Lb-gl-0-Sw en Lepak

SMART NH1 - Manuals list
Comau Robotics
SMART NH2 - Manuals list
Instruction handbook
Sealant system
SmartGlue
Application Software 100.xx
CR00757666_en-01/2011.11
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 11/2011

SUMMARY
1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.5

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
2. DESCRIPTION OF SEALANT APPLICATION SYSTEM . . . . . . . . . . . . . . . . . . . . ..2.15

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
3. INSTALLING / ACTIVATING / DEACTIVATING . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3.17

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Preparation for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Use of the WinApplicationCreator tool for C5G (WAC5G). . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
Installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
Uninstall procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
4. USER INTERFACE ON THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . ..4.22

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
Process control keys (menu on the right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
Specific application environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
Application Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
Setup Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27
DATA Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.33
Integration of the application package with System environment . . . . . . . . . . . . . . . . . . . . . . 4.35
ALARM Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
I/O Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38
Integration with IDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
Entering technological instructions by NODAL system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
5. PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5.43
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
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Technological instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
General routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
Service routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47
General routines of the NODAL system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
Service routines NODAL system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.55
Use of shared System sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.58
Cosmetic Sealer application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.61
6. CUSTOMIZATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.62
Configuration I/O towards PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.62
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Preface
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.

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

precautions that are to be underlined.
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Preface
Reference documents
This document concerns the application Sistema per la spalmatura.
The complete set of Sistema per la spalmatura manuals consists of:
Comau C5GControl Unit – Technical specifications

– Transport and installation
– Maintenance
– Use of Control Unit
Robot – Technical specifications
– Transport and installation
– Maintenance
Programming – PDL2 Programming Language
– Motion Programming
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General Safety Precautions
1. GENERAL SAFETY PRECAUTIONS
It deals with a general specification that apply to the whole Robot System. Due to
ist significance, this document is referred to unreservedly in any system
instruction manual.
This specification deals with the following topics:

– Responsibilities
– Safety Precautions.
1.1 Responsibilities
– The system integrator is responsible for ensuring that the Robot System (Robot
and Control System) are installed and handled in accordance with the Safety
Standards in force in the country where the installation takes place. The application
and use of the protection and safety devices necessary, the issuing of declarations
of conformity and any CE markings of the system are the responsibility of the
Integrator.
– COMAU Robotics & Service shall in no way be held liable for any accidents caused
by incorrect or improper use of the Robot System (Robot and Control System), by
tampering with circuits, components or software, or the use of spare parts that are
not included in the spare parts list.
– The application of these Safety Precautions is the responsibility of the persons

assigned to direct / supervise the activities indicated in the Applicability sectionally
are to make sure that the Authorised Personnel is aware of and scrupulously follow
the precautions contained in this document as well as the Safety Standards in
addition to the Safety Standards in force in the country in which it is installed.
– The non-observance of the Safety Standards could cause injuries to the operators
and damage the Robot System (Robot and Control System).
The installation shall be made by qualified installation Personnel and should

conform to all national and local codes.
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1.2 Safety Precautions

1.2.1 Purpose
These safety precautions are aimed to define the behaviour and rules to be observed
when performing the activities listed in the Applicability section.
1.2.2 Definitions
Robot System (Robot and Control System)
The Robot System is a functional unit consisting of Robot, Control Unit, Programming
terminal and possible options.
Protected Area
The protected area is the zone confined by the safety barriers and to be used for the
installation and operation of the robot
Authorised Personnel
Authorised personnel defines the group of persons who have been trained and assigned
to carry out the activities listed in the Applicability section.
Assigned Personnel
The persons assigned to direct or supervise the activities of the workers referred to in
the paragraph above.
Installation and Putting into Service

The installation is intended as the mechanical, electrical and software integration of the
Robot and Control System in any environment that requires controlled movement of
robot axes, in compliance with the safety requirements of the country where the system
is installed.
Programming Mode
Operating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual handling of robot axes and programming of
work cycles at low speed, programmed cycle testing at low speed and, when allowed,
at the working speed.
Auto / Remote Automatic Mode

