SMART NS - Handbooks

Comau Robotics
Instruction Handbook

Continuous Wire Welding

System - Rel. 4

Integration, Transport and Installation for FRONIUS Weld-

ing System (Field Bus and Serial) with NS Robots

CR00757488_en-01/0607
The information contained in this manual is property of COMAU S.p.A.

Reproduction, even partial, is prohibited, unless written authorisation has been obtained from COMAU S.p.A.

COMAU reserves the right to make changes, without prior notification, to the charateristics of the product de-
scribed in this manual.

Copyright © 2004 by COMAU - Date of publication 06/2007

 Summary

SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V
Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VI

1. WIRE WELDING SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.1

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Information regarding the process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Protection of the eyes and the body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Electrical protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Protections against gas, fumes and fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

2. INSTALLATION SUMMARISING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2.1

3. PREPARATION FOR THE INSTALLATION, LIFTING AND HANDLING . . . . . . . . ..3.1

Preparation for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Installation environment requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Network power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Handling and transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Robot and Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Torch cleaning assembly and lubricator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

4. WIRE WELDING SYSTEM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . ..4.1

Generator installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Torch assembly installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Welding wire installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Torch cleaning assembly and lubricator installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Magnetic torch cleaning assembly installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Tool Master installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Balancer installation (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
TCP Check installation (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15

AP-AW-NS-TINTOC.fm
I
Summary

Location point installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17

5. WIRE WELDING SYSTEM CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1

Cables installation hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Connection between Control Unit and Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Connection between generator and peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Digital I/Os cable (Field bus solution) C4G - torch cleaning assembly. . . . . . . . . . . . . . . . . . 5.4
Multibus cable (Field bus solution) C4G - welding generator. . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Wire joint detection sensor (Field bus solution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Digital I/Os cable (Serial solution) C4G - torch cleaning assembly . . . . . . . . . . . . . . . . . . . . 5.6
Serial cable (Serial solution) C4G - welding generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Wire joint detection sensor (Serial solution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Welding ground cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Connection between generator and wire puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Connection between Control Unit and safeties, Field Bus and line Ethernet. . . . . . . . . . . . . . 5.14
Splitter Connection between C4G and TCP Check (optional) . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
Connection between C4G and Seam Track (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
Connections to the power supply networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
Control Unit connection to the electric power supply line. . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
Generator connection to the electric power supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
Robot and torch cleaning assembly connection to the compressed air distribution line . . . 5.25
Serial line (only for serial solution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
Multibus connectors and cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
Connector positions on board robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
Connector pin-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
Multibus cable electrical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30

6. WIRE WELDING SYSTEM ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1

Precautions to be taken before activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Connectors pin-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Power-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Bleeding the water circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Network addresses configuration for field bus board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Anti-collision kit enabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
SMART-ARC and optionals software modul activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Robot moves programming hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

7. WIRE WELDING SYSTEM DEACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1

AP-AW-NS-TINTOC.fm
II
 Summary

AP-AW-NS-TINTOC.fm
III
Summary

AP-AW-NS-TINTOC.fm
IV
 Preface

PREFACE

Symbols used in the manual

The symbols for WARNING, CAUTION and NOTES are indicated below together with
their significance.

This symbol indicates operating procedures, technical information and

precautions that if ignored and/or are not performed correctly could cause
injuries.

This symbol indicates operating procedures, technical information and

precautions that if ignored and/or are not performed correctly could cause
damage to the equipment.

This symbol indicates operating procedures, technical information and

precautions that it are important to highlight.

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

AP-AW-0-SPT_02.fm
00/0000 V
Preface

Reference documentation
This documentation refers to the Wire Welding System. application
The complete set of Wire Welding System manuals consists of:

Comau Wire Welding – Technical specifications for Fronius

System system
– Fronius system integration, transport and
installation
Programming, – Wire Welding System Application
welding Software
specifications
Electrical diagram

These manuals are to be integrated with the following documents:

Comau Control Unit C4G – Technical Specifications

– Transport and Installation
– Guide to Integration, safeties, I/Os,
communications
– Maintenance
– Use of C4G Control Unit.
Robot – Technical Specifications
– Transport and Installation
– Maintenance
Programming – PDL2 Programming Language Manual
– Move programming
Altersys PLC programming – Workbench di ISaGRAF
Fronius – Transpulse Synergic 4000, 5000 (Generator use instructions)
– Transpulse Synergic 4000, 5000 (Additional information, I/O and
error signals)
– FK 4000 R (Use instructions for the generator cooling system)
– FK 4000 R (Flow meter and water filter installation)
– VR 1500 (Wire-puller service installation)
– VR 1500 (Wire-puller blowing assembly instructions)
– VR 1500 (Wire-puller cover assembly instructions)
– VR 1500 (Wire guide sheath on Wire-puller unit assembly
instructions)
– Robot Device Net interface (hardware, technical characteristics)
– BRG 97 N Torch cleaning assembly (operating instructions)
– Magnetic Torch cleaning assembly (operating instructions)
– Torch for Robot Robacta
– High Speed Touch Sensing (Installation and use of joint detector
sensor).
– Trolley
– Autotransformer

AP-AW-0-SPT_02.fm
VI 00/0000
 Wire Welding Safety Precautions

1. WIRE WELDING SAFETY

PRECAUTIONS

The safety precautions that follow integrate those for the robotic system,
contained in the Chapter SAFETY PRECAUTIONS of the Control Unit or Robot
manuals.

1.1 Responsibilities
– All the activities (installation, start-up, operation, maintenance, etc.) on arc welding
systems are only to be carried out by the authorised personnel.
– The integrator is to perform the correct integration of the arc welding system in the
cell. The integrator shall (without however limiting the activities to the indications
below):
• consider the correct installation spaces
• install the exhaust systems for the welding fumes
• install perimeter protections, access doors
• install protective shields for the eyes and against the sparks caused by the
welding process.

The Wire Welding System is not to be started up before the machine where it is
incorporated has been declared in conformity with the provisions of the
applicable directives

– During the welding operations the personnel are to wear individual protection
devices.
– During welding operations an accident hazard exists caused by rubbing against the
metal edges of the parts to be welded or burns from contact with metal parts heated
by the welding. Wear protective gloves.
– The setting of wrong welding parameters can cause damage to the part to be
welded or to welding channel elements such as the weld torch. For this reason the
welding parameters are only to be set by qualified personnel.

