ROBOTS

C4G-Unit Comau Robotics

Instruction Handbook

External axes rel. 4

Technical Specifications
Integration, Transport and Installation
Maintenance

CR00757497_en-00/1106
T The information contained in this manual is the property of COMAU S.p.A.

Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A.

COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation.

Copyright © 2003 by COMAU - Date of publication 03/2007

Summary

SUMMARY

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. EXTERNAL AXES SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.1

2. DESCRIPTION OF EXTERNAL AXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2.1

Configurations available. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Brushless Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Distribution box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Distribution box ground connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Cables from motor to distribution box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Multi-pole cable between C4G and distribution box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Axes control modules installed in Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Axes modules installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
DSP boards and power modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Motor mechanical integration with axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
External axes software configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Configuration program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Configuration File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
Conveyor Tracking (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

3. INSTALLATION OF EXTERNAL AXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3.1

Installation environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Motor lifting and fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Motor fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Distribution box installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Equipotential connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
External axes connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Electrical wiring and connectors diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Limit switch cable and connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Motor software, parameters and tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Axis calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

LB-AE-0-SPTTOC.fm
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Summary

Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

4. MAINTENANCE OF EXTERNAL AXES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1

Preventive and special maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Motor maintenance precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

LB-AE-0-SPTTOC.fm
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Foreword

FOREWORD

Symbols used in the manual

The WARNING, CAUTION and NOTES symbols used are shown below together with a
description of the meaning

An operating procedure, technical information and precautions that if not

followed and/or executed correctly could cause injuries to the personnel.

An operating procedure, technical information and precautions that if not

followed and/or executed correctly could cause damage to the equipment.

Operating procedures, technical information and precautions that must be

brought to notice.

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Foreword

Reference documentation
This document refers to the application of External Axis.
The complete set of External Axis manuals consists of

Comau External Axis – This manual

Electric diagram

These manuals are to be incorporated with the following documents:

Comau C4G Control Unit – technical specifications

– Transport and installation
– Guide to integration: safeties, I/O and
communications
– Maintenance
– Use of C4G Control Unit
Robot – Technical specifications
– Transport and installation
– Maintenance
Programming – PDL2 Programming Language Manual
– VP2 - Visual PDL2
– Programming and motion
– EZ PDL2 - Easy programming
environment

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External axes safety precautions

1. EXTERNAL AXES SAFETY

PRECAUTIONS

The following safety precautions integrate those relating to the robotic system,
contained in the SAFETY PRECAUTIONS chapter in the Robot Control unit
manual.

Furthermore the following minimum installation and management precautions are to be

borne in mind:
– The integrator is responsible and shall personally provide for the correct integration
of the External axes in the cell
– The integrator shall (without limiting to just the indications listed below):
• take into consideration the correct installation spaces
• install protections
• correctly program the technological process
• calculate the stop times taking into account the maximum speed and the
weight of the mechanical part handled. Bear in mind the stop times set on the
ESK module.

The stop times set on the ESK module are contained in the
“Transport and Installation” manual of the control Unit.
The calculation of the speeds, stop times and instructions for
handling are contained in the “Motion programming” manual. It is
important to read the chapter “Use of positioners managed by
C4G”.

• consider the maximum programming speed so as to guarantee the limit of i

250 mm/s.

The External axes are not to be started up until the machine where they are
incorporated has been declared in conformity with the provisions of the
applicable directives.

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External axes safety precautions

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Description of External axes

2. DESCRIPTION OF EXTERNAL
AXES

The External axes have to be paired with the C4G Control Unit. This manual only
describes the devices installed outside the C4G.
Up to 4 axes can be added, starting from axis 7 up to axis 10 with a limit of an overall 12
kVA on the C4G Control Unit
When robotic systems are used, the External axes can be managed as auxiliary robot
axes at times even in cooperation (with specific software options) providing the kinetic
chain and the mechanical devices handled has equivalent solutions to the positioners
proposed by Comau.
The solution to add External axes requires:

– Brushless Motor (B)

– Distribution box (C) that contains the cables coming from the motor (D) (motor and
encoder) in a single connector directed to the C4G Control Unit
– Multi-pole cable between C4G and distribution box (E) that joins the distribution
box to the C4G.
– Axes control modules installed in Control Unit (F).
– External axes software configuration
– Options.
The integrator shall provide the mechanical integration of the motor with the external
axis and request the configuration file from Comau; to obtain this, it is necessary to
provide Comau with the data of the mechanics paired to the motor (see details in
par. 2.7 Motor mechanical integration with axis on page 2-17).

