Funcionalidades de Segurança do RoboSAFE 2.0

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Safety 
functionalities of the 
Robot control 
system
Safety signals interfacing Information on 
RoboSAFE 2.0 functionalities,
RoboSAFE Joint and RoboSAFE Cartesian
For C5G Plus and R1C-6, S1C-6
Control Units
CR00758165_en-00/2019.04
Instructions handbook
The contents of this handbook are the property of COMAU S.p.A.
Any reproduction, even partial, is prohibited without prior written authorization from COMAU S.p.A.
COMAU reserves the right to modify, without notice, the features of the product presented in this handbook.
Copyright © 2008-2019 by COMAU - Published 04/2019
Comau Robotics Product Instruction
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Documentation storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Limits on the handbook contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Symbols used in the handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Modification History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...12
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Fundamental Requirements applied and respected . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2. INTEGRATED SAFETY SOLUTIONS: ROBOSAFE 2.0 . . . . . . . . . . . . . . . . . . . . . ...21
What is the RoboSAFE 2.0 solution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3. DESIGN PRINCIPLES OF THE ROBOSAFE 2.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...22
Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
The responsibilities of the integrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Steps for proper design and integration of RoboSAFE 2.0 functions . . . . . . . . . . . . . . . . . . . . 24
Define the monitored workspace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Additional auxiliary axes not monitored . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Set parameters to define the workspace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Consider the stopping distances of the Robot mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Stopping modes in RoboSAFE system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Enable the RoboSAFE functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check the active RoboSAFE function through the dedicated safe outputs . . . . . . . . . . . . . . . . 28
Define the strategy to restore the Robot position after rules violation . . . . . . . . . . . . . . . . . . . . 28
Validate the implemented RoboSAFE functionalities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Detailed information to carry out the voluntary violation of the parameters . . . . . . . . . . . . . . 30
Implement strategies for periodic verification of the Robot kinematic chain and of the equipment 
installed on the wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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Comau Robotics Product Instruction
Integrate the cell project documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Protect the Robot configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Instructions for the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4. PRINCIPLES AND FUNCTIONALITIES FOR CELL / LINE AND APPLICATIONS 
INSTALLED ON ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..34
Principles common to the RoboSAFE 2.0 functionalities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
RoboSAFE 2.0 functionalities for the cell / line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
E-Stop from the automated system line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Auto Stop (Fence) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
General Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
E-Stop of the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
RoboSAFE 2.0 functionalities for the applications installed on Robot . . . . . . . . . . . . . . . . . . . . 35
Enabling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Auto Mode and T1 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Drive ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Replicas of E-Stop and Auto Stop signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5. PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES . . . ..36
Principles common to the RoboSAFE Joint and Cartesian functionalities. . . . . . . . . . . . . . . . . 36
System axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
RoboSAFE Joint functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
RoboSAFE Joint definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
RoboSAFE Joint performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Joint Space Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Joint functional sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Joint Speed Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Cartesian Speed Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .with the correct use of RoboSAFE system in order not
to alter the mechanical configuration of equipment, Robot fixings and in any case
of the positions and spaces in the cell on which the parameters of safe areas have
been configured.
3.16 Installation precautions
The following key steps for proper installation and integration are highlighted:
– after the mechanical installation of the Robot, carry out the axes Turn Set
procedure (see detailed procedure in the “Maintenance” handbook of the Robot).
Since the whole RoboSAFE system bases the identification of clearance distances
on the Cartesian reference frame of the Robot, it is important that all movement
programs and parameters refer to a perfectly positioned system;
– lock by a pin the Robot to the fixing base in order to ensure the proper recovery in
case of complete Robot replacement; this possibility does not guarantee a high
precision and may be necessary to carry out one or more positioning checks;
– provide a certain point in the workspace of the Robot where you can perform
periodic checks of Tool Center Point; this check should be repeated at least after
every maintenance operation that alters the kinematic chain of the Robot, the use
of the brake releasing module, etc.;
– comply with the requirements specified in the handbooks of “Installation” of the
Robot and the Control Unit.
Do not use a Robot and RoboSAFE parameters and relative movement program
in an installation position different from that foreseen in origin in the project.
When moving or reinstalling, carry out a new planning and parameter setting as
if it were the first installation.
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Comau Robotics Product Instruction
PRINCIPLES AND FUNCTIONALITIES FOR CELL / LINE AND APPLICATIONS INSTALLED ON ROBOT
4. PRINCIPLES AND FUNCTIONALITIES FOR 
CELL / LINE AND APPLICATIONS 
INSTALLED ON ROBOT 
– Principles common to the RoboSAFE 2.0 functionalities;
– RoboSAFE 2.0 functionalities for the cell / line;
– RoboSAFE 2.0 functionalities for the applications installed on Robot.
4.1 Principles common to the RoboSAFE 2.0 
functionalities
The principle on which the RoboSAFE 2.0 functionalities for the cell / line and
applications are based is the control of the safety signals to be used for interfacing
with the robotic system. The signals are managed by the safety PLC inside the Control
Unit and, where provided, with behaviour that can be parameterized via Web portal
pages. 
The RoboSAFE 2.0 functionalities are always active and can be extended and used with
specific options.
4.2 RoboSAFE 2.0 functionalities for the cell / line
– E-Stop from the automated system line;
– Auto Stop (Fence);
– General Stop;
– E-Stop of the Teach Pendant.
4.2.1 E-Stop from the automated system line
It is an input signal coming from the cell / line to activate the emergency stop of the
Robotic system. 
4.2.2 Auto Stop (Fence)
It is an input signal coming from the cell / line to safely stop the Robotic system, to which
to connect the signal coming from the limit switch that controls the cell accesses.
In case of open cell access, or in the absence of a signal (logic level 0), only movements
in programming mode (T1 mode) are allowed. 
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PRINCIPLES AND FUNCTIONALITIES FOR CELL / LINE AND APPLICATIONS INSTALLED ON ROBOT
Comau Robotics Product Instruction
4.2.3 General Stop
It is an input signal coming from the cell / line to activate the safety stop of the Robotic
system.
Very similar to the functionalities of the e-Stop input, it generates a specific signalling
and prevents the Robot from moving in any mode.
4.2.4 E-Stop of the Teach Pendant
It is an output signal for the cell / line to integrate the status of the emergency stop
push-button installed on the Teach Pendant in the emergency stop circuit of the cell /
line.
4.3 RoboSAFE 2.0 functionalities for the applications 
installed on Robot 
– Enabling device;
– Auto Mode and T1 Mode;
– Drive ON;
– Replicas of E-Stop and Auto Stop signals.
4.3.1 Enabling device
It is an output signal corresponding to the status of the enabling device push-buttons
present on the Teach Pendant.
4.3.2 Auto Mode and T1 Mode
They are signals corresponding to the status of the mode selector switch on the Teach
Pendant: the Auto mode is an output signal corresponding to the Auto mode (Local or
Remote); T1 mode to the status in T1 programming mode.
4.3.3 Drive ON
It is an output signal corresponding to the status of the motors started (STO - Safe
Torque Off deactivated).
4.3.4 Replicas of E-Stop and Auto Stop signals
For applications, in addition to the Enabling device, Auto Mode and T1 Mode, Drive ON
signals, replicas of the E-Stop from the automated system line and Auto Stop (Fence)
line signals are also available.
The emergency stop push-button on the Teach Pendant is not connected to any circuit
and must be correctly integrated by the integrator.
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Comau Robotics Product Instruction
PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
5. PRINCIPLES AND ROBOSAFE JOINT AND 
CARTESIAN FUNCTIONALITIES
– Principles common to the RoboSAFE Joint and Cartesian functionalities;
– System axes;
– RoboSAFE Joint functionality;
– RoboSAFE Cartesian functionality;
– Access and parameter setting of the RoboSAFE functionalities.
5.1 Principles common to the RoboSAFE Joint and 
Cartesian functionalities
The principle on which the RoboSAFE Joint and Cartesian functionalities are based is
the position and speed control for Robots of SMART5 Rel. 2 series, grouped in rules
and functions, set through parameters and activated by a pair of safe signals or bit by
ProfiSAFE protocol. 
The RoboSAFE Joint functionality refers to the joint movements and the RoboSAFE
Cartesian one to the Cartesian movements.
Failure to comply with confinement in the set spaces and/or limit speeds corresponds to
a violation of the rules. 
In response to one or more active and non-violated functions, the system
communicates the status through a safe signal summary (see signal RoboSAFE active).
In case of violation of one or more rules, the Robot applies the behaviour decided by
the parameters set (only one signalling on SAFE signal - see RoboSAFE active -, or
stopped in category 0 or 1 according to standard EN 60204-1).
The stop in category 1 of the Robot set after a violation of a function generates an
effective stop with reduced stop space (details in par. 3.7).
All enabling signals are active in negative logic; with signal to 0 the function is active.
The RoboSAFE Joint functionality is available at the same time as the RoboSAFE
Cartesian functionality (optional). 
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PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
Comau Robotics Product Instruction
5.2 System axes 
The axes of the Robot base X, Y and Z are represented by straight lines coloured in red,
green and blue respectively, and with the positive direction in the direction of the arrow. 
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Comau Robotics Product Instruction
PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
5.3 RoboSAFE Joint functionality 
– RoboSAFE Joint definition;
– RoboSAFE Joint performances:
• Joint Space Limiting;
• Joint functional sectors;
• Joint Speed Limiting;
• Cartesian Speed Limiting;
• Monitoring Points;
• Brake test.
5.3.1 RoboSAFE Joint definition 
The RoboSAFE Joint functionality allows the management of Workspaces and Safe
speeds of the axes and monitoring points.
The RoboSAFE Joint functionality is based on the Rules of principle of the RoboSAFE
functionality (par. 5.1), applied to:
– all axes of the Robot, confined or external to the combination of angular sectors
(angular sectors, not volumes);
– maximum speeds set and not exceeded. 
The Robot monitored Workspace is determined by the combination of one or more
angular sectors for each single axis of the Robot. Different combinations are
possible (defined Set), with flexibility of choice of the desired axes.
The RoboSAFE Joint functionality considers the Robot and the tool as a series of points
in space. Point is the termused to define the position in the space of a “monitored point”
(segments of joining between contiguous joints / points are not taken into consideration).
The RoboSAFE Joint functionality checks only the points of the kinematic chain while
the three-dimensional figure of the Robot is for the sole purpose of representing the
overall dimensions.
In large Robots and/or with long arms or large tools, the monitoring points can be very
far apart; this situation can make it difficult to identify the crossing of narrow or
pillar-shaped objects. 
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PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
Comau Robotics Product Instruction
Fig. 5.1 - Example of a Safe Workspace, consisting of a set of 6 Safe 
Axis Spaces (one for each axis) 
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Comau Robotics Product Instruction
PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
5.3.2 RoboSAFE Joint performances
The RoboSAFE Joint functionality allows to achieve the following SAFE performances
and functions:
– Joint Space Limiting, (up to 7 axes for each set);
– Joint functional sectors, (up to 15 sectors on axis 1 and on axis 7, status signalling
of the position on output safe);
– Joint Speed Limiting, (up to 7 axes in set)
– Cartesian Speed Limiting, (3 distinct speeds);
– Monitoring Points, (further monitoring points in addition to the Robot joints, up to 2
points each set - Elbow, Toolset1 and Toolset2);
– Brake test, (functionality check of the brakes of the Robot axis motors and Robot
Track Motion).
5.3.2.1 Joint Space Limiting
Joint Space Limiting performance is a Safe function that allows to set one Safe
Workspace (see Fig. 5.1), defined from 1 to 6 sectors of angular stroke, one for each
Robot axis*¹. 
Grouping of ranges set (up to 7) is defined Set. Each set safely defines the Robot
workspace (combinations of angular sectors called Safe Workspace), with
configurations always active or conditioned by the response of external events,
generated for example by cell safety devices (light curtains)
Each set of Joint Space Limiting can always be active or activated / deactivated
dynamically through independent safe inputs (see RoboSAFE Joint - Set 1 and the next
ones) (both modes also simultaneously with other RoboSAFE functions).
When enabled and activated by the appropriate inputs, the function operates in
Automatic mode. If required, can also be activated in T1 Programming mode. 
Parameters can be set in “Joint Spaces” menu (see par. 12.3).
*¹ the 7 axes correspond to the typical configuration of the Robot 6 axes and 1 axis 7 (linear - Robot Track
Motion or rotary - table). Available only on certain Control Unit configurations.
5.3.2.2 Joint functional sectors
Joint functional sector performance is a Safe function that allows to know the safe
position of a Robot axis. 
The function identifies and indicates in which sector the axis 1 and axis 7 are located (up
to 15 distinct sectors defined with corner setting). Position outcome is available on a
binary coding (one byte, see Position in the sector AX 1 Joint (bit 1) and the following
ones).
The Joint functional sectors function is activated automatically after setting at least one
corner.
Parameters can be set in the “Joint Spaces” menu (see par. 12.3).
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PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
Comau Robotics Product Instruction
5.3.2.3 Joint Speed Limiting
Joint Speed Limiting performance is a Safe function that allows to set a safe speed
control for each of the 6 axes of the Robot. It is also possible to combine axis 7. 
Grouping of ranges set (up to 7) is defined Set.
The system allows to define a set of Joint Speed Limiting.
The Joint Space Limiting functionality can always be active or activated / deactivated
dynamically through a shared safe input (see RoboSAFE Joint Speed) (both modes also
simultaneously with other RoboSAFE functions).
Parameters can be set in “Speed” menu (see par. 12.7).
5.3.2.4 Cartesian Speed Limiting 
Cartesian Speed Limiting performance is a Safe function that allows to set a safe
Cartesian speed limit on all axes and Monitoring Point (if defined).
The system allows to define the following speeds: 
– low speed (Low Speed), in the range from 2 mm/s to the value set in High Speed;
– high speed (High Speed), in the range from Low Speed to the maximum allowed
by the mechanics of the Robot, with the exception of systems with AURA solution
which have the upper limit at 500 mm/s;
– speed in T1 programming (Progr Speed), 250 mm/s. It is not allowed to change
the value and can only be activated in T1 programming mode.
Cartesian Speed Limiting High and Low functionalities can always be active or
activated / deactivated dynamically through independent safe inputs (see RoboSAFE
High Speed and RoboSAFE Low Speed) (both modes also simultaneously with other
RoboSAFE functions).
Cartesian Speed Limiting Prog functionality can be activated / deactivated only from
the Web portal.
Immediately after activating the Cartesian Speed Limiting functionality, there is always
an idle window of 500 ms within which there will be no violation signalling. If the speed
is higher than the set limit, this time will be used by the system to automatically impose
an adequate slowdown to prevent the violation. If the speed is definitely higher and the
system is not able to reduce the speed adequately, after 500 ms the violation of the
function will be activated. 
During the whole monitoring activation period, speeds lower than those set are always
possible.
Parameters can be set in the “Speed” menu (see par. 12.7).
Precautions for integrator
The Cartesian Speed Limiting functionality simultaneously with other speed controls
are possible: in this condition, the system monitors the slowest one.
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PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
5.3.2.5 Monitoring Points
Monitoring Point performance is a Safe function that allows to define points (overall
dimension of the Robot, of the equipment on the wrist and the dressing installed on axis
3), in order to monitor the speed with the Cartesian Speed Limiting function (see
definition in par. 5.3.1). 
It is possible to define:
– Monitoring Point, position of the points (up to 8) that represent the extremes of
the Tool overall dimensions on the Robot;
– Kinematic Monitoring Point, position of the point representing the joint (6 points,
not modifiable but visible on the Robot for better understanding);
– Elbow Monitoring Point, points to represent the dimensions of the dressing
installed on axis 3 (up to two points). The function is activated automatically after
setting at least one point;
– Toolset 1 and Toolset2, up to 4 additional monitoring points (2 points for each of
the 2 Toolsets) for the Tool. Each set can always be active or activated /
deactivated dynamically through independent safe inputs (see RoboSAFE Toolset
1 and the next ones), also simultaneously with other RoboSAFE functions).
Parameters can be set in the “Monitoring Point” menu (see par. 12.8).
To be able to configure the tool and the layout as volumes, it is necessary to use the
RoboSAFE Cartesian functionality (optional).
5.3.2.6 Brake test
Brake Test performance is a function that allows to periodically check the brake
efficiency of the Robot motors and SAFE Robot Track Motion (if present in the
configuration). The check periodicity event is managed by two SAFE timers. 
Response check and management must be done with a non-safe routine called Brake
Test Check (BTC).
Precautions for integrator
The BTC routine performs a series of mild stress on the brakes of the Robot and of the
safe Robot Track Motion, a brake at one time. The test duration is about 3 minutes.
During this time the Robot can undergo minor deviations (max. 1° from the position in
which is situated at the beginning of the procedure) and can not perform any other
activity.
When the monitoring function is active, two SAFE timers generate specific events (one
when the Control Unit is turnedon, the other periodically) that must be diagnosed
through bits in a PDL 2 program and used to start the BTC routine. If the routine is not
executed within the set time, an alarm stops the system.
Since there is a tolerance between the pre-alarm signalling and the alarm signalling, it
is recommended to coordinate the production process so as to perform the BTC routine
within the deadlines determined by the requests.
Parameters can be set in “Brake” menu (see par. 12.9).
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PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
Comau Robotics Product Instruction
5.4 RoboSAFE Cartesian functionality
– RoboSAFE Cartesian definition;
– RoboSAFE Cartesian performances;
• Cell;
• Dynamic Volumes;
• Functional Spaces;
• Cartesian Speed Limiting;
• Monitoring Point;
• Brake test;
• Tool Orientation;
– Support performances:
• Speed Modulation;
– Coordinate X, Y, Z (origin) in the RoboSAFE Cartesian functionality;
– Functional definition of workspace and volumes;
– Requirements for the extent of the defined volumes.
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PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
5.4.1 RoboSAFE Cartesian definition
The RoboSAFE Cartesian optional functionality allows to manage Cartesian Safe
workspaces (volumes) (see definition in par. 5.4.4) and safe speeds for Robots of
SMART5 series Rel. 2.
The RoboSAFE Cartesian functionality observes the Rules of principle of the
RoboSAFE functionalities (par. 5.1) and is essentially based on verification that:
– volumes of capsules*¹ or spheres*² (connected to the Robot kinematics) are
confined or external to spaces set by the user;
– the maximum speeds set are not exceeded. 
Main volumes refer to the Robot kinematics, consisting of 6 capsules*¹ (6 axes of the
Robot) and always active.
The user can add additional Monitoring Points for some functional areas:
– dressing on axis 3 (up to 2 capsules*¹, automatically active if defined);
– tool space (up to 8 capsules*¹, automatically active if defined);
– free spaces on the tool (up to 2 sets, each consisting of 2 spheres*², always
active or dynamically active).
The coordinates of origin of the volumes (X, Y, Z) refer to the position 0,0,0, at the center
of the Robot base (details in par. 5.4.3).
The violation of the volume and the consequent stop of the Robot intervenes when one
or more of the active points of monitoring points in a given moment do not observe the
rules in the defined volumes. The violation of the speed and the consequent stop of the
Robot intervenes when the speed exceeds the set one, forcing the Robot to stop.
*¹ Capsule is the term used to define the geometric shape that represents the checked
volume, represented by a cylinder that joins 2 spheres built around 2 contiguous
joints (that is, the three-dimensional shape of the link that joins the 2 adjacent joints).
The use of spheres and cylinder allows to check the real dimensions of the Robot and,
where provided, of the equipment, moving in unison with the kinematics of the Robot.
*² Sphere is the term used to define the geometric shape that represents the checked
volume, composed of a single sphere. The use of a single sphere allows to control a
non-continuous space at a previous or next point.
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PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
Comau Robotics Product Instruction
5.4.2 RoboSAFE Cartesian performances
The RoboSAFE Cartesian functionality allows to achieve the following SAFE
performances and functions:
– Cell, (1 cell and up to 10 prohibited volumes);
– Dynamic Volumes, (up to 10 volumes that can be activated dynamically);
– Functional Spaces, (up to 2 sets, each up to 15 volumes and signalling of the tool
position on safe outputs);
– Cartesian Speed Limiting, (3 distinct speeds);
– Monitoring Point, (further check capsules and spheres in addition to the Robot
body, up to 2 spheres each set - Elbow, Toolset1 and Toolset2);
– Tool Orientation;
– Brake test, (functionality check of the brakes of the Robot axis motors and Robot
Track Motion).
In addition, there is available the Speed Modulation function for speed predictive check
(non-SAFE function).
5.4.2.1 Cell
Cell performance is a Safe function that allows to define the main volume where the
Robot must be confined (it represents the space of the physical cell where the Robot will
operate). The definition of the cell includes the perimeter (8 vertical planes defined
through edges), a floor and a roof.
The Volume Cell is always active; within this volume it is possible to create one or more
Forbidden volumes that are always active (see definition in par. 5.4.4) to protect
volumes inside the cell (they typically represent mechanical structures in the cell). 
Any dynamically activated volumes can be created with the Dynamic Volumes
functionality.
Parameters can be set in “Cell” menu (see par. 12.4).
5.4.2.2 Dynamic Volumes
Dynamic Volumes performance is a Safe function that allows to define one or more
dynamic volumes (see definition in par. 5.4.4) inside the cell, where the Robot must be
confined or not authorized to enter (it typically represents the workspace cyclically
occupied by the operator).
The Dynamic volume is essentially constructed as a rectangular parallelepiped and
always checks the entire Robot (joints of the axes and tool, if activated).
Each Dynamic volume can be permanently active or combined with the status of specific
safe inputs and can be assigned to the following types:
– Work volume, that is, space where the Robot will be allowed freedom of
movement without leaving it, and/or
– Forbidden volume, that is, space where the Robot must not enter.
The volumes defined in this function must be inscribed within the volume of the cell (see
par. 5.4.2.1).
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Comau Robotics Product Instruction
PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
The volumes (or part of them) “Work Volume” and “Forbidden Volume” may overlap; in
this case the Forbidden Volume prevails.
Parameters can be set in “Dynamic Volumes” menu (see par. 12.5).
5.4.2.3 Functional Spaces 
Functional Spaces performance is a Safe function that identifies the position of the
Tool in the cell space. It is possible to configure up to 2 sets, each of which up to 15
different spaces (see definition in par. 5.4.4). Spaces (volumes) in the same set must
not overlap.
The space occupied by the tool must be defined in Monitoring Point performance.
These volumes must be inscribed within the volume of the cell (see par. 5.4.2.1).
The binary output (4 bit) that indicates the number of the volume in which the tool is
located is available on:
– Position in volume, Functional Spaces SET-A bit 1 and the next ones for Functional
Space A;
– Position in volume, Functional Spaces SET-B bit 1 and the next ones for Functional
Space B.
Parameters to define the volumes can be set in “Functional Space A” and “Functional
Space B” menu (see par. 12.6); the Tool can be defined in “Monitoring Point” menu (see
par. 12.8).
5.4.2.4 Cartesian Speed Limiting 
The Cartesian Speed Limiting performance is a Safe function that allows safe speed
control by setting the maximum Cartesian speed value accepted for the application, on
all the axes and Monitoring Point (if defined).
This function is identical to the one already described for the RoboSAFE Joint
functionality (see par. 5.3.2.4), as are parameters that can be set in the same Speed
menu (see par. 12.7).
5.4.2.5 Monitoring Point
The Monitoring Point performance is a Safe function that allows to define points
(overall dimension of the Robot, of the equipment on the wrist and the dressing installed
on axis 3), in order to monitor the speed with the Cartesian Speed Limiting function and
the occupied space with the Dynamic Volumes function (see definition in par. 5.4.4). 
It is possible to define:
– Monitoring Point, position and dimensions of the capsules (up to 8) (see definition
in par. 5.4.2) which represent the volume of the Tool on the Robot;
– Kinematic MonitoringPoint, capsule sizes that represent the volume of the
Robot axes;
– Elbow Monitoring Point, position and dimension of the capsules to represent the
dimensions of the dressing installed on axis 3 (up to two capsules). The function is
activated automatically after setting at least one capsule;
– Toolset 1 and Toolset2, up to 4 additional monitoring spheres (2 spheres for each
of the 2 Toolsets) on the Tool. Each set can always be active or activated /
46
PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
Comau Robotics Product Instruction
deactivated dynamically through independent safe inputs (see RoboSAFE Toolset
1 and the next ones), also simultaneously with other RoboSAFE functions).
Parameters can be set in the “Monitoring Point” menu (see par. 12.8).
The performance shares the same interface as the Monitoring Point for RoboSAFE Joint
but the Cartesian option also allows to define the dimensions / volumes.
5.4.2.6 Tool Orientation
Tool Orientation performance is a Safe function that allows to monitor whether a
specific Tool orientation is maintained. 
It is possible to define:
– Behaviour, it can be permanently active or combined with the status of specific
safe inputs (see RoboSAFE Cartesian Orientation Tool) and can stop or not stop
the movement of the Robot in case of violation;
– Orientation Coordinate System, the origin of the vector outgoing from the flange
to the wrist can be modified, as well as the orientation in space and the corner that
represents the tolerated cone of movement.
Parameters can be set in “Tool Orientation” menu (see par. 12.11).
5.4.2.7 Brake test
Brake Test performance is a Safe function that allows to periodically check the brake
efficiency of the Robot motors and SAFE Robot Track Motion (if present in the
configuration). The performance is the same as the RoboSAFE Joint, already described
in the paragraph par. 5.3.2.6.
5.4.2.8 Speed Modulation
Speed Modulation performance is a non safe function which makes it possible to
impose a controlled Cartesian slowdown of the Robot, in order to avoid exceeding and
the consequent violation of defined volumes. 
The Speed Modulation function is activated through specific enabling on the Web portal.
Parameters can be set in the “Speed” menu (see par. 12.7.2).
Precautions for integrator
– Since it is not a safe function, this function cannot be used to ensure the
confinement of the Robot in the volumes;
– it is always necessary to carefully consider the stopping distances;
– the movement program must foresee trajectories and speeds to avoid reaching the
boundaries of the volumes with excessive speeds that do not allow the intervention
of the function, with the consequent activation of the violation.
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Comau Robotics Product Instruction
PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
5.4.3 Coordinate X, Y, Z (origin) in the RoboSAFE Cartesian 
functionality
The 0,0,0 mm coordinate of the RoboSAFE Cartesian functionality corresponds to world
frame and all positions and dimensions of the volumes refer to the world frame.
The coordinates of the Robot base can be moved; this displacement does not change
the position of the cell and the volumes that remain therefore referred to the world frame.
In case of modification of the basic coordinates of the Robot, pay attention to:
– the Web interface does not provide evidence of this displacement and displays the
Robot projected in world coordinates;
– the modification of the coordinates (executable both via PDL2 and by the Teach
Pendant) must be followed by a SAVE command of the parameters (see
par. 12.12), so that the alignment of the values of the Robot base frame with the
safe parameters is guaranteed;
– the modification via PDL2 is not recommended because it is not always possible to
follow the SAVE command and the consequent misalignment between the base
frame and the parameters makes it difficult to identify violation errors.
When the Robotic system consists of the Robot only, the 0,0,0 mm coordinate coincides
with the axis 1 centre; in the case of Robot and Robot Track Motion, it corresponds to
the calibration position typically before the Robot base.
It is important to consider that the 0,0,0 mm coordinate must always be inscribed in the
cell volume, the corners cannot have 0,0 mm coordinates and the faces must not cross
the 0,0 vertex because immediately incurs the violation.
The floor must have a negative dimension (minimum default -41 mm) to avoid
immediately incurring the violation.
The cell must also include the position taken by the joints of the axes that in certain
positions can have negative values.
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PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
Comau Robotics Product Instruction
0,0,0 0,0,0
Base FrameWorld Frame
0,0,0
World Frame
Base Frame
0,0,0
0,0,0
Base Frame
0,0,0
World Frame
World Frame
Base Frame
World Frame
Base Frame
0,0,0 0,0,0
0,0,0
49
Comau Robotics Product Instruction
PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
5.4.4 Functional definition of workspace and volumes
The RoboSAFE Cartesian functionality uses the following functional definitions:
– Workspace, where the Robot is monitored through one or more combinations of
volumes in order to identify the space where the Robot must be confined or must
not enter;
– Volumes, which can be configured in the modes:
• Static volume (always active) or dynamic volumes (active on event with
SAFE inputs for activation);
• Work volume, where the Robot can move freely or Forbidden volume,
where the Robot is not authorized to enter;
• or the combination of the 2 modes;
– Functional volumes, which can be configured in the modes:
• Enabled (always active) and obtain SAFE outputs which indicate the position
of the Robot in the space (up to 15 different volumes);
• Disabled (always deactivated), without any position signalling.
The volumes are defined with 3 coordinates to determine the point of origin,
represented graphically with a coloured sphere (1); additional parameters allow the
rotation of the parallelepiped around the point of origin.
The dimension in the space is defined by 3 values, thus allowing to represent
graphically the coloured parallelepiped (2), of different colour according to the combined
function:
– Work volume: green
– Forbidden volume: yellow;
– Enabled functional volume: blue. 
When defining the dimensions of the volumes, pay attention to the Requirements for the
extent of the defined volumes (see par. 5.4.5 on page 52). 
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PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
Comau Robotics Product Instruction
Fig. 5.2 - Example of a RoboSAFE Cartesian workspace, constituted by 
a set of volumes (work volume and forbidden volume)
The installation of the Robot is typically provided in a position parallel to the floor,
including the ceiling installation. Installation with inclined base is allowed (it depends on
the BASE coordinates of the Robotic system); in any case, the display of the Robot in
the portal is however parallel to the representation of the floor.
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Comau Robotics Product Instruction
PRINCIPLES AND ROBOSAFE JOINT AND CARTESIAN FUNCTIONALITIES
5.4.5 Requirements for the extent of the defined volumes
In order to avoid that a volume violation is immediately generated without being able to
move the Robot during volume activation, it is fundamental to make sure that all
monitoring points of the Robot and tool (in rest position) are inscribed in the Work
Volume.
In the same rest position and for the same reason, all monitoring points of the Robot
and tool must be external to a Forbidden Volume.
The minimum side of the forbidden volume must be greater than 100 mm so that any
high speed of the movement combined with the scanning time can guarantee the
identification of the transit of the monitoring point.
At very low speeds, the compensation algorithm of the reaction time can stop the Robot
up to 40 mm before reaching the volume wall. 
5.5 Access and parametersetting of the RoboSAFE 
functionalities 
All RoboSAFE functionalities are accessible through the WEB interface made available
on all Control Units (details in Chap.11. on page 99).
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PRINCIPLES AND AURA COLLABORATIVE ROBOT FUNCTIONALITY
53
Comau Robotics Product Instruction
6. PRINCIPLES AND AURA COLLABORATIVE 
ROBOT FUNCTIONALITY
AURA (Advanced Use Robotic Arm) is a solution designed to concretely limit the
physical risks of the Robot impact with operator; it can be applied in scenarios of
handling operations in an environment with the presence of people in the immediate
vicinity and/or in collaboration with the Robot.
AURA functionality is based on RoboSAFE concepts (both Joint par. 5.3 and Cartesian
par. 5.4 functionalities are enabled) integrated by features of the collaborative Robot.
Considering the topic particularly structured, information and further details in the AURA
area are available in the relevant handbook Sensorized Skin on AURA Collaborative
Robot: Functionality and user handbook.
Comau Robotics Product Instruction
INTRODUCTION TO SAFETY FUNCTIONALITIES AND TECHNICAL FEATURES
7. INTRODUCTION TO SAFETY 
FUNCTIONALITIES AND TECHNICAL 
FEATURES
– Map of available SAFE functionalities, configurations and connectivity;
– Technical features of a Comau SAFE Robotic System.
7.1 Map of available SAFE functionalities, 
configurations and connectivity
With the Control Unit you can choose the combination of the safe functionalities and
connectivity you want. The choice of one of the connectivity alternatives is mandatory
(see details in the Tab. 7.1).
Tab. 7.1 - Functionality and available performances on the Control Unit 
models
Functionality Available performances
Connection modes
(mandatory choice, according to your preferences)
Digital discrete I/Os Fieldbus
Standard C5G Plus Control Unit, without SAFE axes
SAFE standard 
functionality for 
automated system 
line / cell
– SAFE control signals from 
the automated system line 
(inputs for e-Stop, Fence, 
General Stop);
– SAFE status signals 
towards the automated 
system line (output for 
Teach Pendant e-Stop);
– Stop timer time variation;
– Creation of the report of 
safety parameters set in the 
UDC
– C5GP-E30K 
(X30/CIP) option 
(see par. 8.1)
– C5GP-PIS 
(ProfiSAFE) options 
or alternatives *¹ 
(see par. 8.1)
SAFE functionality 
for applications 
connected to the 
Control Unit (ERM, 
Extended Repetition 
Module)
– Duplication of SAFE status 
signals (Drive ON output, 
Auto-L / T1 mode, Enabling 
device)
– C5GP-EISO (X31/CIP) options and integrations 
(see par. 8.3)
– in addition, 
C5GP-PIS 
(ProfiSAFE) options 
or alternatives *¹ 
(see par. 8.1)
SAFE C5G Plus Control Unit
RoboSAFE 
functionality
in Joint version
– Periodic test of brakes
– Control of joints max speed
– Control and Parameter 
setting of Joint functionality
– C5GP-SMEC 
(X52/CIP) option *² 
(see par. 8.4)
– C5GP-PIS 
(ProfiSAFE) options 
or alternatives *¹ 
(see par. 8.1)
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INTRODUCTION TO SAFETY FUNCTIONALITIES AND TECHNICAL FEATURES
Comau Robotics Product Instruction
RoboSAFE 
functionality
in Cartesian version
– Control and Parameter 
setting of Cartesian 
functionality
– C5GP-SMEC 
(X52/CIP) option *² 
(see par. 8.4)
– C5GP-PIS 
(ProfiSAFE) options 
or alternatives *¹ 
(see par. 8.1)
– SW option for RoboSAFE Cartesian 
Functionality 
In addition:
– SAFE standard functionality for automated system line / cell;
– SAFE functionality for applications connected to the Control Unit (ERM, Extended Repetition Module)
AURA C5G Plus Control Unit
AURA functionality 
and solution
– Control and Parameter 
setting of collaborative 
functionalities
– The Control Unit natively has all the SW 
functionalities 
In addition:
– RoboSAFE functionality in Joint version;
– RoboSAFE functionality in Cartesian version;
– SAFE standard functionality for automated system line / cell;
– SAFE functionality for applications connected to the Control Unit (ERM, Extended Repetition Module)
Tab. 7.1 - Functionality and available performances on the Control Unit 
models (Continued)
Functionality Available performances
Connection modes
(mandatory choice, according to your preferences)
Digital discrete I/Os Fieldbus
55
Comau Robotics Product Instruction
INTRODUCTION TO SAFETY FUNCTIONALITIES AND TECHNICAL FEATURES
*¹ The optional solution C5GP-PIS (ProfiSAFE) is the most complete from the point of view of the quantity of
signals available; it can be replaced with other Fieldbus solutions (C5GP-ABE or C5GP-EISM) but some
signals may not be available.
