragraph given in the next chapter.
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SAFETY CIRCUIT TEST DEVICES
Connector X113 test device:
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C3G Plus
USE
The connector X113 test device has been developed to allow quick fault-finding on the safety chains; in fact
it makes it possible to display the motor switching on chain and the internal and external safety chain through
a simplified wiring diagram which represents these circuits and a set of leds which allow quick identification
of a fault if it occurs.
In addition it is possible to perform tests through a set of microswitches to further simplifyfault-finding.
CONNECTION
Connect the device on connector X113/SDB3 inside the controller (see previous figure)
Meaning of safety chain leds and probable causes
LED MEANING PROBABLE CAUSES
TP1 – TP2 On: Internal (SIM) or external (X30 pins 50 - 51) 24Vdc
present, E.Stop button on control panel OK
Off: Internal (SIM) or external 24Vdc failure, E.Stop button
on control panel pressed
SIM module, V1 Power
supply, fuse F116,
check X30 connection
if external 24Vdc is
used. E.Stop button on
control panel pressed
TP3 – TP4 On: E.Stop button on PTU4 OK
Off: E.Stop button on PTU4 pressed E.Stop button on PTU4
pressed
TP6 – TP7 On: Enable button on PTU4 pressed in PROGRAMMING
Off: Enable button on PTU4 released in PROGRAMMING Enable button on
PTU4 released in
PROGRAMMING
TP9 – TP10 On: external safety gates closed in AUTOMATIC
Off: external safety gates open in AUTOMATIC External safety gates
open in AUTOMATIC
TP14 – TP15 On: Internal/external 24 Vdc present
Off: V1 power supply, fuse
F116, External power
supply
TP16 – TP17 On: E.Stop button at remote OK
Off: E.Stop button at remote pressed E.Stop button at re-
mote pressed
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Meaning of safety chain leds and probable causes
LED MEANING PROBABLE CAUSES
TP12 – TP13 On: internal 24 Vdc present
Off: V1 power supply, fuse
F116
TP8 On: Flash when the robot motors are switched on
Off: failure to close contact
of relay K5 (SIM)
TP11 On: DBU3 (DBU3-2) dynamic braking OK and power
contactors K101/K102 (K121/ K122) OK
Off: DBU3 (DBU3-2) dy-
namic braking or auxil-
iary contacts of K101
K102 (K121/K122)
open
TP20 On: Indicates DRIVE ON ENABLE
Off: relay K6 (SIM)
TP21 On: safety flange and robot 1 alarm OK
Off: safety flange or robot 1
alarm, relay K2-K3
(SIM)
TP30 On: safety flange and robot 2 alarm if present OK
Off: safety flange or robot 2
alarm, relay K7-K8
(SIM)
TP22 – TP23 On: Control unit OK (electronics on)
Off: relay K9 (SIM)
TP24 – TP25 On: safety relay on RBC2 module OK
Off: safety relay on RBC2
module
TP26 – TP27 On: safety relay on SCC2 and SAU2 module OK
Off: safety relay on SCC2
and/or SAU2 module
TP31 – TP32 On: safety relay on SCC2 and SAU2 module machine 2 if
present OK
Off: safety relay on SCC2
and/or SAU2 module
machine 2
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LED LIGHTING UP SEQUENCE
When the DRIVES ON button is pressed on PTU4 or from REMOTE the following sequence may be seen on
the Connector Test:
- leds TP8 - TP11 On
- leds TP20 - TP21 - TP30 - TP23 - TP22 - TP24 - TP25 - TP26 - TP27 - TP31 - TP32 On
- leds TP8 - TP11 Off
FUNCTION OF MICROSWITCHES
The first microswitch starting from the top of the connector test device is to check whether the electronics
and safety relay contacts of modules RBC2, SCC2 and SAU2 are OK without turning the robot motors on.
The 2nd microswitch in the centre of the connector test device is to temporarily bridge the safety relays of
module SCC2 and SAU2 machine 1, thus locating the cause of the problem.
The 3rd microswitch at the bottom of the connector test device is for temporarily bridging the safety relays of
module SCC2 and SAU2 machine 2, if present.
The 2nd and 3rd microswitches bridge certain controller safety devices, use with the ut-
most caution.
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X30 connector test device:
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USE
The X30 connector test device makes it possible to use the C3G Plus controller in the AUTOMATIC/Remote
mode without connecting to an external PLC. It also allows connection of all the safety devices (Emergency
buttons, Safety gates, others).
The device comprises a set of microswitches, signalling leds and two connectors (WEIDMULLER) for con-
necting the external safety devices.
CONNECTION
Connect the device on the X30 connector of the C3G Plus controller.
FUNCTION OF MICROSWITCHES
� DRIVES ON
To switch on the motors in AUTOMATIC/Remote (Pulse)
� DRIVES OFF
To switch off the motors in AUTOMATIC/Local and AUTOMATIC/Remote (Bistable)
� START
To execute a programme in AUTOMATIC/Remote (Pulse)
� HOLD
To hold the execution of a programme in AUTOMATIC/Local and AUTOMATIC/Remote (Bistable)
� U1 - U2 - U3 - U4
Represent 4 digital input signals ($SDIN[13/14/15/16]) available to the user (Bistable).
It works in AUTOMATIC/Local and AUTOMATIC/Remote
� OPTIONAL SAFETY STOP
This is to check the safety circuit, if installed, if not it has no function (BISTABLE).
It works in AUTOMATIC/Local and AUTOMATIC/Remote
MEANING OF THE LEDS
� START/HOLD
It turns on when the START microswitch has been pressed in AUTOMATIC/Remote and with the Robot
motors on and the LOCAL HOLD Button reset (Yellow)
- on NO HOLD
- off HOLD
� LOCAL/REMOTE
This turns on when the status selector is in the AUTOMATIC-Remote position and with the DRIVES
OFF and HOLD buttons reset (Yellow)
- on AUTOMATIC/Remote
- off AUTOMATIC/Local
� DRIVES ON/OFF
This shows the status of the motors in AUTOMATIC/Local and AUTOMATIC/Remote (Green)
- on MOTORS ON
- off MOTORS OFF
� T.P. AUTO/MAN
This turns on when the key selector on the PTU4 (optional) is in the AUTO position (Yellow)
- on PTU4 in AUTO
- off PTU4 in MANUAL
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� TEACH ENABLE
This turns on when the status selector is in the PROGRAMMING position (Yellow)
- on PROGRAMMING
- off AUTOMATIC/Local or AUTOMATIC/Remote
� ALARM
This turns off when the controller is in an alarm status, it works in all modes (Red)
- on NO ALARM PRESENT
- off ALARM
� E.STOP TO REMOTE
This turns off when an emergency button is pressed (Control Panel, PTU4) or when the Enable button
on the PTU4 is released in the PROGRAMMING mode (Red)
- on NO EMERGENCY
- off EMERGENCY PRESSED
� U1- U2 - U3 - U4
These turn on when the user-available $SDOUT[45/46/47/48] outputs are set to ON. It works in all
modes (Green)
- on $SDOUT[45/46/47/48] at ON
- off $SDOUT[..] at OFF
FUNCTION OF WEIDMULLER CONNECTORS
Please remember that before performing any kind of robot movement, the robot system
safety devices must always be installed and working.
The connectors on the top part of the device (see previous figure) make it possible to connect the controller
safety provisions, also during system installation.
The diagram on the right-hand side of the connector shows the various connections to be made for perform-
ing these operations (for further information refer to chapter 2, step 7 of the installation procedure in this
manual).
CONNECTIONS ON THE FIRST WEIDMULLER CONNECTOR (12 TERMINALS)
- Terminals 6-66-68-24 allow the connection of an external device (e.g. trunnion) to the controller external/in-
ternal safety chain.
- Terminals 71-40-42-54 make it possible to pick up the robot mode (PROGRAMMING, AUTOMATIC/Local,
AUTOMATIC/Remote) to the outside.
- Terminals 52-53-55-56 make it possible to pick up the status of Machine 1 and Machine 2 (if present)
power contactors to the outside.
CONNECTION ON THE SECOND WEIDMULLER CONNECTOR (10 TERMINALS)
- Emergency button to remote, terminals 33-34-35-36
- Safety gates (Doors or external photoelectric barriers), terminals 15-16-17-18.
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PROBLEMS DURING NORMAL OPERATION
Alarm/Warning Context Cause/Remedy References
28707-10:
Safety chain circuit open
SAU2
Faulty (SFT led on)
Check circuits of Brakes, Motor
thermal switch, Overtravel
� SAU2 Tables
� Circuit diagram
� Consult cause/remedy with
PCINT programme
Normal operation Check the safety circuit � C3G-DBU3 module table
Check the dynamic braking
enabling contact (C3G-DBU3)
� Safety circuit checking de-
vice (connector X113)
� C3G Plus functional layouts
� C3G Plus circuit diagram
� Consult cause/remedy with
PCINT programme
61440-10:
SAX xxx motion under no servo
control
After an emergency or
blackout
Parking brakes
oxidised/Perform 4-5
emergency stops at low speed
paying attentionto the stopping
spaces needed.
� Consult cause/remedy with
PCINT programme
63492-11:
SAX xxx drive brake locked
Executing the DRIVE ON
command
� Check for the presence of 25 V
on power device G100 (G101)
� Functional layouts
� Check for any short circuits
on brake circuit
� C3G Plus and Robot Circuit
Diagram
� Consult cause/remedy with
PCINT programme
63493-11.
SAX xxx DC bus or motor cable
short circuit
Executing the DRIVE ON
command or during DRIVE
ON status
Check the motor windings, if
there are no short circuits,
change the axis power module
� Functional layouts
� C3G Plus and Robot Circuit
Diagram
� SAU2 Tables
� Consult cause/remedy with
PCINT programme
61442-11:
SAX xxx following error out of
range
During a movement of the
normal automatic work cycle
Unbalance of motor
phases/Check the motor fuses
and impedance
� C3G Plus and Robot Circuit
Diagram
Resolver reading
problems/Check the resolver
windings and annex “22’ DIFF.
2-AXIS I/O INTERFACE
ANNEX”
� Consult cause/remedy with
PCINT programme
� Control unit I/O int. Annex ta-
ble
Robot collision with alarm
61442-11: SAX xxx following
error out of range
Robot collision during work
cycle
Check that the robot moves to
the calibration position
performing the MOVE TO
$CAL.SYS instruction.
If the position is not reached
the system may have
calculated an incorrect resolver
revolution value.