1.2 Information regarding the process

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

AP-AW-0-0_01.fm
00/0404 1-1
Wire Welding Safety Precautions

1.3 Protection of the eyes and the body

The main danger present during the arc welding process is the emission of
electromagnetic waves, caused by the electric arc, having wave lengths that range from
infrared to ultraviolet.
These rays, if they hit the eye, can cause various pathologies: conjunctivitis, burning of
the retina, “glass-blower’s cataract”, deterioration of visual capacity, etc., furthermore
the strong concentration of ultraviolet rays can cause burning of the skin.
It is therefore most important that the operator uses adequate protection systems:
– leather welding gauntlets
– leather welding aprons
– welding spats
– safety boots
– a protection mask (better a helmet) sufficiently wide to cover the entire face, with
protective glass that can filter the radiation and considerably reduce the luminous
intensity absorbed by the eyes.
Tab. 1.1 - DIN classes of standard adiactinic glass indicates the tones of the glass
(always indicated on the glass conforming to relevant standards) to be used according
to the different types of welding executed; mirrored types are indicated to reduce the
action of the infrared rays.

Never use faulty or broken masks, helmets or shields, but promptly arrange for
their replacement. The glass is to be kept clean and is to be promptly replaced if
it becomes broken or cracked. It is a good practice to fit a transparent glass over
the adiactinic glass toward the welding field, so that it can be changed frequently
when the hot splatter that deposits on it reduces the visual range.

Anti-reflection shields are to be mounted around the welding zone to avoid that
other persons, working in neighbouring zones, are hit by the radiation emitted by
the arc.

Never, for any reason whatsoever, look at an electric arc without adequate eye
protection.

AP-AW-0-0_01.fm
1-2 00/0404
 Wire Welding Safety Precautions

Tab. 1.1 - DIN classes of standard adiactinic glass

CLASS FORESEEN USE CONDITIONS
Electrodes with diameters ranging from 3.25 to 5 mm.
9 For arc welding in protected environment with current intensity
up to 75 A
Electrodes with diameters over 5 mm.
10 For arc welding in protected environment with current intensity
up to 200 A
Electrodes with diameters over 5 mm.
11 For arc welding in protected environment with current intensity
up to 250 A
Electrodes that have a very strong luminous effect.
12 For arc welding in protected environment with current intensity
up to 300 A
To weld parts with very thick walls.
13 For arc welding in controlled environment with current intensity
over 300 A and up to 500 A

1.4 Electrical protection

The operator is to always wear protective garments (gauntlets, shoes with insulated
soles, etc.) that are dry and not soiled by grease; never perform welding operations in
wet zones.
Never touch, without adequate protection, parts of the welding circuit that are not
insulated or protected; if this is necessary, cut-out the welding machine and the
interconnected devices.
Electric shocks from contact with parts connected to low voltage and/or low current
generators, although not fatal, can be the cause of induced hazards (e.g. falling).
Check the condition of the cable insulation and replace any cables with zones where the
conductors are exposed.
Check that the insulation of the torches and the connectors is intact.
Never rest the torch directly on the welding table, or on other metal surfaces connected
to the ground circuit, to avoid risks of short circuits or accidental activation of the arc.
Non insulated or non protected parts of the welding circuit are to be located in protected
areas to which the access is limited to authorised personnel only, in conformity with the
current standards of the country where the system is used.

1.5 Protections against gas, fumes and fire

In arc welding considerable quantities of fumes and gas are released, the quality of
which depends on the type of weld material and the quantity of power used.
When welding with covering gas (CO2 and Argon) it happens that, due to the effect of
the high temperatures, the CO2 separates into O+CO recomposing again in CO2 after
cooling. Therefore, close to the operator’s respiratory organs there is a considerable
quantity of oxygen and carbon oxide, as well as small quantities of ozone.

AP-AW-0-0_01.fm
00/0404 1-3
Wire Welding Safety Precautions

Owing to the effect of the base metal (steel) during the welding a development of Iron
Oxide fumes also takes place, but usually the quantity does not exceed the allowed
limits of 10 mg/cu.mt. of air. The welding of galvanised or painted parts is particularly
hazardous.
During welding, vapours are also formed by microscopic particles produced by the
combustion and in part by metal volatilization. At a certain distance from the arc these
vapours condense into very fine particles that in their turn coagulate in larger particles
reaching dimensions that however never exceed 1 micron (1 thousandth of a millimitre).
It has been ascertained that these powders are usually inert, i.e. they do not contain
silica, so they do not cause silicosis risks. These powders, because of their dimensions,
are not treated by natural human filtering devices, determining the risk of
PNEUMOCONIOSIS.
It is important to install appropriate fume exhausts near the point where the operations
take place.
Avoid welding on parts that are painted, galvanised or soiled by grease, oil or other.
It is also necessary to be vary careful when handling freshly welded parts because of
obvious burning hazards caused by the heat of the part.

Make sure that in the immediate vicinity of the welding station there are no bins
containing petrol, diesel, solvents, rags or other inflammable materials.
Special precautions are to be taken for the welding of containers or bins that have
contained inflammable liquids and when welding inside metal vessels or in areas
with poor ventilation. Such operations are always to be carried out in the
presence of experts who are able to give the necessary assistance and taking
special precautions to avoid hazardous situations arising.

MOVING PARTS CAN CAUSE ACCIDENTS!

Moving parts, such as fans, rotors and belts can cause the amputation of fingers
D o no tpo
a pp
in ts,
roasuch
ch p ossib
a s colentro
crul shin
ro llergsha zar d
and hands and can remain entangled in loose clothing.
Keep all doors, panels, covers and protections closed and securely positioned.
Stop the motor before installing or connecting the unit.
Only skilled personnel, should it be necessary, can remove protections or covers
to carry out maintenance operations and/or trouble shooting.
To avoid accidental start-ups during maintenance, disconnect the battery
negative cable (-) from the battery.
Always keep hands, hair, clothes and tools away from moving parts.
Before starting the motor after maintenance operations, re-install the panels or
protections and close the doors.
Do not approach possible crushing hazard points, such as control rollers.

AP-AW-0-0_01.fm
1-4 00/0404
 Wire Welding Safety Precautions

1.6 Safety precautions

1.6.1 Applicability
These precautions are to be applied when carrying out the following activities:
– Installation and Start-up;
– Operation in programming mode;
– Maintenance and Repairs;
– Putting out of service and dismantling

1.6.2 Operating modes

Installation and Start-up
– When foreseen, connect the robot pneumatic system to the air distribution line and
carefully check that the setting of the system is the specified pressure value: a
wrong setting of the system pressure influences the correct robot motion.
– Install filters on the pneumatic system to collect any condensation.
– The automated welding system is to be installed in the specific areas prepared for
this purpose.
– Electrical connections are to be made on the system with power cut-out. After the
connection has been made, restore all the protective coverings against accidental
contacts.
– The welding system supply voltage and cable cross sections are to be those
specified in the technical documentation of the product.
– Electrical connections to the welding system are to be performed to avoid all
negative effects on the functioning of the system devices caused by inductive or
capacitive interferences.
– Connection between the plant mains and the generator are to be by means of the
power plug provided on the generator.
– The welding system components are not to be modified during installation.
Unforeseen drilling or cutting operations on the system components could
deteriorate the safety level foreseen by the manufacturer.
– Before starting welding activities, make sure that there is no inflammable material
close to the welding protection.
– The system is only to be used for ARC WELDING. Improper use of the system
could cause damage to persons, the user, the fixtures or an environment hazard
risk.