*² With the optional solution X52, some signals may not be available simultaneously with other ones.
Standard R1C-6 Control Unit, without SAFE axes
SAFE functionality 
for automated 
system line / cell
– SAFE control signals from 
the automated system line 
(inputs for e-Stop, Fence, 
General Stop);
– SAFE status signals 
towards the automated 
system line (output for 
Teach Pendant e-Stop);
– Stop timer time variation;
– Creation of the report of 
safety parameters set in the 
UDC
– C5GP-E30K 
(X30/CIP) option 
(see par. 8.1) 
– C5GP-PIS 
(ProfiSAFE) options 
or alternatives *¹ 
(see par. 8.1)
SAFE functionality 
for applications 
connected to the 
Control Unit (ERM, 
Extended Repetition 
Module)
– Duplication of SAFE status 
signals (Drive ON output, 
Auto-L / T1 mode, Enabling 
device)
– C5GP-EISO (X31/CIP) options (see par. 8.3) 
and integrations (see par. 9.7.1)
– in addition, 
C5GP-PIS 
(ProfiSAFE) options 
or alternatives *¹ 
(see par. 8.1)
– It is compatible with the presence of SAFE functionality for automated system line / 
cell
S1C-6 SAFE Control Unit
RoboSAFE 
functionality
in Joint version
– Periodic test of brakes
– Control of joints max speed
– Control and Parameter 
setting of Joint functionality
– R1C-SMEC (X52) 
option *² (see 
par. 8.4)
– Not available
RoboSAFE 
functionality
in Cartesian version
– Control and Parameter 
setting of Cartesian 
functionality
– R1C-SMEC (X52) 
option *² (see 
par. 8.4)
– Not available
– SW option for RoboSAFE Cartesian 
Functionality 
In addition:
– SAFE functionality for automated system line / cell;
– SAFE functionality for applications connected to the Control Unit (ERM, Extended Repetition Module)
Tab. 7.1 - Functionality and available performances on the Control Unit 
models (Continued)
Functionality Available performances
Connection modes
(mandatory choice, according to your preferences)
Digital discrete I/Os Fieldbus
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INTRODUCTION TO SAFETY FUNCTIONALITIES AND TECHNICAL FEATURES
Comau Robotics Product Instruction
7.2 Technical features of a Comau SAFE Robotic 
System
Tab. 7.2 lists the technical features of a Comau SAFE Robotic system
*¹ The PL includes the safe control of the limit and, in category 0 (EN 60204-1), the immediate deactivation of
the motors with operation of electromechanical brakes; in category 1 (EN 60204-1), the controlled stop with
the SS1 deceleration ramp (see further details in the par. 3.7 Stopping modes in RoboSAFE system on
page 27).
Tab. 7.2 - Technical features
Topic Feature
Robotic system supported
The system must be composed of the following components:
– Control Unit of C5G Plus series standard and SAFE models
– Control Unit of R1C series R1C-6 and S1C-6 models
– Robot version Rel. 2 or higher
– Integrated Robot Track Motion (in the same Robot ARM) where possible, on axis 7 Safe
– other auxiliary axes standard axes (not Safe)
– Teach Pendant C5G-TP5
RoboSAFE 2.0 functionalities
– Interfacing with cell / automated system line and 
applications
available on all the models
– RoboSAFE Joint available on the SAFE models
– RoboSAFE Cartesian optional on the SAFE models
Controllable axes
With RoboSAFE 2.0 control
where possible, up to 7 axes (Robot with Robot 
Track Motion)
Other standard auxiliary axes where possible, up to 6 axes
System software
For RoboSAFE functionality 2.0 Ver. 3.11.003 or higher
Safety category
Category 0 and category 1 (accordingto the standard EN 
60204-1)
parameterized
Safety level of the RoboSAFE 2.0 system
Includes the functions of: 
– E-stop / Auto-Stop (Fence) / General Stop inputs;
– E-Stop outputs. Auto mode, T1 mode, Enabling Device, 
Drive ON and Auto-Stop (Fence);
– Speed control (Joint and Cartesian);
– Control of reduced speed 250 mm/s (T1 mode);
– Limitation of Joint and Cartesian spaces;
– Status outputs of the RoboSAFE Joint and Cartesian 
functions.
Category 3 - PL d *¹, according to the standard 
EN ISO 13849-1:2015
Scan time of the safety functions 8.8 ms
Response time (Worst case)
Response time from violation of 
the limit to the start of the stop 
command, or
from the status change event to the 
availability of the output signal
80 ms
57
Comau Robotics Product Instruction
DESCRIPTION OF SAFE SIGNALS TO INTERFACE THE AUTOMATED SYSTEM LINE AND APPLICATIONS
8. DESCRIPTION OF SAFE SIGNALS TO 
INTERFACE THE AUTOMATED SYSTEM 
LINE AND APPLICATIONS
The C5G Plus series Control Unit provides the following safety signals to interface with
automated system lines and applications:
– SAFE signals for interfacing with the automated system line (E-Stop, Auto-Stop,
General Stop);
– Interfacing of the E-Stop of the Teach Pendant with Fieldbus;
– SAFE signals (optional) for interfacing applications / automated system line
(E-Stop, Auto mode, T1 mode, Enabling Device, Drive-ON, Auto-Stop outputs);
– SAFE signals for interfacing position and speed control of the Robot.
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DESCRIPTION OF SAFE SIGNALS TO INTERFACE THE AUTOMATED SYSTEM LINE AND APPLICATIONS
Comau Robotics Product Instruction
8.1 SAFE signals for interfacing with the automated 
system line (E-Stop, Auto-Stop, General Stop)
The Control Unit can be interfaced with the automated system line / cell management
system via SAFE signals, optionally with discrete I/Os or Fieldbus (slave node). 
*¹ The optional solution C5GP-PIS (ProfiSAFE) is the most complete from the point of view of the quantity of
signals available; it can be replaced with other Fieldbus solutions (C5GP-ABE or C5GP-EISM) but some
signals may not be available.
Tab. 8.1 - Signals available for SAFE interfacing with the automated 
system line
Available signals 
Connection modes
(mandatory choice, according to your preferences)
Digital discrete I/Os Fieldbus
C5G Plus Control Unit (all versions)
General Stop 
E-Stop from the automated 
system line
– X30/CIP external connector 
with C5GP-E30K option 
– E-Stop push-button also 
available with the Control Unit 
off
– Mapping of I/O signals in 
par. 9.6
– Gateway module with 
C5GP-PIS option (ProfiSAFE) 
*¹
– E-Stop push-button NOT 
connected internally to the 
safety circuit 
– Mapping of I/O signals in 
par. 9.3
General Stop
Auto Stop (Fence) 
from the automated system line
General Stop
General Stop
from the automated system line
Push-button 
E-Stop of the Teach Pendant
towards the automated system 
line
Connect the E-Stop push-button to 
(alternative options):
– connector on X122 with 
C5GP-XPP option
– X130/CIP external connector 
with C5GP-TEC option 
– Details in par. 8.2)
– Note: the simultaneity of the 2 connection modes is not allowed
Details of the options are given in the Available options handbook of the Control Unit.
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Comau Robotics Product Instruction
DESCRIPTION OF SAFE SIGNALS TO INTERFACE THE AUTOMATED SYSTEM LINE AND APPLICATIONS
8.2 Interfacing of the E-Stop of the Teach Pendant with 
Fieldbus
In order to make the E-Stop signal available to the cell / automated system line when
the C5G-PIS option is present, use one of the 2 solutions proposed in Tab. 8.2. 
With the C5G-PIS Fieldbus solution, the E-Stop on the Teach Pendant is not
connected to the Control Unit safety circuit.
Tab. 8.2 - Signals available for interfacing the E-Stop button with the cell 
/ automated system line
Available 
signals 
Corresponding performance
Connection modes
(mandatory choice, according to your preferences)
C5G Plus Control Unit (all versions)
E-Stop 
E-Stop of the 
Teach Pendant
towards the 
automated 
system line
– Input of the state of the 
emergency stop push-button 
located on the Teach Pendant
– Signal always available, even 
with the Control Unit off 
– The signals (dry contacts) 
available on the X130/CIP 
connector (on cabinet base) must 
be connected to the safety 
module / cell PLC / automated 
system line PLC
– X130/CIP external connector with C5GP-TEC 
option 
– Input of the state of the 
emergency stop push-button 
located on the Teach Pendant
– Signal available only with the 
Control Unit on, mapped to 
specific bits on the Fieldbus (see 
E-Stop on the Teach Pendant)
– connector for signal replication with 
C5GP-XPP option 
Details of the options are given in the Available options handbook of the Control Unit.
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DESCRIPTION OF SAFE SIGNALS TO INTERFACE THE AUTOMATED SYSTEM LINE AND APPLICATIONS
Comau Robotics Product Instruction
8.3 SAFE signals (optional) for interfacing 
applications / automated system line (E-Stop, Auto 
mode, T1 mode, Enabling Device, Drive-ON, 
Auto-Stop outputs)
The Control Unit can interface with the SAFE signals of the applications combined with
the Robot through the SAFE digital discrete I/Os on the X31/CIP connector or on the
Fieldbus.
The solution allows the use of the 8 additional signals (see Tab. 8.3) combining them
with:
– SAFE output modules and consequently on the external X31/CIP connector (up to
a maximum of 3 signals, see the limitations and methods in par. 9.7); 
– Fieldbus (all signals except Safe Bridge Out). 
*¹ The optional solution C5GP-PIS (ProfiSAFE) is the most complete from the point of view of the quantity of
signals available; it can be replaced with other Fieldbus solutions (C5GP-ABE or C5GP-EISM) but some
Tab. 8.3 - SAFE signals available for application interfacing
Signals available for 
the application
Corresponding performance
Connection modes
(mandatory choice, according to your preferences)
Digital discrete 
I/Os
Fieldbus
C5G Plus Control Unit (all versions)
Safe Bridge Out 2 
External E-Stop
– Replica of the E-Stop input received 
from the automated system line
– external 
connector 
(X31/CIP) with 
C5GP-EISO 
option and 
additional 
options (details 
in par. 9.7.1).
– Mapping of I/O 
signals in 
par. 9.7
– Gateway 
module with 
C5GP-PIS 
option *¹. 
– Mapping of I/O 
signals in 
par. 9.3
Safe Bridge Out 2 
Output
– Status output in Auto mode (Local or 
Remote)
Safe Bridge Out 2 
T1 Programming mode
– Status output in T1 programming 
mode
Safe Bridge Out 2 
Output
– Output corresponding to the status of 
the enabling device button present on 
the Teach Pendant
Safe Bridge Out 2 
Output
– Output corresponding to the status of 
the motors on
Safe Bridge Out 2 
Output 
– Safety stop output of the Robotic 
system coming from the automated 
system line
– Only movements in programming 
mode are allowed
– Corresponds to the Auto-Stop (fence) 
input received from the automated 
system line
Safe Bridge Out 2
Output
– Outputs available to the user to 
replicate two corresponding SAFE 
inputs from the C5G-PIS Gateway to 
their own application on the connector 
X31/CIP (see par. 9.10)
– Only the 
corresponding 
input signals 
are available 
(see par. 9.10)
Safe Bridge Out 2
Output
– Note: the simultaneity of the 2 connection modes is allowed
61
Comau Robotics Product Instruction
DESCRIPTION OF SAFE SIGNALS TO INTERFACE THE AUTOMATED SYSTEM LINE AND APPLICATIONS
signals may not be available.
Details of the options are given in the Available options handbook of the Control Unit.
62
DESCRIPTION OF SAFE SIGNALS TO INTERFACE THE AUTOMATED SYSTEM LINE AND APPLICATIONS
Comau Robotics Product Instruction
8.4 SAFE signals for interfacing position and speed 
control of the Robot
The Control Unit can be interfaced with the SAFE management system of the Robot
position and speed in the cell via SAFE signals, optionally with discrete I/Os or Fieldbus
(slave node).
*¹ The optional solutionC5GP-PIS (ProfiSAFE) is the most complete from the point of view of the quantity of
signals available; it can be replaced with other Fieldbus solutions (C5GP-ABE or C5GP-EISM) but some
signals may not be available.
Tab. 8.4 - SAFE signals for interfacing position and speed control of the 
Robot
Signals 
available with 
the automated 
system line
Corresponding performance
Connection modes
(mandatory choice, according to your preferences)
Digital discrete I/Os Fieldbus
SAFE C5G Plus Control Unit
Inputs
for monitoring of 
sectors or 
volumes
– Input to activate the monitoring of 
the position of the axes in 
pre-established sectors (in 
RoboSAFE Joint)
– It controls the monitoring of the 
Robot position in pre-established 
volumes (in RoboSAFE Cartesian)
– X52/CIP external 
connector with 
C5GP-SMEC 
option
– Mapping of I/O 
signals in par. 9.8
– Gateway module 
with C5GP-PIS 
option *¹
– Mapping of I/O 
signals in par. 9.3
Inputs
for speed 
monitoring
– Input to activate joint speed 
monitoring (in RoboSAFE Joint)
– It controls Cartesian speed 
monitoring (in RoboSAFE 
Cartesian)
Inputs
for tool 
orientation 
monitoring
– Input to activate tool orientation 
monitoring (only in RoboSAFE 
Cartesian)
Outputs
to signal the 
physical position 
of axes or 
location of the 
tool
– Position status output of axis 1 and 7 
(in RoboSAFE Joint)
– Tool position status output in space 
(in RoboSAFE Cartesian)
Output
to signal the 
status of 
RoboSAFE
– Active and non-violated status 
output of the RoboSAFE Joint and 
Cartesian functionalities
– Note: the simultaneity of the 2 connection modes is not allowed
Details of the options are given in the Available options handbook of the Control Unit.
63
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
9. MAP AND CONNECTION OF SAFE SIGNALS 
The Control Unit can interface with the automated system line / cell SAFE management
system through SAFE signals. The quantity and type of signals available to the user
depend on the type of option chosen (digital I/Os or Fieldbus options):
– Summary of possibilities of interfacing;
– Summary of available SAFE signals and possible uses.
Options available with Fieldbus are:
– C5GP-PIS: ProfiSAFE Fieldbus for interfacing with all systems;
– C5GP-ABE: CIP safety Fieldbus for interfacing with the automated system line;
– C5GP-EISM: CIP safety Fieldbus for interfacing with the automated system line
and for checking the RoboSAFE functionalities;
Options available with discrete I/Os are:
– C5GP-E30K: discrete I/Os for interfacing with the automated system line;
– C5GP-EISO (X31/CIP): discrete I/Os for applications;
– C5GP-SMEC (X52/CIP): discrete I/Os for checking the RoboSAFE functionalities
for the C5GP Control Unit;
– R1C-SMEC (X52): discrete I/O for checking of the RoboSAFE functionalities for
the S1C-6 Control Unit;
– Bridge signals between C5GP-PIS Gateway and applications on the X31/CIP
connector.
64
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
9.1 Summary of possibilities of interfacing
65
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
9.2 Summary of available SAFE signals and possible 
uses
There are available the following signal groups:
– Standard SAFE signals, for interfacing with the automated system line;
– RoboSAFE signals (Joint and Cartesian);
– AURA signals. 
Tab. 9.1 - Overview of available signals
Available signals 
and corresponding performances
Fieldbus Digital I/O 
Control Unit model
S
T
D
SAFE
S
T
D
SAFE
Standard SAFE signals, for interfacing with the automated system line
INPUT
External E-Stop 
Input for emergency stop of the Robotic system coming from the 
automated system line
C5G-PIS
X30*¹
C5GP-E30K
Auto Stop (Fence)
Input for safety stop of the Robotic system coming from the automated 
system line
Only movements in programming mode are allowed
General Stop
Input for safety stop of the Robotic system coming from the automated 
system line
Equivalent to the e-Stop input, it does not generate the alarm 
signalling of the emergency stop in operation but prevents the Robot 
from moving in any mode
Safe Bridge Signal 1
Available for the user to transfer a bit of SAFE signal from his 
application to a 2 SAFE channel output on the application connector 
(X31/CIP, signal of "SAFE SBO 1 output for user application (bridge 
from input bit 1)"). More details in par. 9.10. C5G-PIS --
Safe Bridge Signal 2
See "Safe Bridge Signal 1" for second output (X31, signal of "SAFE 
SBO 2 output for user application (bridge from input bit 2)"). More 
details in par. 9.10.
Legend:
STD = Standard control Unit, SAFE = SAFE Control Unit
*¹ The signals are also available on Fieldbus solutions (C5GP-ABE or C5GP-EISM)
*² Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
66
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
OUTPUT
E-Stop on the Teach Pendant
Input of the state of the emergency stop push-button located on the 
Teach Pendant
C5G-PIS
X30*¹
C5GP-E30K
T1 programming status
Status output in T1 programming mode
X31
C5GP-EISO
Enabling Device status
Output corresponding to the status of the enabling device button 
present on the Teach Pendant
Drive On status
Output corresponding to the status of the motors On
Auto Mode status
Status output in Auto mode (Local or Remote)
E-Stop from the automated system line
Corresponds to the E-Stop input received from the automated system 
line
Auto Stop (Fence)
Corresponds to the Auto-Stop (fence) input received from the 
automated system line
General Stop
Input for safety stop of the Robotic system coming from the automated 
system line
Corresponds to the General Stop input received from the automated 
system line
--
SAFE SBO 1 output for user application 
(bridge from input bit 1)
Output corresponding to "Safe Bridge Signal 1" bit 
--
X31
C5GP-EISOSAFE SBO 2 output for user application 
(bridge from input bit 2)
Output corresponding to "Safe Bridge Signal 2" bit
Tab. 9.1 - Overview of available signals (Continued)
Available signals 
and corresponding performances
Fieldbus Digital I/O 
Control Unit model
S
T
D
SAFE
S
T
D
SAFE
Legend:
STD = Standard control Unit, SAFE = SAFE Control Unit
*¹ The signals are also available on Fieldbus solutions (C5GP-ABE or C5GP-EISM)
*² Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
67
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
RoboSAFE signals (Joint and Cartesian)
INPUT
RoboSAFE Joint - Set 1
Activates the monitoring of the first set of axes through an external 
input (“Activated by RS Input” must be specifically selected in the 
WEB interface, see Tab. 12.5). 
--
C5G-PIS
--
X52 *¹ *²
C5GP-SMECRoboSAFE Cartesian volume 1
Activates the monitoring of the volume 1 through an external input 
(“Activated by RS Input” must be specifically selected in the WEB 
interface, see ). 
C5G-PIS
RoboSAFE Joint - Set 2
For second set of axes, see "RoboSAFE Joint - Set 1"
--
C5G-PIS
--
X52 *¹ *²
C5GP-SMECRoboSAFE Cartesian volume 2 
For volume 2, see "RoboSAFE Cartesian volume 1"
C5G-PIS
RoboSAFE Joint - Set 3
For third set of axes, see "RoboSAFE Joint - Set 1"
--
C5G-PIS
--
X52 *¹ *²
C5GP-SMECRoboSAFE Cartesian volume 3 
For volume 3, see "RoboSAFE Cartesian volume 1"
C5G-PIS
RoboSAFE Joint - Set 4 
For fourth set of axes, see "RoboSAFE Joint - Set 1"
--
C5G-PIS
--
X52 *¹ *² 
C5GP-SMEC
RoboSAFE Cartesian volume 4 
For volume 4, see "RoboSAFE Cartesian volume 1"
C5G-PIS
RoboSAFE Cartesian Orientation Tool 
Activates the orientation check function SLO, Safe LimitedOrientation 
(see Tool Orientation)
C5G-PIS
RoboSAFE Joint - Set 5 
For fifth set of axes, see "RoboSAFE Joint - Set 1".
--
C5G-PIS
--
X52 *¹ *²
C5GP-SMEC
RoboSAFE Cartesian volume 5 
For volume 5, see "RoboSAFE Cartesian volume 1"
C5G-PIS
RoboSAFE CRC Ack *³ 
it is used for the CRT Ack function. If set to 1 for confirmation by the 
PLC that it has acknowledged the change status of one or more 
parameters in the WEB SAFE interface, the system responds by 
bringing to 1 the output of the same name "CRC approved" (and so it 
remains until the parameters are changed again).
Note: this function is available only if the "RoboSAFE Joint - Set 5" o 
"RoboSAFE Cartesian volume 5" function has not been activated.
C5G-PIS
Tab. 9.1 - Overview of available signals (Continued)
Available signals 
and corresponding performances
Fieldbus Digital I/O 
Control Unit model
S
T
D
SAFE
S
T
D
SAFE
Legend:
STD = Standard control Unit, SAFE = SAFE Control Unit
*¹ The signals are also available on Fieldbus solutions (C5GP-ABE or C5GP-EISM)
*² Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
68
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
RoboSAFE Joint - Set 6 
For sixth set of axes, see "RoboSAFE Joint - Set 1".
--
C5G-PIS
--
X52 *¹ *²
C5GP-SMEC
RoboSAFE Cartesian volume 6 
For volume 6, see "RoboSAFE Cartesian volume 1"
C5G-PIS
RoboSAFE Joint Speed 
it is used to activate the monitoring of the joints speed Cartesian 
Speed Limiting and Joint Speed Limiting (must be explicitly activated 
in the appropriate parameter in the WEB interface).
C5G-PIS
RoboSAFE Cartesian volume 7 
For volume 7, see "RoboSAFE Cartesian volume 1"
--
C5G-PIS
--
X52 *¹ *²
C5GP-SMEC
RoboSAFE High Speed 
Activates the monitoring of the speed set in the High Speed parameter 
through an external input (the appropriate parameter must be explicitly 
activated in the WEB interface).
C5G-PIS
RoboSAFE Cartesian volume 8 
See "RoboSAFE Cartesian volume 1" for volume 8
--
C5G-PIS
--
X52 *¹ *²
C5GP-SMEC
RoboSAFE Low Speed 
Activates the monitoring of the speed set in the Low Speed parameter 
through an external input (the appropriate parameter must be explicitly 
activated in the WEB interface).
C5G-PIS
RoboSAFE Cartesian volume 9 
See "RoboSAFE Cartesian volume 1" for volume 9
--
C5G-PIS
--
X52 *¹ *²
C5GP-SMECRoboSAFE Toolset 1 
Enables toolset 1 monitoring
C5G-PIS
RoboSAFE Cartesian volume 10 or Toolset 1 
See "RoboSAFE Cartesian volume 1" for volume 10
--
C5G-PIS
--
X52 *¹ *²
C5GP-SMECRoboSAFE Toolset 2 
For Toolset 2, see "RoboSAFE Toolset 1"
C5G-PIS
CRC Ack
It sends to the Control Unit a confirmation from the PLC that it has 
acknowledged the change status of one or more parameters in the 
WEB SAFE interface.
As a response from the Control Unit, the output of the same name 
"CRC approved" switches to status 1 and remains so until the 
parameters are changed again.
-- C5G-PIS --
X52 *¹
C5GP-SMEC
Tab. 9.1 - Overview of available signals (Continued)
Available signals 
and corresponding performances
Fieldbus Digital I/O 
Control Unit model
S
T
D
SAFE
S
T
D
SAFE
Legend:
STD = Standard control Unit, SAFE = SAFE Control Unit
*¹ The signals are also available on Fieldbus solutions (C5GP-ABE or C5GP-EISM)
*² Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
69
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
OUTPUT
Position in the sector AX 7 Joint (bit 1)
Indicates in which sector the axis 7 is located within the 1..15 range 
set in the WEB interface (Bit 1 of a 4-bit coding). The 0 coding is not 
valid.
--
C5G-PIS
--
X52 *¹ *³
C5GP-SMECPosition in volume, Functional Spaces SET-A bit 1
It shows in which volume (range from 1...15) the Robot is located, 
according to the Functional Spaces A set in the WEB interface (Bit 1 of 
a 4-bit coding). The 0 coding is not valid.
C5G-PIS
Position in the sector AX 7 Joint (bit 2)
For bit 2, see "Position in the sector AX 7 Joint (bit 1)"
--
C5G-PIS
--
X52 *¹ *³
C5GP-SMECPosition in volume, Functional Spaces SET-A bit 2
For bit 2, see "Position in volume, Functional Spaces SET-A bit 1"
C5G-PIS
Position in the sector AX 7 Joint (bit 3)
For bit 3, see "Position in the sector AX 7 Joint (bit 1)"
--
C5G-PIS
--
X52 *¹ *³
C5GP-SMECPosition in volume, Functional Spaces SET-A bit 3
For bit 3, see "Position in volume, Functional Spaces SET-A bit 1"
C5G-PIS
Position in the sector AX 7 Joint (bit 4)
For bit 4, see "Position in the sector AX 7 Joint (bit 1)"
--
C5G-PIS
--
X52 *¹ *³
C5GP-SMECPosition in volume, Functional Spaces SET-A bit 4
For bit 4, see "Position in volume, Functional Spaces SET-A bit 1"
C5G-PIS
Position in the sector AX 1 Joint (bit 1)
Indicates in which sector the axis 1 is located in the Joint functional 
sectors function, as set in the WEB interface (Bit 1 of a 4-bit coding). 
The 0 coding is not valid.
--
C5G-PIS
--
X52 *¹ *³
C5GP-SMECPosition in volume, Functional Spaces SET-B bit 1
It shows in which volume (range from 1...15) the Robot is located, 
according to the Functional Spaces B set in the WEB interface (Bit 1 of 
a 4-bit coding). The 0 coding is not valid.
C5G-PIS
Position in the sector AX 1 Joint (bit 2)
For bit 2, see "Position in the sector AX 1 Joint (bit 1)"
--
C5G-PIS
--
X52 *¹ *³
C5GP-SMECPosition in volume, Functional Spaces SET-B bit 2
For bit 2, see "Position in volume, Functional Spaces SET-B bit 1"
C5G-PIS
Position in the sector AX 1 Joint (bit 3)
For bit 3, see "Position in the sector AX 1 Joint (bit 1)"
--
C5G-PIS
--
X52 *¹ *³
C5GP-SMECPosition in volume, Functional Spaces SET-B bit 3
For bit 3, see "Position in volume, Functional Spaces SET-B bit 1"
C5G-PIS
Tab. 9.1 - Overview of available signals (Continued)
Available signals 
and corresponding performances
Fieldbus Digital I/O 
Control Unit model
S
T
D
SAFE
S
T
D
SAFE
Legend:
STD = Standard control Unit, SAFE = SAFE Control Unit
*¹ The signals are also available on Fieldbus solutions (C5GP-ABE or C5GP-EISM)
*² Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
70
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
Position in the sector AX 1 Joint (bit 4)
For bit 4, see "Position in the sector AX 1 Joint (bit 1)"
--
C5G-PIS
--
X52 *¹ *³
C5GP-SMECPosition in volume, Functional Spaces SET-B bit 4
For bit 4, see "Position in volume, Functional Spaces SET-B bit 1"
C5G-PIS
RoboSAFE active
Signals that one or more RoboSAFE functions are active and no rule 
has been violated
1 = one or more active functions, none violated;
0 = one or more violated functions or no active function.
--
C5G-PIS
--
X52 *¹ *³
C5GP-SMECCRC approved
Signals (with a logic 0 / volt 0 signal) to have identified a variation of 
one or more parameters in the WEB SAFE interface.
1 = no change since the last time
0 = change occurred, confirmation is required through "RoboSAFE 
Joint - Set 5"
C5G-PIS
Tab. 9.1 - Overview of available signals (Continued)
Available signals 
and corresponding performances
Fieldbus Digital I/O 
Control Unit model
S
T
D
SAFE
S
T
D
SAFE
Legend:
STD = Standard control Unit, SAFE = SAFE Control Unit
*¹ The signals are also available on Fieldbus solutions (C5GP-ABE or C5GP-EISM)
*² Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*³ Digital output mutually excluded (only the function selected by the specific output isactive - see par. 12.10)
71
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
AURA signals
INPUT
Collaborative mode deactivated (Robot and gripper)
Deactivates the Robot and gripper collaborative mode (low logic - 0 
signal to activate the collaborative function, to 1 to deactivate)
--
C5G-PIS
(on AURA 
only)
--
X38/X39 
on AURA 
only
Collaborative mode deactivated (gripper only)
Deactivates the collaborative mode only of the gripper (signal 0 - logic 
low to activate the collaborative function, to 1 to deactivate)
-- --
OUTPUT
Collaborative mode active (Robot and gripper)
Signals the active collaborative mode of the Robot and the gripper 
(signal 1 - logic high; signal to 0 when deactivated)
--
C5G-PIS
(on AURA 
only)
--
Collaborative mode active (gripper only)
Signals the active collaborative mode only of the gripper (signal 1 - 
logic high; signal to 0 when deactivated)
--
Violation occurred (Robot and gripper)
Signals the occurred violation of the rules of the collaborative mode 
with activation of one or more events of proximity and pressure of the 
skin of the Robot or gripper (signal 1 - logic high; signal to 0 when not 
violated)
--
Details of the options can be found in the “Technical Specifications, Transport and
Installation, Maintenance” handbook of the Control Unit.
Tab. 9.1 - Overview of available signals (Continued)
Available signals 
and corresponding performances
Fieldbus Digital I/O 
Control Unit model
S
T
D
SAFE
S
T
D
SAFE
Legend:
STD = Standard control Unit, SAFE = SAFE Control Unit
*¹ The signals are also available on Fieldbus solutions (C5GP-ABE or C5GP-EISM)
*² Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
72
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
9.3 C5GP-PIS: ProfiSAFE Fieldbus for interfacing with 
all systems
The C5GP-PIS (Profinet Interface Safe) option makes available a gateway on
ProfiSAFE protocol to transmit all the SAFE signals made available by the C5G Plus
and S1C-6 Control Units. The option cannot be installed on R1C-6 Control Unit.
The signals are available on a mapping of input Bytes and output Bytes, as indicated in
Tab. 9.2:
– Standard SAFE signals, for interfacing with the automated system line;
– RoboSAFE Joint signals;
– RoboSAFE Cartesian signals;
– AURA signals.
Tab. 9.2 - Map of signals available with C5G-PIS
Available signals and corresponding performance
I/O mapping
Byte Bit
Standard SAFE signals, for interfacing with the automated system line
INPUT Byte
External E-Stop 1 0
Auto Stop (Fence) 1 1
General Stop 1 2
Safe Bridge Signal 1 1 3
Safe Bridge Signal 2 1 4
OUTPUT Byte
E-Stop on the Teach Pendant
C5G-XPP option is required (details in Tab. 8.2).
1 0
T1 programming status 1 1
Enabling Device status 1 2
Drive On status 1 3
Auto Mode status 1 4
E-Stop from the automated system line 1 5
Auto Stop (Fence) 1 6
General Stop 1 7
73
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
RoboSAFE Joint signals
INPUT Byte
RoboSAFE Joint - Set 1 3 6
RoboSAFE Joint - Set 2 3 7
RoboSAFE Joint - Set 3 4 0
RoboSAFE Joint - Set 4 4 1
RoboSAFE Joint - Set 5 4 2
RoboSAFE Joint - Set 6 4 3
RoboSAFE Joint Speed 4 4
CRC Ack 4 5
OUTPUT Byte
Position in the sector AX 7 Joint (bit 1) 3 0
Position in the sector AX 7 Joint (bit 2) 3 1
Position in the sector AX 7 Joint (bit 3) 3 2
Position in the sector AX 7 Joint (bit 4) 3 3
Position in the sector AX 1 Joint (bit 1) 3 4
Position in the sector AX 1 Joint (bit 2) 3 5
Position in the sector AX 1 Joint (bit 3) 3 6
Position in the sector AX 1 Joint (bit 4) 3 7
RoboSAFE active 4 0
CRC approved 4 1
Tab. 9.2 - Map of signals available with C5G-PIS (Continued)
Available signals and corresponding performance
I/O mapping
Byte Bit
74
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
RoboSAFE Cartesian signals
INPUT Byte
RoboSAFE Cartesian Orientation Tool 1 7
RoboSAFE Cartesian volume 1 2 0
RoboSAFE Cartesian volume 2 2 1
RoboSAFE Cartesian volume 3 2 2
RoboSAFE Cartesian volume 4 2 3
RoboSAFE Cartesian volume 5 2 4
RoboSAFE Cartesian volume 6 2 5
RoboSAFE Cartesian volume 7 2 6
RoboSAFE Cartesian volume 8 2 7
RoboSAFE Cartesian volume 9 3 0
RoboSAFE Cartesian volume 10 or Toolset 1 3 1
RoboSAFE High Speed 3 2
RoboSAFE Low Speed 3 3
RoboSAFE Toolset 1 3 4
RoboSAFE Toolset 2 3 5
CRC Ack 4 5
OUTPUT Byte
Position in volume, Functional Spaces SET-A bit 1 2 0
Position in volume, Functional Spaces SET-A bit 2 2 1
Position in volume, Functional Spaces SET-A bit 3 2 2
Position in volume, Functional Spaces SET-A bit 4 2 3
Position in volume, Functional Spaces SET-B bit 1 2 4
Position in volume, Functional Spaces SET-B bit 2 2 5
Position in volume, Functional Spaces SET-B bit 3 2 6
Position in volume, Functional Spaces SET-B bit 4 2 7
RoboSAFE active 4 0
CRC approved 4 1
Tab. 9.2 - Map of signals available with C5G-PIS (Continued)
Available signals and corresponding performance
I/O mapping
Byte Bit
75
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
AURA signals
INPUT Byte
Collaborative mode deactivated (Robot and gripper) 4 6
Collaborative mode deactivated (gripper only) 4 7
OUTPUT Byte
Collaborative mode active (Robot and gripper) 4 5
Collaborative mode active (gripper only) 4 6
Violation occurred (Robot and gripper) 4 7
Tab. 9.2 - Map of signals available with C5G-PIS (Continued)
Available signals and corresponding performance
I/O mapping
Byte Bit
76
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
9.4 C5GP-ABE: CIP safety Fieldbus for interfacing with 
the automated system line
The C5GP-ABE (Allen Bradley Ethernet IP) option makes available on Fieldbus with
CIP™ safety protocol over EtherNet/IP™ on Allen Bradley POINT Guard I/O Safe
modules the signals corresponding to the X30/CIP solution, as indicated in Tab. 9.3.