If the RPT module is present
perform a system restart
(CCRW). If the RPT module is
not present carry out the
turn_set procedure on the axes
to be positioned.
� Consult chapter 2 of the
manual, step 11 “TURN_SET
Operation” (for turn_set oper-
ation)
� Consult chapter 3 of the
manual, “SYSTEM COM-
MANDS” paragraph (for
CCRW command)
� 61441-13:
SAX xxx bad resolver
reading
During normal automatic
work cycle
Check the resolver windings � C3G Plus and Robot circuit
diagram
� 62468-13:
SAX xxx resolver open or
short circuit
Check the mobile parts of
wiring on board robot
� Consult cause/remedy of
PCINT programme
Check RPT (if present) � Optional RPT module table
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FUSES AND PROTECTIONS
FUSES TYPE PROTECTION
F1
250V 0,5A
Normal Blow Fuse Optional RPT Module (Robot)
F2
250V 0,7A
Normal Blow Fuse Optional RPT Module (Robot)
F1
125 V/10kA 5A
Quick-Acting-Fuse 24 Vdc output SIM module
F1-F2
125 V/10kA 5A
Quick-Acting-Fuse Outputs 1 to 8 (F1)
Outputs 9 to 16 (F2)
IOM module
F100-F101-F102
16A V/1,5kA (3,8kVA)
32A V/1,5kA (7kVA)
50A V/1,5kA (16,5kVA)
gG 220 Vac three-phase supply SAU2
F103-F104
250V/1,5kA 20A
35 Vac supply for 24 Vdc robot brake power
module (G100)
F105-F106
250V/1,5kA 6,3A
time-lag-fuse 220 Vac monophase supply for conditioner(op-
tional)
F108
250V/1,5kA 6,3A
time-lag-fuse Supplies: SAU 2, CU power module (PWR3),
backup module (BKM), SAU2 and BKM fans
(E110-E111)
F109-F110-F111
250V/1,5kA 6,3A
time-lag-fuse 19 Vac three-phase supply for services 24 Vdc
power module (V1)
F113
250V/ 1,5kA 4A
Quick-Acting-Fuse 24 Vdc internal supply to robot, external field
(X30), CU fans, IOM module
F116
250V/ 1,5kA 2A
Quick-Acting-Fuse SIM module 24 Vdc supply
F117
30 mA differential current
6A internal current
differential
magnetothermal switch
220 Vac supply for service socket and internal
lighting
REPLACEMENTS
Specific cautions:
� Carefully follow the instructions given in GENERAL RULES FOR MAINTENANCE.
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ELECTROMECHANICAL WARNINGS
Fuse warnings (terminal strip X119):
FUSE LED WARNING
F113 RED - ON Protection of internal 24 Vdc supply to: robot, outside field,
IOM module, Control Unit fans tripped.
F116 RED - ON Protection of 24 Vdc supply for SIM module tripped.
Thermal probe S2 warnings (terminal strip X120):
With versions DDMP - DDHP of the C3G Plus the thermal probe S2 terminals are in terminal
strip X119.
TERMINAL LED WARNING
33 RED - OFF Thermal probe S2 for protection of transformer T100 trip-
ped.
36 RED - ON Presence of 24 Vdc supply for thermal probe S2
33 36 WARNING
ON ON 24 Vdc supply present
OFF ON Thermal probe S2 tripped
OFF OFF 24 Vdc supply absent
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CIRCUIT DIAGRAMS
The controller circuit diagrams are gathered in a folder called CONTROL SYSTEM CIRCUIT DIAGRAM
which is provided with this Operations and Maintenance manual.
The wiring diagrams concerning: Application Box, Robot, fittings/cell outside the controller are provided with
the documentation for the robot system, in special folders, separate from the controller circuit diagrams.
EXAMPLE
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SCHEMI ELETTRICI
APPLICATION BOX
SCHEMI
ELETTRICI
CELLA
SCHEMI ELETTRICI
ALLESTIMENTI/
ATTREZZATURE
ROB OT
CIRCUIT
DIAGRAM
CONTROL SYSTEM
CIRCUIT DIAGRAM
APPLICATION BOX
CIRCUIT DIAGRAMS
CELL
CIRCUIT
DIAGRAMS
FITTINGS/EQUIPMENT
CIRCUIT DIAGRAMS
ROBOT
CIRCUIT
DIAGRAMS
Provided with C3G Plus Operations and Maintenance manual
This page has been left intentionally blank
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C3G-PWR3 POWER SUPPLY
This is the power supply of the modules in the Control Unit and it generates the output voltages needed to operate the modules and the
typical signals required by the specifications of VME standard. It has a recharging circuit for the Control Unit buffer battery.
It is inserted in the special slot at the left inside the Control Unit rack and its power rating is 185 W.
FRONT PANEL
MEANING
LED Colour Description
PWR GREEN When on it indicates that the system is correctly supplied and the presence
of the voltages and VME logic signals at the output. It is off when the FLT
led turns on.
FLT RED When on it indicates a fault status which derives from the cutting in of a
protection or from a mains supply failure of over 20 ms, i.e. the condition in
which all the power supply outputs are inhibited up to the removal and
subsequent return of the input voltage. If the mains voltage fails, it stays on
for the status memory storage time (a few seconds); within this time the
power can not be turned on again. When the FLT led lights up the PWR led
goes out.
Test Point of PWR1 module
Test point Colour Description
+ 5 V RED Makes it possible to check the presence of +5V at the power supply output
(measurement referring to black GND test point)
+12 V RED Makes it possible to check the presence of +12V at the power supply output
(measurement referring to black GND test point)
-12 V RED Makes it possible to check the presence of -12V at the power supply output
(measurement referring to black GND test point)
GND BLACK Reference test point for measurement on all the other test points
AC FAIL LIGHT BLUE Makes it possible to check the presence of the standard VME ACFAIL signal
(measurement referring to black GND test point)
SYSRESET LIGHT BLUE Makes it possible to check the presence of the standard VME SYSRESET
signal (measurement referring to black GND test point)
(FUSE - Power supply PWR1 protection fuse)
The checks on the test points must be carried out with instruments with a minimum input impedance of 1 M�.
PWR1 module connectors
Connector Pin no. Functions
X1 5 150 Vdc connection to module C3G-BKM
P1 96 VME BUS CONNECTOR
110 VAC 3 Connection with 110 Vac mains
terminal
PWR1 Module Fuses
FUSE PWR1 power supply module protection fuse
REPLACEMENTS
Specific cautions:
� Comply with the “GENERAL RULES FOR MAINTENANCE” given in this chapter.
� Connection to ground of the CONTROL UNIT is made through the GND terminal in the PWR3 module: it must always be
active.
� Check correct clamping of connector X1.
Time required for replacement: (to be defined)
Special tools: unnecessary
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C3G-RBC2 ROBOT CPU
At cell level this is the central unit for operating system management and interpretation of the user programmes, trajectories,interfaces.
It acts as PLC for the local I/O. It contains a shared memory area accessible from both board and VME bus; if inserted in the first slot it
also works as “system controller” of the VME bus.
It is connected to the operator interface via serial line, to the Personal Computer (option) and to the Floppy Disk Unit (option). It has a
parallel port for fast operating system loading.
The RAM storage installed on the module is supplied by a backup battery capable of ensuring data retention for at least 1000 consecu-
tive hours; the board also has a high capacity condenser which makes it possible to remove the Control Unit module for maintenance
operations and/or installation without losing data for approx. 1 hour.
FRONT PANEL
MEANING
LED Colore Descrizione
BTB RED It turns on when the backup battery of the Control Unit is below a charge
level no longer sufficient to ensure data retention for the time foreseen. The
battery can be replaced without losing the data (see preventive
maintenance).
RUN GREEN It turns on at the end of the diagnostic tests run by the microprocessor if no
module operating faults have been detected.
WDG RED It turns on after cutting in of the watchdog circuit due to microprocessor fault.
BMS GREEN It turns on when the RBC module carries out the Master functions of the
VME Bus.
SYF RED It turns on when a fault has been detected at VME Bus or VME master
board (SYSFAIL) level.
SFT RED It turns on when the safety chain relay is opened.
RBC Module Connectors
Connector Pin no. Functions
J3 female 25 FDU SERIAL LINE, serial line EIA RS232, RS422, with modem signals for
connection with Floppy Disk Unit (RS422) or with the Personal Computer
(RS232).
J4 male 9 SAFETY RELAY Contact available for safety chain. It is closed after the
diagnostic tests run at system power-up; it opens for cutting in of the
watchdog circuit or on microprocessor command
J5 female 9 Not connected.
J6 female 25 OPERATOR PANEL SERIAL LINES Serial lines and supplies connected
with:
- programming terminal (EIA RS422)
- alphanumeric keyboard (EIA RS422)
- User, line available (EIA RS232 or
RS422 with modem signals)
PAR: female 25 Parallel line for loading operating system
P1 male 96 VME BUS CONNECTOR
REPLACEMENTS
Specific cautions:
� Comply with the “GENERAL RULES FOR MAINTENANCE” given in this chapter.
� Remove/insert the module avoiding damaging the components fitted on it.
� Before replacing the module save the RAM DISK contents(see paragraph SUBSEQUENT SYSTEM SOFTWARE LOADING WITH
SAME SOFTWARE VERSION - SYSTEM SOFTWARE of this chapter).
� The module removed from the Control Unit rack can keep the data in storage for 1 hour.
� If the module is replaced the operating system resident on it is lost and it is necessary to reload it after inserting the new module.
Time required for replacement: (to be defined)
Special tools: unnecessary
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C3G-SCC2 SERVO CONTROL CPU
The Servo Control CPU manages axes movement control in a machine receiving the trajectory targets from the RBC module, through
the VME bus in the master-slave mode and microinterpolating the trajectories themselves; it sends information about machine status
and any alarms to the RBC module, also through the VME bus.
The SCC2 module is interfaced with the machine for transmitting the resolver energising signal and resolver reading, and with the
Servo Amplifiers Unit 2 for transmitting current references.
The SCC2 module interface towards the Servo Amplifiers Unit is modular; in fact, on the SCC2 it is possible to install up to four AXIS I/O
annexes; each AXIS I/O annex reads the position and generates the current reference for two motors.
The Servo Control CPU manages up to 8 axes, also subdivided on two arms, as it possesses two interpolators. The RAM storage in-
stalled on the SCC2 module also has an external backup battery supply capable of retaining data for at least 1000 consecutive hours;
there is also a condenser for powering the SCC2 module RAM for about one hour in the event of a power failure (also of the backup bat-
tery) which makes it possible to remove the module from the Control Unit for any maintenance operations and/or installation of 22’
DIFF.2-AXIS I/O INTERFACE annex.