Operating mode in which the robot autonomously executes the programmed cycle at the
work speed, with the operators outside the protected area, with the safety barriers
closed and the safety circuit activated, with local (located outside the protected area) or
remote start/stop.
Maintenance and Repairs

Maintenance and repairs are activities that involve periodical checking and / or
replacement (mechanical, electrical, software) of Robot and Control System parts or
components, and trouble shooting, that terminates when the Robot and Control System
has been reset to its original project functional condition.
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Putting Out of Service and Dismantling

Putting out of service defines the activities involved in the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.
Integrator
The integrator is the professional expert responsible for the installation and putting into
service of the Robot and Control System.
Incorrect Use
Incorrect use is when the system is used in a manner other than that specified in the
Technical Documentation.
Range of Action
The robot range of action is the enveloping volume of the area occupied by the robot
and its fixtures during movement in space.
1.2.3 Applicability
These Specifications are to be applied when executing the following activities:
– Installation and Putting into Service
– Programming Mode
– Auto / Remote Automatic Mode
– Robot axes release
– Maintenance and Repairs
– Putting Out of Service and Dismantling
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1.2.4 Operating Modes

Installation and Putting into Service
– Putting into service is only possible when the Robot and Control System has been
correctly and completely installed.
– The system installation and putting into service is exclusively the task of the
authorised personnel.
– The system installation and putting into service is only permitted inside a protected
area of an adequate size to house the robot and the fixtures it is outfitted with,
without passing beyond the safety barriers. It is also necessary to check that under
normal robot movement conditions there is no collision with parts inside the
protected area (structural columns, power supply lines, etc.) or with the barriers. If
necessary, limit the robot working areas with mechanical hard stop (see optional
assemblies).
– Any fixed robot control protections are to be located outside the protected area and
in a point where there is a full view of the robot movements.
– The robot installation area is to be as free as possible from materials that could
impede or limit visibility.
– During installation the robot and the Control Unit are to be handled as described in
the product Technical Documentation; if lifting is necessary, check that the
eye-bolts are fixed securely and use only adequate slings and equipment.
– Secure the robot to the support, with all the bolts and pins foreseen, tightened to
the torque indicated in the product Technical Documentation.
– If present, remove the fastening brackets from the axes and check that the fixing
of the robot fixture is secured correctly.
– Check that the robot guards are correctly secured and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– If applicable, connect the robot pneumatic system to the air distribution line paying
attention to set the system to the specified pressure value: a wrong setting of the
pressure system influences correct robot movement.
– Install filters on the pneumatic system to collect any condensation.
– Install the Control Unit outside the protected area: the Control Unit is not to be used
to form part of the fencing.
– Check that the voltage value of the mains is consistent with that indicated on the
plate of the Control Unit.
– Before electrically connecting the Control Unit, check that the circuit breaker on the
mains is locked in open position.
– Connection between the Control Unit and the three-phase supply mains at the
works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned
appropriately for the power installed on the Control Unit. See the product
Technical Documentation.
– The power supply cable is to enter the Control Unit through the specific fairlead and
be properly clamped.
– Connect the earth conductor (PE) then connect the power conductors to the main
switch.
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– Connect the power supply cable, first connecting the earth conductor to the circuit
breaker on the mains line, after checking with a tester that the circuit breaker
terminals are not powered. Connect the cable armouring to the earth.
– Connect the signals and power cables between the Control Unit and the robot.
– Connect the robot to earth or to the Control Unit or to a nearby earth socket.
– Check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors could cause permanent damage to the
Control Unit components.
– The C5G Control Unit manages internally the main safety interlocks (gates,
enabling pushbuttons, etc.). Connect the C5G Control Unit safety interlocks to the
line safety circuits, taking care to connect them as required by the Safety
standards. The safety of the interlock signals coming from the transfer line
(emrgency stop, gates safey devices etc) i.e. the realisation of correct and safe
