_lb-aw-arc-man_en

Comau RoboticsInstruction Handbook

SMART NS - E lenco manual i

Arc Welding System

Maintenance for System GaTeWayFRonius (GTWFR) serial connection, with SMART5 Arc4 Robot Robot

CR00757674-en_00/2011.07

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 © 2011 by COMAU - Date of publication 07/2011

Summary

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SUMMARY

1. WIRE WELDING SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Information regarding the process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Protection of the eyes and the body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Protections against gas, fumes and fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2. GENERAL MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10

Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Precautions at the end of the maintenance activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Equipment necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Torque wrench settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3. GENERAL MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...13

General precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance operation sheets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4. MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...17

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Summary of intervention points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5. PRELIMINARY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

Preventive maintenance plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6. SPECIAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23

Special maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7. SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...30

Preface

PREFACE

In this chapter are shown the following topics:

– Reference documents

– Documents preservation

– Limits on the manual content

– Symbols used in the manual

Reference documents

This document concerns the application Arc Welding System.

The complete set of Arc Welding System manuals consists of:

These manual must be integrated with the following documents:

Comau Arc Welding System – Technical specifications – Integration, Transport and installation– Maintenance

Programming, specific for welding

– Software application of the SmartArc Arc Welding System

Wiring diagram of Arc Welding System

Comau C5GControl Unit – Technical specifications– Transport and installation– Maintenance– Use of C5GControl Unit– Wiring diagram

Robot – Technical Specifications– Transport and installation– Maintenance– Wiring diagram

Programming – PDL2 Programming Language Manual– VP2 - Visual PDL2– Motion Programming

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Preface

Documents preservation

All the documents provided should be stored near theRobotic system and be available for all the people that work on it and it mustbe preserved intact for all the operative life of the Robotic System.

Limits on the manual content

The figures inserted in the instruction manual have the purpose to represent the productand can differ from what is actually visible on the Robotic System.

Fronius – Transpulse Synergic 4000, 5000 (Generator use instruction)– 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-feeder service installation)– VR 1500 (Wire-feeder blowing assembly instructions)– VR 1500 (Wire-feeder cover assembly instructions)– VR 1500 (Wire guide sheath on wire-feeder unit assembly

instructions)– BRG 97 N Mechanical Torch cleaning assembly (operating

instructions)– Torch for Robot Robacta– High Speed Touch Sensing (Installation and use of joint seam

track).– Trolley– Autotransformer

The list above is complete in order to represent all the possible configurations and expansion.Typically it is enough to consult only the specification of the purchased part.

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Preface

Symbols used in the manual

Below are listed the symbols that represent: WARNING, CAUTION and NOTES and their meaning

This symbol indicates operating procedures, technical information and precautions that if not observed and/or performed correctly could cause injuries to the personnel.

This symbol indicates operating procedures, technical information and precautions that if not observed and/or performed correctly could cause damage to the equipment.

This symbol indicates operating procedures, technical information and precautions that are to be underlined.

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

The symbol calls the attention to the material disposal that is regulated by the

The symbol calls the attention on avoiding environmental contamination and suggest to dismiss the materials on the appropriate collection facility.

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Wire welding safety precautions

1. WIRE WELDING SAFETY PRECAUTIONS


– Responsibilities

– Information regarding the process

– Protection of the eyes and the body

– Protections against gas, fumes and fire

– Safety precautions

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

Persons wearing a pace-maker are not allowed in any case to operate on arc welding. Danger: high voltage!

Entry is forbidden to persons wearing a pace-maker.Danger of death!

The Sistema di Saldatura a filo continuo 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

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– 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 welding torch. For this reason the welding parameters are only to be set by qualified personnel.

1.2 Information regarding the processThe 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.

1.3 Protection of the eyes and the bodyThe 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, ‚Äúglass-blower‚Äôs cataract‚Äù, deterioration of visual capacity, etc., furthermore the strong concentration of ultraviolet rays can cause burning of the skin.

Tab. 1.1 - DIN classes of standard adiactinic glass on page 7 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.

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.