Tab. 9.3 - Map of signals available on C5GP-ABE
Available signals and corresponding performance
Terminal on module
Channel Common
Standard signals, for interfacing with the cell / automated system line
INPUT
External E-Stop Output 1 module
O0 GND
O1 GND
Auto Stop (Fence) Output 1 module
O2 GND
O3 GND
General Stop Output 1 module
O4 GND
O5 GND
OUTPUT
E-Stop on the Teach Pendant Input 1 module
I0 T0
I1 T1M
Note:
All SAFE inputs have a 5 ms input filter and a 80 ms reaction time (see Tab. 7.2). The times referring to the Allen Bradley POINT Guard 
module and the relative network are not considered. 
Furthermore, the speed monitoring enable inputs have an additional idle window of 500 ms (see details in par. 5.3.2.4).
77
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
9.5 C5GP-EISM: CIP safety Fieldbus for interfacing 
with the automated system line and for checking 
the RoboSAFE functionalities
The C5GP-EISM (Ethernet IP SafeMotion) option makes available on Fieldbus with
CIP™ safety protocol over EtherNet/IP™ on Allen Bradley POINT Guard I/O Safe
modules the signals corresponding to the X30/CIP and X52/CIP solution, as indicated
in Tab. 9.4.
Tab. 9.4 - Map of signals available on C5GP-EISM
Available signals and corresponding performance
Terminal on module
Channel Common
Standard signals, for interfacing with the cell / automated system line
INPUT
External E-Stop Output 1 module
O0 GND
O1 GND
Auto Stop (Fence) Output 1 module
O2 GND
O3 GND
General Stop Output 1 module
O4 GND
O5 GND
OUTPUT
E-Stop on the Teach Pendant Input 1 module
I0 T0
I1 T1M
Standard signals, for interfacing with the RoboSAFE functionalities
INPUT
RoboSAFE Joint - Set 1 and 
RoboSAFE Cartesian volume 1 *¹
Output 2 module
O0 GND
O1 GND
RoboSAFE Joint - Set 2 and 
RoboSAFE Cartesian volume 2 *¹
Output 2 module
O2 GND
O3 GND
RoboSAFE Joint - Set3 and 
RoboSAFE Cartesian volume 3 *¹
Output 2 module
O4 GND
O5 GND
RoboSAFE Joint - Set 4 and 
RoboSAFE Cartesian volume 4 and
RoboSAFE Cartesian Orientation Tool *¹ *³
Output 2 module
O6 GND
O7 GND
RoboSAFE Joint - Set 5 and 
RoboSAFE Cartesian volume 5 and
RoboSAFE CRC Ack *³ *¹
Output 3 module
O0 GND
O1 GND
Legend:
*¹ Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*² Digital output mutually excluded (depends on the selected function)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
*4 CH1 outputs represent the real binary coding while CH2 the reverse coding (antivalent)
Note:
All SAFE inputs have a 5 ms input filter and a 80 ms reaction time (see Tab. 7.2). The times referring to the Allen Bradley POINT Guard 
module and the relative network are not considered. 
Furthermore, the speed monitoring enable inputs have an additional idle window of 500 ms (see details in par. 5.3.2.4).
78
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
RoboSAFE Joint - Set 6 and 
RoboSAFE Cartesian volume 6 and
RoboSAFE Joint Speed *¹ *³
Output 3 module
O2 GND
O3 GND
RoboSAFE Cartesian volume 7 and 
RoboSAFE High Speed *¹
Output 3 module
O4 GND
O5 GND
RoboSAFE Cartesian volume 8 and 
RoboSAFE Low Speed *¹
Output 3 module
O6 GND
O7 GND
RoboSAFE Cartesian volume 9 and 
RoboSAFE Toolset 1 *¹
Output 4 module
O0 GND
O1 GND
RoboSAFE Cartesian volume 10 or Toolset 1 and 
RoboSAFE Toolset 2 *¹
Output 4 module
O2 GND
O3 GND
OUTPUT
Position in the sector AX 7 Joint (bit 1) and
Position in volume, Functional Spaces SET-A bit 1 *¹
Input 1 module
I2 *4 --
I3 *4 --
Position in the sector AX 7 Joint (bit 2) and
Position in volume, Functional Spaces SET-A bit 2 *¹
Input 1 module
I4 *4 --
I5 *4 --
Position in the sector AX 7 Joint (bit 3) and
Position in volume, Functional Spaces SET-A bit 3 *¹
Input 1 module
I6 *4 --
I7 *4 --
Position in the sector AX 7 Joint (bit 4) and
Position in volume, Functional Spaces SET-A bit 4 *¹
Input 2 module
I0 *4 --
I1 *4 --
Position in the sector AX 1 Joint (bit 1) and
Position in volume, Functional Spaces SET-B bit 1 *¹
Input 2 module
I2 *4 --
I3 *4 --
Position in the sector AX 1 Joint (bit 2) and
Position in volume, Functional Spaces SET-B bit 2 *¹
Input 2 module
I4 *4 --
I5 *4 --
Position in the sector AX 1 Joint (bit 3) and
Position in volume, Functional Spaces SET-B bit 3 *¹
Input 3 module
I0 *4 --
I1 *4 --
Position in the sector AX 1 Joint (bit 4) and
Position in volume, Functional Spaces SET-B bit 4 *¹
Input 3 module
I2 *4 --
I3 *4 --
RoboSAFE active and
CRC approved *²
Activation of the CRC approved function deactivates the RoboSAFE 
active function.
Input 3 module
I4 *4 --
I5 *4 --
Tab. 9.4 - Map of signals available on C5GP-EISM (Continued)
Available signals and corresponding performance
Terminal on module
Channel Common
Legend:
*¹ Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*² Digital output mutually excluded (depends on the selected function)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
*4 CH1 outputs represent the real binary coding while CH2 the reverse coding (antivalent)
Note:
All SAFE inputs have a 5 ms input filter and a 80 ms reaction time (see Tab. 7.2). The times referring to the Allen Bradley POINT Guard 
module and the relative network are not considered. 
Furthermore, the speed monitoring enable inputs have an additional idle window of 500 ms (see details in par. 5.3.2.4).
79
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
9.6 C5GP-E30K: discrete I/Os for interfacing with the 
automated system line
The C5GP-E30K (External X30 Kit) option makes all the SAFE signals for interfacing
with the cell / automated system line available on all the Control Units on X30/CIP
multipolar connector, as indicated in Tab. 9.5.
Tab. 9.5 - Map of signals available on X30/CIP
Available signals and corresponding performance
X30/CIP (C5GP)
Channel PIN
Standard signals, for interfacing with the cell / automated system line
INPUT
External E-Stop
CH1 6
CH2 7
Auto Stop (Fence)
CH1 20
CH2 21
General Stop
CH1 27
CH2 28
OUTPUT
E-Stop on the Teach Pendant
CH1 11/14
CH2 12/13
Note:
All SAFE inputs have a 5 ms signal filter.
80
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
9.7 C5GP-EISO (X31/CIP): discrete I/Os for 
applications
The C5GP-EISO (ExpantionInterfaceSafeOutput) option makes available on the C5G
Plus series Control Unit an X31/CIP multipolar connector up to 3 SAFE signals for
interfacing with applications, among those indicated in Tab. 9.6.
The connector is already internally wired to the SAFE output module to obtain the 3
outputs according to the predefined profile by Comau (see par. 12.2.5); any modification
of the profile combinations requires customization of both the wiring on the X31/CIP
connector and the Control Unit internal wiring.
In case of modification to the default profile, it is recommended to change the code of
X31 connector so as not to cause confusion.
The option must be integrated with one or more options to complete and have all
opportunities (see par. 9.7.1).
The procedure for customizing the X31/CIP connector is given in the Control Unit
options handbook
Tab. 9.6 - Map of signals available on X31/CIP
Available signals and corresponding performance
X31/CIP (C5GP)
Channel PIN
Standard signals, for interfacing with the applications
OUTPUT
T1 programming status
must be customized*¹ as T1 programming status
CH1 32 / 34
CH2 33 / 35
Enabling Device status
must be customized*² as Enabling Device status
CH1 -- *²
CH2 -- *²
Drive On status
Comau default profile, on Signal 1 (see par. 12.2.5)
CH1 25 / 27
CH2 26 / 28
Auto Mode status
Comau default profile, on Signal 3 (see par. 12.2.5)
CH1 39 / 41
CH2 40 / 42
External E-Stop
Comau default profile, on Signal 2 (see par. 12.2.5)
CH1 11 / 13
CH2 12 / 14
Auto Stop (Fence)
must be customized*¹ as Auto Stop (Fence)
CH1 18 / 20
CH2 19 / 21
Safe Bridge Signal 1
must be customized*² as Safe Bridge Signal 1
CH1 -- *²
CH2 -- *²
Safe Bridge Signal 2
must be customized*² as Safe Bridge Signal 2
CH1 -- *²
CH2 -- *²
Legend:
*¹ it is necessary to replace an output already connected with this connector / signal. Conductors already labelled on the X31/CIP 
connector
*² no wired conductors are available. Use an existing connector and replace / customize the identification labels.
81
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
9.7.1 Composition of the solution with X31/CIP connector, 
C5GP-EISO
The optional C5GP-EISO solution with X31/CIP external connector requires integration
with the C5GP-EKSO internal cabinet SAFE I/O modules option.
If the use of voltage-free contacts is necessary, it is also necessary to add a power
supply option with C5GP-SEPC and, for each required contact output, a relay option
with C5GP-RESO.
Details of the options and the procedure for customizing the X31/CIP connector can be
found in the Control Unit Available options handbook.
82
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
9.8 C5GP-SMEC (X52/CIP): discrete I/Os for checking 
the RoboSAFE functionalities for the C5GP Control 
Unit
The C5GP-SMEC (SafeMotionExternalConnection) option makes available on the C5G
Plus series Control Unit an X52/CIP multipolar connector, the main SAFE signals for
interfacing with the RoboSAFE solution, as indicated in Tab. 9.7.
Tab. 9.7 - Map of signals available on X52/CIP (C5G Plus)
Available signals and corresponding performance
X52/CIP (C5GP)
Channel PIN
RoboSAFE Joint / Cartesian signals
INPUT
RoboSAFE Joint - Set 1 and 
RoboSAFE Cartesian volume 1
CH1 1a
*¹
CH2 2a
RoboSAFE Joint - Set 2 and 
RoboSAFE Cartesian. . . . . . . . . . . . . . .41
Monitoring Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
RoboSAFE Cartesian functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
RoboSAFE Cartesian definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
RoboSAFE Cartesian performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Dynamic Volumes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Functional Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Cartesian Speed Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Monitoring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Tool Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Speed Modulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Coordinate X, Y, Z (origin) in the RoboSAFE Cartesian functionality . . . . . . . . . . . . . . . . . . 48
Functional definition of workspace and volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Requirements for the extent of the defined volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4
Comau Robotics Product Instruction
Access and parameter setting of the RoboSAFE functionalities . . . . . . . . . . . . . . . . . . . . . . . . 52
6. PRINCIPLES AND AURA COLLABORATIVE ROBOT FUNCTIONALITY . . . . . . . ...53
7. INTRODUCTION TO SAFETY FUNCTIONALITIES AND TECHNICAL FEATURES...54
Map of available SAFE functionalities, configurations and connectivity . . . . . . . . . . . . . . . . . . 54
Technical features of a Comau SAFE Robotic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8. DESCRIPTION OF SAFE SIGNALS TO INTERFACE THE AUTOMATED SYSTEM 
LINE AND APPLICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...58
SAFE signals for interfacing with the automated system line (E-Stop, Auto-Stop, General Stop). 
59
Interfacing of the E-Stop of the Teach Pendant with Fieldbus. . . . . . . . . . . . . . . . . . . . . . . . . . 60
SAFE signals (optional) for interfacing applications / automated system line (E-Stop, Auto mode, 
T1 mode, Enabling Device, Drive-ON, Auto-Stop outputs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SAFE signals for interfacing position and speed control of the Robot . . . . . . . . . . . . . . . . . . . . 63
9. MAP AND CONNECTION OF SAFE SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...64
Summary of possibilities of interfacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Summary of available SAFE signals and possible uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
C5GP-PIS: ProfiSAFE Fieldbus for interfacing with all systems . . . . . . . . . . . . . . . . . . . . . . . . 73
C5GP-ABE: CIP safety Fieldbus for interfacing with the automated system line . . . . . . . . . . . 77
C5GP-EISM: CIP safety Fieldbus for interfacing with the automated system line and for checking 
the RoboSAFE functionalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
C5GP-E30K: discrete I/Os for interfacing with the automated system line . . . . . . . . . . . . . . . . 80
C5GP-EISO (X31/CIP): discrete I/Os for applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Composition of the solution with X31/CIP connector, C5GP-EISO . . . . . . . . . . . . . . . . . . . . 82
C5GP-SMEC (X52/CIP): discrete I/Os for checking the RoboSAFE functionalities for the C5GP 
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
R1C-SMEC (X52): discrete I/O for checking of the RoboSAFE functionalities for the S1C-6 Control 
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Bridge signals between C5GP-PIS Gateway and applications on the X31/CIP connector . . . . 87
10. PDL2 VARIABLES OF THE ROBOSAFE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . ...88
PDL2 variables of RoboSAFE 2.0 system statuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
11. HOW TO ACCESS PARAMETERS OF THE SAFE FUNCTIONALITIES . . . . . . . . ...99
5
Comau Robotics Product Instruction
Overview of access modalities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Access the SAFE parameters via the Web portal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Requirements for accessing the Web portal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Finding the IP address of the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Access via Web browser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Main page of the SAFE functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Status of RoboSAFE components and functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Error solving during the connection to the Web portal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Access password change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
12. PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS. . . . . . . . . . ..107
Access to the functions and configuration parameters of the SAFE functionalities . . . . . . . . . 108
Access login to the configuration Web page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Logout from the configuration Web page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
System Parameters (System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
How to access the System page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
How to change the Robot stop category and the safety timer time . . . . . . . . . . . . . . . . . . . 113
How to change C5GP-PIS Gateway address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
How to deactivate / activate a stop signal coming from the C5GP-PIS Gateway . . . . . . . . 115
How to assign C5G Plus Control Unit status signals to specific safety outputs . . . . . . . . . . 116
Joint space monitoring function (Joint spaces) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
How to access Joint spaces page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
How to modify parameters of a Joint Space Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
How to modify parameters of a Joint Functional Sector. .volume 2
CH1 3a
CH2 4a
RoboSAFE Joint - Set 3 and 
RoboSAFE Cartesian volume 3
CH1 5a
CH2 6a
RoboSAFE Joint - Set 4 and 
RoboSAFE Cartesian volume 4 and
RoboSAFE Cartesian Orientation Tool
CH1 7a
*¹ *³
CH2 8a
RoboSAFE Joint - Set 5 and 
RoboSAFE Cartesian volume 5 and
RoboSAFE CRC Ack *³
CH1 9a
CH2 10a
RoboSAFE Joint - Set 6 and 
RoboSAFE Cartesian volume 6 and
RoboSAFE Joint Speed
CH1 11a
CH2 12a
RoboSAFE Cartesian volume 7 and 
RoboSAFE High Speed
CH1 13a
*¹
CH2 14a
RoboSAFE Cartesian volume 8 and 
RoboSAFE Low Speed
CH1 15a
CH2 16a
RoboSAFE Cartesian volume 9 and 
RoboSAFE Toolset 1
CH1 18a
CH2 19a
RoboSAFE Cartesian volume 10 or Toolset 1 and 
RoboSAFE Toolset 2
CH1 20a
CH2 21a
Legend:
*¹ Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*² Digital output mutually excluded (depends on the selected function - see par. 12.10)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
*4 CH1 outputs represent the real binary coding while CH2 the reverse coding (antivalent)
Note:
All SAFE inputs have a 5 ms input filter and a 80 ms reaction time (see Tab. 7.2).
Furthermore, the speed monitoring enable inputs have an additional idle window of 500 ms (see details in par. 5.3.2.4).
83
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
OUTPUT
Position in the sector AX 7 Joint (bit 1) and
Position in volume, Functional Spaces SET-A bit 1
CH1 *4 1b
*²
Block 1
CH2 *4 2b
Position in the sector AX 7 Joint (bit 2) and
Position in volume, Functional Spaces SET-A bit 2
CH1 *4 3b
CH2 *4 4b
Position in the sector AX 7 Joint (bit 3) and
Position in volume, Functional Spaces SET-A bit 3
CH1 *4 5b
CH2 *4 6b
Position in the sector AX 7 Joint (bit 4) and
Position in volume, Functional Spaces SET-A bit 4
CH1 *4 13b
CH2 *4 14b
Position in the sector AX 1 Joint (bit 1) and
Position in volume, Functional Spaces SET-B bit 1
CH1 *4 15b
*²
Block 2
CH2 *4 16b
Position in the sector AX 1 Joint (bit 2) and
Position in volume, Functional Spaces SET-B bit 2
CH1 *4 18b
CH2 *4 19b
Position in the sector AX 1 Joint (bit 3) and
Position in volume, Functional Spaces SET-B bit 3
CH1 *4 1c
CH2 *4 2c
Position in the sector AX 1 Joint (bit 4) and
Position in volume, Functional Spaces SET-B bit 4
CH1 *4 3c
CH2 *4 4c
RoboSAFE active and
CRC approved
Activation of the CRC approved function deactivates the RoboSAFE active function.
CH1 5c *²
Block 3CH2 6c
Tab. 9.7 - Map of signals available on X52/CIP (C5G Plus) (Continued)
Available signals and corresponding performance
X52/CIP (C5GP)
Channel PIN
Legend:
*¹ Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*² Digital output mutually excluded (depends on the selected function - see par. 12.10)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
*4 CH1 outputs represent the real binary coding while CH2 the reverse coding (antivalent)
Note:
All SAFE inputs have a 5 ms input filter and a 80 ms reaction time (see Tab. 7.2).
Furthermore, the speed monitoring enable inputs have an additional idle window of 500 ms (see details in par. 5.3.2.4).
84
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
9.9 R1C-SMEC (X52): discrete I/O for checking of the 
RoboSAFE functionalities for the S1C-6 Control 
Unit
The R1C-SMEC (SafeMotionExternalConnection) option makes available on the S1C-6
Control Unit an X52 multipolar connector, the main SAFE signals for interfacing with
the RoboSAFE solution, as indicated in Tab. 9.8.
Tab. 9.8 - Map of signals available on X52 (S1C-6)
Available signals and corresponding performance
X52 (S1C-6)
Channel PIN
RoboSAFE Joint / Cartesian signals
INPUT
RoboSAFE Joint - Set 1 and 
RoboSAFE Cartesian volume 1
CH1 1
*¹
CH2 2
RoboSAFE Joint - Set 2 and 
RoboSAFE Cartesian volume 2
CH1 3
CH2 4
RoboSAFE Joint - Set 3 and 
RoboSAFE Cartesian volume 3
CH1 5
CH2 6
RoboSAFE Joint - Set 4 and 
RoboSAFE Cartesian volume 4 and
RoboSAFE Cartesian Orientation Tool
CH1 7
*¹ *³
CH2 8
RoboSAFE Joint - Set 5 and 
RoboSAFE Cartesian volume 5 and
RoboSAFE CRC Ack *³
CH1 9
CH2 10
RoboSAFE Joint - Set 6 and 
RoboSAFE Cartesian volume 6 and
RoboSAFE Joint Speed
CH1 11
CH2 12
RoboSAFE Cartesian volume 7 and 
RoboSAFE High Speed
CH1 13
*¹
CH2 14
RoboSAFE Cartesian volume 8 and 
RoboSAFE Low Speed *¹
CH1 15
CH2 16
RoboSAFE Cartesian volume 9 and 
RoboSAFE Toolset 1 *¹
CH1 17
CH2 18
RoboSAFE Cartesian volume 10 or Toolset 1 and 
RoboSAFE Toolset 2 *¹
CH1 19
CH2 20
Legend:
*¹ Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*² Digital output mutually excluded (depends on the selected function - see par. 12.10)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
*4 CH1 outputs represent the real binary coding while CH2 the reverse coding (antivalent)
Note:
All SAFE inputs have a 5 ms input filter and a 80 ms reaction time (see Tab. 7.2).
Furthermore, the speed monitoring enable inputs have an additional idle window of 500 ms (see details in par. 5.3.2.4).
85
Comau Robotics Product Instruction
MAP AND CONNECTION OF SAFE SIGNALS
OUTPUT
Position in the sector AX 1 Joint (bit 1) and
Position in volume, Functional Spaces SET-A bit 1
CH1 *4 25
*²
Block 1
CH2 *4 26
Position in the sector AX 1 Joint (bit 2) and
Position in volume, Functional Spaces SET-A bit 2
CH1 *4 27
CH2 *4 28
Position in the sector AX 1 Joint (bit 3) and
Position in volume, Functional Spaces SET-A bit 3
CH1 *4 29
CH2 *4 30
Tab. 9.8 - Map of signals available on X52 (S1C-6) (Continued)
Available signals and corresponding performance
X52 (S1C-6)
Channel PIN
Legend:
*¹ Digital input/output shared between RoboSAFE solutions (if activated, enables both RoboSAFE Joint and RoboSAFE Cartesian)
*² Digital output mutually excluded (depends on the selected function - see par. 12.10)
*³ Digital output mutually excluded (only the function selected by the specific output is active - see par. 12.10)
*4 CH1 outputs represent the real binary coding while CH2 the reverse coding (antivalent)
Note:
All SAFE inputs have a 5 ms input filter and a 80 ms reaction time (see Tab. 7.2).
Furthermore, the speed monitoring enable inputs have an additional idle window of 500 ms (see details in par. 5.3.2.4).
86
MAP AND CONNECTION OF SAFE SIGNALS
Comau Robotics Product Instruction
9.10 Bridge signals between C5GP-PIS Gateway and 
applications on the X31/CIP connector
Matching of the C5G-PIS and C5G-EISO options makes it possible to transmit two
SAFE input signals from the Fieldbus to the X31/CIP connector dedicated to the
application.
To activate the functionality, it is necessary to customize the connector (see par. 9.7)
and enable the SBO 1 and SBO 2 outputs (see par. 12.2.5); no further customization is
required on PDL2 programs as signals are automatically replicated with the frequency
of Fieldbus network scanning.
Tab. 9.9 - Transferable signals from Gateway to X31/CIP connector
Available signals 
Source Destination 
C5GP-PIS C5GP-EISO
X31/CIP (C5GP)
Channel PIN
Standard signals, for interfacing with the applications
"Safe Bridge Signal 1" input bit 
"SAFE SBO 1 output for user 
application (bridge from input bit 
1)"
CH1
-- *¹
CH2
"Safe Bridge Signal 2" input bit 
"SAFE SBO 2 output for user 
application (bridge from input bit 
2)"
CH1
CH2
Legend:
*¹ no wired conductors are available (see details in par. 9.7).
87
Comau Robotics Product Instruction
PDL2 VARIABLES OF THE ROBOSAFE SYSTEM
10. PDL2 VARIABLES OF THE ROBOSAFE 
SYSTEM
This chapter deals with the following topics:
– PDL2 variables of RoboSAFE 2.0 system statuses.
10.1 PDL2 variables of RoboSAFE 2.0 system statuses
The RoboSAFE2.0 system statuses can be identified on specific system variables, as
indicated in Tab. 10.1.
The variables and their use is to be intended only for the purpose of diagnostic and/or
operating phases of the production process since they do not provide safety signals but
exclusively functional ones.
Tab. 10.1 - System variables and definitions of the RoboSAFE 2.0 
system
System variable Definition
$SL_IN_ABOO[1]
External Emergency Stop latched:
– 0: External emergency Stop contacts are “open”;
– 1: External emergency Stop contacts are “closed”.
$SL_IN_ABOO[2]
General Stop latched:
– 0: General Stop contacts are “open”;
– 1: General Stop contacts are “closed”
$SL_IN_ABOO[3]
Enabling Device latched (ignored if in AUTO state):
– 0: EnDev contacts are "open";
– 1: EnDev contacts are "closed".
$SL_IN_ABOO[4]
Auto Stop (Fence) latched (ignored if in PROG state):
– 0: Auto Stop contacts are “open”;
– 1: Auto Stop contacts are “closed”.
$SL_IN_ABOO[5]
Selector key was changed. It means SDM cause a Drive-off due 
to mode selector position change:
– 0: Mod selection is changed;
– 1: Mod selection is not changed.
$SL_IN_ABOO[6]
Emergency External Stop on TP latched:
– 0: TP Ext Em Stop contacts are “open”;
– 1: TP Ext Em Stop contacts are “closed”.
$SL_IN_ABOO[7]
Enabling Device latched (ignored if in AUTO state):
– 0: EnDev contacts are “open”;
– 1: EnDev contacts are “closed”.
$SL_IN_ABOO[9]
Emergency stop external – double channel integrity block 
output:
– 0: External emergency Stop contacts are “open”;
– 1: External emergency Stop contacts are “closed”.
88
PDL2 VARIABLES OF THE ROBOSAFE SYSTEM
Comau Robotics Product Instruction
$SL_IN_ABOO[10]
General stop – double channel integrity block output:
– 0: General Stop contacts are “open”;
– 1: General Stop contacts are “closed”.
$SL_IN_ABOO[11]
Enabling device (wired) – double channel integrity block output:
– 0: EnDev contacts are “open”;
– 1: EnDev contacts are “closed”.
$SL_IN_ABOO[12]
Auto stop (fence) – double channel integrity block output:
– 0: Auto Stop contacts are “open”;
– 1: Auto Stop contacts are “closed”.
$SL_IN_ABOO[13]
Error on Mod selection sw block:
– 0: no signals on mode selector.
No selection is available for the system;
– 1: a valid signal on mode selector is output.
$SL_IN_ABOO[14]
Delayed emergency (Cat.1) in progress:
(if an emergency input is active and this bit is one the delay is 
running).
– 0: all emergency input are “closed”;
– 1: an emergency input is “open”.
$SL_IN_ABOO[15]
TP Emergency stop external – double channel integrity block 
output:
– 0: TP External emergency Stop contacts are “open”;
– 1: TP External emergency Stop contacts are “closed”.
$SL_IN_ABOO[16]
Enabling device (ManualGuidance) – double channel integrity 
block output:
– 0: EnDev contacts are “open”;
– 1: EnDev contacts are “closed”.
$SL_IN_ABOO[17]
Programming mode 1 (T1):
– 0: T1 Mod is not selected;
– 1: T1 Mod is selected.
$SL_IN_ABOO[19]
Automatic mode Local:
– 0: AutoL Mod is not selected;
– 1: AutoL Mod is selected.
$SL_IN_ABOO[20]
Automatic mode Remote:
– 0: AutoR Mod is not selected;
– 1: AutoR Mod is selected.
$SL_IN_ABOO[21]
EnT2 output status:
– 0: EnT2 output is disabled;
– 1: EnT2 output is enabled.
$SL_IN_ABOO[22]
EnT1 output status:
– 0: EnT1 output is disabled;
– 1: EnT1 output is enabled.
$SL_IN_ABOO[23]
V24 DRIVEON (means the logical command also if the real 
output are two):
– 0: EnT1 and EnT2 disabled;
– 1: EnT1&EnT2 are enabled.
Tab. 10.1 - System variables and definitions of the RoboSAFE 2.0 system 
(Continued)
System variable Definition
89
Comau Robotics Product Instruction
PDL2 VARIABLES OF THE ROBOSAFE SYSTEM
$SL_IN_ABOO[24]
Monitor Emergency Stop on TP:
– 0: 3rd TP External emergency Stop contact is “open”;
– 1: 3rd TP External emergency Stop contact is “closed”.
$SL_IN_ABOO[30]
Test 24V DRIVE-ON in Drive-Off condition:
(Bit to be ignored in the case of R1C-4).
– 0: test on 24V DRIVE-ON in Drive-Off condition is not in alarm 
state;
– 1: test on 24V DRIVE-ON in Drive-Off condition is in alarm state.
$SL_IN_ABOO[31]
Test 24V DRIVE-ON during Drive-Off/Drive-On transition:
(Bit to be ignored in the case of R1C-4).
– 0: test on 24V DRIVE-ON during Drive-Off/Drive-On transition is 
not in alarm state;
– 1: test on 24V DRIVE-ON during Drive-Off/Drive-On transition is 
in alarm state.
$SL_IN_ABOO[32]
Test 24V DRIVE-ON in drive-On condition:
(Bit to be ignored in the case of R1C-4).
– 0: test on 24V DRIVE-ON in Drive-On condition is not in alarm 
state;
– 1: test on 24V DRIVE-ON in Drive-On condition is in alarm state.
$SL_IN_ABOO[33]
Test about contemporaneity of ENDEVs:
– 0: test is not in alarm state;
– 1: test is in alarm state.
ENDEVs (TP and MG) closed at the same time.
$SL_IN_ABOO[40]
Safe Module OK of newSDM IO:
– 1: safe input communication failed;
– 0: safe input communication OK.
$SL_IN_ABOO[42]
Safe Channel OK of Prog input channel:
– 1: state of physical input channel in fail;
– 0: state of physical input channel OK.
$SL_IN_ABOO[43]
Safe Channel OK of AutoL input channel: 
– 1: state of physical input channel in fail; 
– 0: state of physical input channel OK.
$SL_IN_ABOO[44]
Safe Channel OK of AutoR input channel:
– 1: state of physical input channel in fail;
– 0: state of physical input channel OK.
$SL_IN_ABOO[45]
Safe Channel OK of LSM input channel:
– 1: state of physical input channel in fail;
– 0: state of physical input channel OK.
$SL_IN_ABOO[46]
Safe Channel OK of EnDev input channel:
– 1: state of physical input channel in fail;
– 0: state of physical input channel OK.
$SL_IN_ABOO[47]
Safe Channel OK of BCM_DIAG1 input channel:
– 1: state of physical input channel in fail;
– 0: state of physical input channel OK.
$SL_IN_ABOO[48]
Safe Channel OK of BCM_DIAG2 input channel:
– 1: state of physical input channel in fail;
– 0: state of physical input channel OK.
Tab. 10.1 - System variables and definitions of the RoboSAFE 2.0 system 
(Continued)
System variable Definition
90
PDL2 VARIABLES OF THE ROBOSAFE SYSTEM
Comau Robotics Product Instruction
$SL_IN_ABOO[49]
Safe Channel OK of EmStopExt input channel (two channels):
– 1: state of physical input channel in fail;
– 0: state of physical input channel OK.
$SL_IN_ABOO[50]
Safe Channel OK of AutoStop input channel (two channels):
– 1: state of physical input channel in fail;
– 0: state of physical input channel OK.
$SL_IN_ABOO[51]
Safe Channel OK of GenStop input channel
(two channels):
– 1: state of physical input channel in fail;
– 0: state of physical input channel OK.
$SL_IN_ABOO[52]
Safe Channel OK of TP_EmStopExt input channel (two 
channels):
– 1: state of physical input channel in fail;
– 0: state of physical input channel OK.
$SL_IN_ABOO[55]
Safe Channel OK of En1 output channel:
– 1: state of physical output channel in fail;
– 0: state of physical output channel OK.
$SL_IN_ABOO[56]
Safe Channel OK of En2 output channel:
– 1: state of physical output channel in fail;
– 0: state of physical output channel OK.
$SL_IN_ABOO[57]
Safe Channel OK of Cmd1BCM output channel:
– 1: state of physical output channel in fail;
– 0: state of physical output channel OK.
$SL_IN_ABOO[58]
Safe Channel OK of Cmd2BCM output channel:
– 1: state of physical output channel in fail;
– 0: state of physical output channel OK.
$SL_IN_ABOO[59]
Safe Channel OK of signal 1a output channel of ERM:
– 1: state of physical output channel in fail;
– 0: state of physical output channel OK.
$SL_IN_ABOO[60]
Safe Channel OK of signal 1b output channel of ERM:
– 1: state of physical output channel in fail;
– 0: state of physical output channel OK.
$SL_IN_ABOO[61]
Safe Channel OK of signal 2a output channel of ERM:
– 1: state of physical output channel in fail;
– 0: state of physical output channel OK.
$SL_IN_ABOO[62]
Safe Channel OK of signal 2b output channel of ERM:
– 1: state of physical output channel in fail;
– 0: state of physical output channel OK.
$SL_IN_ABOO[63]
Safe Channel OK of signal 3a output channel of ERM: 
–1: state of physical output channel in fail; 
– 0: state of physical output channel OK.
$SL_IN_ABOO[64]
Safe Channel OK of signal 3b output channel of ERM:
– 1: state of physical output channel in fail;
– 0: state of physical output channel OK.
Tab. 10.1 - System variables and definitions of the RoboSAFE 2.0 system 
(Continued)
System variable Definition
91
Comau Robotics Product Instruction
PDL2 VARIABLES OF THE ROBOSAFE SYSTEM
$SL_IN_ABOO[90]
ByPass of ProfiSAFE remote input (Emergency Stop External 
and General Stop):
– 0: Functions are enabled;
– 1: Functions are disabled.
$SL_IN_ABOO[91]
Data Valid of ProfiSAFE:
– 0: data not valid;
– 1: data valid.
$SL_IN_ABOO[92]
Echo of CRC parameters ACK from Safe Input.