FRONT PANEL
MEANING
LED Colour Description
PRG GREEN When on indicates that the module is in the operating condition.
RUN GREEN Turns on at the end of the diagnostic tests performed by the microprocessor
if no module operating faults have been located.
WDG RED Turns on after the cutting in of the watchdog circuit for microprocessor
malfunctioning.
BMS GREEN This is on when the SCC module performs VME Bus Master functions.
SYF RED Turns on when an error is detected at VME bus or VME master board
(SYSFAIL) level.
SFT RED Turns on when the safety chain relay opens.
SCC Module connectors
Connector Pin no. Functions
J3 male 15 To resolvers of axes 7 - 8
J4 male 50 To resolvers of axes 1 to 6 and serial line RS485 towards RPT
J5 female 50 Analogue signals to SAM modules; serial line RS485 to SAM modules;
safety chain
J6,J7,J8,J9 female 40 Connectors for analogue signals from and to AXIS I/O ANNEX
J6 axes 1-2
J7 axes 3-4
J8 axes 5-6
J9 axes 7-8
J10,J11 female 40 Connectors for digital signals J12, J13 from and to AXIS I/O ANNEX
J10 axes 1-2
J11 axes 3-4
J12 axes 5-6
J13 axes 7-8
P1 male 96 VME BUS CONNECTOR
REPLACEMENTS
Specific cautions:
� Comply with the “GENERAL RULES FOR MAINTENANCE” given in this chapter.
� Remove/insert the module avoiding damaging the components (annex) assembled on it.
� Before replacing the module save the RAM DISK contents (see paragraph SUBSEQUENT SYSTEM SOFTWARE LOADING
WITH SAME SOFTWARE VERSION - SYSTEM SOFTWARE of this chapter).
� The module removed from the Control Unit rack can keep the data in storage for 1 hour.
� If the module is replaced the operating system resident on it is lost and it is necessary to reload it after inserting the new module.
� The jumpers on the module must not be moved or removed.
Time required for replacement: (to be defined)
Special tools: unnecessary
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22’ DIFF. 2-AXIS I/O INTERFACE ANNEX
Each 22’ DIFF. 2-AXIS I/O INTERFACE annex reads the position and generates the current reference signals for two axes.
On a Servo Control CPU module up to four annexes can be installed, for managing a robot with a maximum of eight axes.
The annex connects to the SCC2 module through two connectors P1 (analogue signals) and P2 (digital signals).
LAYOUT
REPLACEMENTS
Specific cautions:
� Comply with the “GENERAL RULES FOR MAINTENANCE” given in this chapter.
� During ANNEX installation, replacement or removal operations the operating system may be lost.
� Remove the SCC2 module carefully to avoid damaging the components assembled on both sides holding it by the fasten-
ing screws.
� Rest the SCC2 module on an insulating surface to avoid discharging the condenser which retains the operating system for
a maximum of 1 hour during operations of this type.
� Insert the ANNEX completely on the connectors on the SCC2 module after inserting the annex screw spacer, pressing in
correspondence of the connectors and avoiding touching the components with the fingers.
� Insert the SCC2 module in the special rack slot, taking care not to damage the components assembled on both faces, hold-
ing it by the fastening screws.
� Firmly tighten the fastening screws to ensure correct connection of the SCC2 module and rear connector, and to ensure
electrical continuity between the module and the chassis.
� Insert the connectors on the front of the SCC2 module tightening the corresponding screws.
� When replacing or removing the annex from the SCC2 module it is better NOT to remove the SCC2 module plastic spac-
ers, but free the annex of the spacers lightly pressing the protruding parts of the spacers themselves.
Timerequired for replacement: (to be defined)
Special tools: unnecessary
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C3G-SIM SYSTEM INTERLOCK MODULE
System I/O module which interfaces certain control unit internal assemblies; it manages the I/O to the transfer and implements part of
the safety circuits with relay logic.
The outputs to the transfer are protected by fuse with specific indication on the monitoring system in the event of breakage.
It is a VME bus slave module.
FRONT PANEL
MEANING
LED Colour Description
A1
A2
A3
A4
A5
A6
A7
A8
B1
B2
RED
RED
RED
RED
RED
RED
RED
RED
RED
RED
Remote DRIVE ON (INP 9)
Remote DRIVE OFF (INP 10)
Remote START (INP 11)
Remote HOLD (INP 12)
Remote U1 (INP 13)
Remote U2 (INP 14)
Remote U3 (INP 15)
Remote U4 (INP 16)
Spare external input (INP 8)
External safety / External emerg. stop (INP4)
B3
B4
B5
B6
B7
B8
C1
C2
C3
C4
C5
C6
C7
C8
RED
RED
RED
RED
RED
RED
RED
RED
RED
RED
RED
RED
RED
RED
Machine 1 alarm (INP 17)
Machine 1 flange (INP 18)
Air pressure (INP 19)
Not used (INP 25)
Not used (INP 26)
Auto/Local (INP 27)
DRIVE ON/OFF to remote (OUT 9)
START/HOLD to remote (OUT 10)
U1 to remote (OUT 13)
U2 to remote (OUT 14)
U3 to remote (OUT 15)
U4 to remote (OUT 16)
Remote/Local to remote (OUT 11)
Enable/Disable teach to remote (OUT 12)
D1
D2
D3
D4
D5
D6
D7
D8
FUSE
RED
ROSSO
RED
RED
RED
RED
RED
RED
RED
Alarm to remote (OUT 4)
DRIVE ON command (OUT 1)
DRIVE ON enable (OUT 2)
Spare external output (OUT 3)
Alarms inhibit (OUT 5)
Alarm (OUT 7)
System ON (OUT 8)
Low voltge during prog. (OUT 6)
Monitor fuse 1 (INP FUSE)
SIM Module connectors
Connector Pin no. Functions
J3 female 15 CONNECTOR WITH OPERATOR PANEL
Carries the following signals:
- EMERGENCY STOP (double channel)
- Programming terminal/EMC connected
- 24 Vdc supply to Operator Panel
J4 male 25 AC POWER DISTRIBUTION CONNECTOR
Carries the following signals:
- Commands to contactors and contactor status feed-back
- External EMERGENCY STOP
- Safety gate external emergency
- 24 Vdc fuse monitoring, machines and transfer
- Monitoring of correct operation of the power on and off
chain relays
- 24 Vdc supply for logic to SIM module relays
J5 male 50 EXTERNAL CONNECTION BOX CONNECTOR
Carries the following signals:
- Input from transfer
- Output to transfer
- Input and alarms from machine
- Servo Control CPU OK and Robot CPU OK
leading from the safety relays of the two modules
P1 96 VME BUS CONNECTOR
REPLACEMENTS
Specific cautions:
� Comply with the “GENERAL RULES FOR MAINTENANCE” given in this chapter.
Time required for replacement: (to be defined)
Special tools: unnecessary
C3G Plus MAINTENANCE
00/1097 7-47
LAYOUT
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Input/Output MODULES
� C3G-IOM, 16 Input/16 Output Module
� C3G-ACI, 32 AC Input Module
� C3G-DCI, 32 DC Input Module
� C3G-DLO, 32 DC 0.5 A Output Module
� C3G-DHO, 32 DC 2A Output Module
� C3G-ACO, 16 AC 1A Output Module
� C3G-RLO, 16 AC 2A Relay Output Module
� C3G-ADM 2 Analogue Output - 8 DC Input - 8 DC Output
The description, layout, meaning of the leds and instructions for connecting the modules are
given in chapter 4 “Guide to integration” of this manual.
REPLACEMENTS
Specific cautions:
� Comply with the “GENERAL RULES FOR MAINTENANCE” given in this chapter.
Time required for replacement: (to be defined)
Special tools: unnecessary
MAINTENANCE C3G Plus
7-48 00/1097
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C3G-DBU3 DYNAMIC BRAKING UNIT
The DBU3 module is a hardware device which increases the safety of the robot. The module cuts in short circuiting the system DC Bus
through suitable resistance, offering a braking effect on the axis which would tend to fall in the event of a fault.
The DBU3 module is active at DRIVE OFF and also when the robot is in the rest condition, but connected to the controller.
FRONT PANEL
MEANING
Connector Function
X114 110 Vac supply to power contactors K101/K102 and DRIVE ON PULSE
signals
REPLACEMENTS
Specific cautions:
� Comply with the “GENERAL RULES FOR MAINTENANCE” given in this chapter.
� In module replacement operations:
- Open the control unit main switch
- Disconnect the connection cables to the DC Bus (�) from terminal strip X119
- Disconnect connector X114 on the DBU3 module
- Slacken the fastening screws and remove the module carefully
- Insert the new module positioning the connection cables accurately
- Connect the cables of the module (�) to terminal strip X119
- Connect connector X114
If the module is partially removed from its slot but not disconnected electrically, the maintenance operator may be in
a potentially dangerous condition as the module is powered.
Time required for replacement: (to be defined)
Special tools: unnecessary
C3G Plus MAINTENANCE
00/1097 7-49
LAYOUT
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Connection to DC BUS from SAU2 (terminal strip X119/PDP)
C3G-BKM BACKUP MODULE
The BKM module is connected to the Control Unit power module (C3G-PWR3) and, in the event of a mains
failure, it has the task of keeping the Control Unit rack active for 2 seconds.
LAYOUT
REPLACEMENTS
Specific cautions
� Comply with the “GENERAL RULES FOR MAINTENANCE” given in this chapter.
� In the case of replacement, before carrying out any work, consider a discharge time of at least 11
minutes for the module condensers.
� The BKM module in the rear compartment of the C3G Plus is connected to connector X1 of module
C3G-PWR3 of the Control Unit rack in the front part of the controller. Before replacing it disconnect con-
nector X1, remove the module cover, disconnect the cables corresponding to connector X1 from termi-
nal strip X165 on module BKM, replace the module and restore the connections.
Time required for replacement: (to be defined)
Special tools: unnecessary
MAINTENANCE C3G Plus
7-50 00/1097
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C3G-MPI MOTORS POLES IDENTIFICATION
This circuit allows the system to identify the motor polar pairs installed on board the robot and to automati-
cally update a special file containing the machine configuration for the rating of the polar pairs and the result-
ing resolver phasing. The circuit is capable of identifying the polar pairs of up to a maximum of eight motors
and it is physically located inside the Distribution Signal (DS) on board the robot.