The welded piece and the parts nearby (included the welding torch) can reach high temperature that must be indicated in the appropriate sign (by the integrator).

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1.4 Protections against gas, fumes and fireIn 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‚Äôs respiratory organs there is a considerable quantity of oxygen and carbon oxide, as well as small quantities of ozone.

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 m 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 millimetre).

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.

Tab. 1.1 - DIN classes of standard adiactinic glass

CLASS FORESEEN USE CONDITIONS

9Electrodes with diameters ranging from 3.25 to 5 mm. For arc welding in protected atmosphere with current intensity up to 75 A

10Electrodes with diameters over 5 mm. For arc welding in protected environment with current intensity up to 200 A

11Electrodes with diameters over 5 mm. For arc welding in protected environment with current intensity up to 250 A

12Electrodes that have a very strong luminous effect. For arc welding in protected environment with current intensity up to 300 A

13To weld parts with very thick walls. For arc welding in protected environment with current intensity over 300 A and up to 500 A

Make sure that in the immediate vicinity of the welding station there are no bins containing petrol, diesel, solvents, rags or other inflammable materials.

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1.5 Safety precautions

1.5.1 Applicability

These precautions are to be applied when carrying out the following activities:

– Installation and Start-up on page 8;

– Operation in programming mode on page 8;

– Maintenance and Repairs on page 9;

– Putting out of service and dismantling on page 9

1.5.2 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 ‚ÄúGENERAL SAFETY PRECAUTIONS"of the Robot.

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Maintenance and Repairs

– Only qualified and authorised persons are allowed 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 auxiliary 24 Vdc power supply may be supplied from an external source, or by the robot control or by the line.

– 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.

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

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

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General maintenance procedures

2. GENERAL MAINTENANCE PROCEDURES


– Precautions before starting

– Precautions before starting

– Precautions at the end of the maintenance activities

– Maintenance staff

– Equipment necessary

– Torque wrench settings.

2.1 Precautions before starting– Before performing any maintenance operation, please read carefully the chapter

Wire welding safety precautions, and in particular the paragraph describing the maintenance operations.

– Any maintenance operation on the Arc Welding System is to be carried out only by qualified and suitably trained staff.

– Before starting with any maintenance activity, be sure that there are no external voltages interconnected to the electronic modules and to the Control Unit components.

– The circuit breaker and the fuses are dimensioned for the foreseen use of the circuits and, in case of damage, they can be replaced only with equivalent parts foreseen in the spare parts catalogue. The use of not foreseen protection can cause danger for the staff and malfunctioning of Arc Welding System.

– Use original spare parts only.

2.2 Precautions before starting– Any removal or installation of electromechanics components, electronic modules,

connectors, cables or any other component must be performed only with main switch opened. Disconnect the C5G Control Unit power supply (interconnected voltage)

– In case of cable replacement re-set the connection of screens previously disconnected.– The replaced cable must have the corresponding COMAU code of the

dismissed one.– Before connection any cable, please refer to the electrical diagrams of the Arc

Welding System.

The maintenance activities that are not described in this manual are not allowed. If necessary, require the manufacturer intervention.

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– During the installation of new cables, please avoid anomalous bending radiuses on behalf of the previous ones. Respect possible fastening points and determined paths already existing.

– If the cable has a cable clamp, check its proper functioning.

2.3 Precautions at the end of the maintenance activities– After any maintenance operation, re-set the protection devices previously

removed.

– After any maintenance operation, before to start the normal working cycle, perform functional checks of the Arc Welding System and in particular of the replaced component.

– In case of partial or complete Arc Welding System dismantling, different materials shall be dismantled separately. The Control Unit shall be dismantled in compliance with the environmental prescriptions in force in the Land where it is installed.

– After the maintenance operations have been terminated, check the correct functioning of the Arc Welding System. Check the correct execution of some robot working cycles and the correct functioning of security devices before leaving the station.

2.4 Maintenance staffThe maintenance staff of the Arc Welding System shall be suitably trained, in order to be able to use the lifting means properly.Moreover, the staff shall be warned or trained (in electrics, mechanics and fluidic field) and therefore aware of the risks associated with electric energy and of the measures to be taken to safely reach the Arc Welding System.

