Comau Robotics

Instruction Handbook

Continuous Wire Welding

System - Rel. 4

Technical Specification, Maintenance for FRONIUS

Welding System (Serial) with SiX Robots

CR00757489_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 © 2006 by COMAU - Date of publication 06/2007

 Summary

SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..III
Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV

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. APPLICATION INTEGRATION PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2.1

Components common to the applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Specific components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

3. DESCRIPTION OF THE WIRE WELDING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . ..3.1

Configurations available. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Robot SiX, Fronius generator and serial connection GTWFR (GaTeWayFRonius) . . . . . . . . . 3.3
Variants for multi machine versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

4. WIRE WELDING SYSTEM ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4.1

Application connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Serial cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Ground cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Cables pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Outfitting on board robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
Internal outfitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
Wire puller assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Bundle and welding torch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Anti-collision kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Tool Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Torch cleaning assembly and lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

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Summary

Mechanical milled torch cleaning assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

Digital I/O cable from mechanical torch cleaning assembly to C4G. . . . . . . . . . . . . . . . . 4.12
Magnetic torch cleaning assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Digital I/Os cable from magnetic torch cleaning assembly to C4G. . . . . . . . . . . . . . . . . . 4.14
Coil holder support or Maraton PAC bell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Arc outfitting board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
Robot support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
SmartArc application software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19

5. OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1
Transport trolley (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
3x500V autotransformer (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Wire joint detector sensor (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Joint detector wiring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Wire-cutter (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
TCP Check (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
TCP Check for Robot Slave (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Location point (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Balancer assembly (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Seam Track (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

6. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1
Preventive and special maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

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 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.

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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 Specification, Maintenance for

System FRONIUS Welding System (Serial) with
SiX Robots
– Integration, Transport and Installation for
FRONIUS Welding System (Serial) with
SiX Robots
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 – ISaGRAF Workbench
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

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 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.

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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.

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 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.

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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.

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 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.

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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.

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 Application integration principle

2. APPLICATION INTEGRATION
PRINCIPLE

The application consists essentially of:

– C4G Control Unit
– Robot
– External device for the technological process (weld gun, gripper, weld torch, etc.)
coupled, where necessary to its specific fixture.
The applications have a modular structure so as to create numerous solutions with a
minor number of components.

2.1 Components common to the applications

The applications are simplified by some common components:
– C4G Control Unit: common to all applications.
– Field bus boards to be installed in the Control Unit. The choice can be made
between DeviceNet, Profibus-DP and Interbus-S rame
– Field Bus cable and power supply, cable installed inside the Control Unit, to
supply 24V and signal from the field bus boards on connector X93 of CDP panel
(at cabinet base).
– Multibus Cable, cable outside the Control Unit, to connect connector X93
from the Control Unit CDP panel to external units having the same bus and an
appropriate connector:
• device mounted on robot
• device control equipment (if present)
• other devices installed near the robot.
– Robot of the N family (NS, NM or NH), to be chosen according to the type of device
(weld gun, gripper, torch) mounted on the robot.

2.2 Specific components

According to the type of application, specific components are available:
– Outfittings, grouping together piping and cables that have to reach the robot to
terminate on the external device
– Equipment to control devices mounted on the robot and/or other devices installed
near the robot.
Both are available also with options to adapt to the requirements of the integrator.
Fig. 2.1 indicates the integration principle.

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Application integration principle

Fig. 2.1 - Integration principle diagram

A C4G Control Unit D Outfitting

B Field bus boards E Device mounted on robot (e.g weld gun)
C Robot F Device control equipment (if required)

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 Description of the Wire Welding System

3. DESCRIPTION OF THE WIRE

WELDING SYSTEM

The wire welding system performs the welding with the following processes (according
to the generator usedSistema di Saldatura a filo continuo):
– MIG/MAG synergic
– MIG/MAG pulsed synergic
– MIG/MAG Brazing pulsed synergic.
The wire welding system is an application composed of Sistema di Saldatura a filo
continuo:

– Control unit C4G *¹

– Robot SMART SiX *¹
– Wire Welding System Elements for Serial configuration:
• System GTWFR (GaTeWayFRonius) connection to CPU SMP serial port via
iRS-422
• Serial cable
– Generator *²
– Application connection cables
– Outfitting on board robot
• Wire puller assembly *²
• Bundle and welding torch
• Anti-collision kit
• Tool Master
– Robot support
– Torch cleaning assembly and lubricator
– Coil holder support or Maraton PAC bell
– Software aplicativo SmartArc
– Options.