Operation in programming mode

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

AP-AW-0-0_01.fm
00/0404 1-5
Wire Welding Safety Precautions

Maintenance and Repairs

– Only qualified and authorised persons are to carry out maintenance operations.
– Maintenance operations on the welding system are only to be carried out with the
system power off. Always check that any interconnected voltages have been
deactivated and if necessary wait before starting to operate for sufficient time for
the discharging of the capacitors present in some system circuits.

The Control Unit and Generator electric circuits are supplied independently.
Always open both main switches.

The auxiliary 24 Vdc power supply may be supplied from an external source, or by
the robot control or by the line.

The input terminals and the wiring elements up to the input terminals of the main
switch remain live when the main switch is open.

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

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

Putting out of service and dismantling

– If present, disconnect the robot pneumatic system from the air distribution mains.
– Disconnect the welding channel pneumatic system from the air distribution mains.

AP-AW-0-0_01.fm
1-6 00/0404
 Installation Summarising Table

2. INSTALLATION SUMMARISING
TABLE

The table below summarises the installation sequence for the Wire Welding System.
The table can be used as a check list for the progress of the installation activities.
In this case it is advised to copy the table below and fill in the “Done” column at the end
of each operation.

Tab. 2.1 - Installation summarising table

Step Operation Done
Preparation for installation
1 Installation environment requirements
2 Equipment required
3 Network power supply
Handling and transport
4 Robot and Control Unit
5 Generator
6 Torch cleaning assembly and lubricator
Installation procedure
7 Wire Welding System Components Installation
8 Connection between Control Unit and Robot
9 Connection between generator and peripherals
10 Connection between generator and wire puller
11 Connection between Control Unit and safeties, Field
Bus and line Ethernet
12 Splitter Connection between C4G and TCP Check
(optional)
13 Control Unit connection to the electric power supply
line
14 Generator connection to the electric power supply
line
15 Robot and torch cleaning assembly connection to
the compressed air distribution line
Activation procedure
16 Precautions to be taken before activation
17 Power-on
18 Bleeding the water circuit
19 Network addresses configuration for field bus board
20 Anti-collision kit enabling
21 SMART-ARC and optionals software modul
activation

AP-AW-NS-TIN_01.fm
02/0606 2-1
Installation Summarising Table

AP-AW-NS-TIN_01.fm
2-2 02/0606
 Preparation for the installation, lifting and handling

3. PREPARATION FOR THE

INSTALLATION, LIFTING AND
HANDLING

This chapter contains:

– Preparation for installation
– Handling and transport.

3.1 Preparation for installation

3.1.1 Installation environment requirements

The integrator is to provide and install the following systems and structures:
– welding fumes exhaust system
– install perimeter protections, access doors
– install protective shields for the eyes (see Tab. 1.1 - DIN classes of standard
adiactinic glass) and against sparks caused by the welding process.
Furthermore, the integrator shall comply to the requirements of current directives and
standards so as to install the Wire Welding System correctly and safely in a cell.

The Wire Welding System is not to be started up before the machine where it is
incorporated has been declared in conformity with the provisions of the
applicable directives.

3.1.2 Equipment required

The following equipment is required for the installation of the Wire Welding System:
– Lifting system (crane)
– Standard workshop equipment (screwdrivers, wrenches, etc.).

AP-AW-NH0-TIN_02.fm
02/0606 3-1
Preparation for the installation, lifting and handling

3.1.3 Network power supply

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

application
Compressed
Device Electric power Gas Notes
air
See Control Unit “Transport and
C4G Control Unit 3 kVA / 4.5 A - -
Installation” manual
from 12.7 kVA See details in Tab. 5.1 - Conductor
Generator - -
to 20.7 kVA cross section and protections.
Torch cleaning and
- 7 l / second - See details in Tab. 5.2 - splitter
lubricator assembly
Compressed air supply
1800 Nl / characteristics.
Welding torch and -
minute
production
procedure According to -
- -
need

AP-AW-NH0-TIN_02.fm
3-2 02/0606
 Preparation for the installation, lifting and handling

3.2 Handling and transport

3.2.1 Robot and Control Unit

The Robot and Control Unit customising for the Wire Welding System does not change
the standard lifting procedure.

The Robot and Control Unit lifting and handling procedures are contained in the
relevant manuals. The instruction manuals are indicated in Chap. Reference
documentation.

3.2.2 Generator

The Generator lifting and handling procedures are contained in the relevant
manuals. The instruction manuals are indicated in Chap. Reference
Th e Ge ne ra to r The ge ne rato r
documentation.

3.2.3 Torch cleaning assembly and lubricator

The torch cleaning assembly and lubricator lifting and handling procedures are
contained in the relevant manuals. The instruction manuals are indicated in
Chap. Reference documentation.

AP-AW-NH0-TIN_02.fm
02/0606 3-3
Preparation for the installation, lifting and handling

AP-AW-NH0-TIN_02.fm
3-4 02/0606
 Wire Welding System Components Installation

4. WIRE WELDING SYSTEM

COMPONENTS INSTALLATION

This chapter contains:

– Generator installation
– Torch assembly installation
– Welding wire installation
– Torch cleaning assembly and lubricator installation
– As an alternative,Magnetic torch cleaning assembly installation
– Tool Master installation
– Balancer installation (optional)
– TCP Check installation (optional)
– Location point installation.

AP-AW-ALR-TIN_01.fm
03/0607 4-1
Wire Welding System Components Installation

4.1 Generator installation

Operating procedure
a. The bearing surface where the generator is to be installed is to be able to support
the weight and must not be sloped.
b. The generator may be supplied
with the optional trolley.

c. In this case, place the generator

on the trolley and move this into
the correct position.

d. If the generator does not have

the trolley, place the generator
directly on the floor.

e. Check the level of the coolant in the pump.

The information for the checking and topping up of the coolant level is contained
in the Generator manual. See the relevant instructions manual indicated in
Chap. Reference documentation.