2.5 Equipment necessaryThe component securing systems (screws, nuts) have been standardised, using as few variations as possible. The table below indicates the minimum equipment needed for maintenance interventions of the Arc Welding System.

At the end of each maintenance session, the first machine start-up shall be regarded as a test for the whole plant. During such phase the operator shall stand outside the Robot range of action but in an position that allows to check its movements. Moreover, he/she shall have the Teach Pendant at disposal nearby.

Tab. 2.1 - Equipment necessary

Preliminary Maintenance Special Maintenance

Suction type cleaner Set of flat tip screwdrivers

Brush with soft bristles Set of cross-tip screwdrivers

Set of cross-tip screwdrivers Set of Allen wrenches (size in mm)

Set of Allen wrenches (size in mm) Set of socket wrenches (size in mm)

Set of socket wrenches (size in mm)


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2.6 Torque wrench settingsWhile disassembling and re-assembling the components comply with the screw torque wrench settings. If not otherwise specified, apply the torque corresponding to the screw typology used.

Do not over tight, as you may damage the thread and therefore the item position in its seat.Do not under tight, as it may cause the item falling and/or overheating (and consequent breaking) due to an incorrect adherence to the dissipating frame.


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3. GENERAL MAINTENANCE PROCEDURES

This chapter describes the general procedures for maintenance:

– General precautions

– Maintenance operation sheets

– Switching off the power supply

3.1 General precautionsMost maintenance activities for the Arc Welding System are to be performed with power supplies cut out:

In those cases the wording "Main switch open" is specified in the maintenance sheet. The procedure is described in par. 3.3 Switching off the power supply on page 15.

If the type of fault allows robot repositioning, it is advised to set it in idle position before starting the maintenance operations.

After the maintenance operations have been terminated, check the correct functioning of the Arc Welding System. Check the correct execution of some robot working cycles before leaving the station.

The maintenance activities that are not described in this manual are not allowed. If necessary require the manufacturer's intervention.


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3.2 Maintenance operation sheetsThe following maintenance sheets describe the maintenance procedures to perform on the Arc Welding System.

Each sheet contains the following information:

Saying Information description

Status: It underlines the condition that the Arc Welding System has to assume before performing the maintenance operations.

Material Necessary material for the activity. This represents both the spare parts and the consumable material.

Equipment Equipment needed for the maintenance operations.

Preliminary procedures / notes

It describes the activities to be performed before the operating procedure. It explains also the notes that give deeper information on the activity.

Operating procedure It describes the operating procedure step by step, with explanation figures, if necessary.

Follow-up procedure It describes the activities to carry out after the operating procedure. Usually the opposite activity of the preliminary procedure is shown.


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Preventive Maintenance - Switching off the power supply

3.3 Switching off the power supply

Status: – Not significant

Material: – Not required

Equipment: – Not required

Preliminary procedures/ notes

– Most maintenance activities are to be performed with power supplies cut out. In those cases the wording "Main switch open" is specified in the maintenance sheet. In order to obtain a complete and secure power sectioning, it is necessary to section the C5G Control Unit power supply too (interconnected sections 24V).

– The maintenance activities to be carried out on the cabinet main powering section shall be performed only after disconnecting the power from the mains. In those cases the wording "Input voltage off" is specified in the maintenance sheet.

Before switching off the Control Unit, perform the shutdown software procedure. For a detailed switching off procedure of the C5G Control Unit, please refer to the related manual.

Operating procedure

Main switch open

a. Disconnect the C5G Control Unit power supply. With closed cabinet door, set the Q100 main switch lever (A) in 0 (OFF) position.

b. Push the lever to access the eyelet.

c. Insert the padlock in eyelet of main switch lever.

d. Remove the padlock only at the end of the maintenance activity.

n

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Preventive Maintenance - Switching off the power supply

e. Remove the padlock only at the end of the maintenance activity.

f. The padlock is not provided with the electrical cabinet.

When the main switch is open, the X120 connector and the related cable on the main switch are energized.

n

Input voltage off

a. Cut the electric power as shown in the previous points at the section Main switch open.

b. Open and lock the main switch on the C5G Control Unit (power supply from busbar). The padlock is not provided with the Control Unit

c. Remove the padlock only at the end of the maintenance activity.