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Description of External axes

2.1 Configurations available

The configurations are many and 1 to 4 additional motors can be paired. The
configurations are mainly based on the layout of Fig. 2.1.
Other configuration layouts are shown in Fig. 2.2 e Fig. 2.3.

Fig. 2.1 - Configuration layout (example with 2 axes: axis 7 and

axis 8)
A

F
B

D
E
C
G
H
E B

D
G
C
H
t

Tab. 2.1 - Composition

Item installation
Description
Fig. 2.1 notes
A C4G Control Unit - RCCx *¹
B Brushless Motor *¹
C Distribution box *¹
D Cables from motor to distribution box *²
E Multi-pole cable between C4G and distribution box *²
F Axes control modules installed in Control Unit *¹
G Axes limit switch cable (see Cables from motor to distribution box) *³
H Distribution box ground connection *¹

*¹ configuration obligatory component

*² obligatory component with available alternatives
*³ optional component

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Description of External axes

Fig. 2.2 - Other possible configuration layouts

(sheet 1 of 2)

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Description of External axes

Fig. 2.3 - Other possible configuration layouts

(sheet 2 of 2)

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Description of External axes

2.2 Brushless Motor

The Brushless motors available are integrated with the encoder and the Flash Memory.
The Flash Memory allows self-recognition of the motor characteristics by the drive in the
C4G control unit providing the software installed is system version 2.4.x or later.
The motors are available in sizes starting from 0.75 Nm, enclosed in IP65 or IP67
protection.
The dimensions vary according to the size, as indicated in Tab. 2.3 - Brushless motor
dimensions.
The motor and encoder connections are available on multi-polar connectors.
The motors are to be connected to the Distribution box using the specific Cables from
motor to distribution box.
The motors are to be paired to the power modules as indicated in Tab. 2.7 - Power
modules pairing with motor size

Tab. 2.2 - Brushless Motor order codes

Characteristics Comau code
Size
Nm RPM Description IP65 *¹ IP67 *²
Motor 0.75 Nm - 600 V - 4500 RPM
0.75 *³ 4500 1 CR82309710 CR82309012
Encoder, Flash Memory, IP 6x
Motor 3.3 Nm - 600 V - 4500 RPM
3.3 *³ 4500 2 CR82309720 CR82309022
Encoder, Flash Memory, IP 6x
Motor 5 Nm - 600 V - 4500 RPM
5 4500 2+ CR82309725 CR82309026
Encoder, Flash Memory, IP 6x
Motor 9 Nm - 600 V - 4000 RPM
9 4000 3 CR82309730 CR82309031
Encoder, Flash Memory, IP 6x
Motor 13 Nm - 600 V - 4000 RPM
13 4000 4 CR82309740 CR82309041
Encoder, Flash Memory, IP 6x
Motor 20 Nm - 600 V - 4000 RPM
20 4000 4+ CR82309745 CR82309046
Encoder, Flash Memory, IP 6x
Motor 30 Nm - 600 V - 4000 RPM
30 4000 5 CR82309750 CR82309051
Encoder, Flash Memory, IP 6x
Motor 36 Nm - 600 V - 4000 RPM
36 4000 6 CR82309760 CR82309061
Encoder, Flash Memory, IP 6x

*¹ IP65 housing,flange side IP65

*² P67housing,flange side IP67
*³ 0.75 and 3.3 Nm motors require the installation of C4G-VLTK filter, code CR17049180
inside the cabinet

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Description of External axes

Tab. 2.3 - Brushless motor dimensions

Brushless motor 0.75 Nm - Size 1

UP TO

UP TO UP TO

Brushless motor 3.3 Nm - Size 2

UP TO

UP TO
UP TO

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Description of External axes

Tab. 2.3 - Brushless motor dimensions

Brushless motor Nm - Size 2+

Brushless motor 9 Nm - Size 3

UP TO

UP TO UP TO

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Description of External axes

Tab. 2.3 - Brushless motor dimensions

Brushless motor 13 Nm - Size 4

UP TO

UP TO UP TO

Brushless motor 20 Nm - Size 4+

UP TO

UP TO
UP TO

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Description of External axes

Tab. 2.3 - Brushless motor dimensions

Brushless motor 30 Nm - Size 5

UP TO

UP TO
UP TO UP TO
UP TO

Brushless motor 36 Nm - Size 6

UP TO

UP TO
UP TO UP TO
UP TO

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Description of External axes

2.3 Distribution box

The distribution box joins the Cables from motor to distribution box coming from the
Brushless Motor (motor cable and encoder cable) and the limit switches (optionals) for
the connection to the Control Unit with just one Multi-pole cable between C4G and
distribution box.
Each motor has to have its own distribution box.
The box is designed for built-in installation (usually in a box or cabinet on board the
machine). The box has protection class IP54 (with coupling of all loose connectors).
On the front of the box there is a multi-pole Harting connector for connection with the
C4G, whereas on the rear there are the multi-pole connectors for the motor, encoder,
limit switch. The box equipotential connection is to be connected to the same robot
ground potential (see par. 2.3.1 Distribution box ground connection on page 2-11).
The distribution box is to be connected to the Control Unit by the Multi-pole cable
between C4G and distribution box.
The template and the installation details are contained in par. 3.4 Distribution box
installation on page 3-3.