circuits, is the responsibility of the Robot and Control System integrator.
In the cell/line emergency stop circuit the contacts must be included of the control
unit emergency stop buttons, which are on X30. The push buttons are not
interlocked in the emergency stop circuit of the Control Unit.
– The safety of the system cannot be guaranteed if these interlocks are wrongly
executed, incomplete or missing.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic states; in Programming the power is cut out (power
contactors open) immediately. The procedure for the selection of the controlled
stop time (that can be set on SDM board) is contained in the Installation manual .
– When preparing protection barriers, especially light barriers and access doors,
bear in mind that the robot stop times and distances are according to the stop
category (0 or 1) and the weight of the robot.
Check that the controlled stop time is consistent with the type of Robot connected
to the Control Unit. The stop time is selected using selector switches SW1 and
SW2 on the SDM board.
– Check that the environment and working conditions are within the range specified
in the specific product Technical Documentation.
– The calibration operations are to be carried out with great care, as indicated in the
Technical Documentation of the specific product, and are to be concluded
checking the correct position of the machine.
– To load or update the system software (for example after replacing boards), use
only the original software handed over by COMAU Robotics & Service.
Scrupulously follow the system software uploading procedure described in the
Technical Documentation supplied with the specific product. After uploading,
always make some tests moving the robot at slow speed and remaining outside the
protected area.
– Check that the barriers of the protected area are correctly positioned.
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Programming Mode
– The robot is only to be programmed by the authorised personnel.
– Before starting to program, the operator must check the Robot System (Robot and
Control System) to make sure that there are no potentially hazardous irregular
conditions, and that there is nobody inside the protected area.
– When possible the programming should be controlled from outside the protected
area.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the hand-held programming unit functions
correctly (slow speed, emergency stop, enabling device, etc.).
– During the programming session, only the operator with the hand-held terminal is
allowed inside the Protected Area.
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (Drive On) is always to be controlled from a position
outside the range of the robot, after checking that there is nobody in the area
involved. The Drive On operation is concluded when the relevant machine status
indication is shown.
– When programming, the operator is to keep at a distance from the robot to be able
to avoid any irregular machine movements, and in any case in a position to avoid
the risk of being trapped between the robot and structural parts (columns, barriers,
etc.), or between movable parts of the actual robot.
– When programming, the operator is to avoid remaining in a position where parts of
the robot, pulled by gravity, could execute downward movements, or move
upwards or sideways (when installed on a sloped plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at slow speed has been executed. The
test is to be controlled from a safe distance.
– Special attention is to be paid when programming using the hand-held terminal: in
this situation, although all the hardware and software safety devices are active, the
robot movement depends on the operator.
– During the first running of a new program, the robot may move along a path that is
not the one expected.
– The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the robot position out
of the path that links two steps of the program), could give rise to movements not
envisaged by the operator when testing the program.
– In both cases operate cautiously, always remaining out of the robot’s range of
action and test the cycle at slow speed.
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Auto / Remote Automatic Mode

– The activation of the automatic operation (AUTO and REMOTE states) is only to
be executed with the Robot System (Robot and Control System) integrated inside
an area with safety barriers properly interlocked, as specified by Safety Standards
currently in force in the Country where the installation takes place.
– Before starting the automatic mode the operator is to check the Robot and Control
System and the protected area to make sure there are no potentially hazardous
irregular conditions.
– The operator can only activate automatic operation after having checked:
• that the Robot and Control System is not in maintenance or being repaired;
• the safety barriers are correctly positioned;
• that there is nobody inside the protected area;
• that the Control Unit doors are closed and locked;
• that the safety devices (emergency stop, safety barrier devices) are
functioning;
– Special attention is to be paid when selecting the automatic-remote mode, where
the line PLC can perform automatic operations to switch on motors and start the
program.
Robot axes release