Follow-up procedure

– Not necessary.

Operating procedure (Continue)


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Maintenance Plan

4. MAINTENANCE PLAN

4.1 OverviewArc Welding System maintenance is divided in:

– Preliminary Maintenance

– Special Maintenance.

Arc Welding System maintenance is:

– detailed with specific procedures described in Maintenance operation sheets

– graphically summarised in Summary of intervention points.

It is recommended to carry out preventive maintenance activities periodically, to preserve the Arc Welding System functional features longer.In case of poor or missing preventive maintenance activities during the warranty period, this will be regarded as prejudicial to the warranty itself.


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Maintenance Plan

4.2 Summary of intervention points

P1P1

ASM

S4S4

S1S1

S2S2

S3S3

P2P2


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Preliminary Maintenance

5. PRELIMINARY MAINTENANCE

To guarantee the Arc Welding System proper operating, it is necessary to carry out preventive maintenance activities periodically, to reduce the amount of faults caused by the ordinary deterioration over time.

.

The preliminary maintenance operations shall be performed by qualified staff. Chap. General maintenance procedures at page 13 describes the preparative operations on theArc Welding System that are to be performed prior to starting preliminary maintenance activities.The maintenance activities that are not described in the following chapters shall be performed by Comau qualified staff.

It is recommended to carry out preventive maintenance activities periodically, to preserve the Arc Welding System functional features longer.In case of poor or missing preventive maintenance activities during the warranty period, this will be regarded as prejudicial to the warranty itself.


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Preliminary Maintenance

5.1 Preventive maintenance planFind in Tab. 5.1 the preventive maintenance plan based on the frequency.

¹The reference is to be found in par. 4.2 Summary of intervention points a pag. 18

Tab. 5.1 - Preventive maintenance plan

Frequency ActivityRef. ¬¼

Control Unit

For a detailed description of the operations, see the specific COMAU maintenance manual.

Robot


Generator

Once a week Generator: coolant level check P1

For a detailed description of the operations, see the specific Manufacturer's maintenance manual.

Torch cleaning assembly and lubricator

Once a week Group cleaning torch and lubrication : liquid level check P2



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Preventive Maintenance - Generator


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5.2 Generator: coolant level check


Material: – Coolant (see Spare parts list).

Equipment: – Cleaning cloth


– Not necessary

Operating procedure

a. Check visually the coolant level present, by means of the indicator (A).

b. If the level is less than or similar to the minimum level (min), fill up the coolant as described in the following points.

c. Open the load cover (B).

d. Fill the coolant, verify the level on the measurement instrument (A) and pay attention not to exceed the maximum level.

e. Close the load cover (B).

f. Remove the coolant on the dirty parts.

Follow-up procedure

– Not necessary.


ASM

Preventive Maintenance - Group cleaning torch and lubrication

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5.3 Group cleaning torch and lubrication : liquid level check


Material: – Liquid (see Spare parts list).

Equipment: – Cleaning cloth


– Not necessary

Operating procedure

a. Check visually the liquid level present in the tank, by means of the indicator (A).

b. If necessary fill up the liquid as described in the following points.

c. Unscrew and remove the tank (A).

d. Fill the liquid in the tank (A) and pay attention not to exceed the maximum level.

e. Screw again the tank(A) on the cleaning and lubricator assembly (B).

f. Remove the liquid on the dirty parts.

Follow-up procedure

– Not necessary.


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Special Maintenance

6. SPECIAL MAINTENANCE

To replace damaged items, follow the procedures described in the maintenance sheets.

The special maintenance operations shall be performed by qualified staff. Chap. General maintenance procedures at page 13 describes the preparative operations on the Arc Welding System that are to be performed prior to starting special maintenance activities.The maintenance activities that are not described in the following chapters shall be performed by Comau qualified staff.