Fig. 2.4 - Distribution box

Tab. 2.4 - Distribution box order code

Comau code
Description
Axis 7 Axis 8 Axis 9 Axis 10
Distribution box for motor
CR18800280 CR18800281 CR18800282 CR18800283
size 1 / 2 / 2+
Distribution box for motor
18825280 18825281 18825282 18825283
size 3 / 4
Distribution box for motor
18825180 18825181 18825182 18825183
size 4+ / 5 / 5F / 6 / 6F

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Description of External axes

2.3.1 Distribution box ground connection

The Distribution box is to be connected to ground to the same potential as the Robot.
The ground conductor is not supplied as an option and is to be provided by the
integrator.
The connection method and the precautions are indicted in par. 3.5 Equipotential
connections on page 3-5.

2.4 Cables from motor to distribution box

The cables connect the Brushless Motor (motor cable and encoder cable) to the
Distribution box.
Motor and encoder cables for loose laying are available that differ in length and for the
axis that is to be paired to the motor. The cables have connectors at both ends with
multi-pole connectors suitable for connection to the motor and the distribution box.
When required by the application a limit switch cable is available fitted with a multi-pole
connector on the distribution box side only. The additional axes in C4G option already
contains the cabinet internal cables necessary to manage the limit switches.
The limit switches are to be configured through the External axes software configuration.

Tab. 2.5 - Motor/encoder/limit switch cables order codes

Comau code
Description of cable 1m 2m 5m 10 m 15 m
(3.3 in) (6.6 in) (16.4 in) (32.8 in) (49.2 in)

Axis 7, loose laying

Motor cables
Motor cable axis 7, size 1/2/2+ CR18000660 CR18000661 CR18000662 CR18000663 CR18000664

Motor cable axis 7, size 3/4 18070260 18071360 18071460 18071560 18071660

Motor cable axis7, size 4+/5/6 18070160 18070960 18071060 18071160 18071260
Encoder / limit switch cables
Encoder cable axis 7 18170160 18170360 18170460 18170560 18170660
Limit switch cable axis 7 18238160 18238260 18238360 18238460 18238560

Axis 8, loose laying

Motor cables
Motor cable axis 8, size 1/2/2+ CR18000760 CR18000761 CR18000762 CR18000763 CR18000764

Motor cable axis 8, size 3/4 18070660 18072460 18072560 18072660 18072760

Motor cable axis 8, size 4+/5/6 18070560 18072060 18072160 18072260 18072360
Encoder / limit switch cables
Encoder cable axis 8 18170260 18170760 18170860 18170960 18171060

Limit switch cable axis 8 18238660 18238760 18238860 18238960 18239060

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Description of External axes

Tab. 2.5 - Motor/encoder/limit switch cables order codes

Comau code
Description of cable 1m 2m 5m 10 m 15 m
(3.3 in) (6.6 in) (16.4 in) (32.8 in) (49.2 in)

Axis 9, loose laying

Motor cables
Motor cable axis 9, size 1/2/2+ CR18000860 CR18000861 CR18000862 CR18000863 CR18000864

Motor cable axis 9, size 3/4 18075160 18075260 18075360 18075460 18075560

Motor cable axis 9, size 4+/5/6 18075660 18075760 18075860 18075960 18076060
Encoder / limit switch cables
Encoder cable axis 9 18171160 18171260 18171360 18171460 18171560

Limit switch cable axis 9 18239160 18239161 18239162 18239163 18239164

Axis 10, loose laying

Motor cables
Motor cable axis 10, size 1/2/2+ CR18000960 CR18000961 CR18000962 CR18000963 CR18000964

Motor cable axis 10, size 3/4 18077160 18077260 18077360 18077460 18077560

Motor cable axis 10, size 4+/5/6 18077660 18077760 18077860 18077960 18078060
Encoder / limit switch cables
Encoder cable axis 10 18171660 18171760 18171860 18171960 18172060

Limit switch cable axis 10 18239260 18239261 18239262 18239263 18239264

2.5 Multi-pole cable between C4G and

distribution box
The multi-pole cable joins the C4G Control Unit with the Distribution box.
Every external axis is to have its own connection cable that, according to the axis
number, starts from the CDP panel at the C4G base or from the Application Box and
ends on the distribution box.
Fixed laying multi-pole cables are available that differ in length and the axis to which the
motor will be paired.