The arc welding application cannot be installed on systems other than those
indicated above.

*¹ For information regarding the C4G Control Unit, the Robot and the field bus
board, see the relevant instruction manuals indicated in Cap. Reference
documentation.
*² The components indicated are Comau customised. The relevant instruction
manuals are indicated in Cap. Reference documentation.

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3.1 Configurations available

The Sistema di Saldatura a filo continuo is available in several configurations
distinguished by
– welding process used
– communication mode between C4G control unit and generator
– type of cooling (water or gas).

Tab. 3.1 - Sistema di Saldatura a filo continuo: configurations

available
Communication
Process Cooling Generator Robot Control Unit Layout
mode
Water TS 4000
MIG/MAG synergic Serial GTWFR SiX C4G - RCC1 Fig. 3.1
Gas TS 4000
MIG/MAG synergic TPS 3200
Water TPS 4000
MIG/MAG pulsed TPS 5000
synergic Serial GTWFR SiX C4G - RCC1 Fig. 3.1

MIG/MAG Brazing Gas TPS 3200

pulsed synergic
Multi machine
variants of previous configurations Fig. 3.2
version

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3.2 Robot SiX, Fronius generator and serial

connection GTWFR (GaTeWayFRonius)
Fig. 3.1 - Configuration layout

R
A F
S L
K J
O
Q M
C Z P
T E B
D N
C H
Y G
D N
Z X U
I
W Z
T
T
V

Tab. 3.2 - Application composition

Item Installation
Description
Fig. 3.1 notes
A Control Unit C4G - RCC1 *¹
B Robot SiX *¹
C Wiring for torch cleaning assembly *³
D Wiring for joint detection option *³
E Generator *²
F Torch cleaning assembly and lubricator *¹
G Wire joint detector sensor (optional) *¹
H Internal outfitting *¹
I Robot support *¹
J Wire puller assembly *¹
Wire puller support *¹
K
Outfitting screws etc. *¹
L Bundle and welding torch *²

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Tab. 3.2 - Application composition (Continua)

Item Installation
Description
Fig. 3.1 notes
Tool Master *¹
M
Anti-collision kit *¹
N Cables pack *²
Internal HSI cable. It is required on Control Unit Rel. 2 and with the option Wire
O *³
joint detector sensor (optional), Seam Track (optional) o TCP Check (optional)
P Coil holder support
*²
Q Maraton PAC bell
R Balancer assembly (optional) *³
S Wire-cutter (optional) *³
TCP Check (optional)
T TCP check cable *³
Cabinet internal connection cable FIA - CDP
U Location point (optional) (alternative to TCP check) *³
V Support column for TCP check or location point *³
W Serial cable *¹
X Ground cable *¹
Y Arc outfitting board *¹
Z Seam Track (optional) *³
*¹ component is obligatory in the configuration
*² component is obligatory with alternatives available
*³ optional component

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3.3 Variants for multi machine versions

Fig. 3.2 - Configuration layout

A C
Power
D

I H
H

F
G B

Tab. 3.3 - Composition of application

Item Installation
Description
Fig. 3.2 notes
A Control Unit C4G - RCC1 *¹
B Robot SiX controlled by Control Unit (A) *¹
C Power control unit (Multi machine) *¹
D Robot SiX controlled by Control Unit (C) *¹
E TCP Check for Robot Slave (optional) *³
F Serial cable for Robot Generator (B), connected on X7/SMP *¹
Serial cable or Robot Generator (D), connected on CAN To Serial C4G-CTSK
G *¹
option
H Wiring for torch cleaning assembly *³
I CAN To Serial C2SL module (in CAN To Serial C4G-CTSK option) *¹

*¹ component is obligatory in the configuration

*² component is obligatory with alternatives available
*³ optional component

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4. WIRE WELDING SYSTEM

ELEMENTS

This chapter contains:

– Application connection cables
– Generator
– Outfitting on board robot
• Internal outfitting
• Wire puller assembly
• Bundle and welding torch
• Anti-collision kit
• Tool Master
– Torch cleaning assembly and lubricator
• Mechanical milled torch cleaning assembly
• Magnetic torch cleaning assembly
– Coil holder support or Maraton PAC bell
– Arc outfitting board
– Robot support
– SmartArc application software.