AP-AW-ALR-TIN_01.fm
4-2 03/0607
 Wire Welding System Components Installation

4.2 Torch assembly installation

Operating procedure
a. Attach the flange adapter to the
robot wrist flange using the 4
screws supplied.

b. Remove the 4 coverings (A)

from the anti-collision assembly

c. Attach the anti-collision

assembly using the 4 screws
provided

AP-AW-ALR-TIN_01.fm
03/0607 4-3
Wire Welding System Components Installation

Operating procedure (Continued)

d. Attach the weld torch to the
anti-collision flange as indicated
in the figure.

e. Clamp the torch in the support,

tightening the screw (B)

f. Adjust the inclination of the

torch by means of the clamping
screw (C)

g. Connect the connector (D)

coming from the torch to the
coupling on the anti-collision
flange.

Connect the weld torch to the wire-puller assembly as shown in the figure:

h. Insert the torch connector in the wire-puller seat, taking care to match the
connectors. To clamp the connector, tighten the ring nut.

i. Couple the signals cable coming from the torch. To clamp the connector, tighten
the ring nut on the connector

j. Connect the cooling system fittings to the wire-puller assembly

AP-AW-ALR-TIN_01.fm
4-4 03/0607
 Wire Welding System Components Installation

Operating procedure (Continued)

IThe anti-collision kit has to be enabled using the configuration tool

(see procedure in par. 6.6 Anti-collision kit enabling on page 6-4).

AP-AW-ALR-TIN_01.fm
03/0607 4-5
Wire Welding System Components Installation

4.3 Welding wire installation

Operating procedure
Reel support on board Robot
a. If there is a reel support on board the Robot, the coil is to be inserted in the coil
holder. If inserted correctly, it automatically locks the support.

b. Insert the wire in the sheath as

indicated in figure.

c. Push the wire into the sheath so

as to extract it at the wire-puller
located on the robot forearm.
Position the wire in the rollers
as indicated in figure.

AP-AW-ALR-TIN_01.fm
4-6 03/0607
 Wire Welding System Components Installation

Operating procedure (Continued)

d. Tighten the rollers and adjust
the wire closing pressure
through the specific clamping
devices as indicated in figure.

MARATON bell
e. If there is the Maraton bell in the
cable, just fasten it on the
Maraton Pack bin.

f. Fasten the end of the sheath (B)

to the wire-puller of step (C).

g. Insert the wire in the sheath

using the adapter kit as
indicated in figure (A).

h. Continue the wire installation reading the previous steps c. and d.

AP-AW-ALR-TIN_01.fm
03/0607 4-7
Wire Welding System Components Installation

4.4 Torch cleaning assembly and lubricator

installation
Fig. 4.1 - Overall dimensions and drilling template

AP-AW-ALR-TIN_01.fm
4-8 03/0607
 Wire Welding System Components Installation

Operating procedure
a. If the column is present, fix it to
the ground with appropriate
blocks as indicated in figure (A).

For the type of blocks to

be used and the
tightening torque
values, see the manual
of the manufacturer.

b. Fasten the torch cleaning

assembly and lubricator on the
column as indicated in figure
(A).

If there is no column,
fasten the torch
cleaning assembly and
the lubricator on an
appropriate support.

AP-AW-ALR-TIN_01.fm
03/0607 4-9
Wire Welding System Components Installation

Operating procedure (Continued)

c. Unscrew the ring nut (B) and fill
the container (C) with the
electrolytic liquid supplied
together with the option.

d. tighten the ring nut (B).

e. To regulate the quantity of

electrolytic liquid:

e.1 remove the cover (D)

e.2 turn the adjustment screw (E)

clockwise to increase,
anticlockwise to decrease.

e.3 refit the cover (D).

AP-AW-ALR-TIN_01.fm
4-10 03/0607
 Wire Welding System Components Installation

4.5 Magnetic torch cleaning assembly

installation
Fig. 4.2 - Overall dimensions and drilling template

AP-AW-ALR-TIN_01.fm
03/0607 4-11
Wire Welding System Components Installation

Operating procedure
a. Fasten the column to the
ground with 4 blocks, through
the holes (A).

For the type of blocks to

be used and the
tightening torque
values, see the manual
of the manufacturer.

b. Fasten the torch cleaning

assembly and lubricator on the
column as shown in the figure.
Further details are given
in the magnetic torch
cleaning assembly
installation manual.

c. Fill the container with the electrolytic liquid.

Further details are given in the magnetic torch cleaning assembly
installation manual.

AP-AW-ALR-TIN_01.fm
4-12 03/0607
 Wire Welding System Components Installation

4.6 Tool Master installation

Operating procedure
a. Insert the Tool Master in the threaded hole on robot axis 6 as indicated in figure
(A).

If SMART NS robot is used, the Tool Master values to be assigned for

the tool calculation are:
X = 150 Y=0 Z=-8
To calculate the user TCP (Tool Center Point) see the C4G - Use of
Control Unit manual

AP-AW-ALR-TIN_01.fm
03/0607 4-13
Wire Welding System Components Installation

4.7 Balancer installation (optional)

Operating procedure
a. Fasten the cradle in an
intermediate point of the bundle
to allow the robot maximum
freedom of movement.

b. The balancer is to be fastened

to a stable point, sufficiently
robust to support the weight of
the balancer and the bundle,
and higher than the cradle
coupling point.

AP-AW-ALR-TIN_01.fm
4-14 03/0607
 Wire Welding System Components Installation

4.8 TCP Check installation (optional)

The functioning of the TCP Check could be impaired if the support it is secured
to is electrically connected with the welding ground. If necessary, install
commercial isolators between the TCP Check plate and the support column.

Operating procedure
a. There are 4 holes for M8x25
socket head cap screws to
fasten the TCP Check.

P1 P2

a. If the support column is present,

the TCP Check can be fixed
directly on the specific plate
with 4 M8 diameter holes.

AP-AW-ALR-TIN_01.fm
03/0607 4-15
Wire Welding System Components Installation

Operating procedure (Continued)

a. To secure the column to the
ground, there are 4 diameter
M13 through holes.

Use WURTH TG12-V

type blocks and tighten
to a torque of 75 Nm.

b. The figure indicates the column

general dimensions.
If there is no column,
the TCP Check has to be
fixed on a support.

AP-AW-ALR-TIN_01.fm
4-16 03/0607
 Wire Welding System Components Installation

4.9 Location point installation

Operating procedure
a. Fasten the location point in an
appropriate place (on fixture or
on column).