Tab. 2.6 - Multi-pole cables order code

Comau code Description of multi-pole cable

Cables for axis 7, fixed laying

18564560 Harting cable for fixed laying/Single axis Harting - Axis 7 - Length 5 m (16.4 ft)

18564561 Harting cable for fixed laying /Single axis Harting -Axis 7 - Length 10 m (32.8 ft)

18564562 Harting cable for fixed laying /Single axis Harting -Axis 7 - Length 15 m (49.2 ft)
18564563 Harting cable for fixed laying /Single axis Harting - Axis 7 - Length 20 m (65.6 ft)

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Description of External axes

Tab. 2.6 - Multi-pole cables order code (Continua)

Comau code Description of multi-pole cable

18564564 Harting cable for fixed laying/Single axis Harting - Axis 7 - Length 25 m (82.0 ft)
18564565 Harting cable for fixed laying/Single axis Harting - Axis 7 - Length 30 m (98.4 ft)

Cables for axis 8, fixed laying

18564460 Harting cable for fixed laying/Single axis Harting - Axis 8 - Length 5 m (16.4 ft)

18564461 Harting cable for fixed laying/Single axis Harting - Axis 8 - Length 10 m (32.8 ft)

18564462 Harting cable for fixed laying/Single axis Harting - Axis 8 - Length 15 m (49.2 ft)
18564463 Harting cable for fixed laying/Single axis Harting - Axis 8 - Length 20 m (65.6 ft)

18564464 Harting cable for fixed laying/Single axis Harting - Axis 8 - Length 25 m (82.0 ft)
18564465 Harting cable for fixed laying/Single axis Harting - Axis 8 - Length 30 m (98.4 ft)

Cables for axis 9, fixed laying

18569460 Harting cable for fixed laying/Single axis Harting - Axis 9 - Length 5 m (16.4 ft)

18569461 Harting cable for fixed laying/Single axis Harting - Axis 9 - Length 10 m (32.8 ft)

18569462 Harting cable for fixed laying/Single axis Harting - Axis 9 - Length 15 m (49.2 ft)

18569463 Harting cable for fixed laying/Single axis Harting - Axis 9 - Length 20 m (65.6 ft)
18569464 Harting cable for fixed laying/Single axis Harting - Axis 9 - Length 25 m (82.0 ft)

18569465 Harting cable for fixed laying/Single axis Harting - Axis 9 - Length 30 m (98.4 ft)
18569466 Harting cable for fixed laying/Single axis Harting - Axis 9 - Length 40 m (131.2 ft)

Cables for axis 10, fixed laying

18569560 Harting cable for fixed laying/Single axis Harting - Axis 10 - Length 5 m (16.4 ft)
18569561 Harting cable for fixed laying/Single axis Harting - Axis 10 - Length 10 m (32.8 ft)

18569562 Harting cable for fixed laying/Single axis Harting - Axis 10 - Length 15 m (49.2 ft)

18569563 Harting cable for fixed laying/Single axis Harting - Axis 10 - Length 20 m (65.6 ft)

18569564 Harting cable for fixed laying/Single axis Harting - Axis 10 - Length 25 m (82.0 ft)

18569565 Harting cable for fixed laying/Single axis Harting - Axis 10 - Length 30 m (98.4 ft)
18569566 Harting cable for fixed laying/Single axis Harting - Axis 10 - Length 40 m (131.2 ft)

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Description of External axes

2.6 Axes control modules installed in Control

Unit
The C4G Control Unit can manage external axes (up to 12 kVA including the basic axes)
only if equipped with the specific options for additional axes.
The options for additional axes are installed inside the Control Unit, in different positions
according to the number of axes installed (see par. 2.6.1 Axes modules installation
position on page 2-14).
The options for additional axes consist of:
– DSP boards and power modules paired to the cabinet internal cables. The cabinet
internal cables have pre-arranged connections on one connector only at the
cabinet base (or Application Box). This connector is connected to the Multi-pole
cable between C4G and distribution box and from here to the Brushless Motor
– C4G-VLTK filter code CR17049180, only necessary for 0.75 and 3.3 Nm motors

2.6.1 Axes modules installation position

The first two additional external axes (axes 7 and 8) can be installed inside the C4G.
Further two axes (for a total of 4 simultaneously) are axes 9 and 10 and require an
additional box (see Fig. 2.5).