It is a strobe signal.
$SL_IN_ABOO[94]
Communication SL/APC started correctly.
Bit latched at start-up:
– 0: communication is NOT OK (hand-shake not successfully 
done);
– 1: communication is OK (hand-shake successfully done).
$SL_IN_ABOO[96]
Configuration architecture mismatch:
– 0: configuration NOT OK;
– 1: configuration OK.
$SL_IN_ABOO[131]
– 0: at least one position&homing NOT valid position&homing valid 
for all axes;
– 1: Position&Homing valid for all axis.
$SL_IN_ABOO[149]
Tool_12 activation request:
– 0: request of tool_12 active;
– 1: request of tool_12 NOT active.
$SL_IN_ABOO[150]
Tool_34 activation request:
– 0: request of tool_34 active;
– 1: request of tool_34 NOT active.
$SL_IN_ABOO[151]
Safe Limiting Orientation (SLO) activation request:
– 0: request of SLO active;
– 1: request of SLO NOT active.
$SL_IN_ABOO[153]
Joint Position Check (JPC) SET 1 activation request:
– 0: request of JPCx active;
– 1: request of JPCx NOT active.
$SL_IN_ABOO[154]
Joint Position Check SET 2 activation request:
– 0: request of JPCx active;
– 1: request of JPCx NOT active.
$SL_IN_ABOO[155]
Joint Position Check SET 3 activation request:
– 0: request of JPCx active;
– 1: request of JPCx NOT active.
$SL_IN_ABOO[156]
Joint Position Check SET 4 activation request:
– 0: request of JPCx active;
– 1: request of JPCx NOT active.
$SL_IN_ABOO[157]
Joint Position Check SET 5 activation request:
– 0: request of JPCx active;
– 1: request of JPCx NOT active.
$SL_IN_ABOO[158]
Joint Position Check SET 6 activation request:
– 0: request of JPCx active;
– 1: request of JPCx NOT active.
Tab. 10.1 - System variables and definitions of the RoboSAFE 2.0 system 
(Continued)
System variable Definition
92
PDL2 VARIABLES OF THE ROBOSAFE SYSTEM
Comau Robotics Product Instruction
$SL_IN_ABOO[161]
Status of Joint Position Check SET 1:
– 1: Robot in work zone;
– 0: Robot out from work zone.
$SL_IN_ABOO[162]
Status of Joint Position Check SET 2:
– 1: Robot in work zone;
– 0: Robot out from work zone.
$SL_IN_ABOO[163]
Status of Joint Position Check SET 3:
– 1: Robot in work zone;
– 0: Robot out from work zone.
$SL_IN_ABOO[164]
Status of Joint Position Check SET 4:
– 1: Robot in work zone;
– 0: Robot out from work zone.
$SL_IN_ABOO[165]
Status of Joint Position Check SET 5:
– 1: Robot in work zone;
– 0: Robot out from work zone.
$SL_IN_ABOO[166]
Status of Joint Position Check SET 6:
– 1: Robot in work zone;
– 0: Robot out from work zone.
$SL_IN_ABOO[169]
Check of Joint Position Check Set 1:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a space violation.
$SL_IN_ABOO[170]
Check of Joint Position Check Set 2:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a space violation.
$SL_IN_ABOO[171]
Check of Joint Position Check Set 3:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a space violation.
$SL_IN_ABOO[172]
Check of Joint Position Check Set 4:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a space violation.
$SL_IN_ABOO[173]
Check of Joint Position Check Set 5:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a space violation.
$SL_IN_ABOO[174]
Check of Joint Position Check Set 6:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a space violation.
$SL_IN_ABOO[177]
Cartesian Position Check Cell activation request:
– 0: request of CPC0 active;
– 1: request of CPC0 NOT active.
$SL_IN_ABOO[178]
Cartesian Position Check Volume 1 activation request:
– 0: request of CPC1 active;
– 1: request of CPC1 NOT active.
$SL_IN_ABOO[179]
Cartesian Position Check Volume 2 activation request:
– 0: request of CPC2 active;
– 1: request of CPC2 NOT active.
Tab. 10.1 - System variables and definitions of the RoboSAFE 2.0 system 
(Continued)
System variable Definition
93
Comau Robotics Product Instruction
PDL2 VARIABLES OF THE ROBOSAFE SYSTEM
$SL_IN_ABOO[180]
Cartesian Position Check Volume 3 activation request:
– 0: request of CPC3 active;
– 1: request of CPC3 NOT active.
$SL_IN_ABOO[181]
Cartesian Position Check Volume 4 activation request:
– 0: request of CPC4 active;
– 1: request of CPC4 NOT active.
$SL_IN_ABOO[182]
Cartesian Position Check Volume 5 activation request:
– 0: request of CPC5 active;
– 1: request of CPC5 NOT active.
$SL_IN_ABOO[183]
Cartesian Position Check Volume 6 activation request:
– 0: request of CPC6 active;
– 1: request of CPC6 NOT active.
$SL_IN_ABOO[184]
Cartesian Position Check Volume 7 activation request:
– 0: request of CPC7 active;
– 1: request of CPC7 NOT active.
$SL_IN_ABOO[185]
Cartesian Position Check Volume 8 activation request:
– 0: request of CPC8 active;
– 1: request of CPC8 NOT active.
$SL_IN_ABOO[186]
Cartesian Position Check Volume 9 activation request:
– 0: request of CPC9 active;
– 1: request of CPC9 NOT active.
$SL_IN_ABOO[187]
Cartesian Position Check Volume 10 activation request:
– 0: request of CPC10 active;
– 1: request of CPC10 NOT active.
$SL_IN_ABOO[196]
Check of Cartesian Position Cell:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a space violation (CELL).
$SL_IN_ABOO[197]
Check of Cartesian Position Dynamic Volume:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a space violation (DYNAMIC 
VOLUMES).
$SL_IN_ABOO[198]
Check of Safe Limiting Orientation (SLO):
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to Tool Orientation violation (SLO).
$SL_IN_ABOO[201]
Cartesian Functional Space SET A activation request:
– 0: request active; 
– 1: request NOT active.
$SL_IN_ABOO[202]
Cartesian Functional Space SET B activation request:
– 0: request active;
– 1: request active.
$SL_IN_ABOO[211]
Functional Space A - coding Bit 1
Signal1 of FS_SET1 coding.
$SL_IN_ABOO[212]
Functional Space A - coding Bit 2
Signal2 of FS_SET1 coding.
$SL_IN_ABOO[213]
Functional Space A - coding Bit 3
Signal3 of FS_SET1 coding.
Tab. 10.1 - System variables and definitions of the RoboSAFE 2.0 system 
(Continued)
System variable Definition
94
PDL2 VARIABLES OF THE ROBOSAFE SYSTEM
Comau Robotics Product Instruction
$SL_IN_ABOO[214]
Functional Space A - coding Bit 4
Signal4 of FS_SET1 coding.
$SL_IN_ABOO[215]
Functional Space B - coding Bit 1
Signal1 of FS_SET2 coding.
$SL_IN_ABOO[216]
Functional Space B - coding Bit 2
Signal2 of FS_SET2 coding.
$SL_IN_ABOO[217]
Functional Space B - coding Bit 3
Signal3 of FS_SET2 coding.
$SL_IN_ABOO[218]
Functional Space B - coding Bit 4
Signal4 of FS_SET2 coding.
$SL_IN_ABOO[219]
Joint Sector Ax 7 - coding Bit 1
Signal1 of Joint Sector AX7 coding.
$SL_IN_ABOO[220]
Joint Sector Ax 7 - coding Bit 2
Signal2 of Joint Sector AX7 coding.
$SL_IN_ABOO[221]
Joint Sector Ax 7 - coding Bit 3
Signal3 of Joint Sector AX7 coding.
$SL_IN_ABOO[222]
Joint Sector Ax 7 - coding Bit 4
Signal1 of Joint Sector AX1 coding.
$SL_IN_ABOO[223]
Joint Sector Ax 1 - coding Bit 1
Signal2 of Joint Sector AX1 coding.
$SL_IN_ABOO[224]
Joint Sector Ax 1 - coding Bit 2
Signal3 of Joint Sector AX1 coding.
$SL_IN_ABOO[225]
Joint Sector Ax 1 - coding Bit 3
Signal4 of Joint Sector AX1 coding.
$SL_IN_ABOO[226]
Joint Sector Ax 1 - coding Bit 4
Signal4 of Joint Sector AX1 coding.
$SL_IN_ABOO[266]
All Safe Channels OK:
– 0: state of some physical output channels in fail;
– 1: state of some physical output channels OK.
$SL_IN_ABOO[267]
Safe Channel_01 OK of safe module43:
– 0: state of physical output channel in fail;
–1: state of physical output channel OK.
$SL_IN_ABOO[268]
Safe Channel_02 OK of safe module43:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[269]
Safe Channel_03 OK of safe module43:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[270]
Safe Channel_04 OK of safe module43:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[271]
Safe Channel_05 OK of safe module43:
– 0: state of physical output channel in fail; 
– 1: state of physical output channel OK.
Tab. 10.1 - System variables and definitions of the RoboSAFE 2.0 system 
(Continued)
System variable Definition
95
Comau Robotics Product Instruction
PDL2 VARIABLES OF THE ROBOSAFE SYSTEM
$SL_IN_ABOO[272]
Safe Channel_06 OK of safe module43: 
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[273]
Safe Channel_01 OK of safe module42:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[274]
Safe Channel_02 OK of safe module42:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[275]
Safe Channel_03 OK of safe module42:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[276]
Safe Channel_04 OK of safe module42:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[277]
Safe Channel_05 OK of safe module42:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[278]
Safe Channel_06 OK of safe module42:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[279]
Safe Channel_01 OK of safe module41§:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[280]
Safe Channel_02 OK of safe module41:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[281]
Safe Channel_03 OK of safe module41:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[282]
Safe Channel_04 OK of safe module41:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[283]
Safe Channel_05 OK of safe module41:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[284]
Safe Channel_06 OK of safe module41:
– 0: state of physical output channel in fail;
– 1: state of physical output channel OK.
$SL_IN_ABOO[285]
Safe Channel_0102 OK of safe module40:
– 0: state of physical input channel in fail;
– 1: state of physical input channel OK.
$SL_IN_ABOO[286]
Safe Channel_0304 OK of safe module40:
– 0: state of physical input channel in fail;
– 1: state of physical input channel OK.
Tab. 10.1 - System variables and definitions of the RoboSAFE 2.0 system 
(Continued)
System variable Definition
96
PDL2 VARIABLES OF THE ROBOSAFE SYSTEM
Comau Robotics Product Instruction
$SL_IN_ABOO[287]
Safe Channel_0506 OK of safe module40:
– 0: state of physical input channel in fail;
– 1: state of physical input channel OK.
$SL_IN_ABOO[288]
– Safe Channel_0708 OK of safe module40:
– 0: state of physical input channel in fail;
– 1: state of physical input channel OK.
$SL_IN_ABOO[289]
Safe Channel_0910 OK of safe module40:
– 0: state of physical input channel in fail;
– 1: state of physical input channel OK.
$SL_IN_ABOO[290]
Safe Channel_1112 OK of safe module40:
– 0: state of physical input channel in fail;
– 1: state of physical input channel OK.
$SL_IN_ABOO[291]
Safe Channel_1314 OK of safe module40:
– 0: state of physical input channel in fail;
– 1: state of physical input channel OK.
$SL_IN_ABOO[292]
Safe Channel_1516 OK of safe module40:
– 0: state of physical input channel in fail;
– 1: state of physical input channel OK.
$SL_IN_ABOO[293]
Safe Channel_1718 OK of safe module40:
– 0: state of physical input channel in fail;
– 1: state of physical input channel OK.
$SL_IN_ABOO[294]
Safe Channel_1920 OK of safe module40:
– 0: state of physical input channel in fail;
– 1: state of physical input channel OK.
$SL_IN_ABOO[295]
Safe Motion all modules OK:
– 0: safe motion ACOPOS - IO communication failed;
– 1: safe motion ACOPOS - IO OK.
$SL_IN_ABOO[296]
Check Speed Control High activation request:
– 0: request of CSC_High active;
– 1: request of CSC_High NOT active.
$SL_IN_ABOO[297]
Check of Speed Control High:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a speed violation.
$SL_IN_ABOO[298]
Check Speed Control Low activation request:
– 0: request of CSC_Low active;
– 1: request of CSC_Low NOT active.
$SL_IN_ABOO[299]
Check of Speed Control Low:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a speed violation.
$SL_IN_ABOO[300]
Check Speed Control Prog activation request:
– 0: request of CSC_Prog active;
– 1: request of CSC_Prog NOT active.
$SL_IN_ABOO[301]
Check of Speed Control Prog:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a speed violation.
Tab. 10.1 - System variables and definitions of the RoboSAFE 2.0 system 
(Continued)
System variable Definition
97
Comau Robotics Product Instruction
PDL2 VARIABLES OF THE ROBOSAFE SYSTEM
$SL_IN_ABOO[302]
JSC activation request:
– 0: request of JSC active;
– 1: request of JSC NOT active.
$SL_IN_ABOO[303]
Check of JSC:
– 0: Robot NOT in alarm;
– 1: Robot in alarm due to a speed violation.
$SL_IN_ABOO[321]
Request CAT1 STOP request:
– 0: request CAT1 STOP NOT active;
– 1: request CAT1 STOP active.
$SL_IN_ABOO[322]
Request CAT0 STOP request:
– 0: request CAT0 STOP NOT active;
– 1: request CAT0 STOP active.
$SL_IN_ABOO[323]
Request CAT2 STOP request:
– 0: request CAT2 STOP NOT active;
– 1: request CAT2 STOP active.
$SL_IN_ABOO[336]
Safe signal of all safe functions:
– 0: no safe functions requested or at least one safe function 
violated;
– 1: all safe functions are in a safe state.
$SL_IN_ABOO[345]
Warning of Brake Test Check Long timer:
– 0: timeout not expired of the Long Warning Timer;
– 1: timeout expired of the Long Warning Timer.
$SL_IN_ABOO[346]
Alarm of Brake Test Check Long timer:
– 0: timeout not expired of the Long Alarm Timer;
– 1: timeout expired of the Long Alarm Timer.
$SL_IN_ABOO[347]
Warning of Brake Test Check Short timer:
– 0: timeout not expired of the Short Warning Timer;
– 1: timeout expired of the Short Warning Timer.
$SL_IN_ABOO[348]
Alarm of Brake Test Check Short timer:
– 0: timeout not expired of the Short Alarm Timer;
– 1: timeout expired of the Short Alarm Timer.
$SL_IN_ABOO[349]
Outcome of Brake Test:
– 0: test failed;
– 1: test was performed successfully.
$SL_IN_ABOO[352]
Safe function status:
– 0: all safe functions are activated;
– 1: all safe functions are disable.
Tab. 10.1 - System variables and definitions of the RoboSAFE 2.0 system 
(Continued)
System variable Definition
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11. HOW TO ACCESS PARAMETERS OF THE 
SAFE FUNCTIONALITIES
– Overview of access modalities;
– Access the SAFE parameters via the Web portal;
– Main page of the SAFE functions;
– Status of RoboSAFE components and functionality;
– Error solving during the connection to the Web portal;
– Access password change.
11.1 Overview of access modalities
Parameter setting of safety functions is possible through:
– Web Portal, already present in the Control Unit system (procedures described in
the pages of this handbook);
– Teach Pendant, through specific configuration pages.
11.2 Access the SAFE parameters via the Web portal
– Requirements for accessing the Web portal;
– Finding the IP address of the Control Unit;
– Access via Web browser.
11.2.1 Requirements for accessing the Web portal
The access to the Web portal in the Control Unit requires the following requirements:
– PersonalComputer (PC) with Ethernet port *¹;
– Web Browser *¹, preferably updated versions of Google Chrome;
– Operating system on PC *¹, preferably Microsoft® Windows® 7 or higher or Linux
distributions;
– Ethernet connection cable of category 5e or higher (or other Wireless
configuration) to connect the Ethernet port of the PC with the Ethernet port of the
Control Unit (ETH2 on the APC Module for C5G Plus, ETH on cabinet for R1C-6 /
S1C-6 );
– identification of the IP address of the Control Unit (see par. 11.2.2).
The topic “RoboSAFE and Teach Pendant” is dealt with in the handbook
“Use of the C5G Plus Control Unit”.
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The connection to the Web portal is permitted to an only one user at a time. The access
from another location is possible only after disconnecting the active one. The icon clearly
shows availability for access or already in use. 
*¹ The JavaScript running in the Web browser must be enabled. Some combinations of
operating system and Web browser may limit the usability of the graphical capabilities
of the interface. 
11.2.2 Finding the IP address of the Control Unit
The IP address of the Control Unit is displayed on the main page of the Teach Pendant
(example in Fig. 11.1). 
Fig. 11.1 - Main page of the Teach Pendant (example)
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11.2.3 Access via Web browser
In the Web browser (requirements in the par. 11.2.1), enter the URL composed by the
IP address of the Control Unit (see par. 11.2.2) in the following format:
http://192.168.29.2
In the Web browser appears the main page that displays the Control Unit and its main
identification data (see Fig. 11.2).
Notes: 
– the example shows the address as it can be seen in Fig. 11.1, to be adjusted
according to what identified on the Teach Pendant. 
– Ports 80 and 8080 are used; therefore it is also possible to write in the format:
http://192.168.29.2:80
or:
http://192.168.29.2:8080
The number of icons and information may differ according to the Control Unit model.
Requires the system Software in Ver. 3.11.003 or higher
Fig. 11.2 - Main page (example)
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11.3 Main page of the SAFE functions
To view the page with all the functions and the SAFE parameter setting, access the Web
portal (see par. 11.2.3) and press “SAFE” icon button.
The SAFE page will appear as shown in the figure.
From the main page of the SAFE it is possible to access the following functions:
– Report, to get the SAFE parameters printed (for further information, see Chap.14.
on page 200);
– Configuration, to set the parameters of the RoboSAFE system and/or verify its
configuration (for further information, see Chap.12. on page 107);
– Service, to consult some of the diagnostic functions and activate the required
procedures during maintenance of the SAFE modules (for further information, see
Chap.15. on page 203);
– Change password, to change the access password of the SAFE system
parameter setting page (for further information, see par. 11.6).
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11.4 Status of RoboSAFE components and 
functionality
The immediate verification of the SAFE functionality is possible by analysing the status
Led shown on all Web pages of the portal, without having to log in with login procedures.
The LED is present in the upper right part, already from the page of
Possible states of the system are identified by the different colour of the LED:
– green, condition everything ok;
– yellow, temporary condition during the system loading or restart;
– yellow with the “L” inside, condition requiring the alignment between the Robot
physical position and reference position for the RoboSAFE system );
– red, condition of anomaly, there are one or more errors. The system can not
resume its functionality autonomously;
– black, temporary condition, during initial loading of the system (bootstrap), during
connection between browser and SLU or update of Web pages.
A colour different from green that lasts for more than 1 minute may be a symptom of
malfunctions.
Fig. 11.3 - Main page with indication of SAFE system status
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11.5 Error solving during the connection to the Web 
portal
Tab. 11.1 - Errors, causes and solutions from the Web portal 
Error Wrong action Solution
401
– Simultaneous access to the portal by a 
second user 
a. Only one user is allowed at a time;
disconnect the first user and try again.
b. It may be necessary to close the browser
used by the first user.
404
– Access to a non-existent page on the 
portal
a. Avoid storing the URL of the portal
sub-pages in the favourites
b. Access again the portal starting from the
main page
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11.6 Access password change
The “Change password” function allows you to change the default password in order to
access the SAFE function page.
1. The password default value is “comau” (without inverted commas).
2. Press the “Change password” button.
3. Insert the current password, then a new password (repeat it a second time in the
“Confirm new password” field).
Tab. 11.2 - Definition of fields in the Password change page
Function: Window for the password change
User: Drop-down list to select the user “safe”.
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Default: The default password is “comau”
Old and new 
password 
accepted 
parameters:
Characters, numbers and symbols. 
In order to allow easy use independent from language and / or 
characters and ideograms, it is advised to use only Latin 
characters (no matter upper or lower cases) and numbers.
“Ok” button: Pressing the button stores the password.
“Cancel” button: By pressing that button the procedure is cancelled.
Error messages Meaning
Please insert old password! The insertion of the old password is required.
Please insert new password! The insertion of the new password is required.
Password does not match! The new password and the confirmation typed for the second time 
are different while it is required that they match.
Tab. 11.2 - Definition of fields in the Password change page (Continued)
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12. PARAMETERS AND CONFIGURATION OF 
THE SAFE FUNCTIONS 
This chapter contains the following topics:
– Access to the functions and configuration parameters of the SAFE functionalities;
– System Parameters (System);
– Joint space monitoring function (Joint spaces);
– Cell monitoring function;
– Monitoring function of Dynamic Volumes;
– Position control function (Functional Space A and B);
– Robot speed definition function (Speed);
– Function to define the equipment on the Robot (Monitoring Point);
– Brakes monitoring function (Brake);
– Function to combine safe outputs with the outcome of functions (Safe Outputs);
– Tool orientation definition function (Tool Orientation);
– Save the changes to the RoboSAFE settings;
– Import / Export all the parameters of the RoboSAFE configuration.
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12.1 Access to the functions and configuration 
parameters of the SAFE functionalities
The functions and the related parameters of the SAFE functionalities are accessible on
the Web portal, on “Safe” icon button (see details in par. 11.3).
Then select “Configuration” page.
Fig. 12.1 - Main page for access to the SAFE parameters
The access to the “Configuration” page requires an access login (see par. 12.1.1). 
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Comau Robotics Product Instruction12.1.1 Access login to the configuration Web page
To access the main page is necessary to press the “Configuration” button.
The access to the configuration pages is protected by a password with the consequent
need to carry out the authentication (Login procedure), with the following parameters:
User: safe
Password: comau
Note: the login parameters given above are the default ones. It is strongly
recommended to modify the password to limit the access to parameters modification
(that are aspects of safety solutions) only to the authorized and trained staff (see
par. 11.6 Access password change on page 105).
In the browser it is shown the authentication window (see Fig. 12.2).
Fig. 12.2 - Authentication window (example)
When the access is confirmed, the main page of the SAFE functions appears (see
Fig. 12.3).
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Fig. 12.3 - Main page of the SAFE functions
The main page and the relative sub-pages are subject to timeout, which intervenes by
deactivating access to the exceedance after a few minutes of inactivity.
The intervention of the timeout does not allow to resume the previous session or save
the parameters possibly modified and not stored with the special “Save” function (see
par. 12.12 Save the changes to the RoboSAFE settings on page 192).
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12.1.2 Logout from the configuration Web page
The exit from the configuration Web page is possible through the appropriate Exit button
visible at the top of the “Configuration” page.
Fig. 12.4 - Detail of the Exit button
As an alternative the disconnection is made automatically when the Web browser is
closed.
Closing the browser does not allow you to resume the previous session or save any
parameters that have been modified and not stored with the special “Save” function (see
par. 12.12 Save the changes to the RoboSAFE settings on page 192).
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12.2 System Parameters (System)
It allows you to configure general system parameters, such as stop category, addresses
and mapping of safe digital I/O signals.
Available procedures
– How to access the System page (see par. 12.2.1 on page 112);
– How to change the Robot stop category and the safety timer time (see par. 12.2.2
on page 113);
– How to change C5GP-PIS Gateway address (see par. 12.2.3 on page 114);
– How to deactivate / activate a stop signal coming from the C5GP-PIS Gateway
(see par. 12.2.4 on page 115);
– How to assign C5G Plus Control Unit status signals to specific safety outputs (see
par. 12.2.5 on page 116).
12.2.1 How to access the System page
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. press the “System” button.
Fig. 12.5 - System page
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12.2.2 How to change the Robot stop category and the safety 
timer time
1. Access the System page;
2. modify “Stop time [s]” parameter according to need by acting directly on the
drop-down list (Tab. 12.1).
The stopping distance and time of the Robot are not influenced by the time set on the
timer. Nevertheless, an inappropriate choice of the stop timer time can generate
persistence of power supply to drives with a consequent increase in exposure to danger
until the power supply continues. 
Also follow the information given in par. 3.7 Stopping modes in RoboSAFE system on
page 27.
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
Tab. 12.1 - Definition of fields on the System page, category and stop 
timer time
System settings
Parameter: Stop time [S]
Use: Set both the Robot stop category and the stop circuit timer time. 
Abbreviations:
– Cat. = category, according to standard EN 60204-1
– 1.5 (ex.) = Time expressed in seconds including decimals
Default: Cat. 1 - 1.5
Accepted values: All those provided in the drop-down list
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12.2.3 How to change C5GP-PIS Gateway address
1. Access the System page;
2. change “PS F-Address” parameter by entering the address number (Tab. 12.2).
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
Tab. 12.2 - Definition of fields on the System page, Gateway address
System settings
Parameter: PS F-Address
Use: Set the C5GP-PIS Gateway address 
Abbreviations:
– PS = ProfiSAFE
Default: 0
Accepted values: from 0 to 65535
Notes: The field is enabled only if the Gateway module is installed.
For suggestions on integration see par. 13.1.1.
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12.2.4 How to deactivate / activate a stop signal coming from the 
C5GP-PIS Gateway
1. Access the System page;
2. activate / deactivate check box “Disable PS Stop” (Tab. 12.3).
The function is designed for temporary uses, typically for the purpose of moving the
Robot in programming mode when the C5G-PIS option is installed but the ProfiSAFE
network is not yet connected, and in any case before start-up.
The activation of the “Disable PS Stop” function excludes all safety signals coming
from the network, even with connected and functioning network; therefore there is the
risk resulting from the lack of acquisition of emergency stops coming from the cell /
automated system line.
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
Tab. 12.3 - Definition of fields on the System page, deactivation of the 
Stop from the Gateway
System settings
Parameter: Disable PS Stop
Use: Activate / deactivate the stop signal coming from the C5GP-PIS 
Gateway. 
Abbreviations:
– PS = ProfiSAFE
Default: not selected
Accepted values: not selected / selected
Notes: The field is enabled only if the Gateway module is installed.
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12.2.5 How to assign C5G Plus Control Unit status signals to 
specific safety outputs
1. Access the System page;
2. change parameter “Signal 1” (or “Signal 2” and “Signal 3”) according to need by
acting directly on the drop-down list (Tab. 12.4). 
3. Note: the combination of up to 3 signals is freely selectable (within the limits of the
possibilities allowed); the signals will be available on the X31/CIP connector (see
details in par. 9.7).
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
Tab. 12.4 - Definition of the statuses at the outputs
Status Signals
Parameter: Signal 1 (or Signal 2 or Signal 3)
Use: Combine the Control Unit statuses with specific signals to be able 
to use in your applications.
Default: The standard profile provides the following default combination:
– Signal 1 -> Drive On (Drive On status)
– Signal 2 -> EmExt Stop (External E-Stop)
– Signal 3 -> Auto (Auto Mode status)
Note: in the case of modification of the combination of outputs, 
consult the par. 9.7.
Accepted values: – Progr (T1 programming status)
– Auto (Auto Mode status)
– En Device (Enabling Device status)
– EmExt Stop (External E-Stop)
– Drive On (Drive On status)
– Safety gates (Auto Stop (Fence))
– SBO 1 (SAFE SBO 1 output for user application (bridge from 
input bit 1))
– SBO 2 (SAFE SBO 2 output for user application (bridge from 
input bit 2))
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Notes: Thefield is enabled only if the C5GP-PIS Gateway module is 
installed or the X31/CIP connector is available with consequent 
enabling of the ERM parameter in “Safe Options”, on the specific 
page on the Teach Pendant:
Tab. 12.4 - Definition of the statuses at the outputs (Continued)
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12.3 Joint space monitoring function (Joint spaces)
It allows you to configure one or more sets of joint spaces where the Robot must be
confined or not authorized to enter (for further information on the concepts see
RoboSAFE Joint functionality (see par. 5.3 on page 38)) or identify the position of the
Robot axis (par. 5.3.2.2). 
Each dynamic joint space can be permanently active or combined with the status of
specific safe inputs and can be assigned to the following types:
– Inside (space where the Robot will be allowed freedom of movement), and/or
– Outside (space where the Robot will not be able to access).
The joint spaces defined in this function must be entered within the cell volume defined
with the Cell monitoring function (see par. 12.4 on page 127).
The joint spaces (or part of them) “Inside” and “Outside” of two distinct sets may overlap;
the signalling will be communicated by the sector in violation.
Available procedures
– How to access Joint spaces page (see par. 12.3.1 on page 119);
– How to modify parameters of a Joint Space Limiting (see par. 12.3.2 on page 120);
– How to modify parameters of a Joint Functional Sector (see par. 12.3.3 on
page 125).
For conceptual details on the Joint spaces see par. 5.3.2.1.
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12.3.1 How to access Joint spaces page
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. press the “Joint spaces” button.
Fig. 12.6 - Joint spaces page
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12.3.2 How to modify parameters of a Joint Space Limiting
1. Access the Joint spaces page (see par. Fig. 12.6 - on page 119);
2. choose one of the available sets;
3. modify parameters according to need by acting directly on fields. The details are
available in Tab. 12.5 - Definition of fields on Set page on page 121).
Fig. 12.7 - Joint Space Limiting page, set parameters
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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Tab. 12.5 - Definition of fields on Set page
Properties
Parameter: Enabled
Use: Set the enabling to set check.
The RoboSAFE functionality checks the set only if the parameter 
is configured with checked.
Default: Not active
Accepted values: Through special check box
– Not checked = set not active
– Checked = set active
Parameter: Activated by
Use: If the Enabled parameter is selected, set the condition to enable 
set check:
– Always active, without necessity to manage the command 
via digital inputs.
– RS Input, active according to the status of Safe digital input 
combined with the specific set (see Tab. 9.1, input 
RoboSAFE Joint - Set 1 and next ones).
Default: Always active
Accepted values: Drop-down list for selection:
– Always active
– RS Input
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Parameter: Stop in AUTO
Use: Set the stopping mode according to EN 60204-1 standard, valid 
only in Automatic Mode (local and remote).
The following options are available:
– Don’t stop, after violation, the Robot is not stopped. An alarm 
message is displayed on the Teach Pendant and its source 
can be identified through the diagnostic bits. The error can be 
silenced by pressing the “Reset” push-button on the Teach 
Pendant.
– Stop Cat. 1, stop occurs by deceleration ramp.
– Stop Cat. 0, stop occurs by immediate brakes actuation.
Default: Don’t stop
Accepted values: Drop-down list for selection:
– Don’t stop
– Stop Cat. 1
– Stop Cat. 0
Diagnostics
Violation 
It is possible to identify the violation with the 
$SL_IN_ABOO[169]...[174] status bit (see Tab. 10.1).
Parameter: Stop in PROG
Use: Set the behaviour of the RoboSAFE functionality after the set 
violation with the Control Unit in Programming mode (T1):
– Don’t stop, after violation, the Robot is not stopped. An alarm 
message is displayed on the Teach Pendant and its source 
can be identified through the diagnostic bits. The error can be 
silenced by pressing the “Reset” push-button on the Teach 
Pendant.
– Stop Cat. 0, after violation, the Robot is stopped; the 
stopping mode is in category 0 in accordance with EN 
60204-1.
Default: Don’t stop
Accepted values: Drop-down list for selection:
– Don’t stop
– Stop Cat. 0
Diagnostics
Violation 
It is possible to identify the violation with the 
$SL_IN_ABOO[169]...[174] status bit (see Tab. 10.1).
Tab. 12.5 - Definition of fields on Set page (Continued)
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Axis, without conditioning the status of axis 1
Parameter: Enabled
Use: Activate the check of the first sector threshold for the axis; it is 
possible to freely configure 1 or more axes.
Default: Through special check box
– max. value of the stroke allowed by the mechanical physical 
limit of the axis
– Working zone: inside
Accepted values: Through special check box
– Not checked = set not active
– Checked = set active
Parameter: Workspace
Use: The value indicated in the Low and High parameters is included in 
the evaluated sector; the stop is performed only if the position of 
the violation is higher (in respect of the direction of mathematical 
sign).
The sector set is evaluated through 2 conditions:
– inside selection, the evaluated sector is included within the 
indicated values;
– outside selection, the evaluated sector is included within the 
indicated extreme values, up to the maximum limit of the 
mechanical stroke of the axis.
Default: Inside
Accepted values: Drop-down list
– inside = the evaluated sector is included inside the indicated 
values;
– outside = the evaluated sector is included within the indicated 
extreme values, up to the maximum limit of the mechanical 
stroke of the axis.
Tab. 12.5 - Definition of fields on Set page (Continued)
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Parameter: Low Limit e High Limit
Use: Values (expressed with degrees in case of Robot axes) are filled 
in advance with the max. value of the allowed stroke by the 
mechanical physical limit of the axis.
The value given is includes in the monitored sector; the stop is 
carried out only if the violation position is higher (respecting the 
mathematical direction sign).
The sector set is evaluated through 2 conditions:
– inside selection, the evaluated sector is included within the 
indicated values;
– outside selection, the evaluated sector is included within the 
indicated extreme values, up to the maximum limit of the 
mechanical stroke of the axis.
Default: Max stroke value allowed by the physical mechanical limit of the 
axis
Accepted values: Numerical values, with positive or negative index
Axis, conditioned by the status of axis 1
Parameter: Condition
Use: Enable the conditional control on axis 1. The values indicated in 
the Workspace / Low / High parameters determine the area of 
axis 1 in which the system activates the control, and only then 
takes into consideration the parameters of the remaining axes. 
The other parameters remain unchanged (see descriptions 
above).
Tab. 12.5 - Definition of fields on Set page (Continued)
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12.3.3 How to modify parametersof a Joint Functional Sector
1. Access the Joint spaces page (see par. Fig. 12.6 - on page 119);
2. choose one of the available axes (axis 1, axis 7 only if present) on which to apply
the position detection (see details in par. 5.3.2.2);
3. modify parameters according to need by acting directly on fields. The details are
available in Tab. 12.6 - Definition of fields on Axis Sector page on page 126).