AP-AW-ALR-TIN_01.fm
03/0607 4-17
Wire Welding System Components Installation

AP-AW-ALR-TIN_01.fm
4-18 03/0607
 Wire Welding System Connections

5. WIRE WELDING SYSTEM

CONNECTIONS

This chapter contains:

– Cables installation hints
– Connection between Control Unit and Robot
– Connection between generator and peripherals:
• For field bus solution:
– Digital I/Os cable (Field bus solution) C4G - torch cleaning assembly
– Multibus cable (Field bus solution) C4G - welding generator
– Wire joint detection sensor (Field bus solution)
• For serial solution:
– Digital I/Os cable (Serial solution) C4G - torch cleaning assembly
– Serial cable (Serial solution) C4G - welding generator
– Wire joint detection sensor (Serial solution)
• Welding ground cable. As alternative, see Ground Cable in Connection
between C4G and Seam Track (optional).
– Connection between generator and wire puller
– Connection between Control Unit and safeties, Field Bus and line Ethernet
– Splitter Connection between C4G and TCP Check (optional)
– Connection between C4G and Seam Track (optional)
– Connections to the power supply networks:
• Control Unit connection to the electric power supply line
• Generator connection to the electric power supply line
• Robot and torch cleaning assembly connection to the compressed air
distribution line.

5.1 Cables installation hints

The connection cables used in the Arc application are to be installed with special care,
paying attention to the following advice:
– protect the cables with appropriate coverings (standard IEC 60204-1)
– arrange the cables in a tidy manner and do not make coils to recover the excessive
length
– avoid power cables and communication cables being too close to each other
– do not use cables that are not foreseen in the Arc application.

AP-AW-C4E-TIN_02.fm
05/0407 5-1
Wire Welding System Connections

5.2 Connection between Control Unit and Robot

Status: – Power off

Material: – Motor cable
– Encoder cable
– Ground cable
Equipment: – 8 mm (0.314 in) wrench

Preliminary procedures / notes

Details of the connections are contained in the relevant Control Unit
and Robot Installation manuals.

Operating procedure

Follow-up procedure
– Not necessary.

AP-AW-C4E-TIN_02.fm
5-2 05/0407
 Wire Welding System Connections

5.3 Connection between generator and

peripherals

Status: – Power off

Material: – Digital I/Os cable
– Multibus cable
– Ground cable
– The cables indicated are supplied in
the application kit.
Equipment: – Wrench, according to the type of
screw used to fasten the ground cable
eyelet.

Preliminary procedures / notes

– The cables indicated are supplied in the application kit, with different lengths
according to the choice made at the time of purchase.
– The following procedures and connections are required:
• For field bus solution: Digital I/Os cable (Field bus solution) C4G - torch
cleaning assembly, Multibus cable (Field bus solution) C4G - welding
generator and Wire joint detection sensor (Field bus solution)
• For serial solution: Digital I/Os cable (Serial solution) C4G - torch cleaning
assembly, Serial cable (Serial solution) C4G - welding generator and Wire
joint detection sensor (Serial solution)
• Welding ground cable.

AP-AW-C4E-TIN_02.fm
05/0407 5-3
Wire Welding System Connections

5.3.1 Digital I/Os cable (Field bus solution) C4G - torch cleaning
assembly

Operating procedure - Digital I/Os cable

a. The digital I/Os cable

electrically connects the torch
cleaning assembly and the
lubricator.

b. Connect the digital I/Os cable

on connector (A) of the
generator.

c. In the case of milled

mechanical torch Cleaning
Unit:

c.1 Connect the other end of the

digital I/Os cable on connector
(C).

d. In the case of magnetic torch

Cleaning Unit:

d.1 Connect the other end of the

digital I/Os cable on connector
(C).

AP-AW-C4E-TIN_02.fm
5-4 05/0407
 Wire Welding System Connections

5.3.2 Multibus cable (Field bus solution) C4G - welding

generator

Operating procedure - Multibus cable

a. Connect the Multibus cable

connector X90 to the IN (B)
connector of the generator.

b. Connect the Multibus cable

connector X93 on connector (D)
X93 on the Control Unit CDP
panel.

The generator network node configuration information (default

settings) is contained in par. 6.5 Network addresses configuration for
field bus board on page 6-3.

5.3.3 Wire joint detection sensor (Field bus solution)

Operating procedure - Wire joint detection sensor (optional)

a. If the joint detection sensor is installed, no connections need to be made. The
signals required are already available through the multibus cable.

AP-AW-C4E-TIN_02.fm
05/0407 5-5
Wire Welding System Connections

5.3.4 Digital I/Os cable (Serial solution) C4G - torch cleaning

assembly

Operating procedure - Digital I/Os cable

X8

a. The digital I/Os cable

electrically connects the torch
cleaning unit and the lubricator
to the C4G

b. Connect the digital I/Os cable

on connector X8 (A) of the C4G
Control Unit.

c. In the case of milled

mechanical torch Cleaning
Unit:

c.1 Connect the other end of the

digital I/Os cable on connector
(C).

d. In the case of magnetic torch

Cleaning Unit:

d.1 Connect the other end of the

digital I/Os cable on connector
(C).

AP-AW-C4E-TIN_02.fm
5-6 05/0407
 Wire Welding System Connections

5.3.5 Serial cable (Serial solution) C4G - welding generator

Operating procedure - Serial cable

X7/SMP

RS422

X90

SERIAL CABLE

a. The serial cable is to come out of the Control Unit through the cable clamp
connector X90 on the CDP panel.
b. The end of the cable inside the
cabinet has an RJ45 connector
(A), connected on X7 of the
CPU SMP.

c. In the case of multi-machine,

there are 2 serial lines and the
second is connected to the
C2SL. module connector
IThe C2SL module (CAN To
Serial) is paty of the option kit
CAN To Serial C4G-CTSK.

RS232/
RS422

AP-AW-C4E-TIN_02.fm
05/0407 5-7
Wire Welding System Connections

Operating procedure - Serial cable (Continued)

d. The other end of the cable has
a SUB-D 9- pin connector (C)
that has to be connected to
connector RS422 on board the
generator.

e. Tighten the connector screws

(C).

AP-AW-C4E-TIN_02.fm
5-8 05/0407
 Wire Welding System Connections

5.3.6 Wire joint detection sensor (Serial solution)

Operating procedure

X1

X81

WIRE JOINT DETECTION SENSOR CABLE

a. Connect the loose connector of

the joint detection sensor cable
on connector X1 (A) of the
generator (B).

b. Connect the joint sensor cable

connector X81 to connector
X81 (C) on the Control Unit
CDP panel.

c. Make sure that the internal

cable connected on connector
X81 CAB is connected to the
FIA board connector X137/FIA
(D).