Fig. 2.5 - Additional axes 7 - 8 and 9 - 10

Axis 9-10

Axis 7-8

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Description of External axes

2.6.2 DSP boards and power modules

The complete solution for the DSP boards and power modules inside the Control Unit
consists of the following:
– Auxiliary axis kit, containing:
• empty OPU power unit
• DSP board (manages up to 2 axes). The DSP board can be chosen according
to the type of position transducer installed (encoder and/or resolver).
• flat cables.
There are 2 versions of auxiliary axis kit:
• For axes 7 and 8: Auxiliary axis kit (for axes 7° and 8°).
• For axes 9 and 10: External axis kit (for axes 9° and 10°) and Application Box
axes 9-10 to be installed on the top of the cabinet.
The kits differ in the length of the connecting flat cables between the DSP board
and the axes modules
The kit can manage 2 axes. If on axis is not used, it has to be excluded via software
to avoid management by the Control Unit.
– Axis module. The module is available in four sizes that differ in the different
current values and it is installed in the OPU compartment. This module is suitable
for one axis only.
– Internal cables kit. The kit contains the 3-section Harting connector (for power,
auxiliary and transducer signals), the brakes power supply cable, the HSI cable
and the extension cable of the D bus. The kit is suitable for the connection of
one axis only.
The additional axes have to be configured (see par. 2.8 External axes software
configuration on page 2-18).

Tab. 2.7 - Power modules pairing with motor size

Motor characteristics Power module
Nm Size Arms current / Peak current Comau code

0.75 *¹ 1 3/13

3.3 *¹ 2 10/43
5 2+ 10/43

9 3 10/43
13 4 10/43 See
20 4+ 25/90 Axis module

5 25/90
30
5F 25/90

6 30/128
36
6F 30/128

*¹ Requires Comau C4G-VLTK filter

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Description of External axes

Tab. 2.8 - Axes expansion modules order codes

Max Position transducer
Comau
Code Description installable
code Axis 1 Axis 2
quantity
Auxiliary axis kit (for axes 7° and 8°)
Auxiliary axis Encoder-Encoder Rel.1.
Contains:
17046580 C4G-AAEE – Empty OPU module 1 Encoder Encoder
– DSP board (2 encoder axes)
– Flat cables
Auxiliary axis Encoder-Resolver Rel.1.
Contains:
– Empty OPU module
17046680 C4G-AAER 1 Encoder Resolver
– DSP board (1 encoder axis/ 1
resolver axis)
– Flat cables
External axis kit (for axes 9° and 10°)
17901080 C4G-EAB Application Box axes 9-10 1 -- --
External axis Encoder-Encoder Rel.1.
Contains:
17047180 C4G-EAEE – Empty OPU module 1 Encoder Encoder
– DSP board (2 encoder axes)
– Flat cables
External axis Encoder-Resolver Rel.1.
Contains:
– Empty OPU module
17047280 C4G-EAER 1 Encoder Resolver
– DSP board (1 encoder axis / 1
resolver axis)
– Flat cables
Axis module
DSA-
10145980 Power module for one axis - 3/13A¹ 2 Not important
AXM3/13
DSA-
10146080 Power module for one axis - 10/43A¹ 2 Not important
AXM10/43
DSA-
10146180 Power module for one axis - 25/90A¹ 2² Not important
AXM25/90
DSA-
10146280 Power module for one axis - 30/128A¹ 2³ Not important
AXM30/128
Internal cables kit
Cables option axis 7° / 8°
CR17490261 C4G-AACE 2 Encoder
Encoder.
Cables option axis 7° / 8°
CR17490361 C4G-AACR 2 Resolver
Resolver.
Cables option axis9° / 10°
CR17490461 C4G-EACE 2 Encoder
Encoder.
Cables option axis 9° / 10°
CR17490561 C4G-EACR 2 Resolver
Resolver.

¹ Equivalent direct current / peak current. Maximum installable quantity refers to each

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Description of External axes

auxiliary axis kit, the other module is to be

² Two modules can be installed, but only one size 25/90 A;the other module is to be 3/13
A or 10/43 A
³ Two modules can be installed, but only one size 30/128 A; the other module is to be
3/13 A or 10/43 A

Further information regarding the C4G Control Unit, the options for additional
axes and the C4G-VLTK filter, as well as other configurations up to 12 kVA can be
found in the C4G”Technical Specifications” manual (see manual references in
par. Reference documentation on page 3-2).

2.7 Motor mechanical integration with axis

It is the responsibility of the integrator to design the axis and installation of the motor.
To avoid breakages, overheating and projection of parts, the axis is to be dimensioned
according to the application requirements and the torque available from the driving shaft
In robotic system applications, the External axes can be managed as auxiliary robot
axes, also in cooperation (with the specific software options) providing the kinematic
chain and the handled mechanical device are appropriate for the positioners solutions
suggested by Comau.
The motor has to be calibrated.The motor assembly is to give the necessary precision
and known location points.
Installation suggestions are contained in Chap.3. - Installation of External axes.