4.1 Application connection cables

The connection cables with the application are.

Tab. 4.1 - Connecting cables for the application

External Serial cable (from Control Unit to Generator)
Ground cable for Generator
Cables for robot:
– Cables pack
– Torch wiring harness (see par. 4.3.3 Bundle and welding torch ” a pag. 4-8)

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4.1.1 Serial cable

The serial cable connects the Control Unit CPU to the generator. The serial cable is only
required in the Serial configuration.

Comau code Description

CR16650260 Serial cable, length 7 m (23 ft)
CR16650261 Serial cable, length 12 m (39.4 ft)
CR16650262 Serial cable, length 17 m (55.8 ft)
CR16650263 Serial cable, length22 m (72.2 ft)
CR16650264 Serial cable, length27 m (88.6 ft)
CR16650265 Serial cable, length 32 m (105 ft)

For further information see the Circuit Diagram.

4.1.2 Ground cable

Comau code Description

19060484 Ground cable 95 mm², 10 m (32.8 ft)

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4.1.3 Cables pack

Comau code Type of cooling Description

Cables pack 95 mm² (AWG
19060483
3/0) length 8 m (26.2 ft)
Cables pack 95 mm² (AWG
19060441
3/0) length 15 m (49.2 ft)
Water
Cables pack 95 mm² (AWG
19060442
3/0) length 20 m (65.6 ft)
Cables pack 95 mm² (AWG
19060443
3/0) length 30 m (98.4 ft)
Cables pack 70 mm² (AWG
CR16658200 Gas
2/0) length 8 m (26.2 ft)

The electric connection detail of the cables is contained in the application Circuit
Diagram.

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4.2 Generator
The generator differs in the following:
– Connection to the C4G Control Unit
– welding process
– cooling method.
The generator is supplied independently and receives the control signals via the
connection cable coming from the Control Unit.

Connection to C4G Control Unit

– the generator includes the serial I/O module. The GTWFR serial interface
developed for the C4G Control Unit is exclusively for Comau use.
– the generator with serial interface does not require the I/O interface module
because the connection of the Torch cleaning assembly and lubricator and the
Wire-cutter (optional) is by means of the DSA I/Os.
– the generator serial port RS 422 is connected to the serial port X7 of the C4G CPU
SMP. In the multi machine cable, the second generator is connected to serial port
CAN To Serial C4G-CTSK option.

Welding process
Generators are available for:
– synergic MIG/MAG with Fronius TS 3200 and TS 4000
– synergic pulsed MIG/MAG with Fronius TPS 3200, TPS 4000 and TPS 5000
– synergic pulsed brazing MIG/MAG with Fronius TPS 3200, TPS 4000 and TPS
5000.
The maximum deliverable current of the 3200 model has a lower limit value than the
4000 model. If cooling is by gas, the use of the TPS 4000 and TPS 5000 generator is
not advisable.

Cooling method
Generators are available with cooling by:
– water
– gas.

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Generator including trolley (side view) Generator (front view)

Tab. 4.2 - Generator order codes

Communication
Comau code Type of process Fronius Cooling
method
CR16659080 Synergic MIG/MAG Serial TS4000
Synergic. pulsed synergic
CR16659180 MIG/MAG welding and synergic Serial TPS3200
pulsed Brazing
Synergic, synergic pulse Water
CR16659280 MIG/MAG, synergic pulsed Serial TPS4000
MIG/MAG brazing
Synergic, synergic pulse
CR16500780 MIG/MAG, synergic pulsed Serial TPS5000
MIG/MAG brazing (500 A) *¹
CR16659480 Synergic MIG/MAG Serial TS4000
Synergic. pulsed synergic Gas
CR16659380 MIG/MAG welding and synergic Serial TPS3200
pulsed Brazing

*¹ To be used with 500 A torch assembly only

4.3 Outfitting on board robot

4.3.1 Internal outfitting

The outfitting assembly consists of brackets and screws to fasten the outfitting on board
the Robot.
The internal outfitting is already installed on robots.

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Tab. 4.3 - Internal outfitting order codes

Comau code Description
CR16500080 Internal outfitting assembly.