Motor pole detection is active in accordance with a provision made on the motor (special
jumper).
LAYOUT
REPLACEMENTS
Specific cautions:
� Comply with the “GENERAL RULES FOR MAINTENANCE” given in this chapter.
� If the RPT module (optional) is present, take the utmost care in disassembling the MPI module to
avoid any contacts that would damage the RPT module which is sensitive to electrostatic discharges.
� For removing the flat cable connecting the module work on the special ejectors.
� When assembling the MPI module interpose all the support spacers removed previously.
Time required for replacement: (to be defined)
Special tools: unnecessary
C3G Plus MAINTENANCE
00/1097 7-51
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C3G-RPT RESOLVER POSITION TRACKER (When installed)
Intelligent module on board machine which makes the machine itself absolute with regard to the control unit.
The RPT module (patented device) based on a microprocessor system with rechargeable backup battery which allows it to work without
external power for a maximum of 600 hours, counts the number of motor revolutions for eight machine axes. It also contains character-
istic information about the machine with which it is associated and allows identification by the control unit.
The RPT module is a Control Unit slave unit (SCC2 module). Via serial line EIA RS485 it is connected to the Servo Control CPU module
(SCC2) and it is in multidrop with the Servo Amplifiers Unit 2. It is connected to the control unit, from which it can be remoted up to 40
metres, on the services cable on which the external supply (24 Vdc) and the serial line pass; it shares the machine axes resolver signals
with the control unit (SCC2).
It receives commandsand sends status messages and the motor revolution count (position) of the machine axes via serial line EIA
RS485 of the SCC2 module.
Constructively, the RPT module is made on two boards: RPT MAIN and RPT ANNEX which are interlinked.
SWITCH SW1 CONFIGURATION
Switch SW1 configuration (on RPT ANNEX board)
1 2 3 4 Description
ON ON x
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OFF ON x 2400 baud
ON OFF x 4800 baud
OFF OFF x 9600 baud
x x ON RPT n° 1
x x OFF RPT n° 2
Switch SW1 configuration (on RPT MAIN board)
1 2 3 4
Description
Tx Rx
ON ON x x Closing of transmission serial line termination
OF
F
OF
F x x Opening of transmission serial line termination
x x ON ON Closing of reception serial line termination
x x OF
F
OF
F
Opening of reception serial line termination
Configuration E1
(on RPT MAIN board)
Jumper on pin Description
1 - 2 RPT on
2 - 3 RPT off
MAINTENANCE C3G Plus
7-52 04/0799
On the RPT module the serial line can be terminated by suitably configuring the dip
switch SW1, on the RPT MAIN board; the normal operating condition is with all the
switches in the OFF position.
The switches are used in the ON position only in particular conditions that are hardly
ever to be found in reality. It is possible to cut off the RPT module from the control
circuit and store the axes position through a jumper E1, on the RPT MAIN board:
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RPT LED
When the led on the RPT module is on, it in-
dicates the presence of the +24 Vdc module
power supply.
REPLACEMENTS
Specific cautions:
� Comply with the “GENERAL RULES FOR MAINTENANCE” given in this chapter.
� Any maintenance and/or checking operation on the module must be carried out only after opening the control unit main switch. If
the RPT module is removed from the signal distribution, carefully follow the instructions given below:
- open the main switch;
- wear the antistatic bracelet;
- remove the fastening screws from the upper part of the signal distribution;
- remove the upper part of the signal distribution;
- disconnect the backup battery;
- remove the module fastening screws;
- remove the RPT Annex from the RPT MAIN using the edge of the RPT Annex to rest the fingers, taking care not to dam-
age the components assembled on both faces;
- rest the removed module on a clean non conductive surface;
- remove the RPT MAIN with the same precautions as for the RPT Annex module.
� When refitting it is important to reverse the sequence. The battery must be connected to the RPT module with the motor and ser-
vices cables connected and with the control unit main switch at ON. The protection fuses inside the module must be replaced only
by equivalent ones specified by COMAU; the use of other fuses may cause danger to the operators and control unit malfunctioning
for which COMAU undertakes no liability.
� The replacement of protection fuses with others not foreseen by COMAU (refer to parts list) does not guarantee compliance of the
equipment with the standards stated.
� Should it be necessary to replace the backup battery following a system alarm warning, it is possible to proceed with the main
switch ON to prevent losing the axes absolute position. This operation however, must be carried out after removing the lid and tak-
ing the utmost care not to invert the poles. The backup battery must be disconnected before machine shipment and re-connected
during machine set-up. Connection of the battery to the RPT module must be made with the motor and services cables connected
and the control unit main switch at ON. For these operations follow the instructions given on the label on the signal distribution.
Time required for replacement: (to be defined)
Special tools: unnecessary
C3G Plus MAINTENANCE
00/1097 7-53
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SERVO AMPLIFIERS UNIT SAU2
The SAU 2 unit is an integrated power unit which has the task of generating controlled terns of sinusoidal
currents to drive up to 8 synchronous three-phase brushless motors.
It is an intelligent unit controlled by microprocessor which manages the commands and statuses from and for
the Servo Control CPU (SCC2) master unit.
It is a complete unit which supports the radiator, recovery resistance, motor brake control circuit, motor ther-
mal switch circuit, axes overtravel circuit, soft start circuit, fan unit.
It is a modular and sectional unit; inside it can host the circuits for managing the eight axes with different
power ratings, up to a continuous available power of 12 kVA. An EPROM flash is provided to keep robot
axes specifications if RPT is not installed in system.
CONFIGURATIONS
The SAU 2 has different power rates and different number of axes depending on the type of robot and num-
ber of axes to be managed (max. 8). A code identifies the configuration of the SAU2. On the front of the
SAU2 stickers show the physical configurations of the rack with the number of the axes and ratings of the
power element associated with them.
Model Description P/N Composition
Model 1 C3G-SAU2 6 Axes S robot Servo Amplifier 10910180 Ax1, Ax2, Ax3 = 15/45
Ax4, Ax5, Ax6 = 4/12
Model 2 C3G-SAU2 6 Axes H robot Servo Amplifier 10910280 Ax1, Ax2, Ax3 = 40/120
Ax4, Ax5, Ax6 = 15/45
Model 3 C3G-SAU2 3 Axes S robot Servo Amplifier 10910380 Ax1, Ax2, Ax3 = 15/45
Ax4, Ax5, Ax6 = option
Model 4 C3G-SAU2 3 Axes H robot Servo Amplifier 10910480 Ax1, Ax2, Ax3 = 40/120
Ax4, Ax5, Ax6 = option
Model 5 C3G-SAU2 Main Frame Servo Amplifier 10910580
Ax1, Ax2, Ax3 = option
Ax4, Ax5, Ax6 = option
present:
� power supply
� soft start
� digital interface electron-
ics
Wirings
Model 1: wiring for 8 axes
Model 2: wiring for 6 axes (the insertion of axes 7-8 implies the addition of the corresponding
wiring to the motors)
Model 3: wiring for 8 axes
Model 4: wiring for 6 axes
Model 5: the wiring is not foreseen; this will be handled depending on the machine configura-
tion.
Options
The options, for each axis, comprise:
� current loop
� power module (in ratings 4/12 Amp, 15/45 Amp, 40/120 Amp)
� wiring if necessary
MAINTENANCE C3G Plus
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FRONT PANEL LAYOUT
Connectors Function Led Colour Meaning
J6 Supplies: 110 Vac auxiliary circuits;
24 Vdc brakes circuit, uninterrupted
24 Vdc (the 0 V is shared with the
24 Vdc of the brakes) for releasing
the brakes on board robot.
ENA1
ENA2
ENA3
ENA4
ENA5
ENA6
ENA7
ENA8
green
green
green
green
green
green
green
green
Off: indicates that the corre-
sponding axis is disabled
Flashing: indicates that the
system is initialising (axis
self-recognition)
On: indicates that the corre-
sponding axis is enabled
C3G Plus MAINTENANCE
01/0498 7-55
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Connectors Function Led Colour Meaning
J7 25-way connector.
Interface to PTU4 emergency termi-
nal (E.M.C.) for:
WDG red Off: indicates that the �C is
working correctly
On: indicates that the �C is
not working correctly
- Serial line EIA RS485 (SAU2
receives commands and supplies
answers on alarm statuses)
- PWM SYNC reference signal
@ 19.53 kHz for generating
PWM command
- Two current references at 120°
shared by all axes
- 20 Vdc supply to PTU4
PWR green Off: indicates the absence of
auxiliary 110 Vac current or
of +5V current for Digital
Card supply or that the sys-
tem has not passed the initial
tests
On: Indicates that all the cur-
rents are present
J8 50-way connector
Makes the interface towards SCC2
through two buses, one analogue
and the other digital.
Through the analogue bus SAU2
receives two current references at
120° for each axis controlled.
Through serial bus EIA RS 485
SAU2 receives:
- commands and gives answers
on alarm statuses
- PWM SYNC reference signal
@ 19.53 kHz for generating
PWM command
SFT red Off: the drive has no type of
fault (Drive OK)
On: the drive is in a FAULT
status.
SAU2 closes the double safety
chain (relay clean double contact)
towards SCC2 and sends DRIVE
FAULT information
Terminal
board
Functionoperation state is provided for)
4.4.1 Emergency Manual Operation can be activated by authorized personnel only.
4.4.2 This operating mode must only be used when special robot system conditions will not allow the
use of manual movement during programming.
4.4.3 Emergency manual operation must be controlled from outside the protected area since the safety
system is downgraded.
4.4.4 If it is absolutely necessary to work inside the protected area, The robot system integrator must
realize an appropriate safety circuit that allows the operator to move the robot with the safety bar-
riers deactivated.
In that case, before performing manual emergency operations, the operator must check, while re-
maining outside the protected area, the correct functioning of the safety devices that are active in
this state and the teach pendant utilized as a portable emergency pushbutton panel..
4.4.5 Take great care during emergency manual operation remaining outside the work envelope of the
robot and its fixtures and pay particular attention to the axes that may drop due to the force of
gravity.
4.4.6 Braking release device of robot axes. With the driving force excluded, the robot can be moved
by the manual brake release device, directly connected to the robot or installed on it, which only
permits the deactivation of the brake of each axis individually .In this situation all the system
safety devices (including the emergency stop and enable buttons) are excluded. Any axes to be
handled (that could drop due to the force of gravity) should be put in slings.