Fig. 12.8 - Joint Functional Sector page, sector parameters
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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Tab. 12.6 - Definition of fields on Axis Sector page
Sector
Button: Add / Remove
Use: Press the “Add” button to add a marker; press “Remove” to 
remove the last marker on the right.
To move a marker, click with the mouse and drag it.
Note: the marker creates sectors, dividing the entire space 
covered by the axis into parts. For example, in the figure above 
there are 4 markers and 5 sectors.
Default: No marker set
Accepted values: Up to 14 markers and resulting 15 sectors
Button: Set / Cancel
Use: Press the “Set” button to confirm a marker; press “Cancel” to 
cancel the last changes and restore to previous condition.
SAFE position 
identification:
The axis position is available on a binary coding (one byte, see 
Position in the sector AX 1 Joint (bit 1) and the following ones).
When also axis 7 (Robot Track Motion) is present, see Position in 
the sector AX 7 Joint (bit 1).
Diagnostics
Violation 
It is possible to identify the position by consulting the 
$SL_IN_ABOO[161]...[166] status bit (see Tab. 10.1).
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12.4 Cell monitoring function
The “cell” is constructed essentially:
– a floor plane;
– a ceiling plane;
– a series of corners to define the walls;
– a series of forbidden Volumes always active (optional).
Available procedures
– How to access the Cell page (see par. 12.4.1 on page 128);
– How to modify the Cell volume parameters (see par. 12.4.2 on page 129);
– How to add corners to the Cell volume (see par. 12.4.3 on page 132);
– How to cancel corners to the Cell volume (see par. 12.4.4 on page 133);
– How to add a Forbidden Volume to the Cell (see par. 12.4.5 on page 134);
– How to modify parameters of a Forbidden Volume in the Cell (see par. 12.4.6 on
page 135);
– How to cancel a Forbidden Volume in the Cell (see par. 12.4.7 on page 138).
For more information on the cell see par. 5.4.2.1.
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12.4.1 How to access the Cell page
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. press the “Cell” button.
Fig. 12.9 - Cell page
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12.4.2 How to modify the Cell volume parameters
1. Access the Cell page (see par. Fig. 12.9 - on page 128);
2. modify parameters according to need by acting directly on fields. The details are
available in the Tab. 12.7 - Definition of fields in the Cell Features page on
page 130):
3. if necessary to modify the cell configuration, consult How to add corners to the Cell
volume (see par. 12.4.3 on page 132);
4. if necessary to permanently protect one or more volumes inside the cell, consult
How to add a Forbidden Volume to the Cell (see par. 12.4.5 on page 134).
Fig. 12.10- Cell Page, cell parameters
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
129
Comau Robotics Product Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Tab. 12.7 - Definition of fields in the Cell Features page
Properties
Parameter: Enabled
Use: Set enabling to cell volume check.
The RoboSAFE functionality checks the cell volume only if the 
parameter is configured with checked.
Default: Not active
Accepted values: Through special check box
– Not checked = volume not active
– Checked = volume active
Parameter: Stop in AUTO
Use: Set the stopping mode according to EN 60204-1 standard, valid 
only in Automatic Mode (local and remote).
The following options are available:
– Don’t stop, after violation, the Robot is not stopped. An alarm 
message is displayed on the Teach Pendant and its source 
can be identified through the diagnostic bits. The error can be 
silenced by pressing the “Reset” push-button on the Teach 
Pendant.
– Stop Cat. 1, stop occurs by deceleration ramp.
– Stop Cat. 0, stop occurs by immediate brakes actuation.
Default: Don’t stop
Accepted values: Drop-down list for selection:
– Don’t stop
– Stop Cat. 1
– Stop Cat. 0
Diagnostics
Violation 
It is possible to identify the violation with the $SL_IN_ABOO[196] 
status bit (see Tab. 10.1).
130
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
Parameter: Stop in PROG
Use: Set the RoboSAFE functionality behaviour after cell volume 
violation with the Control Unit in the T1 Programming mode:
– Don’t stop, after violation, the Robot is not stopped. An alarm 
message is displayed on the Teach Pendant and its source 
can be identified through the diagnostic bits. The error can be 
silenced by pressing the “Reset” push-button on the Teach 
Pendant.
– Stop Cat. 0, after violation, the Robot is stopped; the 
stopping mode is in category 0 in accordance with EN 
60204-1.
Default: Don’t stop
Accepted values: Drop-down list for selection:
– Don’t stop
– Stop Cat. 0
Diagnostics
Violation 
It is possible to identify the violation with the $SL_IN_ABOO[196] 
status bit (see Tab. 10.1).
Height
Parameter: Z-Min, Z-Max
Use: Set the dimension of cell floor and ceiling
Default: -41 / 3000 mm
Accepted values: Numerical value.
Z-Min: negative value, from - 41 or lower
Z-Max: positive value, exceed the minimum height of the 
corresponding to robot axes joints points.
Add new Corner
Use: Add corners to the cell to make up the perimeter (see par. 12.4.3).
Tab. 12.7 - Definition of fields in the Cell Features page (Continued)
131
Comau Robotics Product Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
12.4.3 How to add corners to the Cell volume
1. Access the Cell page (see par. Fig. 12.9 - on page 128);
2. press the “Add new corner” button;
3. a new corner position and, with at least 2 defined corners, the corresponding
graphic visualisation of the occupied space (with default values) will automatically
appear; if one or more corners are already present, the new item will appear at the
bottom of the list;
4. it is possible configure maximum 8 corners; Note: the corners can not have 0.0
(X,Y) coordinates in the Robot origin coincidence; moreover, the faces must not
cross the 0.0 top (further details in par. 5.4.3);
5. default parameters must be adjusted according to needs; the details for configuring
the parameters are given in par. 12.5.4 How to modify parameters of a Dynamic
Volume on page 143.
Fig. 12.11- Page Cell, add new corner
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
132
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
12.4.4 How to cancel corners to the Cell volume
1. Access the Cell page (see par. Fig. 12.9 - on page 128);
2. press the “X” button on the item of the corner you want to cancel; the cancellation
is immediate.
Fig. 12.12- Page Cell, cancel corner
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
133
Comau RoboticsProduct Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
12.4.5 How to add a Forbidden Volume to the Cell
1. Access the Cell page (see par. Fig. 12.9 - on page 128);
2. press the “Add forbidden volume” button;
3. a new position and the corresponding graphic visualisation of the occupied space
(with default values) will automatically appear; if one or more corners are already
present, the new item will appear at the bottom of the list;
4. it is possible to configure maximum 10 volumes;
5. default parameters must be adjusted according to needs; the details for configuring
the parameters are given in par. 12.4.6 How to modify parameters of a Forbidden
Volume in the Cell on page 135.
Fig. 12.13- Cell page, add Forbidden Area
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
134
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
12.4.6 How to modify parameters of a Forbidden Volume in the 
Cell
1. Access the Cell page (see par. Fig. 12.9 - on page 128);
2. press the button corresponding to the name of the volume that is wanted to be
modified;
3. there will automatically appear the parameters page;
4. modify parameters according to need. The details are available in the Tab. 12.8
- Fields definition on the parameters page of the Forbidden Area in the Cell on
page 136):
• Definition;
• Location;
• Dimension;
• Rotation.
5. If necessary, adjust the volume name by clicking on the name that appears in the
window title; then confirm with enter;
6. confirm by pressing the “Set” button.
Fig. 12.14- Cell page, Forbidden Area parameters
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
135
Comau Robotics Product Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Tab. 12.8 - Fields definition on the parameters page of the Forbidden 
Area in the Cell
Definition
Parameter: Volume name
Use: Volume name to be graphically identified in three-dimensional 
representation
Default: Forbidden volume
Accepted values: Designation consisting of characters, numbers, symbols.
To modify the parameter, click on the name (see details 
par. 12.5.5 How to rename the name assigned to a Dynamic 
Volume on page 149).
Location
Parameter: X, Y, Z
Use: Set the lower right corner position of the considered volume, 
referred to the cartesian tern of the Robot or Robot Track Motion / 
Robot
Default: 0 mm
Accepted values: Positive or negative numerical value.
Dimension
Parameters: Width, height and depth
Use: Set the size of the width, height and depth of the considered 
volume
Default: 1000 mm
Accepted values: Positive or negative numerical value.
136
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
Rotation
Parameter: Roll, Pitch, Yaw
Use: Set rotation of the considered volume around to the cartesian tern 
of the Robot or Robot Track Motion / Robot
Default: 0 mm
Accepted values: Positive or negative numerical value.
Tab. 12.8 - Fields definition on the parameters page of the Forbidden 
Area in the Cell (Continued)
137
Comau Robotics Product Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
12.4.7 How to cancel a Forbidden Volume in the Cell
1. Access the Cell page (see par. Fig. 12.9 - on page 128);
2. press the “X” button on the item of the volume you want to cancel; the cancellation
is immediate.
Fig. 12.15- Cell page, cancel Forbidden Area
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
138
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
12.5 Monitoring function of Dynamic Volumes
The “Dynamic volume” can be permanently active or combined with the status of
specific safe inputs and can be assigned to the following types:
– Work volume, that is, space where the Robot will be allowed freedom of
movement, and/or
– Forbidden volume, that is, space where the Robot will not be able to enter.
Available procedures
– How to access the Dynamic Volumes page (see par. 12.5.1 on page 140);
– How to create a new forbidden Dynamic Volume (Forbidden Volume) (see par.
12.5.2 on page 141);
– How to create a new allowed Dynamic Volume (Work Volume) (see par. 12.5.3 on
page 142);
– How to modify parameters of a Dynamic Volume (see par. 12.5.4 on page 143);
– How to rename the name assigned to a Dynamic Volume (see par. 12.5.5 on
page 149);
– How to disable a Dynamic Volume (see par. 12.5.6 on page 150).
For more details see par. 5.4.2.2.
139
Comau Robotics Product Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
12.5.1 How to access the Dynamic Volumes page
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. press the “Dynamic Volumes” button.
Fig. 12.16- Dynamic Volumes Page 
140
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
12.5.2 How to create a new forbidden Dynamic Volume 
(Forbidden Volume)
1. Access the Dynamic Volumes Page (see par. Fig. 12.16 - on page 140); all 6
allowed dynamic volumes are already available and to be used must firstly be
enabled; 
2. press the button corresponding to the name of the volume that is wanted to be
modified and enable the parameter “Enabled”, select the item “Forbidden” in the
field “Area Type” and confirm by pressing the “Set” button;
3. when enabled, the Forbidden Area is represented in figure with an yellow surface;
4. the enabling and default parameters must be adjusted according to needs; further
details on parameters configuration are given in the par. 12.5.4 How to modify
parameters of a Dynamic Volume on page 143.
Fig. 12.17- Dynamic Volumes Page, add new Forbidden Area
141
Comau Robotics Product Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
12.5.3 How to create a new allowed Dynamic Volume (Work 
Volume)
1. Access the Dynamic Volumes Page (see par. Fig. 12.16 - on page 140); all 6
allowed dynamic volumes are already available and to be used must firstly be
enabled; 
2. press the button corresponding to the name of the volume that is wanted to be
modified and enable the parameter “Enabled”, select the item “Work” in the field
“Area Type” and confirm by pressing the “Set” button;
3. when enabled, the Work Area is represented in figure with a green surface;
4. the enabling and default parameters must be adjusted according to needs; further
details on parameters configuration are given in the par. 12.5.4 How to modify
parameters of a Dynamic Volume on page 143.
Fig. 12.18- Dynamic Volumes Page, add new Work Area
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
142
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
12.5.4 How to modify parameters of a Dynamic Volume
1. Access the Dynamic Volumes Page (see par. Fig. 12.16 - on page 140);
2. press the button corresponding to the name of the volume that is wanted to be
modified;
3. there will automatically appear the parameters page;
4. modify parameters according to need. The details are available in the Tab. 12.9
- Definition of fields on the Properties page of Dynamic volumes on page 144):
• Properties;
• Position;
• Dimension;
• Rotation.
5. confirm by pressing the “Set” button.
Fig. 12.19- Properties page of the dynamic volumes (e.g. for Work Area) 
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
143
Comau RoboticsProduct Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Tab. 12.9 - Definition of fields on the Properties page of Dynamic 
volumes
Properties
Parameter: Volume name
Use: Volume name to be graphically identified in three-dimensional 
representation
Accepted values: Designation consisting of characters, numbers, symbols.
To modify the parameter, click on the name (see details 
par. 12.5.5 How to rename the name assigned to a Dynamic 
Volume on page 149).
Parameter: Enabled
Use: Set enabling to the volume check.
The RoboSAFE functionality checks the volume only if the 
parameter is configured with checked.
Default: Not enabled
Accepted values: Through special check box
– Not checked = volume not enabled
– Checked = volume enabled
Parameter: Mode
Default: Check
Accepted values: Drop-down list for selection:
– Check
– On Violation
144
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
Parameter: Area Type
Use: Set the functional type of the area:
– Forbidden, (forbidden volume) is the space where the Robot 
is not allowed to enter;
– Work, (work volume) is a space where the Robot can move 
freely.
Default: Monitor 
Accepted values: Drop-down list for selection:
– Forbidden
– Work
Parameter: Activated by
Use: If the functional Mode for volume check is set to "Check", set the 
condition to enable the volume check:
– Always active, without necessity to manage the command 
via digital inputs.
– RS Input, active according to the status of the Safe digital 
input, automatically combined and listed in the right column 
of the dynamic volumes list (see Tab. 9.1).
Default: Always active
Accepted values: Drop-down list for selection:
– Always active
– RS Input
Tab. 12.9 - Definition of fields on the Properties page of Dynamic 
volumes (Continued)
145
Comau Robotics Product Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Parameter: Stop Category
Use: If the functional Mode for volume check is set to “Check”, set the 
stopping mode according to EN 60204-1 standard referring to the 
parameter On Violation (if configured with “Stop”), valid only in 
Automatic control mode (local and remote).
The following options are available:
– Don’t stop, after violation, the Robot is not stopped. An alarm 
message is displayed on the Teach Pendant and it is possible 
to identify its source through status bits (see Tab. 10.1, 
variable $SL_IN_ABOO[x] “Volume violation of one or more 
points of the Robot). The error can be silenced by pressing 
the “Reset” push-button on the Teach Pendant. Note: if the 
volume violation remains, to the next Drive On the alarm 
message will reappear on the Teach Pendant. 
– Stop Cat. 1, stop occurs by deceleration ramp.
– Stop Cat. 0, stop occurs by immediate brakes actuation.
Default: Stop Cat. 1
Accepted values: Drop-down list for selection:
– Don’t stop
– Stop Cat. 1
– Stop Cat. 0
Tab. 12.9 - Definition of fields on the Properties page of Dynamic 
volumes (Continued)
146
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
Parameter: Program mode
Use: If the functional Mode for volume check is set to “Check”, set the 
behaviour of the RoboSAFE functionality after a violation of the 
rule when the system is in the T1 programming mode:
– Stop, after violation, the Robot is stopped; the stop mode is 
in category 0 (not depending on parameters “Stop 
Category”).
– Don’t stop, after violation, the Robot is not stopped. An alarm 
message is displayed on the Teach Pendant and it is possible 
to identify its source through status bits (see Tab. 10.1, 
variable $SL_IN_ABOO[x] “Volume violation of one or more 
points of the Robot). The error can be silenced by pressing 
the “Reset” push-button on the Teach Pendant. Note: if the 
volume violation remains, to the next Drive On the alarm 
message will reappear on the Teach Pendant.
Note: it is recommended to evaluate the “Don't stop” parameter to 
simplify the Robot release due to violation; otherwise, in the T1 
programming mode the Robot movement will not be allowed.
If the parameter “Program mode” is “Stop”, the violation of a 
volume set can be restored only allowing the access to this page 
to the technician (responsible for restoring the machine 
functionality); this condition could be in contrast with the 
integrator's possible intention to impede the access to the 
parameters page. The restore procedure is described in par. 15.9 
Robot position reset after RoboSAFE rules violation on page 233.
Default: Don’t stop
Accepted values: Drop-down list for selection:
– Stop
– Don’t stop
Position
Parameter: X, Y, Z
Use: Set the lower right corner position of the considered volume, 
referred to the cartesian tern of the Robot or Robot Track Motion / 
Robot
Default: 0 mm
Accepted values: Positive or negative numerical value.
Note: pay attention to the requirements indicated in par. 5.4.4
Tab. 12.9 - Definition of fields on the Properties page of Dynamic 
volumes (Continued)
147
Comau Robotics Product Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Dimension
Parameters: Width, height and depth
Use: Set the size of the width, height and depth of the considered 
volume
Default: 1000 mm
Accepted values: Positive or negative numerical value.
Note: pay attention to the requirements indicated in par. 5.4.4
Rotation
Parameter: Roll, Pitch, Yaw
Use: Set rotation of the considered volume around to the cartesian tern 
of the Robot or Robot Track Motion / Robot
Default: 0 mm
Accepted values: Positive or negative numerical value.
Tab. 12.9 - Definition of fields on the Properties page of Dynamic 
volumes (Continued)
148
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
12.5.5 How to rename the name assigned to a Dynamic Volume
1. Access the Dynamic Volumes Page (see par. Fig. 12.16 - on page 140);
2. press the button corresponding to the name of the volume that is wanted to be
modified;
3. there will automatically appear the parameters page;
4. click on the volume name; immediately field becomes editable;
5. change the volume name;
6. confirm by pressing the “Set” button.
Fig. 12.20- Dynamic Volume Page, change the name assigned to the 
Volume 
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
149
Comau Robotics Product Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
12.5.6 How to disable a Dynamic Volume
1. Access the Dynamic Volumes Page (see par. Fig. 12.16 - on page 140);
2. disable by removing the check on the appropriate parameter Enabled. Note: a
Dynamic volume cannot be cancelled. 
Fig. 12.21- Dynamic Volume Page, disable the Volume
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
150
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
12.6 Position control function (Functional Space A and 
B)
The volumes are constructed essentially as a rectangular parallelepiped, with such a
minimal dimension to contain the Tool, as defined in the Monitoring Point function (see
par. 12.8).
Available procedures
– How to access the Functional Space page;
– How to enable one or more Functional Spaces;
– How to create a new Functional Space;
– How to modify parameters of a Functional Space;
– How to cancel a Functional Space.
For more details see par. 5.4.2.3.
151
Comau Robotics Product Instruction
PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
12.6.1 How to access the Functional Space page
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. press the “Functional Space A” button or as an alternative the “Functional Space
B” button.
Fig.. . . . . . . . . . . . . . . . . . . . . . . . . . 125
Cell monitoring function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
How to access the Cell page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
How to modify the Cell volume parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
How to add corners to the Cell volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
How to cancel corners to the Cell volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
How to add a Forbidden Volume to the Cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
How to modify parameters of a Forbidden Volume in the Cell . . . . . . . . . . . . . . . . . . . . . . . 135
How to cancel a Forbidden Volume in the Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Monitoring function of Dynamic Volumes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
How to access the Dynamic Volumes page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
How to create a new forbidden Dynamic Volume (Forbidden Volume) . . . . . . . . . . . . . . . . 141
How to create a new allowed Dynamic Volume (Work Volume) . . . . . . . . . . . . . . . . . . . . . 142
How to modify parameters of a Dynamic Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
How to rename the name assigned to a Dynamic Volume . . . . . . . . . . . . . . . . . . . . . . . . . 149
How to disable a Dynamic Volume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Position control function (Functional Space A and B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
How to access the Functional Space page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
How to enable one or more Functional Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
How to create a new Functional Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
How to modify parameters of a Functional Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
How to cancel a Functional Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Robot speed definition function (Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6
Comau Robotics Product Instruction
How to access the Speed page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
How to enable Speed Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
How to modify High Speed Cartesian Limiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
How to modify Low Speed Cartesian Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
How to modify Program (T1) Speed Cartesian Limiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Function to define the equipment on the Robot (Monitoring Point) . . . . . . . . . . . . . . . . . . . . . 171
How to access the Monitoring Points page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
How to create a new Monitoring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
How to modify parameters of a Monitoring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
How to cancel a Monitoring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
How to enable / disable the Toolsets and change their positions . . . . . . . . . . . . . . . . . . . . 177
Brakes monitoring function (Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
How to access the Brake page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
How to enable the brake monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Function to combine safe outputs with the outcome of functions (Safe Outputs) . . . . . . . . . . 182
How to access the Safe Outputs page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
How to combine the SAFE outputs with the result of the functions . . . . . . . . . . . . . . . . . . . 183
Tool orientation definition function (Tool Orientation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
How to access the Tool Orientation page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
How to enable the Tool Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
How to adjust Tool Orientation coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Save the changes to the RoboSAFE settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Import / Export all the parameters of the RoboSAFE configuration . . . . . . . . . . . . . . . . . . . . . 193
13. GUIDE TO THE USE OF ROBOSAFE 2.0 FUNCTIONALITIES. . . . . . . . . . . . . . . ...194
C5GP-PIS Gateway integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Integration suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Siemens PLC parameter setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Suggestions for checking the functionalities of the emergency stop mushroom-shaped push-
button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Integration of periodic check of brake functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Integration suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
How to activate the Brake Test Check (BTC) routine in PDL2. . . . . . . . . . . . . . . . . . . . . . . 199
14. PRINTING OF THE SAFE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...200
Considerations on the information obtained and the conservation of the report . . . . . . . . . . . 200
SAFE Report Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
15. MAINTENANCE (SOFTWARE ASPECTS OF THE ROBOSAFE SYSTEM) . . . . . ...203
Personnel in charge of maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Access to the maintenance functions (Service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Access login to the “Service” Web page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Logout from the service Web page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7
Comau Robotics Product Instruction
Requirements and history of Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Overview of the “Service” functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Reset Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Reset after replacement of an axis module, Safe I/O modules or SLU module. . . . . . . . . . 209
Reset after a motor replacement . . . . . . . . . . . . . . . . . . . . . . . . .12.22- Functional Space Page
152
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Comau Robotics Product Instruction
12.6.2 How to enable one or more Functional Spaces
Functional spaces must be enabled before being used and/or modified. It is not possible
to enable a space individually.
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. press the “Functional Space A” button or as an alternative the “Functional Space
B” button;
3. Select the appropriate check “Enabled”.
Fig. 12.23- Functional Space page, enabling one or more spaces
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12.6.3 How to create a new Functional Space
1. Access the Functional Space Page (see par. Fig. 12.22 - on page 152);
2. press the “Add Volume” button;
3. a new space item and the corresponding graphic visualisation of the occupied
space (with default values) will automatically appear; if one or more volumes are
already present, the new item will appear at the bottom of the list;
4. the functional space (conceptually similar to the Volume allowed (Work Area)) is
represented in figure with a blue surface; The functional space is displayed only if
the functional spaces are enabled with the appropriate check “Enabled” (see
par. 12.6.2);
5. it is possible to configure maximum 15 functional spaces;
6. default parameters must be adjusted according to needs; the details for configuring
the parameters are given in par. 12.6.4 How to modify parameters of a Functional
Space on page 155.
Fig. 12.24- Functional page, add new Functional Space
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Comau Robotics Product Instruction
12.6.4 How to modify parameters of a Functional Space
1. Access the Functional Space Page (see par. Fig. 12.22 - on page 152);
2. press the button corresponding to the name of the space that is wanted to be
modified;
3. there will automatically appear the parameters page;
4. modify parameters according to need. The details are available in the Tab. 12.10
- Definition of fields on Properties page of the Functional Spaces on page 156):
• Location;
• Dimension;
• Rotation.
5. confirm by pressing the “Set” button.
Fig. 12.25- Properties page of the Functional Spaces
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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Tab. 12.10- Definition of fields on Properties page of the Functional 
Spaces
Location
Parameter: X, Y, Z
Use: Set the lower right corner position of the considered space, 
referred to the Cartesian reference frame of the Robot or Robot 
Track Motion / Robot
Default: 0 mm
Accepted values: Positive or negative numerical value.
Note: pay attention to the requirements indicated in par. 5.4.4
Dimension
Parameters: Width, height and depth
Use: Set the dimension of the width, height and depth of the 
considered space
Default: 1000 mm
Accepted values: Positive or negative numerical value.
Note: pay attention to the requirements indicated in par. 5.4.4
Rotation
Parameter: Roll, Pitch, Yaw
Use: Set the rotation of the considered space around the Cartesian 
reference frame of the Robot or Robot Track Motion / Robot
Default: 0 mm
Accepted values: Positive or negative numerical value.
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Comau Robotics Product Instruction
12.6.5 How to cancel a Functional Space
1. Access the Functional Space Page (see par. Fig. 12.22 - on page 152);
2. press the “X” button on the item of the space you want to cancel; the cancellation
is immediate.
Fig. 12.26- Functional Page, cancel a functional space
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
12.7 Robot speed definition function (Speed)
The function allows you to monitor the speed of the Robot axes, both in Cartesian and
in joints modes.
Available procedures
– How to access the Speed page (see par. 12.7.1 on page 159);
– How to enable Speed Modulation (see par. 12.7.2 on page 160);
– How to modify High Speed Cartesian Limiting (see par. 12.7.3 on page 161);
– How to modify Low Speed Cartesian Limiting (see par. 12.7.4 on page 165);
– How to modify Program (T1) Speed Cartesian Limiting (see par. 12.7.5 on
page 169).
For more information on the Speed function see par. 5.3.2.3, par. 5.3.2.4 and
par. 5.4.2.8.
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Comau Robotics Product Instruction
12.7.1 How to access the Speed page
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. press the “Speed” button.
Fig. 12.27- Speed Page
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12.7.2 How to enable Speed Modulation
1. Access the Speed Page (see par. Fig. 12.27 - on page 159);
2. modify the parameter according to need by acting directly on the field. The details
are available in Tab. 12.11 - Definition of fields on the Speed Modulation page on
page 160).
Fig. 12.28- Speed Page, enabling Speed Modulation
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
Tab. 12.11- Definition of fields on the Speed Modulation page
Speed Modulation
Parameter: Enabled
Use: Set the enabling to speed modulation control (see par. 5.4.2.8).
The RoboSAFE functionality modulates the speed only if the 
parameter is configured with checked.
Default: Not active
Accepted values: Through special check box
– Not checked = speed modulation not active
– Checked = speed modulation active
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Comau Robotics Product Instruction
12.7.3 How to modify High Speed Cartesian Limiting
1. Access the Speed Page (see par. Fig. 12.27 - on page 159);
2. press High Speed button to access and modify parameters as needed, by acting
directly on fields. The details are available in Tab. 12.11 - Definition of fields on the
Speed Modulation page on page 160).
Fig. 12.29- Speed Page, High Speed Cartesian Limiting
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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Tab. 12.12- Definition of the fields on the High Cartesian Limiting page
High Speed Properties
Parameter: Enabled cartesian speed control
Use: Set the enabling to Cartesian speed high limit control (see 
par. 5.3.2.4).
The RoboSAFE functionality controls the speed only if the 
parameter is configured with checked.
Default: Not active
Accepted values: Through special check box
– Not checked = speed control not active
– Checked = speed control active
Note: in an AURA Control Unit, the selection is automatically set 
to Checked and cannot be changed.
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Comau Robotics Product Instruction
Parameter: Activated by
Use: If the Enabled parameter is selected, set the condition to enable 
the speed control:
– Always active, without necessity to manage the command 
via digital inputs.
– RS Input, active according to the status of Safe digital input 
combined with the specific speed control (see Tab. 9.1, 
RoboSAFE High Speed input).
– Func. Space A, active when the tool is in any of the volumes 
defined in Functional Space A (see par. 12.6).
– RS Input & FS A, active when both Safe digitalinput and 
Functional Space A conditions are true
– Aura Input, active according to the status of Safe digital input 
combined with AURA (see input Collaborative mode 
deactivated (Robot and gripper)).
Default: Always active
Accepted values: Drop-down list for selection:
– Always active
– RS Input (RoboSAFE Input)
– Func. Space A (Functional Space A)
– RS Input & FS A (RoboSAFE Input and Functional Space A)
– Aura Input
Note: in an AURA Control Unit, the selection is automatically set 
to Aura Input and cannot be changed.
Parameter: Stop procedure when cartesian speed limits are violated
Use: Set stop mode according to EN 60204-1 standard.
The following options are available:
– Don’t stop, after violation, the Robot is not stopped. An alarm 
message is displayed on the Teach Pendant and its source 
can be identified through the diagnostic bits. The error can be 
silenced by pressing the “Reset” push-button on the Teach 
Pendant.
– Stop Cat. 1, stop occurs by deceleration ramp.
– Stop Cat. 0, stop occurs by immediate brakes actuation.
Default: Don’t stop
Accepted values: Drop-down list for selection:
– Don’t stop
– Stop Cat. 1
– Stop Cat. 0
Note: in an AURA Control Unit, the selection is automatically set 
to Stop Cat. 1 and cannot be changed.
Diagnostics
Violation 
It is possible to identify the violation with the $SL_IN_ABOO[297] 
status bit (see Tab. 10.1).
Tab. 12.12- Definition of the fields on the High Cartesian Limiting page 
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PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Parameter: Speed limit [mm/s]
Use: Set the maximum speed allowed to control the high limit of 
Cartesian speed (see par. 5.3.2.4).
Default: 0
Accepted values: Positive numeric value, higher than the value set in the Low 
Speed field (see par. 12.7.4).
Note: in an AURA Control Unit, the selection is automatically 
limited to values less than or equal to 500 mm/s
Diagnostics
Violation 
It is possible to identify the violation with the $SL_IN_ABOO[297] 
status bit (see Tab. 10.1).
Tab. 12.12- Definition of the fields on the High Cartesian Limiting page 
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Comau Robotics Product Instruction
12.7.4 How to modify Low Speed Cartesian Limiting
1. Access the Speed Page (see par. Fig. 12.27 - on page 159);
2. press Low Speed button to access and modify parameters as needed, by acting
directly on fields. The details are available in Tab. 12.13 - Definition of the fields on
the Low Cartesian Limiting page on page 166).
Fig. 12.30- Speed Page, Low Speed Cartesian Limiting
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Tab. 12.13- Definition of the fields on the Low Cartesian Limiting page
Low Speed Properties
Parameter: Enabled cartesian speed control
Use: Set the enabling to Cartesian speed Low limit control (see 
par. 5.3.2.4).
The RoboSAFE functionality controls the speed only if the 
parameter is configured with checked.
Default: Not active
Accepted values: Through special check box
– Not checked = speed control not active
– Checked = speed control active
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Comau Robotics Product Instruction
Parameter: Activated by
Use: If the Enabled parameter is selected, set the condition to enable 
the speed control:
– Always active, without necessity to manage the command 
via digital inputs.
– RS Input, active according to the status of Safe digital input 
combined with the specific speed control (see Tab. 9.1, 
RoboSAFE Low Speed input).
– Func. Space B, active when the tool is in any of the volumes 
defined in Functional Space B (see par. 12.6).
– RS Input & FS B, active when both Safe digital input and 
Functional Space B conditions are true
– Aura Input, active according to the status of Safe digital input 
combined with AURA (see input Collaborative mode 
deactivated (Robot and gripper)).
– A.in & FS B, active when both Safe digital input combined 
with AURA and Functional Space B conditions are true
Default: Always active
Accepted values: Drop-down list for selection:
– Always active
– RS Input (RoboSAFE Input)
– Func. Space B (Functional Space B)
– RS Input & FS B (RoboSAFE Input and Functional Space B)
– Aura Input
– A.in & FS B (AURA Input and Functional Space B)
Parameter: Stop procedure when cartesian speed limits are violated
Use: Set stop mode according to EN 60204-1 standard.
The following options are available:
– Don’t stop, after violation, the Robot is not stopped. An alarm 
message is displayed on the Teach Pendant and its source 
can be identified through the diagnostic bits. The error can be 
silenced by pressing the “Reset” push-button on the Teach 
Pendant.
– Stop Cat. 1, stop occurs by deceleration ramp.
– Stop Cat. 0, stop occurs by immediate brakes actuation.
Default: Don’t stop
Accepted values: Drop-down list for selection:
– Don’t stop
– Stop Cat. 1
– Stop Cat. 0
Diagnostics
Violation 
It is possible to identify the violation with the $SL_IN_ABOO[299] 
status bit (see Tab. 10.1).
Tab. 12.13- Definition of the fields on the Low Cartesian Limiting page 
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Parameter: Speed limit [mm/s]
Use: Set the maximum speed allowed to control the high limit of 
Cartesian speed (see par. 5.3.2.4).
Default: 0
Accepted values: Positive numerical value, minor or equal to the value set in the 
High Speed field (see par. 12.7.3).
Note: in an AURA Control Unit, the selection is automatically 
limited to values less than or equal to 500 mm/s and to what is set 
in the High speed field.
Diagnostics
Violation 
It is possible to identify the violation with the $SL_IN_ABOO[299] 
status bit (see Tab. 10.1).
Tab. 12.13- Definition of the fields on the Low Cartesian Limiting page 
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Comau Robotics Product Instruction
12.7.5 How to modify Program (T1) Speed Cartesian Limiting
1. Access the Speed Page (see par. Fig. 12.27 - on page 159);
2. press PROGR Speed button to access and modify parameters as needed, by
acting directly on fields. The details are available in Tab. 12.14 - Definition of the
fields on the Program (T1) Cartesian Limiting page on page 170).
Fig. 12.31- Speed Page, Program (T1) Speed Cartesian Limiting
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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Tab. 12.14- Definition of the fields on the Program (T1) Cartesian Limiting 
page
Program Speed Properties
Parameter: Enabled Reduced speed control
Use: Set the enabling to control the maximum Cartesian speed in 
Programming mode (T1) (see par. 5.3.2.4).
The RoboSAFE functionality controls the speed only if the 
parameter is configured with checked.
Default: Not active
Accepted values: Through special check box
– Not checked = speed control not active
– Checked = speed control active
Parameter: Stop category
Use: Set stop mode according to EN 60204-1 standard.
The following options are available:
– Category 1, stop occurs by deceleration ramp.
– Category 0, stop occurs by immediate brakes insert
Default: Category 1
Accepted values: Drop-down list for selection:
– Category 1
– Category 0
Diagnostics
Violation 
It is possible to identify the violation with the $SL_IN_ABOO[301] 
status bit (see Tab. 10.1).