AP-AW-C4E-TIN_02.fm
05/0407 5-9
Wire Welding System Connections

5.3.7 Welding ground cable

Operating procedure - Welding ground cable

a. Connect the cable to the metal point closest to the welding zone.
b. Connect the ground cable on
connector (E) of the generator.
Position the ground
cable so that there is no
overlaying of spires.

c. Connect the other end of the ground cable to the point previously determined on
the equipment.
d. Perform the system impedance calibration procedure.
The procedure is contained in the Generator manual. See the
instructions manual indicated in Chap. Reference documentation.

AP-AW-C4E-TIN_02.fm
5-10 05/0407
 Wire Welding System Connections

5.4 Connection between generator and wire

puller

Status: – Power off

Material: – 95 mm² (AWG 3/0) cables pack
Equipment: – Cutting pliers.

Preliminary procedures / notes

– The cable indicated is supplied in the application kit, with different lengths
according to the choice made at the time of purchase.
The section of the cables pack that is not overhead is to be positioned
inside metal cable trays to protect against impacts and crushing.
Position the cable pack avoiding overlaying of spires.

Operating procedure

AP-AW-C4E-TIN_02.fm
05/0407 5-11
Wire Welding System Connections

Operating procedure (Continued)

a. Connect the cable pack on the
wire puller installed on board
the robot.
– A = water inlet (blue collar)
– B = water outlet (red collar)
– C =gas inlet
– D = power cable inlet
– E =signals cable inlet
– F = air inlet (yellow collar)
– G = anti-collision

b. Connect the water inlet tube to

connector (A). The tube is
identified by a blue collar.

c. Connect the water outlet tube to

connector (B). The tube is
identified by a red collar.

d. Connect the gas tube to

connector (C). The tube has no
identification collar.

e. Connect the power cable to

connector (D).

f. Connect the signals cable to

connector (E).

g. Check that the air is connected

to connector (F). The tube is
identified by a yellow collar.
Check that connector (G)
(anti-collision) is present.

h. Connect the other end of the cable pack on the generator.

i. The gas tube (H) is excluded.
This has to be connected
directly to the gas bottle or to
the supply coming from the
plant.
– The fitting on the tube is 1/4” G
Fronius code 44.0450.0281.

AP-AW-C4E-TIN_02.fm
5-12 05/0407
 Wire Welding System Connections

Operating procedure (Continued)

j. Connect the water inlet tube to
connector (J). The tube is
identified by a blue collar.

k. Connect the water outlet tube to

connector (K). The tube is
identified by a red collar

l. Connect the power cable to the

+ (plus) connector of the
generator (L).

m. Connect the signals cable to

connector (M).

Follow-up procedure
– Not necessary.

AP-AW-C4E-TIN_02.fm
05/0407 5-13
Wire Welding System Connections

5.5 Connection between Control Unit and

safeties, Field Bus and line Ethernet

Status: – Power off

Material: – According to the type of installation
required.
Equipment: – Standard maintenance equipment.

PLC

Preliminary procedures / notes

– Not necessary.

Operating procedure

a. Safety signals:
– connect the safety signals through connector X30 on the CDP panel at the
cabinet base.
Details of the connections are contained in the Guide to Control Unit
integration manual.

b. C4G slave on field bus:

– if the Control Unit is slave of a field bus network the slave port has to be
connected to the line node.

AP-AW-C4E-TIN_02.fm
5-14 05/0407
 Wire Welding System Connections

Operating procedure (Continued)

Connection details for the field bus network are contained in the
Guide to Control Unit integration manual.
The characteristics of the network connection on the application field
bus are contained in par. 6.5 Network addresses configuration for
field bus board on page 6-3
c. Ethernet network:
– if it is necessary to make
updating though the Ethernet
network, connect the Control
Unit to the line Ethernet. The
connection is to be on
connector X5 of the RPU SMP
board.

Ethernet network connection details are contained in the Guide to

Control Unit integration manual.

Follow-up procedure
– Not necessary.

AP-AW-C4E-TIN_02.fm
05/0407 5-15
Wire Welding System Connections

5.6 Splitter Connection between C4G and TCP

Check (optional)

State: – Power off

Material: – TCP Check cable
Equipment: – Not necessary.

Preliminary procedures / notes

– This procedure is only necessary for the installation of the TCP Check (optional).

Operating procedure

a. Connect the TCP Check cable

on connector (A) of the splitter.
multi machine version, connect the
cable on one of the connectors (B) of
the splitter (C).

b. Connectors (D) are the

connectors of the two optical
sensors used in the TCP
Check.

AP-AW-C4E-TIN_02.fm
5-16 05/0407
 Wire Welding System Connections

Operating procedure (Continued)

c. Connect TCP Check cable
connector X80 on connector
X80 (E) on the Control Unit
CDP panel.

Note: in the Serial solution,

connector X80 (E) is positioned on
the arc outfitting plate.

d. Make sure that the internal

cable connected on connector
X80 CAB is connected to
connector X136/FIA (F) of the
FIA board.

For a multi machine:

e. Repeat the procedure,

connecting the second TCP
Check cable on the second
connector (B) of the splitter.

f. Connect connector X80 of the

second TCP Check cable to
connector X80 (G) on the
Power Control Unit CDP panel.

Follow-up procedure
– Not necessary.

AP-AW-C4E-TIN_02.fm
05/0407 5-17
Wire Welding System Connections

5.7 Connection between C4G and Seam Track

(optional)

Status: – Power off

Material: – Seam Track option
Equipment: – Not necessary.

Preliminary procedures / notes

– This procedure is only necessary for the installation of the Seam Track (optional).
The Seam Track device can only be used in single robot cnfigurations, not with
multi-machine.

Operating procedure
a. Connect the Seam Track loose
connector to connector (A)
installed on the side of the
external box.

b. Connect the Seam Track cable

connector X35 to connector
X35/CDP (B) on the Control
Unit CDP panel.
Note: for the Serial solution,
connector X35 is positioned on the
arc outfitting plate.

AP-AW-C4E-TIN_02.fm
5-18 05/0407
 Wire Welding System Connections

Operating procedure (Continued)

c. Make sure that the internal
cable on connector X35 is
connected to connector (C) on
the CPU MCP-ST

d. Make sure that the 24 Vdc

power supply cable on
connector (D) is connected on
the FIA to connector (E)
X124/FIA.

Operating procedure - Welding ground cable

a. Connect the cable to the metal point closest to the welding zone.
b. Connect the ground cable on
connector (E) of the generator.
Position the ground
cable so that there is no
overlaying of spires.

AP-AW-C4E-TIN_02.fm
05/0407 5-19
Wire Welding System Connections

Operating procedure - Welding ground cable (Continued)

c. Open the cover of the external
box (F) unscrewing the 6
fastening screws.

d. Check the direction of the arrow

on the Hall effect current sensor
(H).

e. The yellow arrow shown in the

figure indicates the direction of
the current flow: it starts from
the ground on the equipment,
and ends on the generator
(from (J) to (G)).