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4.3.2 Wire puller assembly

The wire puller assembly is controlled by the generator. It is installed on board the robot
by a special support and the connections between the wire puller assembly and the
generator are by means of a cable pack. On the front part of the puller the Bundle and
welding torch is connected that starts from the wire puller assembly.
The wire puller assembly is supplied already installed on SiX robots.
The wire puller assembly internal rollers are supplied for iron wire Ø 1.2 mm (0.047 in).
Upon request rollers are available for wire Ø 0.8 mm (0.031 in) and 1 mm (0.039 in).

Wire puller assembly (rear view) Wire puller assembly (front view)

Tab. 4.4 - Wire puller assembly order codes

Comau code Description
FRONIUS Wire puller assembly with rollers for iron wire Ø 1.2 mm
16689485 (0.047 in).
For different diameters ask when ordering.

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4.3.3 Bundle and welding torch

The welding torch is available with different slanting angles and can be fitted, regardless
of the slant angle, with contact tip diameter 0.8 mm (0.031 in), 1.0 mm (0.039 in) and 1.2
mm (0.047 in).
The welding torch requires periodical cleaning to be carried out with the Torch cleaning
assembly and lubricator.
Versions are available with either water or gas cooling.
The bundle and welding torch have to be combined with the sheath and suitable contact
tip kit according to the wire diameter.
The sheath and contact tip become consumed by use and it is necessary to use the
same kit as spare part for replacement according to wear.

Tab. 4.5 - Order codes for bundle and welding torch - water
cooled
Comau code Robot Description
16689488 Bundle and torch 300A D15 angle 0°
16689487 Bundle and torch 300A D15 angle22°
16689489 SiX Bundle and torch 300A D15 angle 36°
16689490 Bundle and torch 300A D15 angle 45°
CR16500880 Bundle and torch 500A D17 angle 22°
16665480 *¹ SiX Sheath and contact tip kit Ø 0.8 (0.031 in) for 300A torch
16665580 *¹ ( Sheath and contact tip kit Ø 1.0 (0.039 in) for 300A torch
16665680 *¹ 300 A torch) Sheath and contact tip kit Ø 1.2 (0.047 in) for 300A torch
CR16100280 *² SiX Sheath and contact tip kit Ø 0.8 (0.031 in) for 500A torch
CR16100380 *² ( Sheath and contact tip kit Ø 1.0 (0.039 in) for 500A torch
CR16100480 *² 500 A torch) Sheath and contact tip kit Ø 1.2 (0.047 in) for 500A torch

*¹ The kit contains 3 sheaths and 3 contact tips.

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*² The kit contains 3 sheaths and 10 contact tips.

Tab. 4.6 - Order codes for bundle and weld torch - gas cooled
Comau code Robot Type Description
CR16658205 Bundle and torch angle 22° up to 200A with CO2
MTG 2500
CR16658201 Bundle and torch angle 45° up to 200A with CO2
SiX
CR16658207 Bundle and torch angle 22° up to 200A with CO2
MTG 4000
CR16658203 Bundle and torch angle 45° up to 200A with CO2
Kit with sheath and contact tip for torch type MTG
16689498 *³ MTG 2500
2500
SiX
Kit with sheath and contact tip for torch type MTG
CR16658211 *³ MTG 4000
4000

*³ The kit contains 1 sheath and 3 contact tips for each wir diameter:
– 1 sheath 0.8/3.5 metres, 1 x 1.0/3.5 metres, 1 x 1.2/3.5 metres
– 3 contact tips 0.8/M10, 3 x 1.0/M10, 3 x 1.2/M10.

4.3.4 Anti-collision kit

The anti-collision kit signals the impact of the torch with parts of fixtures or welded parts
and stops the robot. It is located between the robot wrist and the welding torch.
The anti-collision kit is supplied already installed on SiX robot.

Tab. 4.7 - Anti-collision kit order codes

Comau code Description
CR16500280 Anti-collision kit

The anti-collision kit has to be enabled. See details in the Integration, Transport
and Installation manual in the chapter “Wire Welding System components
installation”.

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4.3.5 Tool Master

The tool master is a calibrated iron round bar section used for the Tool Center Point
(TCP) calculation.

For the Tool calculation see the C4G manual - Use of Control Unit.