C3G Plus SAFETY REGULATIONS
02/1299 1-5
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4.5 Removal from Service and Dismantling
4.5.1 Only authorised personnel may remove the robot system from service.
4.5.2 Position the robot ready for transport and fit anchoring brackets when required.
4.5.3 Prior to starting the removal from service procedure it is obligatory to disable the power grid circuit
breaker and lock it in the open position.
4.5.4 After using a specific instrument to check that the terminals are disconnected, disconnect the sup-
ply cable from the power mains circuit breaker by first disconnecting the power conductors and
then the ground connector. Disconnect the main circuit breaker supply cable on the control unit
and remove this.
4.5.5 Disconnect the cable that powers the internal lighting and the service socket (if these circuits are
powered from outside) on the controller after locking the corresponding circuit breaker on the
mains supply in the open position, and (after) checking that the system is not live disconnecting
first of all the phase conductors and then the ground conductor.
4.5.6 Disconnect the cables connecting the robot and the control unit, then disconnect the earth
4.5.7 Disconnect the robot pneumatic system from the air distribution network (if applicable).
4.5.8 Make sure that the robot is correctly balanced and, if necessary, harness it correctly and then dis-
assemble the robot anchor bolts from the support structure
4.5.9 Remove the robot and the controller from the work area complying with all the prescriptions given
in the manuals provided. If the equipment is to be lifted, check that the eyebolts are correctly se-
cured and use suitable rigging and equipment.
4.5.10 Before starting to dismantle the robot system components (disassembly, demolition and disposal),
contact COMAU , or one of its branches. Depending on the type of robot and control unit, they will
provide information regarding the operations to be carried out so as to comply with the current
safety regulations, and protect the environment.
4.5.11 Any waste must be disposed of in accordance with the current legislation of the country where the
robot system has been installed.
SAFETY REGULATIONS C3G Plus
1-6 02/1299
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4.6 Maintenance and Repairs
4.6.1 Only authorised personnel may perform operations relating to maintenance, troubleshooting and
repairs.
4.6.2 An appropriate notice must be posted on the control panel of the control unit while maintenance
and repairs are being carried out; this notice must not be removed until the operations have been
completed even if they are temporarily suspended.
4.6.3 Maintenance operations and the replacement of components or the control unit must be carried
out with the main circuit breaker padlocked in the open position.
4.6.4 Even when the main circuit breaker is open and the control unit is therefore not supplied, intercon-
nected voltages may come from peripheral units (e.g. input/output 24 Vdc or 110 Vac) or from ex-
ternal power supplies (e.g. internal lighting system 110 Vac or 220 Vac). The relevant external
sources should therefore be deactivated when work is to be carried out on the system.
4.6.5 The main circuit breaker must be padlocked in the open position before removing panels, protec-
tive screens, grilles, etc.
4.6.6 Faulty components must be replaced with others having the same code.
4.6.7 Checks for faults on the control unit must, whenever possible, be performed outside the protected area.
4.6.8 If the control unit needs to be powered in order to proceed with the troubleshooting, all the precautions
required by the safety standards regarding personnel working in the presence of dangerous voltages
must be taken.
4.6.9 All troubleshooting on the robot must be carried out with the power off (Drive off).
4.6.10 All deactivated safety devices (panels, protective screens, interlocks, etc.) must be restored upon
completion of maintenance and troubleshooting.
4.6.11 Upon completion of any maintenance, repairs and troubleshooting, the robot system and all its
safety devices must be checked for correct operation from outside the protected area.
4.6.12 Only the original disks, provided by COMAU S.p.A. with the robot, must be used to load software
(e.g. after replacing electronic cards). Always run a safety test cycle from outside the protected
area, once the software has been loaded. When loading the system software, follow the proce-
dure described in the Product User Manual to the letter.
C3G Plus SAFETY REGULATIONS
02/1299 1-7
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SAFETY REGULATIONS C3G Plus
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SAFETY REGULATIONS 1-1
INSTALLATION 2-1
OPERATOR INTERFACE 3-1
INTEGRATION GUIDE 4-1
MAIN OPERATIONS FOR SYSTEM USE 5-1
EMERGENCY PROCEDURES 6-1
MAINTENANCE 7-1
SUMMARY
Paragraph Page
Installation summary table 2-i
Provisions for installation 2-1
Check packing list 2-1
Acquaintance with operator interface 2-1
Connection to power mains 2-2
C3G Plus - robot connections 2-5
Application Box connections 2-6
Connection of safety devices and cutting off commands leading from the transfer 2-6
Activation of C3G Plus 2-11
RPT buffer battery connection (optional) 2-12
C3G Plus - robot off line functional check 2-13
Turn_Set operation 2-17
Deactivating the C3G Plus 2-17
Robot system integration 2-17
Functional check of the installed robot system 2-18
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Operations and
Maintenance Manual
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Operations and
Maintenance Manual C3G Plus
C3G Plus INSTALLATION
04/0799 2-i
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YInstallation Summary Table
STEP OPERATION FURTHER REF. DONE
1. PROVISIONS FOR INSTALLATION C3G Plus Technical Specifications
2. CHECK PACKING LIST –
3. ACQUAINTANCE WITH OPERATOR INTERFACE Chapter 3 of manual
4. CONNECTION TO POWER MAINS C3G Plus circuit diagrams
5. C3G Plus - ROBOT CONNECTIONS C3G-MMUX manual
6. APPLICATION BOX CONNECTIONS Application Box
manual
7. CONNECTION OF SAFETY DEVICES AND CUTTING OFF
COMMANDS LEADING FROM THE TRANSFER
Robot manual/
chapter 4 of manual
8. ACTIVATION OF C3G Plus Application manual
9. RPT BACK-UP BATTERY CONNECTION (WHEN
INSTALLED)
Chapter 7 of manual
10. C3G Plus - ROBOT ROBOT OFF LINE FUNCTIONAL
CHECK
Chapters 3 and 5 of manual
11. TURN_SET OPERATION Chapter 3 of manualJ9 Supplies: three-phase 220 Vac in-
put (R-S-T); bus 310 Vdc output (L+
L-)
MAINTENANCE C3G Plus
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The PWR and SFT leds may light up
simultaneously
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SAU2 MAIN COMPONENTS LAYOUT
ADDITIONAL AXES
If it is decided to add an axis to the configuration of the SAU2 (e.g.: axis 7) a special kit is available including
assembly instructions and composed as mentioned in the SAU2 CONFIGURATIONS paragraph.
When connecting the power modules the phase sequence necessary is U-V-W
When working on the SAU2 follow the rules of safety and the instructions given in the re-
placements paragraph.
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SOFT START CIRCUIT ENABLING/DISABLING
On the soft start circuit a switch (SW1) is available which makes it possible to cut off the circuit. Setting the
switch to ON the circuit is cut off. The circuit should not normally be cut off. Cutting off is allowed only for
fault finding and when considered absolutely necessary. Cutting off of the circuit may cause fuses F100 -
F101 - F102 to cut in upstream of SAU2 and/or the fuse of the DC bus inside SAU2 (DC bus +HV protec-
tion). At all events after the maintenance operation the circuit must be reactivated setting the switch to OFF.
AXES ELECTRIC LIMIT SWITCHE ENABLING/DISABLING
To disable the negative or positive limit switch of an axis the dip switch of the corresponding axis must be set
to ON.
EG.: Disabling AXIS 1+/1-
ELECTRONIC RESET BUTTON
The electronic reset button is only used by the manufacturer during testing. This button must not be used by
persons carrying out maintenance or repairs on the SAU2 as abnormal conditions for correct system opera-
tion may result.
REPLACEMENTS
Specific cautions
� Carefully follow the GENERAL RULES FOR MAINTENANCE.
� The assembly instructions are included with the components to be replaced.
� Before doing any maintenance work on the SAU2 wait for the DC BUS condensers to discharge:
discharge time 6 minutes, after opening the main switch.
� After any replacement operation, carefully check that all the connections are correct (ground, flat, cables ...).
� All operations carried out on the bench must be performed with the supply subtended to protection
switch, earth connection . If necessary, reproduce the normal operating environment of SAU2:
Cooling fans on.
� When replacing the DIGITAL CARD and/or SAU2 unit, after replacement it is necessary to issue the
CARS (Configure Arm, Reten_Mem, Save) command.
� the SAU2 rack must be handled in compliance with the rules of safety in force considering that the total
weight is approx. 40 Kg 88.18 lb.
Time required for replacement: (to be defined)
Special tools: - - -
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1+ 1-
OAX bypassed
SYSTEM SOFTWARE LOADING
The system software comprises a set of files stored on three floppy disks. Normally the controller is delivered
with the system software already loaded. Should it be necessary to load system software, the files contained
in the floppy disks must be loaded in the controller memory (Ram Disk) following the procedures given be-
low.
The system software floppy disks are kept in a container inside the controller. Each disk and the box that
contains them are labelled with the specific data of the software contained.
It is advisable to make a reserve copy of all the disks supplied by COMAU.
PROCEDURE
To load the system software from a PC, use the C3G Plus parallel port (PAR:) (time required approx. 3 min-
utes) and the PCINT programme. The detailed procedure is described in chapter 3 OPERATOR INTER-
FACE, paragraph C3G Plus INTERFACE ON PC, PCINT PROGRAMME.
The system software may also be loaded through the floppy disk unit (if present) or the serial communication
port COM0:
The system software loading time, through the COM0: serial port or floppy disk unit is higher
than using the parallel port PAR:.
LOADING WITH FLOPPY DISK UNIT (FDU)
� Insert the C3G Plus SYSTEM SOFTWARE disk 1/3 in the Floppy Disk unit.
� Turn on the controller moving the main switch to ON. The system starts automatically and, after an initial
test, it starts loading the operating system.
� When the programming terminal displays the following flashing message:
Press any key to continue press any key twice.
� You will then be asked to insert disks 2/3 and 3/3. Insert the disks and confirm with ENTER.
LOADING WITH PORTABLE PERSONAL COMPUTER PORT COM0
� Connect the special cable between the communication port of the control unit COM0 and the personal
computer serial port. Turn on the personal computer and go to the DOS prompt.
� Insert the C3G Plus SYSTEM SOFTWARE disk 1/3 in the Floppy Disk unit slot of the personal com-
puter.
� Activate the floppy disk in which the first disk has been inserted (for example with the command A: from
the personal computer keyboard).
� Turn on the control unit moving the main switch to ON.
� Using the keyboard of the personal computer type in the command C3GBOOT and press ENTER or
type the command Transf and press ENTER to select the transfer speed.