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Special Maintenance

6.1 Special maintenance planFind in Tab. 6.1 the special maintenance plan based on the frequency.

¹The reference is to be found in par. 4.2 Summary of intervention points a pag. 18

Tab. 6.1 - Special maintenance plan

Activity Ref.¬¼

Control Unit


Robot


Robot outfitting

Removable welding torch: replacement S01

Outfitting upper cable package replacement (from welding torch to wire feeder)

S02

Outfitting: kit connection pack replacement (from wire feeder to robot base) S03

Generator


Torch cleaning assembly and lubricator

Sostituzione fresa S04



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Special Maintenance - Removable welding torch


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6.2 Removable welding torch: replacement

Status: – Power off

Material: – Removable welding torch (see Spare parts list).

Equipment: – -



– Enter the unit of the Arc Welding System in a secure manner.

See the complete machine manual (welding unit) for details on the access procedure due to maintenance.

Operating procedure

a. Unscrew manually the sleeve bushing (B) and take it off from the removable torch (A).

a. Set a new removable torch (A) and screw manually the sleeve bushing (B).

Follow-up procedure

– Check the correct functioning of the welding torch, controlling that the first working cycles are performed properly.

ASM

Special Maintenance - Outfitting

6.3 Outfitting upper cable package replacement (from welding torch to wire feeder)


Material: – Outfitting (see Spare parts list).

Equipment: – Adequate wrench



– Enter the cell of the Arc Welding System in a secure manner.

See the complete machine manual (welding cell) for details on the access procedure due to maintenance.

Operating procedure

a. Follow the welding torch replacement procedure (see paragraph Removable welding torch: replacement).

b. Unscrew the threaded bushing B by means of the suitable wrench C and take it off from the anti-collision assembly D

c. Remove the cable package connections from the wire feeder assembly.

d. Take off the cable pack Apassing it in sequence through:

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d.1 The lock E to put the outfitting in the wire puller installation zone;

d.2 The guide ring F on the robot arm;

d.3 The anti-collision / robot wrist D.

e. Assembly a new cable pack A following the previous operations but in the opposite order: for further details see the procedure Welding torch assembly installation

f. Connect the cable pack to the wire puller assembly.

g. Position the threaded bushing B on the anti-collision assembly D.

h. Screw the threaded bushing Bby means of the suitable wrench C.

i. Set the welding torch (see paragraph Removable welding torch: replacement).

Follow-up procedure

– Not necessary



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6.4 Outfitting: kit connection pack replacement (from wire feeder to robot base)


Material: – Outfitting (see Spare parts list).

Equipment: – Adequate wrench


– Enter the cell of the Arc Welding System in a secure manner.

See the complete machine manual (welding cell) for details on the access procedure due to maintenance.

Operating procedure

a. Remove the cable package connections from the generator and from the wire feeder.

b. Unscrew the 2 fixing screws (B).

c. Separate the two components of the semi-collar (C).

d. Unscrew the 2 fixing screws (D).

e. Separate the two components of the semi-collar (C) and position it on the Robot axis 1.

ASM


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f. Unscrew the 2 fixing screws (F).

g. Separate the two components of the semi-collar (G).

h. Unscrew the 3 fixing screws (H) of the signal exchange unit(J).

i. Take off the outfitting (A) from the robot.

j. Assembly a new cable package (A) following the previous operation from the bottom: for further detail see the Wire feeder installation procedure.

k. Connect the cable package to the generator and the wire feeder unit.

Follow-up procedure

– Not necessary



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Spare parts list

7. SPARE PARTS LIST

This chapter contains the spare parts list divided according to the machine part:

– COMAU C5G Control Unit

– SMART5 Robot Arc4 COMAU

– Generator

– 3x500V Autotransformer for generator

– Wire feeder assembly

– Weld torch

– Anti-collision assembly

– Tool Master

– Location point

– TCP Check

– Mechanical torch cleaning assembly


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Spare parts list

Tab. 7.1 - COMAU C5G Control Unit

Position Comau code Description

A CR17132680 HSK5 C5G option for Control Unit

For a complete spare parts list of the Control Unit, see the C5G Control Unit maintenance manual.