The tool master is supplied on the SiX robot outfitted for arc welding application.

Tab. 4.8 - Tool Master order code

Comau code Description
81783801 Tool Master

4.4 Torch cleaning assembly and lubricator

There are two torch cleaning systems currently used in the Wire Welding System:
– Mechanical milled torch cleaning assembly
– Magnetic torch cleaning assembly.

4.4.1 Mechanical milled torch cleaning assembly

The mechanical torch cleaning assembly is a device that removes the accumulation of
splatter by milling. Since this is a mechanical operation, the device can be applied to all
wire welding processes.
The mechanical milled torch cleaning assembly includes:
– cleaning unit
– lubricator
– supporting column.
The assembly can be used with the Wire-cutter (optional).
The installation requires the Arc outfitting board.

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Serial configuration
The assembly is electrically connected to the C4G Control Unit by means of a multi-pole
cable and using the DSA I/Os.
To operate it requires (not included in the cleaning assembly):
– Digital I/O cable from mechanical torch cleaning assembly to C4G
– compressed air supply.

Torch cleaning assembly and lubricator (rear view) Torch cleaning assembly and lubricator (front view)

Tab. 4.9 - Mechanical milled torch cleaning assembly order

codes
Comau code Description
Mechanical milled torch cleaning assembly Robacta REAMMER,
16689494
with lubricator and support column, height 700 mm (27.56 in).

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4.4.1.1 Digital I/O cable from mechanical torch cleaning assembly to C4G
This cable has to be used to connect the mechanical torch cleaning assembly to the
C4G Control Unit when Serial communication is used.

Comau code Description

Digital I/O cable, length 8
CR16651380
metres (26.25 ft)
Digital I/O cable, length 15
CR16651381
metres (49.21 ft)

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4.4.2 Magnetic torch cleaning assembly

The magnetic torch cleaning assembly is a device suitable for all types of torches since
there is no mechanical contact between the device and the torch.
The accumulation of splatter is removed by a short, strong magnetic field created by a
coil inside the device. Since this is an electromagnetic phenomenon, this torch cleaning
assembly is not applicable where there are materials that are non ferrous or not
steel.
The magnetic torch cleaning assembly includes:
– cleaning assembly
– lubricator
– supporting column.
The assembly can be used with the Wire-cutter (optional).

Serial configuration
The assembly is connected electrically to the C4G Control Unit by a multipole cable and
the use of the DSA I/Os.
For operation the following is required (not included in the cleaning assembly):
– Digital I/Os cable from magnetic torch cleaning assembly to C4G
– 230 Vac electric power supply.
The installation requires the Arc outfitting board.

Torch cleaning assembly and lubricator

Tab. 4.10 - Magnetic torch cleaning assembly order codes

Comau code Description
Magnetic torch cleaning assembly Robacta TC1000, with
CR16658183
lubricator and support column, height 700 mm (27.56 in).

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4.4.2.1 Digital I/Os cable from magnetic torch cleaning assembly to C4G
This cable has to be used to connect the magnetic torch cleaning assembly to the C4G
Control Unit in Serial communication mode.

Comau code Description

Digital I/Os cable, length 8
CR16651480
metres(26.25 ft)
Digital I/Os cable, length 15
CR16651481
metres (49.21 ft)

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4.5 Coil holder support or Maraton PAC bell

The welding wire is usually available in coil or in a container.
According to the type of wires purchased, they can be installed using one of these
alternatives:
– coil holder support (for wire on coil), installed on board the robot
– Maraton PAC bell (for wire in container), that can be positioned according to
installation requirements, considering a maximum distance of 3.5 m (11.48 ft) or 6
m (19.68 ft) between bell and wire puller.
It is advised to support the cables pack and welding wire with the specific Balancer
assembly (optional).

Coil holder support Maraton PAC bell

Tab. 4.11 - Coil holder support or bell order codes

Comau code Description
CR16500180 Coil holder cupport with wire-guide sheath
16689493 Maraton PAC bell with 3.5 m (11.48 ft) sheath
CR16100080 Maraton PAC with 6 m (19.68 ft) sheath

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4.6 Arc outfitting board

This board has to be installed at the base of the C4G Control Unit cabinet if one of the
following items is installed:
– Torch cleaning assembly and lubricator
– TCP Check (optional)
– Seam Track (optional)
– Wire joint detector sensor (optional).
The board is necessary in the serial configuration.