Parameter: Speed limit [mm/s]
Use: The maximum speed allowed to control the high limit of Cartesian 
speed (see par. 5.3.2.4).
Default: 250
Accepted values: The value cannot be changed.
Diagnostics
Violation 
It is possible to identify the violation with the $SL_IN_ABOO[301] 
status bit (seeTab. 10.1).
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PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
12.8 Function to define the equipment on the Robot 
(Monitoring Point)
It allows to add a series of points to define the shape of the equipment on the Robot, so
that the points that represent the Robot and the Tool (or additional dressings) are all
involved in the Cartesian RoboSAFE functionalities.
Available procedures
– How to access the Monitoring Points page;
– How to create a new Monitoring Point;
– How to modify parameters of a Monitoring Point;
– How to cancel a Monitoring Point;
– How to enable / disable the Toolsets and change their positions.
For more details see par. 5.4.2.5.
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12.8.1 How to access the Monitoring Points page
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. press the “Monitoring Points” button;
Fig. 12.32- Monitoring Points Page
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Comau Robotics Product Instruction
12.8.2 How to create a new Monitoring Point
1. Access the Monitoring Points Page (see par. Fig. 12.32 - on page 172);
2. press the “Add Monitoring Point” button;
3. a new monitoring point item and the corresponding graphic visualisation of the
occupied space (with default values) will automatically appear; if one or more
monitoring point items are already present, the new one will appear at the bottom
of the list;
4. each monitoring point is represented in figure with an orange point;
5. it is possible to configure maximum 8 monitoring points;
6. default parameters must be adjusted according to needs; the details for configuring
the parameters are given in par. 12.8.3 How to modify parameters of a Monitoring
Point on page 174.
Fig. 12.33- Tool Page, add new Monitoring Point
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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12.8.3 How to modify parameters of a Monitoring Point
1. Access the Monitoring Points Page (see par. Fig. 12.32 - on page 172);
2. press the button corresponding to the name of the Monitoring Point that is wanted
to be modified;
3. there will automatically appear the parameters page;
4. modify parameters according to need. The details are available in the Tab. 12.15
- Field definitions on the Monitoring Point parameters page on page 175):
• Definition;
• Location.
5. confirm by pressing the “Set” button.
Fig. 12.34- Tool Page, a Monitoring Point parameters
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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PARAMETERS AND CONFIGURATION OF THE SAFE FUNCTIONS
Comau Robotics Product Instruction
Tab. 12.15- Field definitions on the Monitoring Point parameters page
Definition
Parameter: Monitoring Point Name
Use: Monitoring Point Name 
Note: the monitoring point in the graphic representation is defined 
only with a progressive number, from 1 to 8; therefore it is 
recommended to keep the numerical reference in the final part of 
the name (e.g. Monitoring Point 1).
Default: monitoring point x, where x represents the progressive number
Accepted values: Designation consisting of characters, numbers, symbols.
To modify the parameter, click on the name (see a similar method 
in par. 12.5.5 How to rename the name assigned to a Dynamic 
Volume on page 149).
Location
Parameter: X, Y, Z
Use: Set the point position in the space, referred to the Cartesian 
reference frame of the Robot wrist 
Default: 0 mm
Accepted values: Positive or negative numerical value.
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12.8.4 How to cancel a Monitoring Point
1. Access the Monitoring Points Page (see par. Fig. 12.32 - on page 172);
2. press the “X” button on the Monitoring Point item that is needed to be cancelled;
the cancellation is immediate.
Fig. 12.35- Tool Page, cancel Monitoring Point
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
176
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Comau Robotics Product Instruction
12.8.5 How to enable / disable the Toolsets and change their 
positions
1. Access the Monitoring Points Page (see par. Fig. 12.32 - on page 172);
2. modify parameters according need. The details are available in the Tab. 12.16
- Definition of fields in the Toolset parameters page on page 178):
• Enabling / disabling;
• Location.
Fig. 12.36- Tool Page, a Toolset parameters
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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Tab. 12.16- Definition of fields in the Toolset parameters page
Enabling / disabling
Parameter: Enabled
Use: Set enabling to the Toolset control.
The Toolset is enabled only if the parameter is “checked”
Default: Disabled
Accepted values: Through special check box
– Not checked = Toolset not active
– Checked = Toolset active
Parameter: Activated by
Use: Set the condition to enable Toolset control:
– Always, always active, without necessity to manage the 
command via digital inputs.
– RS Input, active according to the status of the Safe Digital 
Input (see Tab. 9.1, RoboSAFE Toolset 1 and 2 input).
Default: Always
Accepted values: Drop-down list for selection:
– Always
– RS Input
Location
Parameter: X, Y, Z
Use: Set the point position in the space, referred to the Cartesian 
reference frame of the Robot wrist 
Default: 0 mm
Accepted values: Positive or negative numerical value.
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Comau Robotics Product Instruction
12.9 Brakes monitoring function (Brake)
The function enables the monitoring of brakes of the Robots and of the SAFE Robot
Track Motion (if present in the configuration); subsequently it is necessary to activate a
program in PDL2 to periodically perform Brake Test Check (BTC) routine.
Available procedures
– How to access the Brake page;
– How to enable the brake monitoring.
12.9.1 How to access the Brake page
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. press the “Brake” button.
Fig. 12.37- Brake Page
For more details see par. 5.3.2.6. For suggestions on integration see par. 13.2.1.
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12.9.2 How to enable the brake monitoring
1. Access the Brake Page (see par. Fig. 12.37 - on page 179);
2. select the flag “Enabled”;
3. the parameters Reminder and Alarm cannot be modified Tab. 12.17).
Fig. 12.38- Brake page, enables the monitoring of the brake
Enabling of brake monitoring does not perform the test of the brake; the test is
performed only by the routine BTC (see par. 13.2.1).
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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Comau Robotics Product Instruction
Tab. 12.17- Definition of fields on Brake page
Brake test timer
Parameter: Enabled
Use: Set enabling to brake check.
Default: Disabled
Accepted values: Through special check box
– Not checked = Brake check not active
– Checked = Brake check active
Parameter: Reminder [h]
Use: Indicate the number of hours before the pre-alarm, equal to 144hours (6 days). Once this value is reached, the warning remains 
until the BTC routine is performed (see par. 13.2.1).
Default: 144 hours, not modifiable
Diagnostics It is possible to identify:
– the pre-alarm status of the Long Timer, $SL_IN_ABOO[345] 
status bit (see Tab. 10.1);
– the outcome of the BTC routine (see par. 13.2.1), 
$SL_IN_ABOO[349] status bit (see Tab. 10.1).
Parameter: Alarm [h]
Use: Indicate the number of hours before the alarm, equal to 168 hours 
(7 days). Once this value is reached, the error blocks the Robot 
until the BTC routine is performed (see par. 13.2.1).
Default: 168 hours, not modifiable
Diagnostics It is possible to identify:
– the alarm status of the Long Timer, $SL_IN_ABOO[346] 
status bit (see Tab. 10.1);
– the outcome of the BTC routine (see par. 13.2.1), 
$SL_IN_ABOO[349] status bit (see Tab. 10.1).
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12.10 Function to combine safe outputs with the 
outcome of functions (Safe Outputs)
The function allows to convey the outcome of the functions Joint functional sectors or
Functional Spaces on the SAFE outputs of the C5GP-SMEC, C5GP-ABE or
C5GP-EISM options (see the OUTPUT of the RoboSAFE signals (Joint and Cartesian)).
The limits of contemporaneity are described in Tab. 9.1.
Available procedures
– How to access the Safe Outputs page (see par. 12.10.1 on page 182);
– How to combine the SAFE outputs with the result of the functions (see par. 12.10.2
on page 183).
12.10.1 How to access the Safe Outputs page
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. press the “Safe Outputs” button.
Fig. 12.39- Safe Outputs Page
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Comau Robotics Product Instruction
12.10.2 How to combine the SAFE outputs with the result of the 
functions 
1. Access the Safe Outputs Page (see par. Fig. 12.39 - on page 182);
2. select the drop-down list related to the selected Block (see Tab. 12.18).
Fig. 12.40- Safe Output Page, combination of the result of the functions
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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Tab. 12.18- Definition of fields on the Safe Outputs page
Safe Outputs
Parameter: Block 1
Use: Combines the needed function with the OUTPUT of the 
RoboSAFE signals (Joint and Cartesian).
Default: Joint functional sector Axis 1
Accepted values: Drop-down list for selection:
– Ax. 1 sector = Joint functional sectors Axis 1 (always 
available)
– Func. space A = Functional Spaces SET A (with Cartesian 
RoboSAFE only)
Parameter: Block 2
Use: Combines the needed function with the OUTPUT of the 
RoboSAFE signals (Joint and Cartesian).
The face is not available in the S1C-6 Control Units.
Default: Functional Space SET B
Accepted values: Drop-down list for selection:
– Ax. 7 sector = Joint functional sectors Axis 7 (only if the axis 
7 of the Robot Track Motion is present)
– Func. space B = Functional Spaces SET B (with Cartesian 
RoboSAFE only)
Parameter: Block 3
Use: Combines the needed function with the OUTPUT of the 
RoboSAFE active and CRC approved signals.
The face is not available in the S1C-6 Control Units.
Default: Motor active
Accepted values: Drop-down list for selection:
– Motor active = one or more RoboSAFE active and not 
violated functions
– CRC check = output to approve the CRC approved
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12.11 Tool orientation definition function (Tool 
Orientation)
The function allows to identify the tool orientation check.
Available procedures
– How to access the Tool Orientation page (see par. 12.11.1 on page 185);
– How to enable the Tool Orientation (see par. 12.11.2 on page 186);
– How to adjust Tool Orientation coordinates (see par. 12.11.3 on page 188).
12.11.1 How to access the Tool Orientation page
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. press the “Tool Orientation” button.
Fig. 12.41- Tool Orientation Page
For more information on the Tool Orientation see par. 5.4.2.6.
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12.11.2 How to enable the Tool Orientation
1. Access the Tool Orientation Page (see par. Fig. 12.41 - on page 185);
2. modify parameters according to need by acting directly on fields. The details are
available in Tab. 12.19 - Definition of fields on the Tool Orientation page on
page 187).
Fig. 12.42- Tool Orientation Page, enabling and operation
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
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Tab. 12.19- Definition of fields on the Tool Orientation page
Tool Orientation
Parameter: Enabled
Use: Set enabling to Tool orientation check.
The RoboSAFE functionality checks the tool only if the parameter 
is configured with checked.
Default: Not active
Accepted values: Through special check box
– Not checked = tool orientation check not active
– Checked = tool orientation check active
Parameter: Stop in AUTO
Use: Set the stopping mode according to EN 60204-1 standard, valid 
only in Automatic Mode (local and remote).
The following options are available:
– Don’t stop, after violation, the Robot is not stopped. An alarm 
message is displayed on the Teach Pendant and its source 
can be identified through the diagnostic bits. The error can be 
silenced by pressing the “Reset” push-button on the Teach 
Pendant.
– Stop Cat. 1, stop occurs by deceleration ramp.
– Stop Cat. 0, stop occurs by immediate brakes actuation.
Default: Don’t stop
Accepted values: Drop-down list for selection:
– Don’t stop
– Stop Cat. 1
– Stop Cat. 0
Diagnostics
Violation 
It is possible to identify the violation with the $SL_IN_ABOO[198] 
status bit (see Tab. 10.1).
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12.11.3 How to adjust Tool Orientation coordinates
1. Access the Tool Orientation Page (see par. Fig. 12.41 - on page 185);
2. modify parameters according to need by acting directly on fields. The details are
available in Tab. 12.19 - Definition of fields on the Tool Orientation page on
page 187).
Parameter: Stop in PROG
Use: Set the behaviour of the RoboSAFE functionality after a Tool 
orientation violation in Programming mode (T1):
– Don’t stop, after violation, the Robot is not stopped. An alarm 
message is displayed on the Teach Pendant and its source 
can be identified through the diagnostic bits. The error can be 
silenced by pressing the “Reset” push-button on the Teach 
Pendant.
– Stop Cat. 0, after violation, the Robot is stopped; the 
stopping mode is in category 0 in accordance with EN 
60204-1.
Default: Don’t stop
Accepted values: Drop-down list for selection:
– Don’t stop
– Stop Cat. 0
Diagnostics
Violation 
It is possible to identify the violation with the $SL_IN_ABOO[198] 
status bit (see Tab. 10.1).
The settings are not stored automatically and must be stored with the suitable function
described in par. 12.12 Save the changes to the RoboSAFE settings on page 192.
Tab. 12.19- Definition of fields on the Tool Orientation page (Continued)
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Fig. 12.43- Tool Orientation Page, Tool coordinates
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Tab. 12.20- Definition of fields on the Tool Orientationpage, coordinates
Orientation Coordinate System, Flange Vector
Parameter: Location
Parameter: X, Y, Z
Use: Set the lower right corner position of the considered space, 
referred to the Cartesian reference frame of the Robot wrist
Default: 0 mm
Accepted values: Positive or negative numerical value.
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Orientation Coordinate System, Flange Orientation Limiting
Parameter: Rotation
Use: Set the rotation of the considered space around the Cartesian 
reference frame of the Robot wrist 
Default: 0 mm
Accepted values: Positive or negative numerical value.
Parameter: Angle
Use: Set the corner of the cone projected on the Z vertex of the 
Cartesian reference frame of the Robot wrist 
Default: 0 mm
Accepted values: Positive or negative numerical value.
Tab. 12.20- Definition of fields on the Tool Orientation page, coordinates 
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12.12 Save the changes to the RoboSAFE settings
It allows to save the configuration of all parameters on the Safe Key present in the SLU
CPU of the Safe system.
Requirements
– The Robotic system must be set in Programming (T1) mode;
– The motors must be switched off.
Procedure
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Configuration” button;
2. Press the “Save” button.
3. The message “Are you sure you want to save this configuration?” will appear to
request confirmation.
4. Confirm by pressing the “OK” button.
Next steps
1. The SLU CPU carries out the automatic restart. During the restart, the Web page
will display the progression with the status lamp on the browser page that firstly
becomes yellow and then green again.
2. It could be necessary to wait up to one minute.
3. At the end of start phase, it is necessary to carry out some test cycles to check the
parameters coherence with the project.
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12.13 Import / Export all the parameters of the RoboSAFE 
configuration
It allows to memorize on external support the configuration of all the Safe Key
parameters present in the SLU CPU of the Safe system and, if necessary, to restore
after a replacement of the Safe components.
Requirements
– The Robotic system must be set in Programming (T1) mode;
– The motors must be switched off.
Procedure
1. On the page of Access to the functions and configuration parameters of the SAFE
functionalities (see par. 12.1 on page 108), press the “Import / Export” button;
2. To export a configuration file:
• Press the “Export” button.
• Wait for the XML file to download;
• store the file on a storage device.
3. To import a configuration file:
• Press “Choose File” button and select the XML file to be imported
• Press the “Import” button;
• Wait for the XML file to upload.
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13. GUIDE TO THE USE OF ROBOSAFE 2.0 
FUNCTIONALITIES
– C5GP-PIS Gateway integration;
– Integration of periodic check of brake functionality.
13.1 C5GP-PIS Gateway integration
– Integration suggestions;
– Siemens PLC parameter setting;
– Suggestions for checking the functionalities of the emergency stop
mushroom-shaped push-button.
13.1.1 Integration suggestions
– ProfiSAFE node address inside the Control Unit: set the node address through
the appropriate field on the Web portal pages (see par. 12.2.3);
– the same address must be entered in the special Siemens PLC configuration
parameters;
– properly configure the Siemens PLC (see par. 13.1.2);
– check the emergency stop mushroom-shaped push-button of the Teach Pendant
(see par. 13.1.3).
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13.1.2 Siemens PLC parameter setting
– Siemens PLC (Step 7, setting):
• import the correct GSDML descriptor
(GSDML-V2.31-BuR-X20IF10E3_1-20170224.xml); 
• identify the X20IF10E3-1_SAFE_NETXV1.3.X.X peripheral device and
connect it to the ProfiNET bus;
• Select the X20IF10E3 peripheral device and add a safe data
PS_4BYTE_1INT_IO_Safe24 and then the I/O bytes as configured in the
IO_CNFG;
• In “Object Properties” of the device (right-click on the image), indicate the
same name of the device as nominated in the IO_CNFG;
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• In “Object Properties” of PS_4BYTE_1INT_IO_Safe24 (right-click on the
connection line), indicate the node address as configured in the Web portal;
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– Siemens PLC (Step 7, programming):
• to allow a correct operation, an Ack (bit ACK_REI_GLOB) is required after
each restart of the Safe Logic;
• the F_ACK_GL is always necessary.
– I/O SAFE signals: in the SAFE PLC program of the cell, integrate all the necessary
signals drawing from those available in the interchange bytes (see par. 9.3);
– Emergency stop push-button on the Teach Pendant:
• Attention: E-Stop of the Teach Pendant not connected to the safety circuit of
the Control Unit;
• hardware: 
• choose one of the 2 options available between C5GP-XPP or
C5GP-TEC (see par. 8.1);
• software: 
• with the C5GP-XPP option, consider the push-button status bit available
on the interchange bytes (see par. 9.3);
• with the C5GP-TEC option, the push-button status bit will be available in
the SAFE PLC of the cell / line (in a manner chosen by the integrator);
the bit on the interchange signals (see par. 9.3) will always be at value
0 (open signal);
– First start-up: if it is necessary to allow the Drive ON even without connection to
the ProfiSAFE network, set the deactivation of the Stop signal received from the
ProfiSAFE network (see par. 12.2.4).
13.1.3 Suggestions for checking the functionalities of the 
emergency stop mushroom-shaped push-button
– Press each emergency stop push-button individually, including the one of the
Teach Pendant and make sure that each one corresponds to the stop of the Robot
(and the combined area).
The use of the “Disable PS Stop” may expose you to risks. Pay attention
to the prescriptions and limitations given in par. 12.2.4.
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13.2 Integration of periodic check of brake functionality
– Integration suggestions;
– How to activate the Brake Test Check (BTC) routine in PDL2.
13.2.1 Integration suggestions
– To implement the brake check it is necessary to:
• enable the specific function on the Web Portal page (see par. 12.9.2)
• activate a program in PDL2 to periodically perform the Brake Test Check
(BTC) routine (see par. 13.2.2), coordinating the cycle in accordance with the
needs of the production process;
– before activating the BTC routine, provide a movement cycle of the Robot to move
it to a safe position, where the possible fall of the axes does not generate risks for
people or for the machine;
– if the test fails, it may be useful to repeat it: the oxidation or excessive temperature
of the motor can temporarily alter the effectiveness of the motor brake;
– in case of repeated negative results, it may be useful to assess the value of the
motor brake degradation by consulting the error log (for any clarifications, ask
Comau technical assistance) .
How many activations of the BTC routine are needed
The brake monitoring function is triggered by two SAFE timers that generate two distinct
events:
– every time the Control Unit is powered up, with an almost immediate pre-alarm
after the power-up and an alarm with the obligation to activate the test within an
hour (this timer is identified as Brake test check Short Timer, variables
$SL_IN_ABOO[347]...[348] - see Tab. 10.1);
– periodically, with pre-alarm after 144 hours and alarm with theobligation to
activate the test within 168 hours (this timer is identified as Brake test check Long
Timer, variables $SL_IN_ABOO[345]...[346] - see Tab. 10.1).
Only the positive outcome of the BTC routine allows to reset the counting of timers
(variables $ SL_IN_ABOO [349] - see Tab. 10.1).
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13.2.2 How to activate the Brake Test Check (BTC) routine in 
PDL2
Fig. 13.1 - Program in PDL2 for test of the brake (example in summary)
PROGRAM braketestcheck 
ROUTINE BTC(ai_arm : INTEGER) EXPORTED FROM BrakeTestLib
BEGIN
 
 CYCLE
DELAY 100
-- Move to for main productive cycle
MOVE TO station1
.....
MOVE TO station2
.....
-- Wait a new cycle start
.....
-- BRAKE BIT TEST EVENT: LONG TIMER $SL_IN_ABOO[345] 
-- OR SHORT TIMER $SL_IN_ABOO[347] CHECK bits. 
-- IF TRUE, start BRAKE test routine on SAFE ARM
IF ($SL_IN_ABOO[345] OR $SL_IN_ABOO[347]) = TRUE THEN
-- BRAKE test routine on SAFE ARM
BTC(1)
DELAY 1000
-- CHECK BRAKE TEST RESULT. IF FALSE, BREAK TEST FAILLED
IF $SL_IN_ABOO[349] = FALSE THEN
-- Brake test KO
MOVE TO maintenance position
-- DRIVE OFF by MACHINE CONTROL PLC 
...
ELSE
-- Brake test OK
MOVE TO other position 
...
ENDIF
ENDIF
-- BRAKE TIMEOUT ERROR: LONG TIMER $SL_IN_ABOO[346] OR 
-- SHORT TIMER $SL_IN_ABOO[348] CHECK bits. 
-- IF TRUE, start BRAKE test routine on SAFE ARM
IF ($SL_IN_ABOO[346] OR $SL_IN_ABOO[348]) = TRUE THEN
-- Robot stopped, must be reset fault and then 
-- immediately executing the BTC routine
...
ENDIF
END braketestcheck
The description of each status bit is given in Tab. 10.1.
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PRINTING OF THE SAFE PARAMETERS
14. PRINTING OF THE SAFE PARAMETERS
– Considerations on the information obtained and the conservation of the report;
– SAFE Report Page.
14.1 Considerations on the information obtained and 
the conservation of the report
The report allows you to view, hold and print the configuration of all the functions and
the values of the Safe system parameters, stored in Safe-key, including the CheckSum
(CRC) of the parameters. 
The report includes the values stored; the parameters changed in the Web pages but
not saved are not considered. 
The “Report page” allows you to get a report (in digital format PDF - Portable Digital
Format). 
It is recommended to keep a copy of the PDF in the technical file of the automated
system line / cell.
The function is always allowed, except when the system is in “SAFE LINE UP” status. It
is highly recommended to print the parameters to ensure a subsequent check (e.g. due
to maintenance).
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14.2 SAFE Report Page
The “Report page” is available after accessing the Main page of the SAFE functions (see
par. 11.3 on page 102).
Procedure
1. To access the Report generation function, from the Main page of the SAFE
functions (see par. 11.3 on page 102), press the “Report” button.
2. On the “Report” page, wait for the Report to appear.
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Fig. 14.1 - Example of Report
3. Use the browser / viewer storage functionality to save the PDF file.
Following steps
– Hold the document.
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15. MAINTENANCE (SOFTWARE ASPECTS OF 
THE ROBOSAFE SYSTEM)
This chapter contains the following topics:
– Personnel in charge of maintenance;
– Access to the maintenance functions (Service);
– Requirements and history of Service functions;
– Overview of the “Service” functions;
– Reset Procedures;
– Software loading procedure;
– Verification of the checksum (CRC) of the RoboSAFE Cartesian parameters;
– Activating / deactivating the Speed Modulation feature;
– Robot position reset after RoboSAFE rules violation;
– Recovery system procedures after serious error.
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15.1 Personnel in charge of maintenance
The maintenance personnel of RoboSAFE system must be trained (with the
prerequisites specified in par. 3.1 Personnel qualifications on page 23), aware of the
precautions needed to maintain properly the components and/or restore the system
parameters.
15.2 Access to the maintenance functions (Service)
The maintenance functions set in the RoboSAFE system are accessible for the user
starting from the "Service" page.
On the Main page of the SAFE functions (see par. 11.3 on page 102), press the
“Service” button.
Fig. 15.1 - Main page to access the maintenance functions
The access to the “Service” page requires an access login (see par. 15.2.1).
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15.2.1 Access login to the “Service” Web page
To access the main service page it is necessary to press the “Service” button.
Access to the maintenance (service) pages is protected by a password with deriving
need to carry out the authentication (Login procedure), with the following parameters:
User: service
Password: comau
Note: the logon parameters given above are the default ones. It is strongly
recommended to modify the password to restrict the access only to the authorised and
trained maintenance personnel (see par. 11.6 Access password change on page 105).
In the browser it is shown the authentication window (see Fig. 15.2).
Fig. 15.2 - Authentication window (example)
15.2.2 Logout from the service Web page
Disconnection of the service Web pages is automatic after closing the page.
As an alternative the disconnection is made automatically when the Web browser is
closed.
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15.3 Requirements and history of Service functions
Service functions are usually necessary on request of the system. 
The need is highlighted by a specific message present in the Message Bar area, on the
upper side of the page ).
In addition, consider that the organization and the physical position of the buttons on the
page, often represent the standard temporal sequence required to obtain the
completion of RoboSAFE system commissioning, after repair and/or replacement of
parts of the system (hardware modules and firmware updates).
Fig. 15.3 - Safe Maintenance Diagram
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15.4 Overview of the “Service” functions
After obtaining the Access to the maintenance functions (Service) it is possible to enter
the following functions:
– Reset Procedures;
– Software loading procedure;
– Verification of the checksum (CRC) of the RoboSAFE Cartesian parameters.
Fig. 15.4 - Main page of the “Service” functions
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15.5 Reset Procedures
– Reset after replacement of an axis module, Safe I/O modules or SLU module;
– Reset after a motor replacement;
– Reset after unexpected loss of Turn Set and/or calibration constants;
– Procedure for enabling manual movement in alarm status (Recovery Mode);
– SAFE LINE UP procedure.
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15.5.1 Reset after replacement of an axis module, Safe I/O 
modules or SLU module
Following the replacement of a module of Safe type, is necessary to carry out the SAFE
LINE UP procedure as described below.
Note: the replacement of a Safe axis module deliberately prevents the start-up of the
robotic system; it allows limited functionalities in “Recovery Mode” until the encoder
position consistency is restored.
Requirements
– The Robotic system must be set in Programming (T1) mode;
– The motors must be switched off.
Procedure
1. When powering up again the system, wait for the restart. The restart procedure
may take about 10 minutes to allow the firmware loading. During charging, theLED
R/E on the axis module lights up in flashing mode.
2. when the loading is finished, the LED R/E must be a steady green.
3. access the Web pages; the status LED is yellow;
4. on the Service Web page (mode of Access to the maintenance functions (Service),
carry out the Acknowledgement of new hardware modules installed in the
RoboSAFE system (see par. 15.6.5 on page 228);
5. wait for the completion of the acknowledgement procedure;
6. On the Teach Pendant, run the Restart Cold command; wait for the system restart.
7. Access the Web pages; on the Service Web page, press the “RECOVERY MODE”
button;
Fig. 15.5 - Service Page, Recovery Mode
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8. the system asks for confirmation of the change of the mode; answer by pressing
the Yes button
9. the new Recovery Mode state is highlighted by the yellow LED on the button and
the text below
10. from this moment it is possible to activate DRIVE ON and move in Jog mode.
11. move in JOG the Robot axes to get them as close as possible to the calibration
position;
12. carry out the Turn Set on the axes subject of maintenance.
13. when close to the calibration position and without risk of impacts with the structures
of the cell, run the command "Execute Move to $CAL_USER" (which corresponds
to $CAL_SYS if the calibration position has not been customized);
14. on the Web page, press the "NORMAL MODE" button and confirm with “Yes”;
15. wait for the complete return to the Normal Mode, which also includes the restore of
the encoder positions consistency; the completion is indicated by the green LED
on the button.
16. at the end of the procedure and to confirm the successful completion, the status
LED must be green.
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15.5.2 Reset after a motor replacement
Following the replacement of a motor of Safe type (installed on Robot Rel. 2), it is
necessary to carry out the SAFE LINE UP procedure as described below.
Note: the replacement of a Safe motor deliberately prevents the start-up of the robotic
system; it allows limited functionalities in “Recovery Mode” until the axis is calibrated and
the encoder position consistency is restored.
Requirements
– The Robotic system must be set in Programming (T1) mode;
– Motors must be switched off:
– in case of replacement of axis modules, before performing the SAFE LINE UP
procedure, it is necessary to carry out the Acknowledgement of new hardware
modules installed in the RoboSAFE system procedure.
Procedure
1. When powering up again the system, wait for the restart. 
2. Just in case it was necessary to replace an axis module, the restart process takes
about 10 minutes to allow the firmware loading. During charging, the LED R/E on
the axis module lights up in flashing mode.
3. when the loading is finished, the LED R/E must be a steady green.
4. access the Web pages; the status LED is yellow;
5. on the Service Web page (mode of Access to the maintenance functions (Service),
carry out the Acknowledgement of new hardware modules installed in the
RoboSAFE system (see par. 15.6.5 on page 228);
6. Just in case it was necessary to replace an axis module, the recognition procedure
may require to confirm 2 or more modules.
7. wait for the completion of the acknowledgement procedure;
8. On the Teach Pendant, run the Restart Cold command; wait for the system restart.
9. Access the Web pages; on the Service Web page, press the “RECOVERY MODE”
button;
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Fig. 15.6 - Service Page, Recovery Mode
10. the system asks for confirmation of the change of the mode; answer by pressing
the Yes button
11. the new Recovery Mode state is highlighted by the yellow LED on the button and
the text below
12. from this moment it is possible to activate DRIVE ON and move in Jog mode.
13. move in JOG the Robot axes to get them as close as possible to the calibration
position;
14. calibrate the axis of the Robot which has been subject to maintenance (refer to the
Robot Maintenance handbook);
15. when close to the calibration position and without risk of impacts with the structures
of the cell, run the command "Execute Move to $CAL_USER" (which corresponds
to $CAL_SYS if the calibration position has not been customized);
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16. on the Web page, press the "NORMAL MODE" button and confirm with “Yes”;
17. wait for the complete return to the Normal Mode, which also includes the restore of
the encoder positions consistency; the completion is indicated by the green LED
on the button.
18. at the end of the procedure and to confirm the successful completion, the status
LED must be green.
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15.5.3 Reset after unexpected loss of Turn Set and/or calibration 
constants
Following the replacement of an axes module of Safe type, it is necessary to perform
the procedure as described below.
Note: the replacement of a Safe axis module deliberately prevents the start-up of the
robotic system; it allows limited functionalities in “Recovery Mode” until the encoder
position consistency is restored.
Requirements
– The Robotic system must be set in Programming (T1) mode;
– The motors must be switched off.
Procedure
1. When power up again the system, wait for the restart; after complete restart, the
LED R/E must be steady green.
2. access the Web Pages to the Service page (mode of Access to the maintenance
functions (Service) (see par. 15.2 on page 204);
3. press the “RECOVERY MODE” button;
Fig. 15.7 - Service Page, Recovery Mode
4. the system asks for confirmation of the change of the mode; answer by pressing
the Yes button
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5. the new Recovery Mode state is highlighted by the yellow LED on the button and
the text below
6. from this moment it is possible to activate DRIVE ON and move in Jog mode.
7. move in JOG the Robot axes to get them as close as possible to the calibration
position;
8. carry out the Turn Set or axes calibration;
9. when close to the calibration position and without risk of impacts with the structures
of the cell, run the command "Execute Move to $CAL_USER" (which corresponds
to $CAL_SYS if the calibration position has not been customized);
10. on the Web page, press the "NORMAL MODE" button and confirm with “Yes”;
11. wait for the complete return in the Normal Mode, which also includes the restore of
the consistency of the encoder positions; the completion is indicated by the green
LED on the push-button;
12. at the end of the procedure and confirmation of successful completion, the LED
status should be green.
Next steps
Following the procedure, run several working cycles of the Robot in order to verify the
proper functioning of all safety systems.
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15.5.4 Procedure for enabling manual movement in alarm status 
(Recovery Mode)
The “Recovery Mode” can be used to activate a minimal movement of the RoboSAFE
system when the SAFE LINE UP procedure is required; typically not necessary unless
specifically requested, the procedure can be used to resolve situations where traditional
procedures have not allowed the resolution (e.g. in the case of the Control Unit powered
up and Ethernet POWERLINK cable and/or motor cables disconnection).
Requirements
– The Robotic system must be set in Programming (T1) mode;
– The motors must be switched off.
Procedure
1. On the page of Access to the maintenance functions (Service) (see par. 15.2 on
page 204), press the “RECOVERY MODE” button;
Fig. 15.8 - Service Page, Recovery Mode
The speed control in the T1 programming mode isnot active in the “Recovery Mode”
mode. 
If the installation has requested and activated this functionality, the performance is
temporarily suspended; therefore pay more attention when moving the Robot in jog.
The recovery from the “Recovery Mode” in “Normal Mode” requires the repositioning of
all the Robot axes on the calibration position
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2. the system asks for confirmation of the change of the mode; answer by pressing
the Yes button
3. the new Recovery Mode state is highlighted by the yellow LED on the button and
the text below
4. from this moment it is possible to activate DRIVE ON and move in Jog mode.
5. to return in Normal Mode, move in JOG the Robot axes to approach a few
degrees from the calibration position; if already in the calibration position, to move
the axes of a few degrees; 
6. on the Web page, press the "NORMAL MODE" button and confirm with “Yes”;
7. if there are no errors, wait for the complete return in the Normal Mode, which also
includes the restore of the consistency of the encoder positions; the completion is
indicated by the green LED on the push-button.
8. in case of error as in the message below, see the SAFE LINE UP procedure (see
par. 15.5.5 on page 218).
Next steps
Following the procedure, run several working cycles of the Robot in order to verify the
proper functioning of all safety systems.
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15.5.5 SAFE LINE UP procedure
The “SAFE LINE UP” is the name of the alignment procedure between physical position
of the Robot and reference position for the RoboSAFE system.
The “SAFE LINE UP” request is highlighted:
– on the Teach Pendant with the message “RS - Position communication error
(SAFE LINE UP required)” or “RS - Position diagnostic error (SAFE LINE UP
required)”;
– on the Web page with the status LED in yellow and the “L” inside.
The need to carry out the “SAFE LINE UP” is generated after one or more of the
following situations:
– axis brake release operations with the Control Unit switched off or disconnected;
– extreme stresses during transport and installation;
– motor / encoder cables disconnection (Control Unit powered on);
– Ethernet Power Link cables disconnection (Control Unit powered on);
– drives modules replacement;
– motors replacement.
The RoboSAFE system cannot be started until the procedure has not been completed.
The DRIVE ON command is not allowed.