– In the absence of motive power, the robot axes movement is possible by means of
optional release devices and suitable lifting devices. Such devices only enable the
brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enable button) are cut out; also the robot
axes can move upwards or downwards because of the force generated by the
balancing system, or the force of gravity.
Before using the manual release devices, it is strongly recommended to sling the
robot, or hook to an overhead travelling crane.
– Enabling the brake releasing device may cause the axes falling due to gravity as
well as possible impacts due to an incorrect restoration, after applying the brake
releasing module. The procedure for the correct usage of the brake releasing
device (both for the integrated one and module one) is to be found in the
maintenance manuals.
– When the motion is enabled again following the interruption of an unfinished
MOVE, the track recovery typical function may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next automatic cycle
restarting. Avoid moving the Robot to positions that are far away from the ones
provided for the motion restart; alternatively disable the outstanding MOVE
programmes and/or instructions.
Maintenance and Repairs

– When assembled in COMAU Robotics & Service, the robot is supplied with
lubricant that does not contain substances harmful to health, however, in some
cases, repeated and prolonged exposure to the product could cause skin irritation,
or if swallowed, indisposition.
First Aid. Contact with the eyes or the skin: wash the contaminated zones with
abundant water; if the irritation persists, consult a doctor.
If swallowed, do not provoke vomiting or take anything by mouth, see a doctor as
soon as possible.
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– Maintenance, trouble-shooting and repairs are only to be carried out by authorised

personnel.
– When carrying out maintenance and repairs, the specific warning sign is to be
placed on the control panel of the Control Unit, stating that maintenance is in
progress and it is only to be removed after the operation has been completely
finished - even if it should be temporarily suspended.
– Maintenance operations and replacement of components or the Control Unit are to
be carried out with the main switch in open position and locked with a padlock.
– Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages coming from connections to peripheral units or external
power sources (e.g. 24 Vdc inputs/outputs). Cut out external sources when
operating on parts of the system that are involved.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Faulty components are to be replaced with others having the same code, or
equivalent components defined by COMAU Robotics & Service.
After replacement of the SDM module, check on the new module that the setting
of the stop time on selector switches SW1 and SW2 is consistent with the type of
Robot connected to the Control Unit.
– Trouble-shooting and maintenance activities are to be executed, when possible,

outside the protected area.
– Trouble-shooting executed on the control is to be carried out, when possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards are to be observed
when operating with hazardous voltages present.
– Trouble-shooting on the robot is to be carried out with the power supply cut out
(Drive off).
– At the end of the maintenance and trouble-shooting operations, all deactivated
safety devices are to be reset (panels, protection shields, interlocks, etc.).
– Maintenance, repairs and trouble-shooting operations are to be concluded
checking the correct operation of the Robot System (Robot and Control System)
and all the safety devices, executed from outside the protected area.
– When loading the software (for example after replacing electronic boards) the
original software handed over by COMAU Robotics & Service is to be used.
Scrupulously follow the system software loading procedure described in the
specific product Technical Documentation; after loading always run a test cycle to
make sure, remaining outside the protected area
– Disassembly of robot components (motors, balancing cylinders, etc.) may cause
uncontrolled movements of the axes in any direction: before starting a disassembly
procedure, consult the warning plates applied to the robot and the Technical
Documentation supplied.
– It is strictly forbidden to remove the protective covering of the robot springs.
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Putting Out of Service and Dismantling

– Putting out of service and dismantling the Robot and Control System is only to be
carried out by Authorised Personnel.
– Bring the robot to transport position and fit the axis clamping brackets (where
applicable) consulting the plate applied on the robot and the robot Technical
Documentation.
– Before stating to put out of service, the mains voltage to the Control Unit must be
cut out (switch off the circuit breaker on the mains distribution line and lock it in
open position).
– After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the distribution line,
first disconnecting the power conductors, then the earth. Disconnect the power
supply cable from the Control Unit and remove it.
– First disconnect the connection cables between the robot and the Control Unit,
then the earth cable.
– If present, disconnect the robot pneumatic system from the air distribution line.
– Check that the robot is properly balanced and if necessary sling it correctly, then
remove the robot securing bolts from the support.
– Remove the robot and the Control Unit from the work area, applying the rules
indicated in the products Technical Documentation; if lifting is necessary, check the
correct fastening of the eye-bolts and use appropriate slings and equipment only.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU Robotics & Service,
or one of its branches, who will indicate, according to the type of robot and Control
Unit, the operating methods in accordance with safety principles and safeguarding
the environment.
– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.
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1.2.5 Performance
The performances below shall be considered before installing the robot system:
– Stop distances
– Mission time (typ. case).
Stop distances
– With Robot in programming modality (T1), if you press the sttop pushbutton (red
mushroom-shaped one on WiTP) in category 0 (secondo norma EN60204-1), you
will obtain:
Tab. 1.1 - Stop spaces in programming modality (T1)