Further information regarding a typical mechanical integration of an external axis

can be found i the positioners manuals (for example “MP Positioners”).

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Description of External axes

2.8 External axes software configuration

2.8.1 Configuration program

The external axes and limit switches (optionals installed) are to be configured with the
specific configuration program.
See the manual “Use of Control Unit” in the chapter “Programs for I/O configuration”.

2.8.2 Configuration File

The external axis configuration file is fundamental for correct motor operation.
To obtain the appropriate configuration file from Comau, fill in the form below and hand
it to the reference Comau Sales Manager
The form is also available in the complete version requesting it from the same Comau
Sales Manager office.

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2.9 Options

2.9.1 Conveyor Tracking (optional)

The C4G-CT (Conveyor Tracking) option adds the possibility to track parts that are
moving on linear or circular conveyors for the axes where there is a read-only
ENCODER.

The option is described in the C4G Control Unit C4G “Technical Specifications”
manual, whereas the integration procedure is contained in the “Guide to
integration, Safeties, I/O, Communication” manual of the Control Unit.

Fig. 2.6 - Typical application diagram for 2 axes

Tab. 2.9 - Conveyor Tracking

Comau code Code Description
CR17043280 C4G-CT9 Conveyor Tracking axis 9
CR17043380 C4G-CT9-10 Conveyor Tracking axes 9 and 10
kit to be used for the second Conveyor Tracking with
the first already installed. It contains:
CR17043480 C4G-CT10U – Encoder cable from DSP to cabinet base
– External cable 20 m (66 ft)
– Encoder
17920407 -- Conveyor Tracking Motion management software.

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Description of External axes

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Installation of External axes

3. INSTALLATION OF EXTERNAL
AXES

The External axes are to be installed in combination with the C4G Control Unit, equipped
with the necessary options (if necessary, see Chap.2. - Description of External axes).
The installation of the external axes requires at least the following steps:
– Installation environment
– Safety precautions
– Motor lifting and fastening
– Distribution box installation
– Equipotential connections
– External axes connections
– Electrical wiring and connectors diagram
– Motor software, parameters and tests
– Axis calibration
– Functional checks.

3.1 Installation environment

– Install in compatibility with the motors IP protection class.
– The motor requires heat dissipation. Do not enclose the motor in an closed
environment without ventilation.
– The distribution box has class IP54 protection only if all the connectors are
occupied. If the limit switch connectors are not used, connect a loose casing to
cover the connector on the distribution box.

3.2 Safety precautions

The integrator is to take into consideration the indications contained in Chap. External
axes safety precautions (speed, stop times, etc.).

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Installation of External axes

3.3 Motor lifting and fastening

3.3.1 Lifting
– Lift the motor using appropriate lifting equipment.
According to the size, the weight of the motor may be considerable (see Tab. 3.1
- Brushless motor weights). On motors where provided for, tightly screw an
appropriate eye bolt on the motor casing and lift with a crane (see Fig. 3.1).

Tab. 3.1 - Brushless motor weights

Characteristics Weight
Nm Description Size kg / lb

0.75 Motor 0.75 Nm - 600 V - IP 6x 1 3 kg / 6.6 lb

3.3 Motor 3.3 Nm - 600 V - IP 6x 2 8 kg / 17.6 lb

5 Motor 5 Nm - 600 V - IP 6x 2+ 10 kg / 22.0 lb

9 Motor 9 Nm - 600 V - IP 6x 3 15 kg / 33.1 lb

13 Motor 13 Nm - 600 V - IP 6x 4 18 kg / 39.7 lb

20 Motor 20 Nm - 600 V - IP 6x 4+ 30 kg / 66.1 lb

30 Motor 30 Nm - 600 V - IP 6x 5 37 kg / 81.6 lb

36 Motor 36 Nm - 600 V - IP 6x 6 44 kg / 97.0 lb

Fig. 3.1 - Motor lifting with eyebolts and crane

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3.3.2 Motor fastening

– Engage the driving shaft in the seat, pushing the motor.
Do not use a hammer and do not knock on the engine casing to avoid breaking
the motor internal parts.
– IF an oil seal is required, apply a film of sealant type AREXONS 35A73 for the
oil-proof surfaces
– Fasten the motor using 4 screws with lock washers. Tighten the screws to the
correct torque (see Tab. 3.2 - Brushless motors fastening screws).
– The motor housing is to be connected to the same ground potential of the Robot
(see details in par. 3.5 Equipotential connections on page 3-5).