When the procedure is started but not completed, a specific message is periodically
displayed.
Requirements
– The Robotic system must be set in Programming (T1) mode;
– Motors must be switched off:
– if after a replacement of the Safe modules, the "SAFE LINE UP" procedure is
required, see Reset after replacement of an axis module, Safe I/O modules or SLU
module (see par. 15.5.1 on page 209).
Procedure
1. On the page of Access to the maintenance functions (Service) (see par. 15.2 on
page 204), press the “RECOVERY MODE” button;
The speed control in the T1 programming mode is not active in the “Recovery Mode”
mode. 
If the installation has requested and activated this functionality, the performance is
temporarily suspended; therefore pay more attention when moving the Robot in jog.
The recovery from the “Recovery Mode” in “Normal Mode” requires the repositioning of
all the Robot axes on the calibration position
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Fig. 15.9 - Service Page, Recovery Mode
2. the system asks for confirmation of the change of the mode; answer by pressing
the Yes button
3. the new Recovery Mode state is highlighted by the yellow LED on the button and
the text below
4. from this time it is possible to activate the DRIVE ON and move the Robot in Jog
mode to position it in the calibration position;
5. when close to the calibration position and without risk of impacts with the structures
of the cell, run the command "Execute Move to $CAL_USER" (which corresponds
to $CAL_SYS if the calibration position has not been customized);
6. on the Web page, press the "NORMAL MODE" button and confirm with “Yes”;
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7. if there are no errors, wait for the complete return in the Normal Mode, which also
includes the restore of the consistency of the encoder positions; the completion is
indicated by the green LED on the push-button.
8. in case of an error message as below, carry out the Turn Set and press again
“NORMAL MODE” button.
Next steps
Following the procedure, run several working cycles of the Robot in order to verify the
proper functioning of all safety systems.
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15.6 Software loading procedure
– Safe-Key preparation (formatting);
– Loading RoboSAFE application in the Safe-Key;
– Reset of one previous configuration of the RoboSAFE parameters;
– Acknowledgement of a new Safe-Key;
– Acknowledgement of new hardware modules installed in the RoboSAFE system;
– Acknowledgement of the new loaded firmware.
15.6.1 Safe-Key preparation (formatting)
The function allows to set the Safe-Key for the first use (Safe-Key formatting).
Precautions
Pay attention during the “Safe-Key preparation” procedure:
– if the procedure is carried out on a Control Unit already configured, all the user's
parameters and the system software will be deleted;
– If the Safe-Key derives form another RoboSAFE System, the setting operation will
delete all its content.
Procedure
1. On the page of Access to the maintenance functions (Service) (see par. 15.2 on
page 204), press the “Format Safe-Key” button;
2. press “Ok” to start the procedure.
Fig. 15.10- Service Page, Format Safe-Key function
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Next steps
After setting the Safe-Key:
1. the RoboSAFE system cannot be used;
2. the status LED “RoboSAFE Status” becomes black;
3. if necessary to load the software and the parameters of the RoboSAFE
system, activating in the order:
4. Loading RoboSAFE application in the Safe-Key;
5. setting of the RoboSAFE parameters (see par. 15.4 Overview of the “Service”
functions on page 207), or, depending of necessity, proceed with a Reset of one
previous configuration of the RoboSAFE parameters;
• Note: until both “System software loading” and “RoboSAFE parameters
setting” procedures are not carried out, both buttons are yellow (see
illustrative image in Fig. 15.11).
6. then, confirm the new configuration, activating in order the following hardware
recognition items:
• Acknowledgement of a new Safe-Key;
• Acknowledgement of new hardware modules installed in the RoboSAFE
system;
• Acknowledgement of the new loaded firmware.
Fig. 15.11- Service Page, after activation of “Format Safe-Key” 
procedure
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15.6.2 Loading RoboSAFE application in the Safe-Key
The function allows the first writing or update of the Comau Safe application in
Safe-Key.
Precautions
Pay attention when implementing the “RoboSAFE system software loading” procedure:
– if the procedure is carried out on a Control Unit already configured, all the user's
parameters and the system software will not be deleted;
– updated versions of the Comau Safe application may have additional
non-parametrized functions.
Requirements
– In case it is necessary to update the Comau Safe application, it it first necessary to
update the Control Unit system software; 
– Comau Safe application is already present in the Control Unit system software and
it is not provided separately.
Procedure
1. On the page of Access to the maintenance functions (Service) (see par. 15.2 on
page 204), press the “Reload Software SM” button;
2. press “Ok”to start the procedure; 
3. if in the Safe-key there is already the user parameter setting, it will not be deleted.
Fig. 15.12- Service Page, System software loading
Note: the button can be yellow if the procedure is required.
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Next steps
After loading the system software:
1. the RoboSAFE system cannot be used;
2. during the course RoboSAFE software loading procedure, the status LED is black;
at the end, the SLU module restarts;
3. after the next restart, LED becomes:
• yellow (only if there has been previous formatting); so activate the Procedure
for enabling manual movement in alarm status (Recovery Mode) (see par.
15.5.4 on page 216);
• black, proceed with the setting of the RoboSAFE parameters (see par. 15.4
Overview of the “Service” functions on page 207), or, depending on needs,
proceed with a Reset of one previous configuration of the RoboSAFE
parameters;
• Note: until both “System software loading” and “RoboSAFE parameters
setting” procedures are not carried out, both buttons are yellow (see
illustrative image in Fig. 15.11).
4. where allowed, perform some movements in programming mode in order to
deliberately violate the workspaces and verify the response from the active
RoboSAFE functions (see par. 3.11.1 Detailed information to carry out the
voluntary violation of the parameters on page 30);
5. carry out several Robot working cycles to verify that the operating parameters are
consistent with the safety solutions provided in the application.
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15.6.3 Reset of one previous configuration of the RoboSAFE 
parameters
The function allows the user configuration parameters to be restored by retrieving them
from a previous file saved on a storage device.
Precautions
Pay attention during the “Restore” procedure:
– if the procedure is made on Control Unit already configured, the user's parameters
will be cancelled and replaced with the ones stored in the indicated file;
Procedure
1. On the page Access to the maintenance functions (Service) (see par. 15.2 on
page 204), press the “Restore configuration” button;
2. select the file “cmu_safe.zip” that contains the user's parameters. The file is
located inside the folders of a Control Unit backup;
3. press the “Upload” button to confirm. The file will be automatically copied to the
system folder LD:\SAFE.
Fig. 15.13- Service Page, Restore Configuration
Invasion risk of not foreseen areas: one wrong or not updated file
compromises the safe operating environment of the Robot, with deriving
risk (even severe) for the operator.
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Next steps
After recovery a previous configuration of RoboSAFE system parameters:
1. if required, perform the Procedure for enabling manual movement in alarm status
(Recovery Mode) (see par. 15.5.4 on page 216);
2. check that the original CRC is coherent (see procedure of Verification of the
checksum (CRC) of the RoboSAFE Cartesian parameters (see par. 15.7 on
page 230);
3. where allowed, perform some movements in programming mode in order to
deliberately violate the workspaces and verify the response from the active
RoboSAFE functions (see par. 3.11.1 Detailed information to carry out the
voluntary violation of the parameters on page 30);
4. carry out several Robot working cycles to verify that the operating parameters are
consistent with the safety solutions provided in the application.
Tab. 15.1 - Definition of fields in the Restore configuration page
Function: Window for uploading the configuration parameters file
“Choice file” 
button
Select the file name “cmu_safe.zip”.
The file is located inside the folders of a Control Unit backup.
“Upload” button: By pressing the button, the new configuration in the system is 
loaded.
“Cancel” button: By pressing that button the procedure is cancelled.
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15.6.4 Acknowledgement of a new Safe-Key
The function allows to confirm the replacement of the Safe Key and combine it univocally
with the SLU module.
Precautions
Pay attention before confirming the acknowledgement of the replaced Safe-Key.
Procedure
1. Before the request for Acknowledge, the status Led is yellow and the Message Bar
displays the message "Please, ack safe key changed";
2. On the page of Access to the maintenance functions (Service) (see par. 15.2 on
page 204), press the “Acknowledge Safe-Key” button;
3. wait for the completion of the procedure.
Fig. 15.14- Service Page, Acknowledge Safe-Key
Next steps
After acknowledgement of the replaced Safe-Key:
1. carry out the Safe-Key preparation (formatting) (see par. 15.6.1 on page 221).
Invasion risk of not foreseen areas: in case of Safe-Key recovered by
another RoboSAFE system (and not previously formatted), the
parameters present in the inserted Safe-Key are automatically loaded in
the system. Note: There are no particular impediments and, at the next
Drive-ON, the only condition that prevents starting is the possible
different Robot family.
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15.6.5 Acknowledgement of new hardware modules installed in 
the RoboSAFE system
The function allows to confirm the solution of one or more modules of the Safe System
(SLU module, I/O Safe modules, and Safe axes modules) excluded the Safe-Key that
has a specific procedure (see par. 15.6.4 Acknowledgement of a new Safe-Key on
page 227).
Precautions
Pay attention before confirming the acknowledgement of the replaced Safe Modules:
– after replacement of 1 or more safe modules, up to 4 modules (both I/O safe
modules on SLU module and Safe axes module on drive) it is necessary to
Acknowledge the push-button which identifies the number of replaced modules;
– after replacement of 5 or more safe modules (both I/O safe modules on SLU
module and Safe axes module on drive) Use the "N" push-button;
– the encoder interface sheet on axes module cannot be replaced singularly.
Procedure
1. Before the request for Acknowledge, the status LED is yellow and the Message Bar
displays the message "Please, ack xx new module".
2. On the page of Access to the maintenance functions (Service) (see par. 15.2 on
page 204), press the button indicating the number of combined modules, that is "N"
in case of replacement of 5 or more;
3. wait for the completion of the procedure.
Fig. 15.15- Service page, Acknowledge hardware modules
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Next steps
After Acknowledgement of the replaced Safe Modules:
1. if required, perform the Procedure for enabling manual movement in alarm status
(Recovery Mode) (see par. 15.5.4 on page 216);
2. carry out several Robot working cycles to verify that the operating parameters are
consistent with the safety solutions provided in the application.
15.6.6 Acknowledgement of the new loaded firmware
The function allows to confirm the update of the new firmware in the SLU module, The
update is automatically started (when necessary) during the update of the system
software.
Precautions
– The firmware acknowledgement procedure may be necessary regardless of the
will of the operator since it is an update that starts automatically; 
– the need is highlighted by the yellow colour of the graphic LED and also by
FW-ACKN LED (Firmware Acknowledge) present on the SLU module.
Procedure
1. Before the Acknowledge requirement, the status Led is yellow and the Message
Bar displays the message "Please, acknowledge firmware";
2. On the page of Access to the maintenance functions (Service) (see par. 15.2 on
page 204), press the “Acknowledge Firmware” button;
3. wait for the completion of the procedure.
Fig. 15.16- Service Page, AcknowledgeFirmware
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Next steps
After firmware acknowledgement of the firmware:
1. carry out the Procedure for enabling manual movement in alarm status (Recovery
Mode) (see par. 15.5.4 on page 216);
2. where allowed, perform some movements in programming mode in order to
deliberately violate the workspaces and verify the response from the active
RoboSAFE functions (see par. 3.11.1 Detailed information to carry out the
voluntary violation of the parameters on page 30);
3. carry out several Robot working cycles to verify that the operating parameters are
consistent with the safety solutions provided in the application.
15.7 Verification of the checksum (CRC) of the 
RoboSAFE Cartesian parameters
The user can verify if the value of the checkSum (CRC) of the RoboSAFE parameters
is consistent with what issued during start-up, also in order to identify the correct restore
(in case of Restore), authorized modifications and/or tampering. 
Procedure
1. To access the identification function of the CheckSum (CRC), on the page of
Access to the functions and configuration parameters of the SAFE functionalities
(see par. 12.1 on page 108) press the “Report” button.
– In the web browser you add a new page with the report, ready to be viewed or
printed. Printing is possible with the integrated “Print” function of the browser.
– Since we are dealing with a list of parameters formatted in text mode, it is also
allowed to select and copy the text in a text document. Note: in order to allow report
pagination and formatting it is necessary that the text is displayed with a non
proportional font (e.g. Courier New).
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Fig. 15.17- RoboSAFE Cartesian parameters checksum (CRC) position 
identification in the configuration report (example)
 SAFETY PARAMETERS REPORT
File informations 
 Name: Report_CNTRLC5G_63
 WinC5G Terminal-PC: 
 WinC5G Terminal-User: 
 Date: 2013-10-10 12:04:30
C5G Control informations
 Sys_Id: CNTRLC5G_1
 Custom_Id: 010R1
 Robot: Comau spa
 type: NJ1_1
 Software version: 2.40.004
 SafeLogic S/N: 00168464
 
SAFE parameters
 
 CRC: 7ba3ba5a [A]
 
 
Parameters 
Cell configuration
Enabled
Online braking distance OFF
Stop category 1
Don't stop in program mode
Height: 
Z (Min) = -100 mm
Z (Max) = 2250 mm
.... snip .....
[A]: Parameters 
(CRC) CheckSum
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15.8 Activating / deactivating the Speed Modulation 
feature
The Speed Modulation function must be deactivated to prevent the trajectory and speed
control during the validation test of the set areas, so that the only active OBD
functionality is easily breakable and it is possible to verify that the Robot does not
exceed the set perimeters. 
Precautions
– the functionality should be kept deactivated for only the time needed to Validate the
implemented RoboSAFE functionalities (see par. 3.11 on page 28).
Procedure
1. Note: the status LED of the Speed Modulation is green to indicate the active
function while it is grey if it is deactivated;
2. On the page of Access to the maintenance functions (Service) (see par. 15.2 on
page 204), press the “Speed Modulation” button;
3. confirm the request message;
4. Carry out an Restart Cold.
Fig. 15.18- Service page, Speed Modulation
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15.9 Robot position reset after RoboSAFE rules 
violation
The combination of the active functions with the correct RoboSAFE system parameters
generates an immediate stop of the Robot, with consequent positioning of the same
outside the foreseen workspaces. In this case, if the RoboSAFE safe functions are
active, it is not possible to move the Robot in order to reposition it inside the allowed
work area.
The possibility to move the Robot after violation of the RoboSAFE rules are conditioned
by the combination of the solutions and parameters foreseen in the safety strategies
chosen by the integrator.
Tab. 15.2 - Possible solutions to move the Robot
Overview of the possible solutions chosen by the 
integrator
Possible solution to 
move the Robot 
(if properly implemented by the integrator) 
*¹
– The RoboSAFE functions are enabled through suitable 
Safe inputs, in one of the following configurations: 
• only with machine selected in automatic mode
• with machine selected both in automatic and manual 
mode 
• (details in par. 3.8 Enable the RoboSAFE functions 
on page 27).
– The parameters of the “Always active” type have not 
been activated on any function.
Image with example of parameter
– The parameter “Activate monitor in Program mode” have 
not been activated.
a. Silence the alarm on the Teach Pendant
(or equivalent through PDL2 instructions);
b. Activate the Programming mode on the
Teach Pendant;
c. Activate the DRIVE ON.
d. Move the Robot bringing it in the work
volume;
e. Release the DRIVE ON.
f. Re-silence the alarm on the Teach
Pendant (or equivalent through PDL2
instructions). This last silencing
command resets the violation status *¹. 
 *¹ The zero setting is not a safety command.
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– The RoboSAFE functions are enabled through suitable 
Safe inputs, in one of the following configurations: 
• only with machine selected in automatic mode
• with machine selected both in automatic and manual 
mode 
• (details in par. 3.8 Enable the RoboSAFE functions 
on page 27).
– The parameters of the “Always active” type have not 
been activated on any function.
Image with example of parameter
– The parameter “Activate monitor in Program mode” has 
been activated.
Note: the programming mode selected on the 
Teach pendant does not allow to move the 
Robot if it its outside the monitored space.
a. Temporarily deactivation of the enabling
Safe inputs;
b. Silence the alarm (or equivalent through
PDL2 instructions). This last silencing
command resets the violation status *¹.
c. Activate the DRIVE ON.
d. Move the Robot bringing it in the work
volume;
e. Release the DRIVE ON.
f. Restore the function of the Safe inputs
previously disabled.
– The parameters of the “Always active” type have been 
activated.
Image with example of parameter
– The parameter “Activate monitor in Program mode” have 
not been activated.
– Note: The Safe inputs status is not important, because the 
RoboSAFE is always active.
a. Acknowledge the alarm;
b. Activate the Programming mode on the
Teach Pendant;
c. Activate the DRIVE ON.
d. Move the Robot bringing it in the work
volume;
e. Release the DRIVE ON.
f. Re-silence the alarm on the Teach
Pendant (or equivalent through PDL2
instructions). This last silencing
command resets the violation status *¹.
Tab. 15.2 - Possible solutions to move the Robot (Continued)
Overview of the possible solutions chosen by the 
integrator
Possible solution to 
move the Robot 
(if properly implemented by the integrator) 
*¹
 *¹ The zero setting is not a safety command.
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*¹ The integrator is responsible for the proper implementation of the solution, respecting
the safety restoring also after temporary deactivation of the RoboSAFE function.
– The parameters of the “Always active” type have been 
activated.
Image with example of parameter
– The parameter “Activate monitor in Program mode” has 
been activated.
a. Acknowledge the alarm;
b. Access the Information page and
transcribe the CRC, for verification
purposes at the end of procedure (see
par. 15.7 Verification of the checksum
(CRC) of the RoboSAFE Cartesian
parameters on page 230).
c. Access the RoboSAFE parameters
configuration page (see par. 11.2 Access
the SAFE parameters via the Web portal
on page 99).. . . . . . . . . . . . . . . . . . . . 211
Reset after unexpected loss of Turn Set and/or calibration constants . . . . . . . . . . . . . . . . . 214
Procedure for enabling manual movement in alarm status (Recovery Mode) . . . . . . . . . . . 216
SAFE LINE UP procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Software loading procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Safe-Key preparation (formatting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Loading RoboSAFE application in the Safe-Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Reset of one previous configuration of the RoboSAFE parameters. . . . . . . . . . . . . . . . . . . 225
Acknowledgement of a new Safe-Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Acknowledgement of new hardware modules installed in the RoboSAFE system . . . . . . . 228
Acknowledgement of the new loaded firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Verification of the checksum (CRC) of the RoboSAFE Cartesian parameters . . . . . . . . . . . . 230
Activating / deactivating the Speed Modulation feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Robot position reset after RoboSAFE rules violation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Recovery system procedures after serious error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Restore after a failed update of the basic system software on a RoboSAFE system . . . . . 236
8
Comau Robotics Product Instruction
PREFACE
PREFACE
This chapter contains the following topics:
– Reference documentation;
– Documentation storage;
– Limits on the handbook contents;
– Symbols used in the handbook;
– Modification History.
Reference documentation
This document refers to C5G Plus, R1C-6 and S1C-6 Control Units. 
The complete set of handbooks is composed of:
These handbooks must be integrated with the following documents:
Comau C5G Plus Control 
Unit
– Technical Specifications, Transport and 
Installation, Maintenance 
– Use of the Control Unit 
– Available options 
R1C-6, S1C-6 
Control Units
– Technical Specifications, Transport and 
Installation, Maintenance 
Electrical circuit 
diagram
– C5G Plus Control Unit
– R1C-6, S1C-6 Control Units
Comau Robot SMART5 
Rel. 2 (all models)
– Technical Specifications *¹
– Transport and installation *¹
– Maintenance *¹
– Stopping distances and times
Programming – PDL2 Programming Language Manual 
– VP2 - Visual PDL2 
– Motion programming 
Applications – Depending on the type of application 
required.
AURA – Sensorized Skin on AURA Collaborative 
Robot: Functionality and user handbook
*¹ specific depending on the type of Robot installed
The handbooks mentioned above shall be maintained intact for as long as the Robotic
System is installed and operational, and must always be available to the personnel
working on the Robotic System. 
9
PREFACE
Comau Robotics Product Instruction
Documentation storage
All the provided documents shall be placed nearby the Robotic System, kept available
for all the operators that work on it and shall be maintained intact for the entire operating
life of the Robotic System.
Limits on the handbook contents
Figures inserted in the instructions handbook have the purpose to represent the product
and can differ from what actually visible on the Robotic System.
Symbols used in the handbook
Below are indicated the symbols that represent: WARNINGS, CAUTION and NOTES
and their meaning
This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed may cause injuries to the personnel.
This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed may cause damage to the equipment.
This symbol indicates operating procedures, technical information and precautions that
must be underlined.
The symbol draws the attention to materials disposal that is regulated by the WEEE
Directive.
The symbol points out to avoid environmental contamination and to properly dismiss the
materials in the appropriate collection sites.
10
MODIFICATION HISTORY
11
Comau Robotics Product Instruction
Modification History
The following table shows the history of the Handbook editions, with related changes /
improvements made.
Date
Edition of the 
Handbook
Contents
2019-01 00/2019.01 First preliminary release of the Handbook.
2019-03 00/2019.03 Improvement of definitions of the RoboSAFE 2.0 functions.
Improvement of description of the restore procedure after a 
violation.
Reaction Time (Worst case) changed to 80 ms.
2019-04 00/2019.04 Correction of the map of signals available on X31/CIP
Comau Robotics Product Instruction
1. GENERAL SAFETY PRECAUTIONS
In this chapter are shown the following topics:
– Responsibilities
– Safety precautions.
1.1 Responsibilities
– The system integrator is responsible for ensuring that the Robotic system (Robot
and Control Unit) are installed and handled in accordance with the Safety
Standards in force in the country where the installation takes place. The application
and use of the protection and safety devices necessary, the issuing of declarations
of conformity and any EC markings of the system are the responsibility of the
Integrator.
– COMAU Robotics shall in no way be held liable for any accidents caused by
incorrect or improper use of the Robotic system (Robot and Control Unit), by
tampering with circuits, components or software, or the use of spare parts that are
not included in the spare parts list.
– The application of these Safety Precautions is the responsibility of the persons
assigned to direct / supervise the activities indicated in the Applicability section are
to make sure that the Authorised Personnel is aware of and scrupulously follow the
precautions contained in this document as well as the Safety Standards in addition
to the Safety Standards applicable to Robotic system (Robot and Control Unit) in
force in the Country where the system is installed.
– The non-observance of the Safety Standards could cause to the operators
permanent injuries or death and can damage the Robotic system (Robot and
Control Unit).
It deals with a general specification that applies to the whole Robot System. Due to its
significance, this document is referred to unreservedly in any system instructions
handbook.
The installation shall be made by qualified installation Personnel and should conform to
all National and Local standards.
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Comau Robotics Product Instruction
1.1.1 Safety Fundamental Requirements applied and respected
The robotic system is composed of C5G Control Unit and Robot series SMART 5
considers as applied and respected the following Safety Fundamental Requirements,
Annex 1 of Directive on Machinery 2006/42/CE: 1.1.3 – 1.1.5 – 1.2.1 – 1.2.2 – 1.2.3 –
1.2.4.3 – 1.2.5 – 1.2.6 – 1.3.2 – 1.3.4 – 1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4 – 1.5.6 – 1.5.8 –
1.5.9 – 1.5.10 – 1.5.11 – 1.5.13 – 1.6.3 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2 – 1.7.4.
1.2 Safety precautions
1.2.1 Purpose
These safety precautions define the behaviour and rules to be observed when
performing the activies listed in the Applicability section.
1.2.2 Definitions
Robotic system (Robot and Control Unit)
Robotic system is the workable unit composed of: Robot, Control Unit, Teach Pendant
and other options.
Protected Area
The protected area is the zone confined by the protection barriers and to be used for the
installation and operation of the robot. 
Authorised Personnel
Authorised personnel defines the group of persons who have been trained and assigned
to carry out the activities listed in the Applicability section
Staff in charge 
Thed. Temporarily turn off the “Activate in
Program mode” function of the violated
function;
e. Save parameters and wait for the restart;
f. Activate the Programming mode on the
Teach Pendant;
g. Move the Robot bringing it in the work
volume;
h. Restore “Activate in Program mode”
function previously deactivated;
i. Save parameters and wait for the restart;
j. Verify that the actual CRC is identical to
the transcript at the start procedure.
Tab. 15.2 - Possible solutions to move the Robot (Continued)
Overview of the possible solutions chosen by the 
integrator
Possible solution to 
move the Robot 
(if properly implemented by the integrator) 
*¹
 *¹ The zero setting is not a safety command.
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Comau Robotics Product Instruction
MAINTENANCE (SOFTWARE ASPECTS OF THE ROBOSAFE SYSTEM)
15.10 Recovery system procedures after serious error
– Restore after a failed update of the basic system software on a RoboSAFE system.
15.10.1 Restore after a failed update of the basic system software 
on a RoboSAFE system 
Due to some incompatibilities between new versions of the system software and
installed version, the update can generate errors and does not allow to complete the
procedure.
Requirements
– Parameters Backup RoboSAFE System;
– WinC5G Program.
Procedure
1. Copy for backup purposes the following files to a folder on the PC (Personal
Computer):
• CNTRLC5G.c5g
• CNTRLC5G.cio
• LD/EPL/eplcfg.xml
• LD/EPL/hwd4all.xml
• LD/SAFE/cmu_emoi.zip
For this purpose, use the WinC5G software (see further details in the “Use of the
Control Unit” handbook in paragraph “Files management between PC and Control
Unit”).
2. Carry out the Backup function with the SaveSet SRV, that can be activated from
the Teach Pendant (see paragraph “Backup of the SaveSet” in the “Use of the
Control Unit” handbook);
3. Rename the file CNTRLC5G_serialNumber.c5g in
CNTRLC5G_serialNumber.c5_TMP in the folder UD:\SYS\CNFG\ (see further
details in the “Use of the Control Unit” handbook);
4. Carry out the Restart Cold with the CONFIGURE CONTROLLER RESTART
COLD command (CCRC) (see paragraph in the “Use of the Control Unit”
handbook);
Note: The system will restart in minimal configuration.
5. Carry out the system software update; for this purpose, use the SETUP-Page,
Reload-SW function on Teach Pendant (see paragraph of the same name in the
“Use of the Control Unit” handbook);
Note: The system will restart automatically (Restart Cold).
6. Rename the previous file CNTRLC5G_serialNumber.c5_TMP in
CNTRLC5G_serialNumber.c5g, folder UD:\SYS\CNFG\ (see further details in the
“Use of the Control Unit” handbook);
7. Carry out the Restart Cold with the CONFIGURE CONTROLLER RESTART
COLD command (CCRC) (see paragraph in the “Use of the Control Unit”
handbook);
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MAINTENANCE (SOFTWARE ASPECTS OF THE ROBOSAFE SYSTEM)
Comau Robotics Product Instruction
8. Complete the system software update; for this purpose, use the SETUP-Page,
Reload-SW function on Teach Pendant (see paragraph of the same name in the
“Use of the Control Unit” handbook), confirming with “Next” until the end of the
procedure;
9. Save and carry out the Restart Cold with the CONFIGURE CONTROLLER
RESTART COLD command (CCRC) (see paragraph of the same name in the “Use
of the Control Unit” handbook);
10. Carry out the EPL_GEN.cod program, folder UD:\SYS\UTIL\, with PROGRAM
GO (PG) command (see paragraph of the same name in the “Use of the Control
Unit” handbook);
11. Carry out the Reload Software SM procedure (see par. 15.6.2);
12. Carry out the Save procedure of the parameters (see par. 12.12);
13. Carry out the SAFE LINE UP procedure (see par. 15.5.4);
14. Carry out some working cycles of the Robot to check that the operating parameters
are consistent with the safety solutions foreseen in the application.
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Comau Robotics Product Instruction
MAINTENANCE (SOFTWARE ASPECTS OF THE ROBOSAFE SYSTEM)
238
Made
in
Comau
Original instructions
	Safety functionalities of the Robot control system
	Summary
	Preface
	Modification History
	1. General safety precautions
	1.1 Responsibilities
	1.1.1 Safety Fundamental Requirements applied and respected
	1.2 Safety precautions
	1.2.1 Purpose
	1.2.2 Definitions
	1.2.3 Applicability
	1.2.4 Operating modes
	2. Integrated safety solutions: RoboSAFE 2.0
	2.1 What is the RoboSAFE 2.0 solution
	3. Design Principles of the RoboSAFE 2.0
	3.1 Personnel qualifications
	3.2 The responsibilities of the integrator
	3.3 Steps for proper design and integration of RoboSAFE 2.0 functions
	3.4 Define the monitored workspace
	3.4.1 Additional auxiliary axes not monitored
	3.5 Set parameters to define the workspace
	3.6 Consider the stopping distances of the Robot mechanics
	3.7 Stopping modes in RoboSAFE system
	3.8 Enable the RoboSAFE functions
	3.9 Check the active RoboSAFE function through the dedicated safe outputs
	3.10 Define the strategy to restore the Robot position after rules violation
	3.11 Validate the implemented RoboSAFE functionalities
	3.11.1 Detailed information to carry out the voluntary violation of the parameters
	3.12 Implement strategies for periodic verification of the Robot kinematic chain and of the equipment installed on the wrist
	3.13 Integrate the cell project documentation
	3.14 Protect the Robot configuration
	3.15 Instructions for the user
	3.16 Installation precautions
	4. Principles and functionalities for Cell / Line and applications installed on Robot
	4.1 Principles common to the RoboSAFE 2.0 functionalities
	4.2 RoboSAFE 2.0 functionalities for the cell / line
	4.2.1 E-Stop from the automated system line
	4.2.2 Auto Stop (Fence)
	4.2.3 General Stop
	4.2.4 E-Stop of the Teach Pendant
	4.3 RoboSAFE 2.0 functionalities for the applications installed on Robot
	4.3.1 Enabling device
	4.3.2 Auto Mode and T1 Mode
	4.3.3 Drive ON
	4.3.4 Replicas of E-Stop and Auto Stop signals
	5. Principles and RoboSAFE Joint and Cartesian functionalities
	5.1 Principles common to the RoboSAFE Joint and Cartesian functionalities
	5.2 System axes
	5.3 RoboSAFE Joint functionality
	5.3.1 RoboSAFE Joint definition
	5.3.2 RoboSAFE Joint performances
	5.3.2.1 Joint Space Limiting
	5.3.2.2 Joint functional sectors
	5.3.2.3 Joint Speed Limiting
	5.3.2.4 Cartesian Speed Limiting
	5.3.2.5 Monitoring Points
	5.3.2.6 Brake test
	5.4 RoboSAFE Cartesian functionality
	5.4.1 RoboSAFE Cartesian definition
	5.4.2 RoboSAFE Cartesian performances
	5.4.2.1 Cell
	5.4.2.2 Dynamic Volumes
	5.4.2.3 Functional Spaces
	5.4.2.4 Cartesian Speed Limiting
	5.4.2.5 Monitoring Point
	5.4.2.6 Tool Orientation
	5.4.2.7 Brake test
	5.4.2.8 Speed Modulation
	5.4.3 Coordinate X, Y, Z (origin) in the RoboSAFE Cartesian functionality
	5.4.4 Functional definition of workspace and volumes
	5.4.5 Requirements for the extent of the defined volumes
	5.5 Access and parameter setting of the RoboSAFE functionalities
	6. Principles and AURA collaborative Robot functionality
	7. Introduction to safety functionalities and technical features
	7.1 Map of available SAFE functionalities, configurations and connectivity
	7.2 Technical features of a Comau SAFE Robotic System
	8. Description of SAFE signals to interface the automated system line and applications
	8.1 SAFE signals for interfacing with the automated system line (E-Stop, Auto-Stop, General Stop)
	8.2 Interfacing of the E-Stop of the Teach Pendant with Fieldbus
	8.3 SAFE signals (optional) for interfacing applications / automated system line (E-Stop, Auto mode, T1 mode, Enabling Device, Drive-ON, Auto-Stop outputs)
	8.4 SAFE signals for interfacing position and speed control of the Robot
	9. Map and connection of SAFE signals
	9.1 Summary of possibilities of interfacing
	9.2 Summary of available SAFE signals and possible uses
	9.3 C5GP-PIS: ProfiSAFE Fieldbus for interfacing with all systems
	9.4 C5GP-ABE: CIP safety Fieldbus for interfacing with the automated system line
	9.5 C5GP-EISM: CIP safety Fieldbus for interfacing with the automated system line and for checking the RoboSAFE functionalities9.6 C5GP-E30K: discrete I/Os for interfacing with the automated system line
	9.7 C5GP-EISO (X31/CIP): discrete I/Os for applications
	9.7.1 Composition of the solution with X31/CIP connector, C5GP-EISO
	9.8 C5GP-SMEC (X52/CIP): discrete I/Os for checking the RoboSAFE functionalities for the C5GP Control Unit
	9.9 R1C-SMEC (X52): discrete I/O for checking of the RoboSAFE functionalities for the S1C-6 Control Unit
	9.10 Bridge signals between C5GP-PIS Gateway and applications on the X31/CIP connector
	10. PDL2 variables of the RoboSAFE system
	10.1 PDL2 variables of RoboSAFE 2.0 system statuses
	11. How to access parameters of the SAFE functionalities
	11.1 Overview of access modalities
	11.2 Access the SAFE parameters via the Web portal
	11.2.1 Requirements for accessing the Web portal
	11.2.2 Finding the IP address of the Control Unit
	11.2.3 Access via Web browser
	11.3 Main page of the SAFE functions
	11.4 Status of RoboSAFE components and functionality
	11.5 Error solving during the connection to the Web portal
	11.6 Access password change
	12. Parameters and configuration of the SAFE functions
	12.1 Access to the functions and configuration parameters of the SAFE functionalities
	12.1.1 Access login to the configuration Web page
	12.1.2 Logout from the configuration Web page
	12.2 System Parameters (System)
	12.2.1 How to access the System page
	12.2.2 How to change the Robot stop category and the safety timer time
	12.2.3 How to change C5GP-PIS Gateway address
	12.2.4 How to deactivate / activate a stop signal coming from the C5GP-PIS Gateway
	12.2.5 How to assign C5G Plus Control Unit status signals to specific safety outputs
	12.3 Joint space monitoring function (Joint spaces)
	12.3.1 How to access Joint spaces page
	12.3.2 How to modify parameters of a Joint Space Limiting
	12.3.3 How to modify parameters of a Joint Functional Sector
	12.4 Cell monitoring function
	12.4.1 How to access the Cell page
	12.4.2 How to modify the Cell volume parameters
	12.4.3 How to add corners to the Cell volume
	12.4.4 How to cancel corners to the Cell volume
	12.4.5 How to add a Forbidden Volume to the Cell
	12.4.6 How to modify parameters of a Forbidden Volume in the Cell
	12.4.7 How to cancel a Forbidden Volume in the Cell
	12.5 Monitoring function of Dynamic Volumes
	12.5.1 How to access the Dynamic Volumes page
	12.5.2 How to create a new forbidden Dynamic Volume (Forbidden Volume)
	12.5.3 How to create a new allowed Dynamic Volume (Work Volume)
	12.5.4 How to modify parameters of a Dynamic Volume
	12.5.5 How to rename the name assigned to a Dynamic Volume
	12.5.6 How to disable a Dynamic Volume
	12.6 Position control function (Functional Space A and B)
	12.6.1 How to access the Functional Space page
	12.6.2 How to enable one or more Functional Spaces
	12.6.3 How to create a new Functional Space
	12.6.4 How to modify parameters of a Functional Space
	12.6.5 How to cancel a Functional Space
	12.7 Robot speed definition function (Speed)
	12.7.1 How to access the Speed page
	12.7.2 How to enable Speed Modulation
	12.7.3 How to modify High Speed Cartesian Limiting
	12.7.4 How to modify Low Speed Cartesian Limiting
	12.7.5 How to modify Program (T1) Speed Cartesian Limiting
	12.8 Function to define the equipment on the Robot (Monitoring Point)
	12.8.1 How to access the Monitoring Points page
	12.8.2 How to create a new Monitoring Point
	12.8.3 How to modify parameters of a Monitoring Point
	12.8.4 How to cancel a Monitoring Point
	12.8.5 How to enable / disable the Toolsets and change their positions
	12.9 Brakes monitoring function (Brake)
	12.9.1 How to access the Brake page
	12.9.2 How to enable the brake monitoring
	12.10 Function to combine safe outputs with the outcome of functions (Safe Outputs)
	12.10.1 How to access the Safe Outputs page
	12.10.2 How to combine the SAFE outputs with the result of the functions
	12.11 Tool orientation definition function (Tool Orientation)
	12.11.1 How to access the Tool Orientation page
	12.11.2 How to enable the Tool Orientation
	12.11.3 How to adjust Tool Orientation coordinates
	12.12 Save the changes to the RoboSAFE settings
	12.13 Import / Export all the parameters of the RoboSAFE configuration
	13. Guide to the use of RoboSAFE 2.0 functionalities
	13.1 C5GP-PIS Gateway integration
	13.1.1 Integration suggestions
	13.1.2 Siemens PLC parameter setting
	13.1.3 Suggestions for checking the functionalities of the emergency stop mushroom-shaped push-button
	13.2 Integration of periodic check of brake functionality
	13.2.1 Integration suggestions
	13.2.2 How to activate the Brake Test Check (BTC) routine in PDL2
	14. Printing of the SAFE parameters
	14.1 Considerations on the information obtained and the conservation of the report
	14.2 SAFE Report Page
	15. Maintenance (software aspects of the RoboSAFE system)
	15.1 Personnel in charge of maintenance
	15.2 Access to the maintenance functions (Service)
	15.2.1 Access login to the “Service” Web page
	15.2.2 Logout from the service Web page
	15.3 Requirements and history of Service functions
	15.4 Overview of the “Service” functions
	15.5 Reset Procedures
	15.5.1 Reset after replacement of an axis module, Safe I/O modules or SLU module
	15.5.2 Reset after a motor replacement
	15.5.3 Reset after unexpected loss of Turn Set and/or calibration constants
	15.5.4 Procedure for enabling manual movement in alarm status (Recovery Mode)
	15.5.5 SAFE LINE UP procedure
	15.6 Software loading procedure
	15.6.1 Safe-Key preparation (formatting)
	15.6.2 Loading RoboSAFE application in the Safe-Key
	15.6.3 Reset of one previous configuration of the RoboSAFE parameters
	15.6.4 Acknowledgement of a new Safe-Key
	15.6.5 Acknowledgement of new hardware modules installed in the RoboSAFE system
	15.6.6 Acknowledgement of the new loaded firmware
	15.7 Verification of the checksum (CRC) of the RoboSAFE Cartesian parameters
	15.8 Activating / deactivating the Speed Modulation feature
	15.9 Robot position reset after RoboSAFE rules violation
	15.10 Recovery system procedures after serious error
	15.10.1 Restore after a failed update of the basic system software on a RoboSAFE systemstaff in charge to direct or supervise the activities of the workers referred to in the
paragraph above.