� When the programming terminal displays the following flashing message:
Press any key to continue press any key twice.
� You will then be asked to insert disks 2/3 and 3/3. Insert the disks and confirm with ENTER.
Should the system software loading procedure fail (for instance when inserting the wrong
floppy disk), the programming terminal display shows the Bootmon environment. Activate the
characters menu pressing the CHAR key on the PTU4 keyboard and then type the com-
mand RESET/INIT. Confirm the command pressing ENTER. The procedure automatically
starts again from the beginning.
C3G Plus MAINTENANCE
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SUBSEQUENT SYSTEM SOFTWARE LOADING WITH SAME VERSION OR LATER
VERSIONS (1/2)
PRELIMINARY OPERATIONS
1. Using the FD (Filer Delete) command erase the backup files of the user programmes from the C3G
RAM DISK
COMMAND : FD
TYPE : *.bk* or press and select *.bk*
2. Make a backup of the C3G RAM DISK on Personal Computer or on integrated floppy disk by copying all
the files with the FUB (Filer Utility Backup) command.
If the PC is used as backup device, connect to COMP: and activate the video/keyboard emu-
lator of the C3G Plus through the PCINT programme (see chapter 3).
3. Load the system software again following the procedure described in the previous paragraph.
4. Load all the files saved previously in the C3G RAM DISK with the FUR command.
5. Take the robot to the calibration notches either by hand or with the Execute command.
COMMAND: EXECUTE
TYPE: MOVE TO $CAL_SYS
To better understand the software versions, consider:
version X.YZ
where X stands for hardware/software links
Y means Major Release
Z means Minor Release
Examples:
a). from 5.01 to 5.02 Minor Release
b). from 5.01 to 5.10 Major Release
c). from 5.01 to 5.01 Same version
d). from 5.01 to 6.01 Major Release with hardware change.
MAINTENANCE C3G Plus
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SUBSEQUENT SYSTEM SOFTWARE LOADING WITH SAME VERSION OR LATER
VERSIONS (2/2)
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SOFTWARE OPERATIONS FOR ROBOT REPLACEMENT
PRELIMINARY OPERATIONS
1. Replace the robot in compliance with the rules of safety.
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SOFTWARE OPERATIONS FOR CONTROLLER REPLACEMENT (1/2)
PRELIMINARY OPERATIONS
1. Replace the controller in compliance with the rules of safety.
2. Using the FD (Filer Delete) command erase the backup files of the user programmes from the C3G
RAM DISK:
COMMAND : FD
TYPE : *.bk* or press and select *.bk*
3. Make a backup of the C3G RAM DISK on Personal Computer or on integrated floppy disk by copying all
the files with the command.
If the PC is used as backup device and in the case of the FUB command, connect to COMP:
and activate12. DEACTIVATING THE C3G Plus Chapter 3 of manual
13. ROBOT SYSTEM INTEGRATION Chapter 4 of manual/
cell documentation
14. FUNCTIONAL CHECK OF THE INSTALLED ROBOT
SYSTEM
Chapter 4 of manual/
cell documentation
This page has been left intentionally blank
INSTALLATION C3G Plus
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To simplify installation operations, the provisions for installation are given in the C3G Plus TECHNICAL
SPECIFICATIONS manual which may be supplied in advance of the product (before installation); in any case
the above-mentioned manual is also supplied herewith.
In the cell controller cabin there is the STANDARD PRODUCT APPROVAL card (scheda di DELIBERA
PRODOTTO STANDARD). Check the presence of the components listed on the card.
Prior to proceeding with installation it is necessary to get acquainted with the cell controller interfaces with
the outside world. Operator interface means all devices suitable for dialogue between the cell controller and
the operator.
� Control panel and serial and parallel interfaces
� Programming and PTU4 emergency terminal
� Display PTU4
� Provisions for activating the emergency terminal
� Emergency terminal active keys
� Connector for additional Enabling Device push-button
� C3G Plus interface on PC
- Connection cable for COMP: - PC connectors
- Connection cable for serial ports COM0 and COM1 connectors;
- Connection cable for parallel port PAR:
- PCINT programme
- C3G Plus video on PC
� System commands
� Stand-by function
� Brake Release Device (C3G-BRD)
Detailed explanations of each interface are given in Chapter 3 of this manual.
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.1. PROVISIONS FOR INSTALLATION
2. CHECK PACKING LIST
3. ACQUAINTANCE WITH OPERATOR INTERFACE
CONNECTION POWER SUPPLY TO CONTROLLER
CHECKS BEFORE CONNECTION
� The connection cable must meet CEI Std. 2022 and be of the shielded four-core type (three phases plus
earth).
� The cable cross section must be suited to the power rating of the controller installed.
� The setting of the magnetothermal and differential protection upstream of the controller must be suited
to the power rating of the controller installed.
Differential current � 30 mA
version inst. power Ir (therm.) Im (magn.) Cable cross section
SDLP 3,8 kVA (380 � 500 Vca) 7,5 A 140 A 2,5 mm2 (13 AWG)
SDMP
7 kVA (380 � 500 Vca) 13,5 A 220 A
4 mm2 (11 AWG)
7 kVA (220 Vca) 23 A 350 A
SDHP
DDMP 16,5 kVA (380 � 500 Vca) 29 A 425 A 10 mm2 (7 AWG)
DDHP 31,5 kVA (380 �500Vca) 55 A 800 A 25 mm2 (3 AWG)
� The mains voltage must correspond to the one on the data plate next to the connection terminal strip.
OPERATION
Connect the power supply cable inserting it in the special cable clamp at the bottom right of the cabin as il-
lustrated.
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. 4. CONNECTION TO POWER MAINS
Only for Rel. 1.x
The length of the cable inside the cabin must be correct to avoid interfering with already
existing cables.
CHECKS AFTER CONNECTION
� The screws of the terminals in which the wires of the power cable have been inserted (phases R-S-T
and GND) must be correctly tightened. Try pulling the wires.
� The cable clamp must be closed to lock the cable at the controller infeed. Try pulling the cable from out-
side the cabin.
POWER SUPPLY CONNECTION TO CONTROLLER INNER LIGHT BULB
AND SERVICE SOCKET (Only for Rel. 1.x)
Normally the supply connection to the inner light bulb and service socket is already provided
and this operation is not necessary.
If the decision is taken to supply the bulb and socket with a power source outside the con-
troller, proceed carefully following the instructions given below.
MATERIAL
Before proceeding with connection, prepare the following material:
� 2 cables: colour red, cross section 2.5 mm2, length approx. 1 m.
� 1 connection cable to CEI 2022 Std., of the three-core reinforced type (two phases + earth), wire cross
section 2.5 mm2.
� 1 13.5 PG; 7 terminals for 2.5 mm2 cable and numbers 368,369 to be inserted on the cable.
PROCEDURE
When making the connection, refer to the procedure and the explanatory diagrams given below:
� the controller main circuit breaker must be at OFF
� Disconnect wires no. 370 and 371 from F117, isolate them with cap terminals and place them in the
fairlead.
� Connect terminals 368 and 369 of terminal strip:
- X119 for C3G Plus versions SDLP, SDMP, SDHP
- X116 for C3G Plus versions DDMP, DDHP
with two wires with 2.5 mm2 cross section (red), passing in the special grooves (after inserting the cor-
responding number on the wire), to the terminals of F117 from where wires no. 370 and 371 were re-
moved previously.
� Connect to terminals 368, 369 and Earth (GND) of terminal strip:
- X119 for C3G Plus versions SDLP, SDMP, SDHP
- X116 for C3G Plus versions DDMP, DDHP
the outside supply cable inserting it in the special clamp at the left of the controller power supply cable,
after removing the cap and replacing it with PG 13.5.
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INSTALLATION C3G Plus
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. Connection for C3G Plus Versions SDLP - SDMP - SDHP
Connection for C3G Plus Versions DDMP - DDHP
CHECKS AFTER CONNECTION
� Make sure connections have been made according to the procedure.
� The screws of the terminals into which the connection cables have been inserted must be correctly tight-
ened. Try to remove the wires.
� The fairlead clamp must lock the controller input cable. Try to remove the cable by pulling from outside
the cabin.
CHECKS BEFORE CONNECTION
� Check that the cell controller to be connected is the one associated with the robot. On the controller
cabin there is a label stating the serial number of the robot with which it is associated; the robot has a la-
bel stating its serial number. The two numbers on the labels must correspond.
� Check that the pins of the connectors to be connected are not knocked inwards or damaged.
OPERATION
Connect the cables as illustrated:
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5. C3G Plus - ROBOT CONNECTIONS
� During connection avoid kinking the cables. The cable should not be too taut.
� The connection between harting connectors (male/female) must take place without
forcing to avoid knocking in or breaking the pins.
� Carefully close the harting connector clamps after inserting them.
� If X10 Ext and X60 Ext connectors are present, refer to the literature about the C3G
MMUX device and the specific cell documentation for connection.
CHECKS AFTER CONNECTION
� The ground cable must be connected correctly between the control unit and the robot.
� The harting connectors must be perfectly clamped, pull the cable with the hands to check that connec-
tion is correct.
The electrical connections of the Application Box (if present) depend on the type of application controlled.
For connection refer to the specific literature provided with the robot system.
CONNECTION OF SAFETY DEVICES
You are reminded that before performing any type of movement with the robot, the robot system safety de-
vices must always be installed and operational.
Depending on the type of connection intended to be made to the safety devices, the C3G Plus offers the so-
lutions described in the C3G Plus TECHNICAL SPECIFICATIONS manual.
For connecting the safety devices on board the robot (flange/machine alarm) use the counterpart of the ser-
vices connector and refer to the robot use and maintenance manual.
CHECKS BEFORE CONNECTION
Check for the presence of the optional safety stop device relay K107 and of connector X80 (presence of sec-
ond operator in the work area). Connect them if present.
OPERATION
The connection of safety devices takes place through connectors X30 (X30-2 if double machine) and X80 at
the bottom left of the cabin. The following diagram and summary table show how to connect the safety de-
vices.
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6. APPLICATION BOX CONNECTIONS
7. CONNECTION OF SAFETY DEVICES AND CUTTING OFF COMMANDS
LEADING FROM THE TRANSFER
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If Controller Stop Module C3G-CSM is provided as standard on control unit with 16,5 KVA
power and optional on control unit with 7 KVA power, in AUTO LOCAL and AUTO REMOTE
states, an emergency stop and/or opening of the safety gates causes controlled stopping of
the robot (EN 60204-1), category 1 stop). In this way, power is cut off (opening of the power
contactor) after 1 second. In PROGR. programming status, the power is cut off immediately
(EN 60204-1, category 0 stop). These times must be taken into account when installing the
protective barriers in particular if light curtains are used.