Tab. 3.2 - Brushless motors fastening screws

Motor characteristics Screw
Recommended Tightening
Lock washer
Nm Description Size socket head torque
type “A”
cap screw Nm
0.75 Motor 0.75 Nm - 600 V - IP 6x 1 M5 x 20 - 8.8 5 x 10 - C72 - DAC 5 6

3.3 Motor 3.3 Nm - 600 V - IP 6x 2 M8 x 20 - 8.8 8 x 15 - C72 - DAC 5 24.6

5 Motor 5 Nm - 600 V - IP 6x 2+ M8 x 20 - 8.8 8 x 15 - C72 - DAC 5 24.6

9 Motor 9 Nm - 600 V - IP 6x 3 M10 x 25 - 8.8 10 x 18 - C72 - DAC 5 50.1

13 Motor 13 Nm - 600 V - IP 6x 4 M10 x 25 - 8.8 10 x 18 - C72 - DAC 5 50.1

20 Motor 20 Nm - 600 V - IP 6x 4+ M12 x 30 - 8.8 12 x 20.5 - C72 - DAC 5 84.8

30 Motor 30 Nm - 600 V - IP 6x 5 M12 x 30 - 8.8 12 x 20.5 - C72 - DAC 5 84.8

36 Motor 36 Nm - 600 V - IP 6x 6 M12 x 30 - 8.8 12 x 20.5 - C72 - DAC 5 84.8

3.4 Distribution box installation

– The box requires built-in installation, fastened with 4 screws (see Fig. 3.2 - Overall
dimensions and drilling template for the distribution box).
– The box has IP54 class protection with all the connectors installed. Install in an
appropriate environment or housing.
– The distribution box housing is to be connected to the same ground potential as
the Robot (see details in par. 3.5 Equipotential connections on page 3-5).

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Installation of External axes

Fig. 3.2 - Overall dimensions and drilling template for the

distribution box

(*)

Ø7

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3.5 Equipotential connections

Points where connection is required
– The distribution box and the motor housings are to be connected to the same
ground potential of the Robot.
– The ground connection of the distribution box is to be made with the specific screw
(see Fig. 3.3).

Fig. 3.3 - Ground connection on distribution box

– The motor ground connection may be on its housing or on a metal part where the
motor is fastened, providing it is connected to the motor housing.

Ground conductor section

– Use conductors with a section equal to or greater than 6 mm² (10 AWG).

Connection diagram
– Connect the housings to each other and with the robot ground screw, or if nearer,
to the external ground screw on the CDP panel of the Control Unit.
– Do not connect the ground conductor inside the Control Unit.
– Do not create loop circuits: it is better to have connections between components
without closing the circuit.
– If there are 2 or more external axes in the application, connect the grounds to the
robot or to a common terminal board, according to the location of the components.

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Installation of External axes

Fig. 3.4 - Connection diagram example of the equipotential

circuit

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3.6 External axes connections

– Motor, encoder
– Limit switch on board machine
– Motor, encoder and limit switch on distribution box
– Cable from distribution box to C4G Control Unit
– Multi-pole cable on C4G Control Unit.

Motor, encoder
– The connections are on the motor casing (see Fig. 3.5).
– The plates on the motor connectors are to be customised by the integrator,
according to the axis number.
– Insert the motor/brake connector on connector (A).
– Insert the encoder connector on connector (B).
– All the connectors are with bayonet coupling and locking and require a slight
clockwise rotation for the complete fastening, except for motors sizes 1, 2 and 2+
that have a screw type power connector.

Fig. 3.5 - Connections on motor (example of motor)

Limit switch on board machine

– The limit switches are optionals, according to the application requirements.
– The multi-polar cable coming from the distribution box is not fitted with connector
to allow the integrator the possibility of complete customising.

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Installation of External axes

Motor, encoder and limit switch on distribution box

– The connectors are on the rear of the distribution box (see Fig. 3.6).
– The plates on the connectors (A), (B) and (C) are customised according to the axis
number.
– Insert the connector / cable coming from the motor / brake on connector (A).
– Insert the connector / cable coming from the encoder on connector (B).
– Where foreseen, insert the connector / cable coming from the limit switches on the
connector (C). If connector (C) is not used and the box is not installed in a
protective housing, cover the contacts with a cap fitted with gasket.
– All the connectors have bayonet coupling and have to be slightly turned clockwise
to fasten properly.

Cable from distribution box to C4G Control Unit

– the connector is on the front of the distribution box (see Fig. 3.6).
– Connect the ground cable coming from the Control Unit on screw (D).
– Insert the connector / multi-pole cable coming from the Control Unit on connector
(E).
– Clamp the connector with the levers.