Comau code Description

CR16650180 Arc outfitting board

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4.7 Robot support

With the support, the correct positioning is obtained for the robot, which is fastened on
the upper base.
Different types of supports are available for robots with different heights.

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Tab. 4.12 - Robot support order code

Comau code Description
CR82221809 Support for robot SiX H=500 mm
CR82221810 Support for robot SiX H=750 mm
CR82221811 Support for robot SiX H=1000 mm
CR82221812 Support for robot SiX H=1350 mm sloped 30°

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For further information see the SiX robot manuals.

4.8 SmartArc application software

An application software, installed on the C4G Control Unit, to manage a Wire Welding
System in a simple and homogenous manner.
The software is only supplied together with the outfitted robot and is configured
according to the order of the Customer. The user interface is available on the teach
pendant.
The basic configuration consists of the SMART-ARC package, to which additional
functions can be added through optional packages.

For information, see the SMART-ARC software manual.

Tab. 4.13 - SMART-ARC software and optional packages code

Comau code Description Notes
Main software package for wire welding applications (arc
13607360 SMART-ARC
welding).
Requires SMART-ARC package.
13607560 SMART-ARC SPOT Software option to execute an intermittent process without
stopping the robot motion.
Requires SMART-ARC package.
SMART-ARC SCRATCH
13607660 Software option to move the robot for easier arc spark
START
starting.
Requires SMART-ARC package.
13607760 SMART-ARC OVERLAP
Software option to restart overlapping the weld bead.
Requires SMART-ARC package.
CR17920408 WEAVING MOTION Software option for torch weaving along a Cartesian path
and crosswise to it.
Software option to manage the search routine.
13607860 SMART-SEARCH
Separate from the SMART-ARC package.
Requires SMART-ARC package.
-- SMART-ARC SEAM TRACK
Only available with Seam Track option
Requires SMART-ARC package.
-- SMART-ARC TCP-CHECK
Only available with TCP Check option
SMART-ARC WIRE Requires SMART-ARC package.
--
SEARCH FRONIUS Only available with Wire joint detector sensor option

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5. OPTIONS

The following options are available for the Wire Welding System:
– Transport trolley (optional)
– 3x500V autotransformer (optional)
– Wire joint detector sensor (optional)
– Wire-cutter (optional)
– TCP Check (optional)
– Location point (optional)
– Balancer assembly (optional)
– Seam Track (optional).

5.1 Transport trolley (optional)

The transport trolley permits easy handling of the generator. It can sustain the generator
models indicated in this manual, including, if required, a 3x500V autotransformer
(optional).

Tab. 5.1 - Transport trolley order code

Comau code Description
19060449 Transport trolley

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5.2 3x500V autotransformer (optional)

The autotransformer is used to supply the generator in cases of a 550 Vac power supply
from the mains. The module is installed in the lower zone of the generator. The
generator base profile is not changed.
When the autotransformer is installed, the generator power supply cable comes out
directly from the autotransformer module and the main switch to cut out electric power
is on the new autotransformer module.

Tab. 5.2 - 3x500V autotransformer order code

Comau code Description
CR19061436 Autotransformer

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5.3 Wire joint detector sensor (optional)

The wire joint detector sensor uses the welding wire as sensor to find the position of the
part to be welded if this is subject to position variation.
The operating principle is based on a high frequency voltage applied directly to the
welding wire. The indication is by the electric arc created when the wire approaches the
part.
The option also includes the function libraries for the identification of the part in space in
6 dimensions (considering the most complicated case with transpallet).
The wire joint detector sensor is installed on board the Generator and customised by
Comau.
It is connected to the Control Unit through the Joint detector wiring assembly. The
installation requires the presence of the Arc outfitting board.

Tab. 5.3 - Joint detector sensor order code

Comau code Description
Joint detector sensor complete with software option for the use of
the device (SMART-ARC WIRE SEARCH FRONIUS).
16657680
Note: the C4G requires the HSI option (see HSI option order
code).

Tab. 5.4 - HSI option order code

Comau code Description
CR17047881 Option C4G-HSK3 for control unit Rel. 4.

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5.3.1 Joint detector wiring assembly

The joint detector wiring assembly connects the Wire joint detector sensor (optional) of
the C4G Control Unit generator. The wiring is only required for the Serial configuration.
The joint detector wiring assembly includes the internal cable.