Expected Stopping Stopping
Mode Case
speed time space
Nominal 120 ms 30 mm
T1 250 mm/s
Limit 500 ms 125 mm
Tab. 1.2 - Safety electronics reaction time in programming

modality (T1)
Expected Stopping
Mode Case
speed time
For the safety inputs of the SDM module (e.g.
stop pushbutton of TP in wired version)
For the stop stop and enabling device inputs 150 ms
from the TP in wireless version, when the
T1 250 mm/s
safety wire trasmission is active.
For the time-out of stop input and enabling
device from TP in wireless version, when the 350 ms
safety wire transmission is lost or interrupted.
– Considering the Robot in automatico modality, under full extension, full load and
maximmum speed conditions, if you press the stop pushbutton (red
mushroom-shaped one on WiTP) in category 1 (according to norm EN60204-1)
you will trigger the Robot complete stop with controlled deleration ramp.
Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 °
motion, that correspond to about 3000 mm movement measured on TCP flange.
Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5
seconds.
Mission time (typ. case)

– We remind you that the safety system efficiency covering is equal to 20 years
(mission time of safety-related parts of control systems (SRP/CS), according to
EN ISO 13849-1).
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Description of sealant application system
2. DESCRIPTION OF SEALANT
APPLICATION SYSTEM
2.1 Introduction
This chapter introduces to the COMAU Stud Welding, in particular to the SmartGlue
application software.
SmartGlue application, provided by Comau, is a software tool for managing sealant
systems.
SmartGlue handles several sealant systems and the most common types of fieldbuses.
By means of a PC application provided by Comau, the User is able to select the being
handled devices and to generate a specific application Software for his/her own
configuration (see par. 3.4 Use of the WinApplicationCreator tool for C5G (WAC5G) a
pag. 19 )
The installation procedure automatically and transparently executes some operations.
In particular:
– it copies the needed files onto the Control Unit;
– it makes the application software resident: at each Control Unit restart, the
application software is loaded into memory and activated;
– it autonomously configures the signals towards the devices which are connected
to the fieldbus handled by the robot. At the end of the installation procedure, the
communication is active, with all the connected devices;
– it autonomously configures the Input/Output signals towards the devices and
provides a textual description.
SmartGlue application provides a set of Technological instructions for the process
complete handling, ready to to be used within the User program. It is not needed to
integrate the process instructions by means of writing further programming code. The
Technological Instructions take care of anomalies and resume handling.
Other features of the SmartGlue as follows:
– a standard profile of signals towards PLC (application inclusion, process activation,
dry-cycle, alarm reset and corresponding state feedbacks towards PLC), common
to all application software provided by Comau;
– a graphic environment composed by:
• main page providing the most important state information (last executed
welding program, electrodes state, welding phase, etc.), configuration
information and Software version, User informational area available;
• process control keys: the most common functionalities are associated to the
process keys (application inclusion, weld activation, open/close gun) and the
corresponding icons are created;
• setup environment: to modify and save the general settings (not included as
parameters of the Technological Instructions) which control the application
way of operating;
The name of the module (s) and the related address to set in the net is provided by the
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00/0211 15
Description of sealant application system
tool WAC5G by means of a PDF file that reports an example of how the configuration
should be managed (as shown by the arrow in the example of Fig. 2.1).
Fig. 2.1 - Example of configuration
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16 00/0211
Installing / Activating / Deactivating
3. INSTALLING / ACTIVATING
/ DEACTIVATING
3.1 Introduction
This chapter describes the procedures for installing, activating, deactivating SmartGlue
application.
In particular, the following topics are dealt with:
– System requirements
– Preparation for installation
– Use of the WinApplicationCreator tool for C5G (WAC5G)
– Installation procedure
– Uninstall procedure
3.2 System requirements