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Spare parts list

Tab. 7.2 - SMART5 Robot Arc4 COMAU


A

CR16654480 Cables pack 95 mm² (AWG 3/0) lunghezza 4 m (13.1 ft)




For a complete spare parts list of the Control Unit, see the Robot SMART5 Arc4.maintenance manual.


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Spare parts list

Tab. 7.3 - Generator


FRONIUS TPS4000 SER PAP Generator Unit - Comau Code CR16660080

A 19060468 TPS 4000 Sinergic Fronius Generator

B 19060450 FK 4000-R Cooling Unit

C 19060451 Water flux controller for FK 4000-R

D CR19060573 Gateway Interface

E CR19078015 i KIT VR CONTR INT A

FRONIUS TPS5000 SER PAP Generator Unit - Comau Code CR16660180

A 19060510 TPS 5000 Sinergic Fronius Generator

B 19060450 FK 4000-R Cooling Unit

C 19060451 Water flux controller for FK 4000-R

D CR19060573 Gateway Interface

E CR19078015 i KIT VR CONTR INT A

Cable for FRONIUS TPS4000 / TPS5000 Generator Unit

F

CR16041460 Serial cable, length 7 m (23 ft)

CR16041461 Serial cable, length 12 m (39.4 ft)




CR16041465 Serial cable, length 32 m (105 ft)

G 19060484 Welding ground 95 mm², 10 m (32.8 ft)


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Spare parts list

Tab. 7.4 - 3x500V Autotransformer for generator


A CR19061436 3x500V Autotransformer


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Spare parts list

Tab. 7.5 - Wire feeder assembly


A CR16654380FRONIUS Wire puller assembly with rollers for iron wire diam. 1.2 mm (0.047 in) in ferro.

BCR16655380 Rollers kit for AL/CUSI3 wire diam. 1 mm (0.039 in)

CR16655480 Rollers kit for iron wire diam. mm (0.039 in)


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Spare parts list

Tab. 7.6 - Weld torch


Robacta torch body Kit RA280 angle 22° Code CR19072009

A

CR19072009

Robacta torch body 280 22°

B Locking treated ring nut

C Conic gas nozzle


A CR19072004 Robacta torch body 400 22° DIAM 15,2

B CR19074017 Locking treated ring nut

C CR19074018 Threaded conic gas nozzle diam.13/diam.22x67


A CR19072005 Robacta torch body 400 36° DIAM 15,2

B CR19074017 Locking treated ring nut



A CR19072006 Robacta torch body 5000 22° L=241,0mm H=50,0mm

B CR19074015 Locking treated ring nut M25x1,5

C CR19074016 Threaded conic gas nozzle 17/diam.25x79










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Spare parts list

Tab. 7.7 - Anti-collision assembly


Kit anticollisione CR16654880

A CR19078024 Adapter Flange Pap

B CR19078025 Collision Box Pap


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Spare parts list

Tab. 7.8 - Tool Master


A 81783801 Tool Master (Calibrated tool assembly) L=117

Tab. 7.9 - Location point


A 166542200400 Location point


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Spare parts list

Tab. 7.10 - TCP Check


TCP Check Code 16654480

A 16654360 TCP Check cable, length 10 m (32.8 ft)

B 19061423 Optical sensor

C CR19061439 T splitter


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Spare parts list

Tab. 7.11 - Mechanical torch cleaning assembly


Robacta Reammer Torch Cleaner with 00 mm (27.56 in) column Code 16689494

A 19060480 Robacta Reamer Torch Cleaner device

B 19060481 Support column, height 700 mm (27.56 in)

C CR19074003 Electrolyte fluid (0.5 litres (16.90 oz container)

D

CR19074019 Milling for RA280 Torch with nozzle diam. 12 mm



E

CR16654180 Digital I/Os cable, length 8 meters (26.25 ft)

CR16654280 Digital I/Os cable, length 15 meters (49.21 ft)

CR16655980 Digital I/Os cable, length 8 meters (26.25 ft) (Double Robot)

CR16656080 Digital I/Os cable, length 15 meters (49.21 ft) (Double Robot)

A

B

C


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Original instructions

COMAU Robotics servicesRepair: [email protected]: [email protected] parts: [email protected] service: [email protected]/robotics