1
For safety purposes, the interface connectors to the outside must be fitted with a suitable ca-
ble clamp, the cables must be screened and the screening appropriately connected to the
ground, in order to guarantee electromagnetic compatibility of the system as per directive
89/392.
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DESCRIPTION PIN X30 NOTES
Safety circuits power supply connec-
tion
bridge 48-50 (x) (+24 Vcc)
bridge 49-51 (y) (0 V)
Without connecting the power
supply DRIVE ON is impossi-
ble
Safety gates connection 15 - 16
17 - 18
Dual channel
Emergency push-button connection
to C3G Plus (External E-Stop)
33 - 34
35 - 36
Dual channel
Tool supply contacts (Safety Relay
Logic
6 (+24Vdc External)
66 ( 0 V External)
24 (+24 Vdc) Tool
68 (0V) Tool
Tool not supplied (contacts
open), cutting in of:
- Emergency buttons on C3G
Plus, PTU4 and external field
- Safety gates in
AUTOMATIC-Local/Remote
status
- Enabling device push-button
on PTU4 in
PROGRAMMING status
Tool supplied (contacts
closed):
- DRIVE ON command
- All above safety devices
(closed)
At a DRIVE OFF
command following
DRIVE ON the tool
remains supplied
Power contactor redundancy
(Power contactors K101 and K102)
52 - 53
55 - 56
The auxiliary contactors of the
power contactors are made
available.
Closing of the power contactors
and auxiliary contactors is sub-
ordinate to all the safety de-
vices.
Connecting the supply of the
tools to the auxiliary contacts
the power supply is cut off in
the event of:
- Opening of a contact of the
safety chain
- DRIVE OFF command
Thus any event that causes
opening of the power
contactors.
02/1198 2-9
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DESCRIPTION PIN X30-2 NOTE
Machine exclusion 1-K123;
machine exclusion 2-K124
6-24
66-68
The auxiliary contacts of the
machine exclusion relays
are made available.
Power contactor redundancy
(Power contactors machine 2 K121 and
K122)
52-53
55-56
The function of the auxiliary
contacts of the power
contactors K121 and K122
is the same as that of
contactors K101 and K102.
DESCRIPTION PIN X80 NOTES
Presence of second operator in working
area (Optional Enabling Device)
1 - 2
3 - 4
If the option is present it is
possible to connect a sec-
ond three-position enabling
button (Enabling Device)
CUTTING OFF COMMANDS LEADING FROM THE TRANSFER
For running the controller/robot functional standalone check it is necessary to make the bridges illustrated on
connector X30 at the bottom left of the cabin.
PIN
X30 SIGNALS DESCRIPTION
7
81
User Input Common Return
Internal 0V (24Vcc) to external equipment
Internal 0V (24 Vdc) connection to common
user inputs on SIM module
19
20
45
DRIVE OFF
HOLD
Internal 24Vcc to external equipment
Internal 24 Vdc power supply connection to
DRIVE OFF and HOLD signals that must be
powered to allow the controller to operate off
line
CHECKS AFTER CONNECTION
� Pulling with the hands, check that the cables leading from connectors X30 (X30-2) and X80 are clamped
correctly.
� The safety devices on board the robot must be connected.
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CHECKS BEFORE SWITCHING ON
The magnetothermal and differential circuit breaker from which the supply for the C3G Plus is shunted must
be closed.
Before switching on the controller remove the box containing the floppy disks (operating sys-
tem, application programmes, general utility programmes) which is located inside the control-
ler. The high temperature value reached could severely damage the floppy disks.
OPERATION
� Move the cell controller main switch to ON
When the controller is activated, the following occurs:
- the supply to the control unit is turned on;
- the system software is activated;
- the programming terminal display is activated.
CHECKS AFTER SWITCHING ON
� The programming terminal PTU4 must be operational and the display must show the operating system
bootstrap test. (for further information refer to chapter 7 - DIAGNOSIS) At the end of this test the display
should show the following:
If an application programme (spot, arc welding ...) has been set up and down loaded in sys-
tem start-up, after the bootstrap, the PTU4 display will show a message saying to wait for
downloading of the application programme. Then the layout of the programme loaded will be
shown. If wanting to display the system display press the SCRN key on PTU4.
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Arm
Conf
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Iocf
Exec
Load
Filr
Save
Mem Prog Set Util
PROGR HOLD % 100 Arm: 1 CAL Typ: Jnt - -
8. ACTIVATION OF C3G Plus
PROBLEMS WHEN THE CONTROLLER IS SWITCHED ON
Fault Check Suggestions/Possible causes
The PTU4 terminal is off Presence of mains supply The magnetothermal/differential
circuit breaker upstream of the
C3G Plus is faulty or there is a
mains current failure
That all the fuses inside the Control-
ler are intact (See summary table in
maintenance chapter)
The mains power voltage does
not correspond to the one for
which the controller is made
Errors on the wiring of connector
X30
That the PTU4 and corresponding
cable are intact
The PTU4 or cable is faulty. Re-
place the cable or the terminal
The PTU4 terminal turns on, but
operating system downloading is
requested
The Control Unit buffer battery switch
is at OFF
Move the switch to ON and load
the operating system following
the procedure given in the Main-
tenance chapter
The PTU4 terminal displays er-
ror messages
Presence of error messages Using the PCINT programme
consult the explanation
(cause/remedy) on the error
message shown (Operator inter-
face chapter)
This step of the installation procedure must only be carried out if the RPT module (Resolver Position
Tracker) is present. If not, proceed with the next step of the procedure.
CHECKS BEFORE CONNECTION
� Presence of the RPT module in the Distribution Signal (robot electric sorting) at the base of the robot.
OPERATION
Connect the buffer battery using the switch, as shown below:
The PTU4 status window will show the word TURN. Perform the Turn_set operation.
(See step 11 of the installation procedure).
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Move the switch to ON position
9. RPT BUFFER BATTERY CONNECTION (when installed)
CHECKS BEFORE FUNCTIONAL TESTS
� Before moving the robot make sure that the working area is clear of unforeseen obstacles and that there
are no persons inside.
� Check if the robot calibration position can be reached without knocking any equipment. The calibration
position changes depending on the type of robot, therefore refer to the robot literature.
� The control unit main switch must be at ON .
FUNCTIONAL TESTS
Set the status selector on the control panel to the programming position
1. Checking the Enabling Device button and DRIVE ON
� Press the PTU4 Enabling Device button in the intermediate position, the robot motors turn on (the
green led associated with the DRIVE ON key flashes and then stays on)
� Press the Enabling Device button completely, the motors go off (DRIVE ON led off)
� Press the PTU4 Enabling Device button in the intermediate position, themotors turn on again
(DRIVE ON led on)
� Release the PTU4 Enabling Device button; the motors go off (DRIVE ON led off)
� Press the PTU4 Enabling Device button in the intermediate position, the motors turn on again
(DRIVE ON led on)
� If the additional Enabling Device button is present (connector X80) perform the same test as de-
scribed for the PTU4 considering that both must be closed for performing DRIVE ON
2. Checking the safety devices
+ Safety buttons and gates
a. Press the PTU4 Enabling Device button in the intermediate position, the robot motors turn on
(DRIVE ON led on)
b. Press the emergency button on the PTU4, the power contactors are opened, the robot brakes are
activated and the motors are switched off. The PTU4 presents the following situation:
- the display shows alarm 28694:11 Safety Gates or Emergency Stop
- the leds of the ALARM, DRIVE OFF, HOLD buttons are lit
c. Release the emergency button on the PTU4 and press the ALARM button (emergency reset)
� Repeat the operation from point a) to point c) for: external Emergency Stop button and Emer-
gency Stop button on the control panel
� Set the status selector on the control panel to the local automatic position
� Press the DRIVE ON button on the PTU4, the robot motors turn on
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.10. C3G Plus - ROBOT OFF LINE FUNCTIONAL CHECK
� Open the safety gates: the power contactors are opened, the robot brakes are activated and the
motors are turned off. The following situation is present on the PTU4:
- the display shows alarm 28694:11 Safety Gates or Emergency Stop
- the ALARM, DRIVE OFF, HOLD button leds are lit
� Press the ALARM, HOLD buttons (emergency reset)
� Set the status selector on the control panel to the programming position
+ Equipment power supply contacts (safety relay logic)
� Press the PTU4 Enabling Device button in the intermediate position, the robot motors turn on
(DRIVE ON led lit)
� Run a continuity test to check that the equipment power supply contacts (safety relay logic)
open/close. Refer to step 7 of the installation procedure for the pins involved in the test.
+ Redundancy of power contactors K101 and K102 (K121 and K122 only for C3G Plus versions
DDMP-DDHP) (power contactor)
� Press the PTU4 Enabling Device button in the intermediate position, the robot motors turn on
(DRIVE ON led lit)
� Run a continuity test to check that the auxiliary contacts of power contactors K101 and K102 (K121
and K122 only for C3G Plus versions DDMP-DDHP) close. Refer to step 7. of the installation proce-
dure for the pins involved in the test. To check that they open, release the Enabling Device button.
3. Checking manual robot motion
� Reduce the robot speed to 25% pressing the key of the PTU4
� On the PTU4 select JNT movement using the TYP key
� Press the PTU4 Enabling Device button in the intermediate position, the robot motors turn on
(DRIVE ON led lit)
� Move each single axis of the robot keeping the Enabling Device button pressed and pressing the
button corresponding to the axis to be moved.
Releasing the axis movement button the robot stops. Releasing the Enabling Device button while the
robot is in motion the robot stops and the motors turn off.
Press the ALARM button to reset and turn the motors on again.
4. Checking TURN_SET
� Check that the word TURN appears on the PTU4 status window.
� If this word is present, perform the TURN_SET operation following the procedure given in step 11 of
installation, then continue with point 5 of the checks. If the word turn is not shown, perform step 5 of
the check.
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5. Checking the robot calibration position
� If in order to reach the calibration position, the risk exists that the robot may collide with any equip-
ment, take the robot close to the calibration indexes (fixed and mobile index) moving the axes indi-
vidually; if not (robot working field completely free) perform the next operation immediately.
� Select the EXEC (Execute) command on the PTU4
� Activate the Help of the commands menu with the SHIFT and HELP keys; pressing ENTER selects
the instruction MOVE TO SCAL_SYS, confirm the command pressing ENTER twice.