3.2.1 Software
It is necessary to enable the software option, which allows the application software
usage.
Comau code for SmartGlue CR13613060
The SmartGlue application software can be used in combination with the C5G System
Software, whose version is identified by the first figures in the application software
version. For example the version 100.01 of the application software, requires a system
software version that is equal to or higher than 1.0x.
3.2.2 Hardware
The following basic hardware components are needed to use the SmartGlue
application:
– Robot Control Unit C5G
– one of the following interface:
• C5G-Devicenet
• C5G-Profibus
• C5G-Profinet.
3.3 Preparation for installation

Before starting the actual installation procedure of the SmartGlue application (par. 3.5
Installation procedure a pag. 19) it is strictly necessary to set the net Fieldbus Master of
the Control Unit C5G.
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01/1111 17
NOTE: For the setting of the net Fieldbus Master (by means of SYCON.net and
WINC5G), refer to the manual Use of the Control Unit C5G - cap. Project of the net
Fieldbus Master.
It is possible to distinguish two different cases of configuration:

– Application configuration generated by the user through WAC5G tool
– Application configuration generated by COMAU Robotics.
In both modes, if the application configuration includes some slave fieldbus modules
controlled by the master in the robot Control Unit, it is necessary to display a file .spb
(SyCoNet Project Backup) in order to configure the master fieldbus net, to go on with
the installation.
Application configuration generated by the user through WAC5G tool

This mode is the one normally used from every customer.
In this mode of the same tool (WAC5G) provides the user with all the files and
information useful for the user in order to generate the file SPB related to the specific
generated configuration. The user will
– generate the project file, by means of the tool SYCON.net, with extension .spj,
– from the project file (extension .spj,) create, by means of the tool WinC5G, a file
with extension spb,
– to transfer the file with extension .spb in the directory UD:\sys\config of the
Control Unit before to go on with the installation.
The name of the module (s) and the related address to set in the net is provided by the
tool WAC5G by means of a PDF file that shows an example of how the configuration
should be managed.
Application configuration generated by COMAU Robotics

This mode is typically applied in customer projects where COMAU Robotics provides
several standard application packages, also combined among them and that can be
assimilated in homogeneous groups.
The applications are distributed as a group of files, included in an appropriate folders
structure, with a configuration file for the installation, with extension .appl (for example
CustomerProjectxxx.appl).
The installation, in this case is carried out by copying the entire folders structure and the
file .appl, on the source device (such as flash disk USB)I, inserting in the USB port of
the system C5G (on APC or Teach Pendant) and selecting, from the menu SETUP -
Installation , before the specific project and then the chosen sub-configuration.
In this mode the specific file SPB is distributed by COMAU Robotics, taking into
consideration that:
– that file is charged on the Control Unit during the installation and/or further updating
of the application, only if a .spb file is not already present on the Control Unit, in
order to avoid user configurations overwriting;
– in case of "hybrid" configuration, where the configured fieldbus modules managed
by the COMAU applications coexist with the user modules (for example I/O on
manipulation grippers), .spb the file distributed by COMAU will contain only the
related configuration related to the applicative modules and therefore it will have to
be modified by the user/installer by adding his own modules.
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3.4 Use of the WinApplicationCreator tool for