Installation and Putting into Service
The installation is intended as the mechanical, electrical and software integration of the
Robot and Control System in any environment that requires controlled movement of
robot axes, in compliance with the safety requirements of the country where the system
is installed.
Operation in Programming Mode
Operating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual handling of robot axes and programming of
work cycles at low speed, programmed cycle testing at low speed and, when allowed,
at the working speed.
Auto / Remote Automatic Mode
Operating mode in which the robot autonomously executes the programmed cycle at the
work speed, with the operators outside the protected area, with the protection barriers
closed and the safety circuit activated, with local (located outside the protected area) or
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Comau Robotics Product Instruction
remote start/stop.
Maintenance and Repairs
Maintenance and repairs are activities that involve periodical checking and / or
replacement (mechanical, electrical, software) of Robot and Control System parts or
components, and trouble shooting, that terminate when the Robot and Control System
has been reset to its original project functional condition.
Putting Out of Service and Dismantling
Putting out of service defines the activities involved in the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.
Integrator
The integrator is the professional expert responsible for the installation and putting into
service of the Robot and Control System.
Misuse
Misuse is when the system is used in a manner other than that specified in the Technical
Documentation.
Action area
The robot action area is the enveloping volume of the area occupied by the robot and its
fixtures during movement in space.
1.2.3 Applicability
These Precautions are to be applied when carrying out the following activities:
– Installation and Putting into Service
– Operation in programming mode
– Auto / Remote Automatic Mode
– Robot axes brake
– Maintenance and Repair
– Putting Out of Service and Dismantling.
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Comau Robotics Product Instruction
1.2.4 Operating modes
Installation and Putting into Service
– Putting into service is only possible when the Robot and Control System has been
correctly and completely installed.
– The system installation and putting into service is exclusively the task of the
authorised personnel.
– The system installation and putting into service is only permitted inside a protected
area of an adequate size to house the robot and the fixtures it is outfitted with,
without passing beyond the protection barriers. It is also necessary to check that
under normal robot movement conditions there is no collision with parts inside the
protected area (structural columns, power supply lines, etc.) or with the barriers. If
necessary, limit the robot working areas with mechanical hard stop (see optional
assemblies). 
– Any fixed robot control protections are to be located outside the protected area and
in a point where there is a full view of the robot movements.
– The robot installation area is to be as free as possible from materials that could
impede or limit visibility.
– During installation the robot and the Control Unit are to be handled as described in
the product Technical Documentation; if lifting is necessary, check that the
eye-bolts are fixed securely and use only adequate slings and equipment.
– Secure the robot to the support, with all the bolts and pins necessary, tightened to
the torque indicated in the product Technical Documentation.
– If present, remove the fastening brackets from the axes and check that the fixing
of the robot fixture is secured correctly.
– Check that the robot guards are correctly secured and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– Install the Control Unit outside the protected area: the Control Unit is not to be used
to form part of the fencing. 
– Check that the voltage value of the mains is consistent with that indicated on the
plate of the Control Unit.
– Before electrically connecting the Control Unit, check that the circuit breaker on the
mains is locked in open position.
– Connection between the Control Unit and the three-phase supply mains at the
works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned
appropriately for the power installed on the Control Unit. See the product Technical
Documentation.
– The power supply cable is to enter the Control Unit through the specific cable entry
and be properly clamped.
– Connect the earth conductor (PE) then connect the power conductors to the main
switch. 
– Connect the power supply cable, first connecting the earth conductor to the circuit
breaker on the mains line, after checking with a tester that the circuit breaker
terminals are not powered. Connect the cable armouring to the earth.
– Connect the signals and power cables between the Control Unit and the robot.
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Comau Robotics Product Instruction
– Connect the robot to earth or to the Control Unit or to a nearby earth socket.
– Check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors could cause permanent damage to the
Control Unit components.
– The C5G Control Unit manages internally the main safety interlocks (gates,
enabling push-buttons, etc.). Connect the C5G Control Unit safety interlocks to the
line safety circuits, taking care to connect them as required by the Safety
standards. The safety of the interlock signals coming from the transfer line
(emergency stop, gates safety devices etc.) i.e. the realisation of correct and safe
circuits, is the responsibility of the Robot and Control System integrator.
– The safety of the system cannot be guaranteed if these interlocks are wrongly
executed, incomplete or missing.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active under Automatic mode; under Programming mode the power is
powered off immediately. The procedure for the selection of the controlled stop
time (that can be set on SDM board) is contained in the Transport and Installation
Manual of the Control Unit.
– When preparing protection barriers, especially light curtains and access doors,
bear in mind that the robot stop times and distances are according to the stop
category (0 or 1) and the weight of the robot.
– Check that the environment and working conditions are within the range specified
in the specific product Technical Documentation.
– The calibration operations are to be carried out with great care, as indicated in the
Technical Documentation of the specific product, and are to be concluded
checking the correct position of the machine.
In the cell/line emergency stop circuit the contacts must be included of the control unit
emergency stop buttons, which are on X30. The push-buttons are not interlocked in the
emergency stop circuit of the Control Unit.
Check that the controlled stop time is consistent with the type of Robot connected to the
Control Unit. The stop time is selected using selector switches SW1 and SW2 on the
SDM board.
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Comau Robotics Product Instruction
– To load or update the system software (for example after replacing boards), use
only the original software handed over by COMAU Robotics. Scrupulously follow
the system software uploading procedure described in the Technical
Documentation supplied with the specific product. After uploading, always make
some tests moving the robot at slow speed and remainingoutside the protected
area.
– Check that the barriers of the protected area are correctly positioned.
Operation in programming mode
– The robot is only to be programmed by the authorised personnel.
– Before starting to program, the operator must check the Robotic system (Robot
and Control Unit) to make sure that there are no potentially hazardous irregular
conditions, and that there is nobody inside the protected area.
– When possible the programming should be controlled from outside the protected
area.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the hand-held programming unit functions
correctly (slow speed, emergency stop, enabling device, etc.).
– During the programming session, only the operator with the Teach Pendant is
allowed inside the Protected Area
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (DRIVE ON) is always to be controlled from a position
outside the range of the robot, after checking that there is nobody in the area
involved. The Drive On operation is concluded when the relevant machine status
indication is shown.
– When programming, the operator is to keep at a distance from the robot to be able
to avoid any irregular machine movements, and in any case in a position to avoid
the risk of being trapped between the robot and structural parts (columns, barriers,
etc.), or between movable parts of the actual robot.
– When programming, the operator is to avoid remaining in a position where parts of
the robot, pulled by gravity, could execute downward movements, or move
upwards or sideways (when installed on a sloped plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at slow speed has been executed. The
test is to be controlled from a safe distance.
– Special attention is to be paid when programming using the Teach Pendant: in this
situation, although all the hardware and software safety devices are active, the
robot movement depends on the operator.
– During the first running of a new program, the robot may move along a path that is
not the one expected.
– The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the robot position out
of the path that links two steps of the program), could give rise to movements not
expected by the operator when testing the program.
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Comau Robotics Product Instruction
– In all cases operate cautiously, always remaining out of the robot’s range of action
and test the cycle at slow speed.
Auto / Remote Automatic Mode
– The activation of the automatic operation (AUTO and REMOTE states) is only to
be executed with the Robotic system (Robot and Control Unit) integrated inside an
area with protection barriers properly interlocked, as specified by Safety Standards
currently in force in the Country where the installation takes place.
– Before starting the automatic mode the operator is to check the Robot and Control
System and the protected area to make sure there are no potentially hazardous
irregular conditions.
– The operator can only activate automatic operation after having checked:
• that the Robot and Control System is not in maintenance or being repaired;
• the protection barriers are correctly positioned;
• that there is nobody inside the protected area;
• that the Control Unit doors are closed and locked with the key;
• that the safety devices (emergency stop, protection barrier devices) are
functioning;
– Special attention is to be paid when selecting the automatic-remote mode, where
the line PLC can perform automatic operations to switch on motors and start the
program.
Robot axes brake
– In the absence of motive power, the robot axes movement is possible by means of
optional release devices and suitable lifting devices. Such devices only enable the
brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enable button) are powered off; also the
robot axes can move upwards or downwards because of the force generated by
the balancing system, or the force of gravity. 
– Enabling the Brake releasing Module may cause the axes falling due to gravity as
well as possible impacts due to an incorrect restoration, after applying the brake
releasing module. The procedure for the correct usage of the Brake releasing
Module (both for the integrated one and module one) is to be found in the
maintenance manuals. 
Before using the manual release devices, it is strongly recommended to sling the robot,
or hook to an overhead travelling crane.
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Comau Robotics Product Instruction
– When the motion is enabled again following the interruption of an unfinished
MOVE, the track recovery typical function may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next automatic cycle
restarting. Avoid moving the Robot to positions that are far away from the ones
provided for the motion restart; alternatively disable the outstanding MOVE
programmes and/or instructions.
Maintenance and Repair
– At the COMAU works all robots are lubricated using products that do not contain
any harmful substances. However, in some cases, repeated and prolonged
exposure to such products may cause irritation of the skin and they may be harmful
if swallowed.
First Aid Measures In case of contact with the eyes or skin: rinse the affected
areas with copious amounts of water; should irritation persist, seek medical advice.
If swallowed, do not induce vomiting or administer anything by mouth; see a doctor
as soon as possible.
– Maintenance, trouble-shooting and repairs are only to be carried out by authorised
personnel.
– When carrying out maintenance and repairs, the specific warning sign is to be
placed on the control panel of the Control Unit, stating that maintenance is in
progress and it is only to be removed after the operation has been completely
finished - even if it should be temporarily suspended.
– Maintenance operations and replacement of components or the Control Unit are to
be carried out with the main switch in open position and locked with a padlock.
– Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages coming from connections to peripheral units or external
power sources (e.g. 24 Vdc inputs/outputs). Power off external sources when
operating on parts of the system that are involved.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Faulty components are to be replaced with others having the same Part number,
or equivalent components defined by COMAU Robotics.
– Trouble-shooting and maintenance activities are to be executed, when possible,
outside the protected area.
– Trouble-shooting executed on the control is to be carried out, when possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards are to be observed
when operating with hazardous voltages present.
– Trouble-shooting on the robot is to be carried out with the power supply powered
off (DRIVE OFF).
– At the end of the maintenance and trouble-shooting operations, all deactivated
safety devices are to be reset (panels, protection shields, interlocks, etc.).
After replacement of the SDM module, check on the new module that the setting of the
stop time on selector switches SW1 and SW2 is consistent with the type of Robot
connected to the Control Unit.
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Comau Robotics Product Instruction
– Maintenance, repairsand trouble-shooting operations are to be concluded
checking the correct operation of the Robotic system (Robot and Control Unit) and
all the safety devices, executed from outside the protected area.
– When loading the software (for example after replacing electronic boards) the
original software handed over by COMAU Robotics is to be used. Scrupulously
follow the system software loading procedure described in the specific product
Technical Documentation; after loading always run a test cycle to make sure,
remaining outside the protected area
– Disassembly of robot components (motors, balancing cylinders, etc.) may cause
uncontrolled movements of the axes in any direction: before starting a disassembly
procedure, consult the warning plates applied to the robot and the Technical
Documentation supplied.
– It is strictly forbidden to remove the protective covering of the robot springs.
Putting Out of Service and Dismantling
– Putting out of service and dismantling the Robot and Control System is only to be
carried out by Authorised Personnel.
– Move the robot to transport position and mount the axes locking items (if present),
following the instructions on the plate posted on the robot and its Technical
Documents.
– Before starting to put out of service, the mains voltage to the Control Unit must be
powered off (switch off the circuit breaker on the mains distribution line and lock it
in open position).
– After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the distribution line,
first disconnecting the power conductors, then the earth. Disconnect the power
supply cable from the Control Unit and remove it.
– First disconnect the connection cables between the robot and the Control Unit,
then the earth cable.
– If present, disconnect the robot pneumatic system from the air distribution mains.
– Check that the robot is properly balanced and if necessary sling it correctly, then
remove the robot securing bolts from the support.
– Remove the robot and Control Unit from the working area, following all
prescriptions in the product Technical Documents; in case of lifting, check the
eyebolts fastening and use only suitable slinging devices and equipment.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU Robotics & Service,
or one of its branches, who will indicate, according to the type of robot and Control
Unit, the operating methods in accordance with safety principles and safeguarding
the environment.
– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.
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INTEGRATED SAFETY SOLUTIONS: ROBOSAFE 2.0
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Comau Robotics Product Instruction
2. INTEGRATED SAFETY SOLUTIONS: 
ROBOSAFE 2.0
This chapter deals with the following topics:
– What is the RoboSAFE 2.0 solution.
2.1 What is the RoboSAFE 2.0 solution
C5G Plus series, R1C-6 and S1C-6 Control Units are industrial electrical equipment
created for a simplified and efficient native management of SAFE functionalities for the
whole range of Comau Robots of SMART5 series Rel. 2.
RoboSAFE 2.0 functionalities are obtained from a combination of Hardware and
Software solutions, extended by specific options created to simplify certain installations. 
Among the main functions there are available:
– interfacing with the cell / line;
– interfacing with applications on Robot;
– control of trajectories of the Robot; these are more advanced functions that are
called RoboSAFE Joint and RoboSAFE Cartesian*¹.
This handbook describes all RoboSAFE 2.0 functionalities, including their main features
and methods of use. To find out more about installation aspects and electrical
connections it may be necessary to consult the specific handbooks of the Control Unit
(see par. Reference documentation on page 9).
*¹ The RoboSAFE Joint and Cartesian functionality is obtained exclusively in the case
of a Robotic System including Safe Control Unit with a Robot of SMART5 series Rel. 2,
provided with specific Encoders. These functionalities are guaranteed by additional
safety components not present in the standard versions of the Control Units.
Comau Robotics Product Instruction
DESIGN PRINCIPLES OF THE ROBOSAFE 2.0
3. DESIGN PRINCIPLES OF THE ROBOSAFE 
2.0
This chapter deals with the following topics:
– Personnel qualifications;
– The responsibilities of the integrator;
– Steps for proper design and integration of RoboSAFE 2.0 functions;
– Define the monitored workspace;
– Set parameters to define the workspace;
– Consider the stopping distances of the Robot mechanics;
– Stopping modes in RoboSAFE system;
– Enable the RoboSAFE functions;
– Check the active RoboSAFE function through the dedicated safe outputs;
– Define the strategy to restore the Robot position after rules violation;
– Validate the implemented RoboSAFE functionalities;
– Implement strategies for periodic verification of the Robot kinematic chain and of
the equipment installed on the wrist;
– Integrate the cell project documentation
– Protect the Robot configuration;
– Instructions for the user;
– Installation precautions.
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DESIGN PRINCIPLES OF THE ROBOSAFE 2.0
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3.1 Personnel qualifications
Only the informed and trained personnel who have read this document and have
experience with the additional documentation for the RoboSAFE 2.0 system are allowed
to operate on the RoboSAFE 2.0 system. In addition, the personnel must have
completed relevant safety training in order to recognize and avoid potential sources of
risk. This personnel must have received a technical education, collected knowledge and
experience from the field and be able to foresee and directly recognize dangerous
situations that may result from the use of this product, modifying its settings or from the
mechanical, electrical and electronic components used throughout the entire system
where this product will be used.
All persons who work with or near this product must be well-versed in all standards,
guidelines and accident prevention guidelines relevant to their activities.
3.2 The responsibilities of the integrator
The integrator is responsible for the correct application of the RoboSAFE 2.0 solution in
the complete machine, as required by the legislation of the destination country.
The RoboSAFE 2.0 solution is to be intended as a support for a better operational and
motion control of the Robot, that the Integrator will have to combine with other
complementary solutions and physical protection barriers, as well as an appropriate
design of the cell and equipment.
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Comau Robotics Product Instruction
DESIGN PRINCIPLES OF THE ROBOSAFE 2.0
3.3 Steps for proper design and integration of 
RoboSAFE 2.0 functions
The design and use of RoboSAFE functions requires the performance of the following
activities, described in the following paragraphs:
3.4 Define the monitored workspace
It is necessary to assess the risk of the robotic system in the project and
consequently to define the Workspace where the Robot should be monitored in a safe
manner, possibly also simultaneously checking the motion speed. 
3.4.1 Additional auxiliary axes not monitored
The auxiliary axes are not included in the selection of safe monitored areas. 
Nevertheless, consider that the violation of one or more rules, stops the entire Robotic
system (further details in par. 3.7 Stopping modes in RoboSAFE system on page 27).
Step Activity Performed
1 Define the monitored workspace, where the Robot must be checked in a safe manner
2 Set parameters to define the workspace
3 Consider the stopping distances of the Robot mechanics, not included in the 
Workspace 
4 Enable the RoboSAFE functions
5 Check the active RoboSAFE function through the dedicated safe outputs
6 Define the strategy to restore the Robot position after rulesviolation
7 Validate the implemented RoboSAFE functionalities
8 Implement strategies for periodic verification of the Robot kinematic chain and of the 
equipment installed on the wrist
9 Integrate the cell project documentation
10 Protect the Robot configuration
11 Instructions for the user
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DESIGN PRINCIPLES OF THE ROBOSAFE 2.0
Comau Robotics Product Instruction
3.5 Set parameters to define the workspace
By means of appropriate fields available on Web pages, the parameters can be defined
by entering the positions and dimensions that determine the overall dimensions of the
sectors (RoboSAFE Joint) or space (RoboSAFE Cartesian).
The Safe Axes Spaces are defined through numerical values or activation of events
determining the limit beyond which a violation of the rules occurs with consequent stop
of the Robotic system (further details in par. 3.7 Stopping modes in RoboSAFE system
on page 27).
Special features of parameter setting:
– the parameters can be set in advance, even without enabling the function. The
values remain stored until a new change and do not depend on enablings;
– the parameters can be imported from an external file;
– numerical parameters cannot be read by PDL2 variables.
statuses of functions and control signals can be read by PDL2 variables.
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Comau Robotics Product Instruction
DESIGN PRINCIPLES OF THE ROBOSAFE 2.0
3.6 Consider the stopping distances of the Robot 
mechanics
The workspaces are defined through numerical values that do not consider the
stopping distances required by the Robot mechanics to stop completely.
The application of the RoboSAFE solution requires therefore the following
considerations and minimum precautions:
– during the risk assessment of the machine, the integrator must consider the
stopping distances of the Robot (consult specific handbook for Stopping
distances and times) that must be added to the ends of the spaces that determine
the monitored workspace;
– the violation of the RoboSAFE safety functions gives a stop ramp defined Quick
Stop in order to minimize the stopping distance. The equipment added to the Robot
must be designed appropriately;
– stopping distances and trajectories depend on the selected stopping category
(category 0 or 1 according to the EN 60204-1 standard, see further details in
par. 3.7 Stopping modes in RoboSAFE system on page 27);
– after a violation and consequent stop, the Robot physical position will be outside
the monitored workspace. With active and violated RoboSAFE functions, it is
not possible to move the Robot; it is therefore essential that the integrator
provides for a strategy to allow repositioning of the Robot in the intended area (see
par. 3.10 Define the strategy to restore the Robot position after rules violation on
page 28).
The integrator is responsible for considerations and solutions adapted to delimit the
clearance distance of the Robot in the machine.
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DESIGN PRINCIPLES OF THE ROBOSAFE 2.0
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3.7 Stopping modes in RoboSAFE system
The stop category (according to EN 60204-1 standard), selected in the specific
parameters of Web interface, determines the stop behaviour in case of violation: in the
case of category 1, the stop is performed with a steep deceleration ramp; in the case
of category 0, the stop is performed without deceleration ramp with immediate
application of brakes.
The stop of the entire Robotic system includes all the axes and is indifferent to
configuration with 2 or more separated ARMs or the presence of safety options.
In category 1, the SS1 function:
– intervenes in SS1 mode - Safe Stop With Ramp-Based Monitoring in case of
violation of one or more rules set in the RoboSAFE system; this SS1 function
ensures that the Robot stopping distance is carried out safely and as efficiently as
possible;
– intervenes in SS1 mode - Safe Stop With Time-Based Monitoring in case of
command received on the traditional emergency stop inputs (E-stop, General Stop
and Fence), for which it remains valid when set on the timer (see parameter on the
Web portal - par. 12.2.2).
3.8 Enable the RoboSAFE functions
The RoboSAFE functions are activated permanently or through special safe inputs (on
digital input modules or Fieldbus).
The inputs can be activated according to the process requirements, one or more
simultaneously and at different times.
The input electrical signal is in negative logic and the activation of the corresponding
function is made when the signal is lacking (0 state).
The replication of input signals status is also available on specific system variables,
which can be freely used in PDL2 programs. The use of system variables is limited only
to the diagnostic or elaboration of the production cycle and do not replace the safety
derived from the specific safe inputs.
The stopping distance in category 0 in optimal conditions of the brakes can be smaller
than the stopping distance in category 1.
In the case of stopping mode in category 0, pay attention to loss of trajectory and to
mechanical stresses generated by the Robot systems (also matched with additional
axes such as Robot Track Motions or tables) on supporting structures.
The integrator is responsible for the proper evaluation of the stresses resulting from the
parameter settings, which have been chosen by himself.
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DESIGN PRINCIPLES OF THE ROBOSAFE 2.0
3.9 Check the active RoboSAFE function through the 
dedicated safe outputs
The status of active RoboSAFE functions is available through specific safe outputs.
These signals are usable directly on digital output modules or on Fieldbus.
The replication of output signals status is also available on specific system variables,
which can be freely used in PDL2 programs. The use of system variables is limited only
to the diagnostic or elaboration of the production cycle and do not replace the safety
derived from the specific safe outputs.
3.10 Define the strategy to restore the Robot position 
after rules violation
The integrator must consider that the workspace violation stops the Robot outside the
foreseen space (see how Consider the stopping distances of the Robot mechanics (see
par. 3.6 on page 26)).
The integrator will have to prepare specific information to allow the machine user to
recover its functionality after a violation of the workspace.
3.11 Validate the implemented RoboSAFE 
functionalities
It is recommended to take into consideration the following suggestions:
– in the project phase:
• define the functional requirements of the production process, the workspaces
and stopping distances of the Robot and operating limits of the entire system; 
• report what is required graphically on layout of the cell to identify the
feasibility;
• consider all life phases of the complete machine and evaluate the resulting
aspects (e.g. in case of Robot replacement, a new unit must be installed in
the same position and the parameters restored exactly as set during the
start-up phase);
To see what are the user requirements for performing the recovery after a violation,
consult par. 15.9 Robot position reset after RoboSAFE rules violation on page 233.
The RoboSAFE settings and functionalities must be checked carefully before the
start-up of the complete machine.
The RoboSAFE functions contribute to achieve compliance with the Essential Safety
Requirements of the Machine Directive, but can not fulfill them in totality and the
integrator is responsible for the proper integration of RoboSAFE system in order to set
up a compliant machine.
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DESIGN PRINCIPLES OF THE ROBOSAFE 2.0
Comau Robotics Product Instruction
• consider that it is always possible to integrate the RoboSAFE solutions with
the mechanical options provided on the Robot (e.g. mechanical stops);
– during the installation and start-up phase:
• check that each parameter (also eventually pre-entered in Web pages in the
preliminary test phase) is consistent with what was defined at the project
level;
• create a strategyto allow a conscious access to the Safe Control Unit (and
exclusive in case of 2 or more Control Units in the same project), customizing
the access passwords and the univocal name (see details in par. 3.14 Protect
the Robot configuration on page 32); the univocality of the name, password
and IP addresses of the Safe Control Unit ensures awareness and univocality
of access;
• temporarily change the value of the software stroke-end outside the area
foreseen by the RoboSAFE parameters, so as to avoid the distortion of the
stopping tests on the RoboSAFE functions by other parameters / limitations;
• temporarily disable the performances that prevent the exceeding of the
defined areas;
• with all perimeter guards present and functioning (fixed and movable guards)
and with area cleared of people, activate each RoboSAFE function foreseen
in project and intentionally violate every parameter and setting (see
par. 3.11.1 Detailed information to carry out the voluntary violation of the
parameters on page 30); 
• in order to achieve the set goal, it may be necessary to create specific Robot
programs, performing the MOVE at cycle speed (with Safe speed limits
active); alternatively, set the 100%;
• create a Report document of the test performed to improve the traceability of
the process;
– in the final phase:
• reset the value of the software stroke-end eventually modified;
• reactivate any deactivated performances;
• store an accurate report with the project layout and the parameters set in the
RoboSAFE system;
• include in the documentation supplied to the customer the value of Checksum
(CRC) of the RoboSAFE parameters, automatically generated by the system
and given in the configuration report;
• archive the documentation in the Technical File (reference the Machine
Directive).
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Comau Robotics Product Instruction
DESIGN PRINCIPLES OF THE ROBOSAFE 2.0
3.11.1 Detailed information to carry out the voluntary violation of 
the parameters
The voluntary violation of the parameters is a fundamental operation for the proper
verification of the entered parameters, and may require the creation of specific Robot
positions, out of the workspace.
Proceed as it is described below:
1. Identify the position and orientation of the Robot in the space
• In the case of cell area, move the Robot so as to check at least three points
for each plane of the cell;
• In the case of dynamic volumes, for each volume, move the Robot so as to
check at least three unaligned points for one of the parallelepiped planes and
then at least one point for the remaining planes (in order to correctly identify
its size and orientation);
2. Identify the speed limit of the Robot: 
• move the Robot changing the Cartesian speed, so as to reach and then
exceed the value set in the speed limit parameter (see par. 5.3.2.4); in this
regard, it may be useful to consult the “Movement programming” handbook,
“Cartesian Speed Control” paragraph; 
• during the movement, verify the Robot stop for violation of RoboSAFE
parameters. 
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DESIGN PRINCIPLES OF THE ROBOSAFE 2.0
Comau Robotics Product Instruction
3.12 Implement strategies for periodic verification of 
the Robot kinematic chain and of the equipment 
installed on the wrist
The spaces occupied by Robot and by its equipment on the wrist are monitored via
encoders installed on each joint of the kinematic chain.
After impacts or brake release with the Control Unit turned off, it is necessary to check
the Robot efficiency, verifying the consistency with a reference position that must be
predisposed at project level. When necessary, this reference position will allow the
verification of correct status of equipment on the Robot wrist and the absence of
mechanical damages on the Robot itself.
It is recommended to take into consideration the following suggestions:
– implement a strategy of periodic check of the parking brakes status on the motors
(see par. 12.9 Brakes monitoring function (Brake) on page 179);
– implement a strategy of periodic check of Tool Center Point, identifying a significant
monitoring point that includes all the kinematic chain joints of the Robot and of the
equipment installed on the Robot wrist. This periodic check (at least every time the
system is powered up) must also be carried out at the end of mechanical
installation, following the Robot maintenance, after the use of the C5G-OBR brake
releasing module, after a new configuration of the parameters and in all the
circumstances in which the kinematic chain is involved.
The integrator is responsible for the proper integration of RoboSAFE system in order
to constitute a compliant machine according to the legislation in force.
The user is responsible for the proper use of RoboSAFE system in order not to alter the
mechanical configuration of equipment, Robot fixings and in any case of the positions
and spaces in the cell on which the parameters of safe areas have been configured.
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DESIGN PRINCIPLES OF THE ROBOSAFE 2.0
3.13 Integrate the cell project documentation
The RoboSAFE settings are located inside the system, on the Safe Key installed in the
CPU of the SLU module. 
It is recommended to take into consideration the following suggestions:
– it is possible to obtain an archive file (parameter backup on XML file) containing all
RoboSAFE parameter settings and a report including checkSum (CRC), available
on system variable $SL_CRC; 
– the integrator may have a personal warranty of the software version and
parameters set in the complete machine if carefully manages the configuration
storage and files distribution with the purpose to restore them after maintenance
operations.
3.14 Protect the Robot configuration
RoboSAFE settings must be protected to prevent inconsistent changes by third parties
and/or inappropriate restores with parameters of other installations; this condition is
particularly significant in automated systems lines with a considerable number of Robots
and/or with network connection from a remote station.
It is recommended to take into consideration the following suggestions:
– define a univocal name of the Robot and define it in the user interface of the Control
Unit ($ CUSTOM_CNTRL_ID); so the name will be constantly visible on the setting
web pages;
– protect the settings by changing the default password; it is recommended to
include the number / univocal name of the Robot in the password so as to
automatically make the person in charge of accessing / restoring the parameters
aware of the direct association with the Robot in question.
The complete procedures to create the project documentation can be
found in par. 14.1 Considerations on the information obtained and the
conservation of the report on page 200 and par. 12.13 Import / Export all
the parameters of the RoboSAFE configuration on page 193.
Backup / restore procedure associates the content of the
$CUSTOM_CNTRL_ID variable to check the validity of the restore and its
subsequent modification would impede its restore. 
The procedures for the password change can be found in par. 11.6 Access
password change on page 105.
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3.15 Instructions for the user
The instructions for use to be delivered to the user must contain the precautions and
requirements to guarantee the maintenance of the adopted RoboSAFE safety solutions
over time.
It is recommended to take into consideration the following suggestions:
– refer to the necessary precautions to restore the configuration correctly, in
particular after maintenance; 
– highlight the need to:
• correctly hold and restore the RoboSAFE parameters; 
• carry out a verification test after any maintenance on the Robot kinematic
chain (especially those that require Turn Set procedures).
• do not perform system software updates if functional details and parameters
set are not known; in case of need, opt for the intervention of a trained
personnel;
– emphasize the compliance