Follow the direction indicated by the arrow stamped on the Hall effect
sensor: the direction represents the current flow that comes from the
ground point on the equipment to reach the generator.

f. Insert the ground cable in the cable clamp (G).

g. Pass the ground cable into the Hall effect current sensor (H).

h. Bring the ground cable out from the cable clamp (J).

AP-AW-C4E-TIN_02.fm
5-20 05/0407
 Wire Welding System Connections

Operating procedure - Welding ground cable (Continued)

i. Close the external box cover.

j. Lock down the cable clamps (G) and (J).

k. Connect the other end of the ground cable on the point previously determined on
the fixture.
l. Perform the system impedance calibration procedure.
The procedure is contained in the Generator manual. See the
instructions manual indicated in Chap. Reference documentation.

Follow-up procedure
– Not necessary.

AP-AW-C4E-TIN_02.fm
05/0407 5-21
Wire Welding System Connections

5.8 Connections to the power supply networks

The Wire Welding System requires the following connection to the power supply lines:
– Control Unit connection to the electric power supply line
– Generator connection to the electric power supply line
– Robot and torch cleaning assembly connection to the compressed air distribution
line.

5.8.1 Control Unit connection to the electric power supply line

The information for connection to the electric power supply line is contained in
the C4G installation manual (see Chap. Reference documentation).

AP-AW-C4E-TIN_02.fm
5-22 05/0407
 Wire Welding System Connections

5.8.2 Generator connection to the electric power supply line

Connect the generator power supply plug to an appropriate socket.
Upstream of the generator there may be a switch/protection fuse connection of the
power supply cable with appropriate characteristics.
Tab. 5.1 contains the electrical connection characteristics.

Tab. 5.1 - Conductor cross section and protections

Power supply
Power supply Network protection
Type of generator Power conductor cross
voltage characteristics
section
Fronius 3 x 400 V ac ± 15% Primary continuous 35 A delayed
(all models without 50 / 60 Hz power (100% of
transformer) insertion time): 12.7
kVA 4 mm²
(for long sections
Fronius 3 x 500 V ac ± 10% Primary continuous 32 A delayed provide an adequate
(all models with 50 / 60 Hz power (100% of cross section)
transformer) insertion time):
20,7 kVA
cos ϕ 0.9

Status: – Power cut-out directly from the supply

(busbar)
Material: – Not necessary
Equipment: – Not necessary

Preliminary procedures / notes

– Not necessary

AP-AW-C4E-TIN_02.fm
05/0407 5-23
Wire Welding System Connections

Operating procedure
a. Set the main switch lever (A) to
0 (OFF).

b. Connect the plug (B) to the

socket.

c. The socket must have

connection to ground.

Before connecting, make sure that there is no power in the power

supply line

Follow-up procedure
Do not close the main switch to supply the Generator until the
installation procedure has terminated.

AP-AW-C4E-TIN_02.fm
5-24 05/0407
 Wire Welding System Connections

5.8.3 Robot and torch cleaning assembly connection to the

compressed air distribution line
Tab. 5.2 contains the pneumatic connection characteristics

Tab. 5.2 - splitter Compressed air supply characteristics

Required air pressure
Device Supply fitting /tube
and flow rate
7 l / second
Torch cleaning 1.53 gallon / second
1/4“G fitting
assembly and lubricator 0.6 MPa
6 bar
1800 Nl / minute
395.94 gallon / minute
Robot 3/8“G fitting
0.6 MPa, 0.7 MPa (max)
6 bar, 7 bar (max)

State: – Pneumatic supply cut out directly from

mains
Material: – Not necessary
Equipment: – Standard maintenance equipment.

Preliminary procedures / notes

– The procedure gives information on the compressed air connection points.
– The air is to be suitably filtered, adjusted to the pressure indicated and provided
with gate to cut out for maintenance purposes.
– The connection is made directly on the inlet fitting of the devices.

AP-AW-C4E-TIN_02.fm
05/0407 5-25
Wire Welding System Connections

Operating procedure
a. Supply compressed air to the
fitting (A) installed at the robot
base.

b. Supply compressed air to the

fitting (B) installed on the Torch
Cleaning Assembly and
lubricator.

Before connecting, check there is no air in the supply line.

Follow-up procedure
Do not open the manual valve to supply the devices until the
installation procedure has terminated.

AP-AW-C4E-TIN_02.fm
5-26 05/0407
 Wire Welding System Connections

5.9 Serial line (only for serial solution)

Follow the serial line diagram used for C4G Control unIt and Fronius Generator
connection.

For further information regarding connections and wire sections, see the robot
Circuit Diagram.

AP-AW-C4E-TIN_02.fm
05/0407 5-27
 - Multibus connectors and cable

5.10 Multibus connectors and cable

– Connector positions on board robot
– Connector pin-out
– Multibus cable electrical characteristics.

5.10.1 Connector positions on board robot

The multibus cable starts from the robot base and, according to the type, terminates on
board, with position and connecto name as indicated in Tab. 5.3.
Tab. 5.3 - Connector position on board robot
Connector at robot Connector on board
Robot
base Robot
SiX X90 *¹ X100 *¹ (on axis 3)
NS X100 (on axis 3)
NM X100 (on axis 3)
X200 (on axis 3)
NH1/2/3
X202 *¹ (on wrist)
NH4 X200 *¹ (on wrist)
X90
X100 (on axis 3)
NJ
X202 *¹ (on wrist)
X100 (on axis 3)
NX1-600
X202 *¹ (on wrist)
NX1-800 X100 (on axis 3)

*¹ Optional, according to the type of outfitting or bazooka installed

AP-0-0-0_01.fm
5-28 03/0106
 - Multibus connectors and cable

5.10.2 Connector pin-out

The multibus cable is connected at the ends to connectors with the pin-out indicated in
Tab. 5.4.

– Connector for:
• field bus signals
• 24 Vdc
• KSR/HSI *¹
– 17 Pins
– female on robot wrist
– male on robot base.

Front view - Male connector Front view female connector

Tab. 5.4 - Multibus connector pin-out

Connector INTERBUS PROFIBUS DEVICENET

Pin out Description Description Description
1 0 Vdc US1 0 Vdc US1 0 Vdc US1
2 0 Vdc US2 0 Vdc US2 0 Vdc US2
3 24 Vdc US2 24 Vdc US2 24 Vdc US2
4 24 Vdc US1 24 Vdc US1 24 Vdc US1
5 Ground Ground Ground
6 Not used PROFIBUS B Not used
7 DO Not Used Not used
8 DO Not Used Not used
9 DI Not used Not used
10 DI Not used Not used
11 COM PROFIBUS A Not used
12 KSR / HSI + *¹ KSR / HSI + *¹ KSR / HSI + *¹
13 Not used Not Used CAN_H
14 Not used Not Used CAN_L
15 Reserved Reserved Reserved
16 Reserved Reserved Reserved
17 KSR / HSI - KSR / HSI - KSR / HSI -
*¹ the conductor definition becomes HSI for HANDLING applications and KSR for SPOT
WELDING.