C5G (WAC5G)
SmartGlue software supplied by Comau, is distributed in just one file (version file) with
.wac5g extension (SmartStudVxxx.xx.waC5G) including all available configurations,
i.e. all the allowed devices.
The filename is referred to the application type and the version number (e.g.:
SmartGluev10001.waC5G).
WAC5G is a PC application provided by Comau, to the User, in order to import files of
.wac5g type. It shows, in graphical form, all the allowed devices, grouped in
columns,depending on their type. The User can choose among the existing devices in
his/her own configuration and generate a specific installation file.
For a detailed description, about use and functionality of WAC5G tool, please
refer to the dedicated manual.
The installation file which is generated by WACC5G is an archive file (.zip extension)
whose name is composed by
<name of the version file>< name of the configuration>.zip
The configuration name is asked by WACC5G before generating the installation file.
The user can choose any string that helps to better identify the configuration. Such a
string is the one displayed on the Teach Pendant in the application About pages.
3.5 Installation procedure

To install the application, proceed as follows:
a. Activate the SETUP page on the Teach Pendant

(see Fig. 3.1).
Fig. 3.1 - SETUP - Installation
b. Selection the Install icon and push ENTER to confirm
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01/1111 19
c. Press ENTER again, then down arrow key, to select the device (COMP:, XD:, UD:,
TX:) containing the project/application to be installed, i.e SmartGlue (seeFig. 3.2).
d. Press ENTER to confirm. Press down arrow to select the application to be

installed,i.e. SmartGlue (seeFig. 3.2).
Fig. 3.2 - SETUP - Install - Application
In case of installation of big projects, select the desired project (seeFig. 3.3),
confirm with ENTER and choose the connected Type.
Fig. 3.3 - Installation of customer projects - example
e. Confirm with ENTER.
f. Press the key corresponding to the Install (F5) command, to perform the
installation;
g. If any error occurs while installing, messages and suggestions are issued.
h. In case of any error, the installation is stopped, the error is indicated with a
message and the C5G red alarm lamp of the Control Unit lights up. The system
remains in such a condition until the RESET key is pressed.
The installation will continue from the point where it was interrupted, as soon as the
condition that caused the error is removed.
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20 01/1111
i. After the installation has been accomplished, it is necessary to restart the system
(Restart Cold).
3.6 Uninstall procedure

To uninstall the application package it is needed to execute the following procedure:
a. Activate SETUP page (see Fig. 3.1) on the Teach Pendant
b. Select APPL icon and press ENTER
c. Select Uninstall icon and press ENTER (seeFig. 3.4)
Fig. 3.4 - SETUP - Uninstall
d. In the displayed combobox, select the wished application to be uninstalled, if

necessary select the checkbox to delete the technological parameters, then press
ENTER.
Fig. 3.5 - SETUP - Uninstall - 2
e. At the end of the procedure the User is requested to restart the System (Restart
Cold).
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01/1111 21
User interface on the Teach Pendant
4. USER INTERFACE ON THE TEACH

PENDANT
4.1 Introduction
This chapter describes the user interface on the Teach Pendant,corresponding to
SmartGlue application.
It is composed of the following environments:
– Process control keys (menu on the right)
– Specific application environments
– Integration of the application package with System environment
– Integration with IDE.
As for the use of the Teach Pendant, please refer to

the specific manual USE of the Control Unit, chapter Use of the Teach Pendant
Programming.
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4.2 Process control keys (menu on the right)

The Right Menu displays the softkeys and “software leds” for the process control.
The commands related to the softkeys can be enabled or disabled as shown in the icons
displayed in Tab. 4.1.
Tab. 4.1 - Meaning of softkey

Icon enabled / disabled - description
When the corresponding softkey is enabled, the icon that represents the
function is seen in colours.
When the corresponding softkey is disabled, the icon that represents the
function is seen in grey.
The colour of the software led is always displayed to show the component
status.
The "led software" present in each softkey shows the status of the component,
according to the colour displayed. Please see the description in the following Tab. 4.2.
Tab. 4.2 - Meaning of the led software

LED colour - description
When the led colour is yellow, it means that the command ($DOUT) is given to
the component, but the confirmation of executed function ($DIN) did not arrive
jet.
In the case in the figure, the function of the key is disabled (for example when the
command derives from remote) but the LED software continues to indicate the
status of the component: in the example beside, the green indicates that the
function has be performed in the right way.
In particular, there have been given description for each softkey, by referring all the
possible positions in the selector status of the Control Unit C5G:
– T1 Position (System in Prog mode)
– AUTO Position (system in Local)
– REMOTE Position (System in Remote status)
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01/1111 23
Tab. 4.3 - Function and status selector position