Comau Code Description

Joint detector wiring assembly, length 5 m
CR16650380
(16.6 ft)
Joint detector wiring assembly, length 10 m
CR16650381
(32.8 ft)
Joint detector wiring assembly, length 15 m
CR16650382
(49.2 ft)
Joint detector wiring assembly, length 20 m
CR16650383
(65.6 ft)
Joint detector wiring assembly, length 25 m
CR16650384
(82.0 ft)
Joint detector wiring assembly, length 30 m
CR16650385
(98.4 ft)

For further information, see the Circuit Diagram.

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5.4 Wire-cutter (optional)

The wire-cutter is a mechanical type controlled by a pneumatic switch. The wire cutter
is to be installed close to the Torch cleaning assembly and lubricator with which it shares
the compressed air supply.
The wire cutter coupled to the Mechanical milled torch cleaning assembly shares the
compressed air supply.
The wire cutter coupled to Magnetic torch cleaning assembly requires a compressed air
supply.

Tab. 5.5 - Wire-cutter order code

Comau code Description
19060447 Wire cutter for Mechanical milled torch cleaning assembly
Wire cutter and protective casing for Magnetic torch cleaning
CR16658184
assembly

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5.5 TCP Check (optional)

To check the torch alignment the TCP Check can be installed as an alternative to the
Location point (optional).
The TCP Check is connected directly by a specific cable to the High Speed Input (HSI
1, X136/FIA) in the Control Unit.
The kit includes:
– TCP Check
– connection cable between TCP Check and Control Unit
– Control Unit internal cable
– software package.
The operating principle consists of an automatic program in which the Robot, with
appropriate movements, identifies the position of the wire interrupting the beam emitted
by the two optical sensors positioned at 90° to each other. The position calculated by
the wire tip (Tool Center Point, TCP) is checked to control that it is within the range set
by the operator and updated in automatic mode.
The installation requires the presence of the Arc outfitting board.
The TCP Check requires the wire cutter to be chosen according to the type of torch
cleaner installed.

Tab. 5.6 - TCP Check order codes

Comau code Description
TCP Check consisting of:
– TCP Check and correction
– TCP Check cable, length 10 m (32.8 ft)
– FIA -CDP cabinet internal connection cable
16654480
– Software option for the use of the device (SMART-ARC
TCP-CHECK).
Note: the C4G requires the HSI option (see HSI option order
code).

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Tab. 5.6 - TCP Check order codes

Comau code Description
16654580 Support column for TCP Check, height 800 mm (31.50 in)

Tab. 5.7 - HSI option order code

Comau code Description
CR17047881 Option C4G-HSK3 for control unit Rel. 4.

TCP Check Column

Connection cable between TCP Check and Control Unit

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5.5.1 TCP Check for Robot Slave (optional)

To allow the use of the TCP Check also for Robot Slave connected by means of a multi
machine solution, a divider and additional cables are necessary.
With this kit, the TCP Check (optional) is connected to the High Speed Input (HSI 1,
X136/FIA) of the first robot and to the High Speed Input (HSI 1, X136/MSA) of the
second robot.
the kit contains:
– the divider
– the connection cable between TCP Check and Control Unit
– the Control Unit internal cable.
The kit has to be coupled to the TCP Check (optional).
In the serial configuration, the installation requires the Arc outfitting board.

Tab. 5.8 - TCP Check for Robot Slave order codes

Comau code Description
TCP Check for Robot Slave containing:
– divider
CR16650980
– TCP Check cable, length 10 m (32.8 ft)
– Connection cable inside cabinet FIA -CDP

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5.6 Location point (optional)

To check the torch alignment the Location Point can be installed as an alternative to the
TCP Check (optional).
The location point is to be used for manual checks that do not require precision. To use,
the operator has to manually store the check position (the wire tip aligned to the location
point).
Subsequent checks have to be made bringing the robot to the check position and
visually checking the alignment.
It is the task of the integrator to position the location point.

Tab. 5.9 - Location point order code

Comau code Description
166542200400 Location point

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Options

5.7 Balancer assembly (optional)

The balancer assembly is used to support the cable pack and the welding wire.
It is advised to install the balancer assembly to avoid that the cables pack interferes with
the robot movements. The balancer assembly also includes the cradle.