� Reduce the robot speed to 20% pressing the key of the PTU4
� Press the PTU4 Enabling Device button in the intermediate position, the robot motors turn on
(DRIVE ON led lit)
� Press the START button and keep it pressed until reaching the calibration position. A message on
the PTU4 display will confirm the end of the movement. Physically check that the calibration in-
dexes (fixed and mobile index) coincide.
PROBLEMS DURING FUNCTIONAL TESTS
Fault Check Suggestions/Possible causes
1. Checking Enabling Device button and DRIVE ON
Pressing the Enabling Device but-
ton DRIVE ON is not performed
(motors off)
The PTU4 display shows REMOTE
DRIVE OFF
Wiring error on connector X30,
consult step 7 of the procedure
If relay K107 is present (optional
safety stop) check that it is working
properly
Presence of alarms on PTU4 Using the PCINT programme con-
sult the explanation (cause/rem-
edy) of the error message shown
(Operator Interface chapter)
If rack SAU2 is off General check of fuses inside the
controller (see summary table in
maintenance chapter)
2. Checking safety devices
Presence of alarms on PTU4 refer-
ring to safety devices on which the
functional check is performed
Wiring on X30, external safety de-
vices installed
Errors in wiring of external safety
devices or fault on safety devices
installed (consult step 7 of the pro-
cedure)
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Fault Check Suggestions/Possible causes
3. Checking manual robot movement
The axis intended to be moved is
still
Check that: the Enabling Device
button is pressed and the motors
are on DRIVE ON (led on); the but-
ton of the axis to be moved is
pressed
Incorrect pressing of buttons, keys
or sequence of commands
If the clamping brackets for trans-
porting the robot have been re-
moved
Remove the brackets
The axis to be moved moves badly Check the mechanical geometry of
the axis for distortion or interfer-
ence
Removed the damaged robot parts
4. Checking TURN_SET
Difficulty in performing the opera-
tion
Correct command sequence and
correct robot positioning
Carry out the procedure carefully
following the instructions. Consult
chapter 3 of this manual for further
information about commands
5. Check the robot calibration position
The robot does not position cor-
rectly in the calibration position
(fixed and mobile indexes mis-
aligned, on all or on some axes)
Check that the controller is the one
associated with the robot con-
nected (serial numbers corre-
sponding)
Correctly associate controller and
robot
Check that the robot geometry has
no distortions or interferences
Replace the damaged robot parts
This step of the procedure must be carried out if the word TURN appears in the PTU4 status window. TURN
may be shown following movement of one or more axes of the robot with the C3G Plus CONTROL UNIT off.
If TURN is not shown on the PTU4 carry out the next step of the procedure.
PROCEDURE
1. Set the status selector on the control panel to the PROGRAMMING position
2. On the PTU4 select the JNT type of movement using the TYP key
3. Reduce the robot speed to 20% using the key
4. Pressing the PTU4 Enabling Device button the robot motors turn on (green led lit in correspondence
with the DRIVE ON button)
5. Position the robot aligning the reference notches (fixed and mobile index) of the axis on which Turn_set
is to be performed using the key corresponding to the axis.
After executing the CAT command (Configure Arm Turn_Set) the following messages may
appear: Joints position insufficiently accurate and/or Negative (positive) adjustment is
required. In which case position the robot on the reference notches more accurately, as de-
scribed.
6. From the PTU4 command menu execute: Conf(F1) Arm (F1) Turn (F3)
7. Repeat the operation on all the robot axes.
INSTALLATION C3G Plus
2-16 00/1097
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11. TURN_SET OPERATION
CHECK AFTER TURN_SET
At the end of the Turn_set operation the word CAL is shown in the PTU4 status window.
PROBLEMS IN EXECUTING THE TURN_SET PROCEDURE
Should any difficulty be found in performing the procedure, carefully consult chapter 3 of this manual for further
explanations about the commands to be given. Chapter 5 contains basic instructions for moving the robot.
CHECKS BEFORE THE SWITCHING OFF
The Enabling Device button must be released and the robot motors off (DRIVE OFF).
OPERATION
� Move the cell controller main switch to OFF .
When the controller is deactivated the following occurs:
- the power supply to the control unit is turned off
- the system software is deactivated
- the programming terminal is deactivated
After moving the main switch to OFF the CONTROL UNIT power is still present for approx.
10 seconds. No operations are allowed on the C3G Plus or robot until after this length of
time.
Robot system integration means: the connection of all the devices and equipment provided for the cell con-
troller and robot in the specific application and the creation of software programmes for executing the pro-
cess.
The technical information for performing integration is given in specific manuals provided with the robot sys-
tem. Chapter 4 of this manual gives part of this information and in particular that referring to the cell control-
ler, listed below:
� remote safety signals
� System Inputs/Outputs
� Parallel Inputs/Outputs
� Serial Inputs/Outputs - specific booklet
� List of general utility software programmes (tool PDL2)
� In performing the integration operations comply with the specific safety specifications of
each tool or device to be integrated. At all events after connection check that each
single component is correctly installed to avoid dangerous situations for the operator or
damage/malfunctioning of the tools.
� All integration operations must take place fully meeting the rules of safety of the Firm in
which one is working and in compliance with the specific standards of the application.
� Any remaining risks caused by system integration must be noted on the system
documentation by the integrator.
C3G Plus INSTALLATION
00/1097 2-17
13. ROBOT SYSTEM INTEGRATION
12. DEACTIVATING THE C3G Plus
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After the integration operations it is necessary to check the functionality of the system completely integrated
in the operating system.
� This check must take place systematically (checking all the parts installed) and gradually
(proceeding by small steps). With particular attention to any additional safety devices.
� Checking working programmes must take place firstly in programming at low speed
(normal speed in cases in which AUTO/MAN on PTU4 is indispensable) under the direct
control of the operator (PTU4) and point to point.
� Checking the working programmes in AUTOMATIC Local or Remote must take place
fully complying with the safety specifications for Automatic operation of the robot system
given in this manual and with any other rules applicable to the specific application.
INSTALLATION C3G Plus
2-18 00/1097
14. FUNCTIONAL CHECK OF THE INSTALLED ROBOT SYSTEM
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SAFETY REGULATIONS 1-1
INSTALLATION 2-1
OPERATOR INTERFACE 3-1
INTEGRATION GUIDE 4-1
MAIN OPERATIONS FOR SYSTEM USE 5-1
EMERGENCY PROCEDURES 6-1
MAINTENANCE 7-1
SUMMARY
Paragraph Page
Control panel and serial and parallel interfaces 3-1
Programming and emergency terminal (C3G-PTU4) 3-3
C3G-PTU4 display 3-9
Provision for activating the emergency terminal 3-11
Emergency terminal active keys 3-11
Emergency control C3G-EMC2 3-12
Connector for enabling device additional button 3-14
C3G Plus interface on Personal Computer 3-15
Connection cable for COMP: - PC connectors 3-15
Cable for connecting serial port connectors COM0: and COM1: 3-15
Parallel port PAR: connection cable 3-15
PCINT programme 3-15
C3G Plus video on PC 3-18
System commands 3-21
Stand-by function 3-68
Brake Release Device (C3G-BRD) 3-69
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C3G Plus
Operations and
Maintenance Manual
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Operations and
Maintenance Manual C3G Plus
CONTROL PANEL AND SERIAL AND PARALLEL INTERFACES
The push-buttons, selectors, connectors and serial and parallel interfaces are shown in the following figures
and described in the table below.
REF. SYMBOL and NAME DESCRIPTION
1. Main circuit breaker Cuts off the power supply to the control unit. Wait at least 10 seconds
before switching on again. If the control panel is opened and then
closed again, make sure that the control and/or extension spindle of the
main circuit breaker Q100 are in the same position (ON/OFF), to pre-
vent damaging the control itself.
2. Key status selector
Controls the control unit operating mode: in the programming position
editing and teaching are possible for the development of programmes; in
the automatic local position it is possible to run programmes auto-
matically through the programming terminal; in the automatic remote po-
sition it is possible to run programmes through commands leading
from remote devices (a line PLC or local control boards for example).
3. Mushroom-head
emergency stop button
Used to stop the machine immediately. If pressed, power to the motors is cut
off and the brakes are applied. It is of the “forced opening” type with mechani-
cal latch; it must be pulled for reset.
If the C3G-CSM (Controlled Stop Module) is installed on the controller, in
AUTO LOCAL and AUTO REMOTE states, an emergency stop and/or open-
ing of the safety gates causes controlled stopping of the robot (EN 60204-1),
category 1 stop). In this way, power is cut off (opening of the power contactor)
after 1 second. In PROGR. programming status, the power is cut off immedi-
ately (EN 60204-1, category 0 stop).
C3G Plus OPERATOR INTERFACE
02/1198 3-1
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Serial and parallel
interfaces (inside cabin)
Control panel
Commands and indicators (continued)
REF. SYMBOL and NAME DESCRIPTION
4. COMP: connector Serial communication port for connecting a PC on which it is possible to
install the C3G Plus video/keyboard emulator and download/unload
programmes.
25-pin connector (female).
5. COM0: and COM1: con-
nectors
Serial communication ports available for the connection of a PC or other
devices. If the floppy disk unit is installed, serial port COM0: is not avail-
able. 9-pin connectors (male).
Of the two serial ports only COM0: can be utilized to load system soft-
ware.
6. X113 connector 37 pin connector (female) for connecting the test device
7. PAR: connector Parallel port for system software fast downloading.
8. 230 Vac socket 230 Vac 6 A service socket Schuko type. (Only for Rel 1.x).
9. Housing for Floppy Disk
unit
Panel that is removed to install a Floppy Disk unit.
Two SDB3 modules are provided for C3G Plus versions DDMP-DDHP. Connectors
COM0:/COM1: (ref. 5) and X113 (ref. 6) of the SDB3-2 module cannot be used. Connectors
of SDB3 module should be used for any connections.
OPERATOR INTERFACE C3G Plus
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COM P:
PROGRAMMING AND EMERGENCY TERMINAL (Only for Rel. 1.x)
(C3G-PTU4)
PTU4 may be installed as programming terminal and also as emergency terminal, on Rel. 1.x version. In the
first case it works as system monitor and programming terminal and makes it possible to manually control ro-
bot movements, programme the robot or carry out or modify step-by-step movements, while in the second
case it works as emergency terminal (only for Rel. 1.x) and makes it possible to move one axis at a time at
low speed, with the Control Unit deactivated.
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