AP-0-0-0_01.fm
03/0106 5-29
 - Multibus connectors and cable

5.10.3 Multibus cable electrical characteristics

The electrical characteristics of the multibus cable are the following:
• maximum voltage is not to exceed 30 Vdc
• maximum current for the conductors is 4 A
• 24 Vdc Bus US1 corresponds to +24Vdc I/O on the C4G. It is always present and
can be used to supply the inputs and electronics of the slave modules on board the
robot
• 24 Vdc SFT US2 corresponds to +24Vdc I/O SAFE on the C4G. It is only present
with K101 and K102 closed (DRIVE ON) and can be used to supply the outputs of
the slave modules on board the robot.
The cable can also be used for other purposes besides for field buses.

For further details regarding the connection and cross section of the wires, see
the robot Circuit Diagrams.

To select the power supply source inside the C4G control unit, see the “Guide to
integration: safeties, I/O and communications” manual in the chapter “Choice of
24 dc power supply source”.

AP-0-0-0_01.fm
5-30 03/0106
 Wire Welding System Activation

6. WIRE WELDING
SYSTEM ACTIVATION

This chapter contains:

– Precautions to be taken before activation
– Connectors pin-out
– Power-on
– Bleeding the water circuit
– Network addresses configuration for field bus board
• Generator
– Anti-collision kit enabling
– SMART-ARC and optionals software modul activation.

6.1 Precautions to be taken before activation

a. Check presence and efficiency Installation environment requirements.

b. Wear the individual protection devices as indicated in par. 1.3 Protection of the
eyes and the body on page 1-2

6.2 Connectors pin-out

For information regarding the arrangement and the pin-out of the connectors, see
the Robot manual (Chap. Reference documentation).

AP-AW-C4E-TIN_03.fm
02/0607 6-1
Wire Welding System Activation

6.3 Power-on
Proceed as follows:

If the generator has been stored at a temperature different to that for use,
power-on and wait for it to acclimatise

a. Power on the C4G Control Unit, as indicated in the Instructions for use manual.

For information regarding faults that could occur on the C4G Control Unit, see the
Instructions for Use manual (see Chap. Reference documentation).

b. Bring the main switch on the generator to ON

c. Open the pneumatic system cut-out ball valve. Supply the robot and the Torch
Cleaning assembly and lubricator with compressed air.

d. Open the gas system flow regulator.

For information regarding faults that could occur on the generator, see the
Instructions for Use manual (see Chap. Reference documentation).

6.4 Bleeding the water circuit

For information regarding the water bleeding procedure, see the Generator
manual (Chap. Reference documentation).

AP-AW-C4E-TIN_03.fm
6-2 02/0607
 Wire Welding System Activation

6.5 Network addresses configuration for field

bus board

6.5.1 Generator
The configuration of the addresses changes according to the type of board installed on
the generator, as indicated in Tab. 6.1

Tab. 6.1 - Field bus connection characteristics

Type of board
Characteristic
Device Net *² Profibus-DP *² Interbus-S
Node 13 13 self-determination
Speed 500 kbaud set in software self-determination
Termination active (On) *¹ active (On) *¹ not required

*¹ if the generator is the last network node.

*² The settings on the DeviceNet and Profibus-DP nodes are performed on the
DIP-SWITCHES of the network module installed inside the generator

Example of configuration with DIP-SWITCH Example of configuration with rotary selector

switches

For information regarding the addresses configuration procedure, see the

Generator manual (see Chap. Reference documentation).

AP-AW-C4E-TIN_03.fm
02/0607 6-3
Wire Welding System Activation

6.6 Anti-collision kit enabling

Operating procedure
Summary of the enabling procedure

a. From left menu of IDE environment, select “SETUP”

b. Select the “I/O Tool” icon

c. From the menu displayed on the bottom section of the screen select “DSA”

d. Set “ROBOT ALARM” to ON

e. Select “SET”

f. Confirm and save with “SAVE”

g. Restart the system with Restart Cold to make the parameter change operative.
Robot reset after a crash

a. On the Teach Pendant there is a function to cut out the robot alarm signal for 60
seconds.

b. If it is not reset within 60 seconds the robot returns to alarm state.

Further details and information can be found in the C4G manual. Control Unit use,
chapter “I/Os configuration program” (see Chap. Reference documentation).

6.7 SMART-ARC and optionals software modul

activation

For information regarding the activation and use of the software:

• SMART-ARC
• SMART-ARC SPOT
• SMART-ARC SCRATCH START
• SMART-ARC OVERLAP
• WEAVING MOTION
• SMART-SEARCH
see the related manual (see Chap. Reference documentation).

AP-AW-C4E-TIN_03.fm
6-4 02/0607
 Wire Welding System Activation

6.8 Robot moves programming hints

During the welding cycle programming the maximum range of axis 1 has to be checked.
An amplitude of more than 140° could cause excessive wear and damage the outfitting
on board the robot.
Therefore the amplitude is to be limited within a range of 140°.

If the robot axis 1 amplitude is excessive, it could cause damage to the outfitting.
It is recommendedto limit the range of axis 1 to -70°/+70° from a hypothetical
central work point (140° maximum range).

-70

+70

AP-AW-C4E-TIN_03.fm
02/0607 6-5
Wire Welding System Activation

AP-AW-C4E-TIN_03.fm
6-6 02/0607
 Wire Welding System Deactivation

7. WIRE WELDING SYSTEM

DEACTIVATION

Operating procedure

a. Perform the C4G Control Unit shut-down and set the main switch to OFF

For detailed information on the C4G shut-down procedure, see the relevant
instructions manual (see Chap. Reference documentation).
For d etai led i nfor matio n on th e

b. Set the Generator main switch to OFF

c. Bring the compressed air cut-out ball valve to closed position

d. Close the gas system cut-out ball valve.

AP-AW-C4E-TIN_04.fm
00/0404 7-1
Wire Welding System Deactivation

AP-AW-C4E-TIN_04.fm
7-2 00/0404
COMAU Robotics services
Repair: repairs.robotics@comau.com
Training: training.robotics@comau.com
Spare parts: spares.robotics@comau.com
Technical service: service.robotics@comau.com