Fig. 3.6 - Connections on distribution box

Multi-pole cable on C4G Control Unit

– The connector is to be connected to the cabinet base on panel CDP or on the
application Box, according to the solution of the integrator.
– Clamp the connector with the levers.
– Connect the ground cable coming from the distribution box on one of the ground
terminals of the Control Unit.

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3.7 Electrical wiring and connectors diagram

– See the complete electrical diagram for further information regarding the cable and
distribution box connections.
– The codes of the connectors used on the cables and box are contained in
Chap. Maintenance of External axes.

3.7.1 Limit switch cable and connection diagram

When the application requires limit switches, these are to be connected as indicated in
the diagrams below.

Fig. 3.7 - Limit switch cable diagram

Color mm2 Signal

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Installation of External axes

3.8 Motor software, parameters and tests

– The motor and any limit switches are to be configured using the specific
configuration program. See the “Use of Control Unit” manual, in the chapter
“Programs for I/O configuration”.
– Do not rotate the motor installed on the bench. The motor rotation is to be tested
with a load applied to the driving shaft.
– Load the correct configuration file supplied by Comau. The file is supplied after
the specific form has ben filled in with the characteristic data of the mechanics
paired to the motor (see details in par. 2.8.2 Configuration File on page 2-18).

3.9 Axis calibration

– The calibration and the Turn-Set procedures are essential for the precise use of the
mechanical system paired to the external axis.
– The procedure changes according to the paired mechanics.

information regarding a typical mechanical integration of an external axis

including the calibration procedure is contained in the positioner manuals (for
example “MP Positioners”). See for an example of the calibration procedure.

3.10 Functional checks

– Before starting to use the external axis, test slow speed motion, emergency stop
and hold.
– Remaining at a safe distance, repeat these tests at maximum speed.
– Check and run several production cycles before leaving the cell

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Maintenance of External axes

4. MAINTENANCE OF EXTERNAL
AXES

This chapter contains:

– Preventive and special maintenance
– Motor maintenance precautions
– Spare parts.

4.1 Preventive and special maintenance

Considering that the composition of the External axes is based on simple components,
this chapter only contains the more important information.The safety precautions, well
known to the maintenance engineer, can be consulted in the Control Unit manuals. In
the same way, see the “Control Unit Maintenance” manual for maintenance on the
drives.

4.2 Motor maintenance precautions

– Where foreseen, before disassembling the motor support it with appropriate lifting
systems.
According to the size, the weight of the motor my be considerable (see Tab. 3.1
- Brushless motor weights). On the motors provided for it, firmly screw an
appropriate eye bolt on the motor casing and lift with a crane. (see Fig. 3.1 - Motor
lifting with eyebolts and crane).
– When assembling, engage the driving shaft in the seat pushing the motor. Do not
use a hammer and do not hit on the motor casing to avoid breaking internal parts
of the motor.
– If there is sealant on the flange, remove the old sealant and replace with a film of
sealant for oil-proof surfaces, type AREXONS 35A73.
– Fasten the motor using 4 screws with lock washers. Tighten the screws with the
correct tightening torque If the recommended screws have been used, see
Tab. 3.2 - Brushless motors fastening screws. Otherwise see the generic table in
Tab. 4.1 - Hex head and socket head cap screws tightening torque. (Nm ± 10%)).
– Do not test motor rotation with shaft without load.
– Calibrate the external axis. See par. 3.9 Axis calibration on page 3-10.

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Tab. 4.1 - Hex head and socket head cap screws tightening
torque. (Nm ± 10%)
dia x depth Screws class 8.8 Screws class 10.9 Screws class 12.5
3 x 0.5 1.5 1.9 2.3
4 x 0.7 3.1 4.3 5.2
5 x 0.8 6 8.5 10.1
6x1 10.4 14.6 17.5
8 x 1.25 24.6 34.7 41.6
10 x 1.5 501 70.5 84.6
12 x 1.75 84.8 119 143
14 x 2 135 190 228
16 x 2 205 288 346
20 x 2,5 400 562 674
24 x 3 691 971 1170

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4.3 Spare parts

– Brushless motor
– Distribution box
– Cables and connectors

Tab. 4.2 - Brushless motor

Code: ---

Item Comau code Description

A See Tab. 2.2 - Brushless Motor order codes.

Tab. 4.3 - Distribution box

Code: ---

Item Comau code Description

A See Tab. 2.4 - Distribution box order code.

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Tab. 4.4 - Cables and connectors

Code: ---

Item Comau code Description

A SeeTab. 2.5 - Motor/encoder/limit switch cables order codes.

B See Tab. 2.6 - Multi-pole cables order code.

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COMAU Robotics services
Repair: [email protected]
Training: [email protected]
Spare parts: [email protected]
Technical service: [email protected]