Balancer Cradle

Tab. 5.10 - Balancer assembly order code

Comau code Description
16689491 Balancer assembly and cradle

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 Options

5.8 Seam Track (optional)

The Seam Track option is used to track the joint with arc parameters.
The option consists of:
– a CPU-MCP named MCP-ST that replaces the one usually present in the Control
Unit RPU module.
In the new MCP-ST there is a dedicated acquisition board, to which a Hall effect
current sensor inserted in the welding ground and the 24 Vdc coming from the FIA
board are connected.
– an external box with Hall effect current sensor (LEM sensor).
– an internal cable to supply the 24 Vdc for the MCP-ST. board. The 24 Vdc is taken
from connector X124/FIA.
– an external cable between C4G Control Unit and external box. The external box
connection is through a multi-pole connector X35/CPD installed at the cabinet base
– Seam Track software option, cannot be purchased separately. The Seam Track
option and related software option requires the SMART-ARC application.
The Seam Track device can only be used in single robot configuration, not in
multi-machine.
In the serial configuration, the installation requires the presence of the Arc outfitting
board.

A:CPU MCP-ST board

B: external box with current sensor
C: Hall effect current sensor

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Options

D: connector X35/CDP at cabinet base

Connection cable between C4G and external

box

Tab. 5.11 - Seam Track order code

Control Unit
Comau code Description
version
Seam Track option complete with MCP-ST board, internal cables,
C4G-Rel. 2 *¹ CR16658209 external cable length 10 m (32.8 ft), external box and software option
SMART-ARC SEAM TRACK.
Seam Track option complete with Rack RPU cosisting of CPU SMP and
C4G-Rel. 3 *¹
CR16501380 MCP-ST, internal cables, external cable length 10 m (32.8 ft), external
C4G-Rel. 4 *¹
box and application software SMART-ARC SEAM TRACK.

This option, in most cases, is used with the Wire joint detector sensor (optional)..

*¹ The mainteance for the CPU SMP and MCP-ST boards is described in the
maintenance manual for Control Unit C4G-Rel. 2/3.

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 Maintenance

6. MAINTENANCE

This chapter contains:

– Preventive and special maintenance
– Spare parts list.

6.1 Preventive and special maintenance

Considering that the composition of the Sistema di Saldatura a filo continuo is based on
components that are supplied with their specific manuals, for the preventive and special
maintenance see the procedures described in the component manuals:
– C4G Control Unit: Maintenance
– SiX robot: Maintenance
– Fronius components: Fronius maintenance manuals.

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Maintenance

6.2 Spare parts list

Tab. 6.1 - Mechanical torch cleaning assembly

Code: COMAU 16689494

A
C

Position Comau code Description

A 19060480 Robacta REAMMER torch cleaner

B 19060481 Supporting column height 700 mm (27.56 in)

C 19060466 1 litre pack of electrolytic liquid (33.81 oz)

For the cutter spare parts codes, see the Gas nozzle milling tool” Fronius
document.

Tab. 6.2 - Magnetic torch cleaner assembly

Code: COMAU CR16658183

C
B

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 Maintenance

Tab. 6.2 - Magnetic torch cleaner assembly (Continua)

Code: COMAU CR16658183
Position Comau Code Description
A CR19061437 Robacta TC1000 torch cleaner

B CR19060533 Supporting column for TC1000 height 700 mm (27.56 in)

C CR19060534 1 litre pack of electrolytic liquid for TC1000 (33.81 oz)

Tab. 6.3 - Spare parts for options

Code: ---

C
C
A E

B
D

F G

Position Comau code Description

Wire joint detector sensor COMAU 16657680
A 19060440 Wire joint detector sensor
TCP Check COMAU 16654480
B 16654360 TCP Check wire, length 10 m (32.8 ft)

C 19061423 Optic sensor

D CR19061439 “T” divider
Seam Track COMAU CR16658209
CR10151180 CPU MCP-ST
E*¹
10150680 CPU SMP

F CR16501060 External cable, length 10 m (32.8 ft)

G CR16501180 External box with LEM sensor

*¹ The maintenance of the CPU SMP and MCP-ST boards is described in the
C4G-Rel. 2/3 Control Unit maintenance manual .

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Maintenance

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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