KEY ICON FUNCTION
Hardware inclusion/exclusion
It is useful in order to exclude (figure on the left) or include (figure on the right)
the hardware devices of the application (specified in the summary present on
R1
the related icon). If the hardware is excluded, the operation are executed
without using those devices (BUT those that could injury the user's and tools
security).
Doser
It allows to display / command Glue YES’(green) / Glue NO (grey).
R2
When the status selector is in T1 position, this softkey is enabled only if the
system is in DRIVE ON.
Vision (inclusion/exclusion) or Purge (in purge / not in purge)

In the figure on the side, included Vision (on the left) and system in purge (on
the right).
R3
Note - in order to perform the purge, press the related softkey for at least one
second, then the the material will start to come out and the LED becomes
green. Keep pressed for as long as the purge is required.
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4.3 Specific application environments

The specific Pages of the application are as follows:
– Application Page
– Setup Page
It follows a description of each of them, focused on their use in the field of SmartGlue.
4.3.1 Application Page

The Application Page on the Teach Pendant, is the main page of the installed
application, in this case it is the SmartGlue application. On the Teach Pendant, by
pushing the key Appl (L6) of the Left Menu, the main page of the application is
activated.
This page (seeFig. 4.1) is divided in four sections, also called areas, that display
different information on the application. If more than one application are installed on the
Control Unit, there will be as many tabsheets as the total amount of applications, in the
Application Page: just move the focus to the different tabsheets labelled with the names
of the existing applications on the Control Unit, to display the corresponding pages.
Fig. 4.1 - Application Page - starting screen
Here follows a detailed description of the following topics related to the Application
Page:
– Areas Description
– About
– Object
4.3.1.1 Areas Description

The four areas of the Application Page are as follows (seeFig. 4.1):
– The first area (top left area - (1)) - identifies the selected application, specifying its
installation version.
– The second (top right area - (2)) - Dynamic Data, including the most important
process data, related to the selected application. They are dynamic data, so they
are updated as soon as their value changes.
– The third area (bottom left area - (3)), called Device Status, shows the information
on the hardware configuration of the selected application.
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01/1111 25
– In the end, the fourth area (bottom right area - (4)) it is the User dedicated area and
therefore it is called User Area. A table is made up in which the user can see the
information that he considers opportune in form of strings (no more than four).
The strings for the application SmartGlue are:
glxs_user_1 : ARRAY [ki_row] OF STRING [19] EXPORTED FROM gl_dd
glxs_user_2 : ARRAY [ki_row] OF STRING [19] EXPORTED FROM gl_dd
where:
– ki_row, is the highest number of strings, that is 4
– glxs_user_1 it is the reference variable of the first column
– glxs_user_2 it is the reference variable of the second column
In the central menu of the Application Page there are two softkey available connected
to the following function:
– About (F5)
– Object (F1)
A detailed description of each one follows.
4.3.1.2 About
It displays a drop menu containing the following information on the selected application:
– Configuration: this function displays the application name and the installation
version, the application configuration name which is the User assigned identifier (at
the .zip file generation time, by means of the WAC tool) and the application
hardware configuration.
For further information, please refer to the WAC5G manual.
Fig. 4.2 - Configuration
– Version: this function displays the application name and the installation version,
the application configuration name which is the User assigned identifier and the
existing software modules version.
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Fig. 4.3 - Version
– Version CL: it displays the Common Libraries version, shared by the installed
applications.
Fig. 4.4 - Version CL :
4.3.1.3 Object
Object (F1) softkey, if present, allows accessing to further object pages, related to the
selected application.
It also allows to go back to the Application Page environment if the currently displayed
page is different (e.g. About environment or Object Pages).
The application SmartGlue does not contain other pages than the Application Page
4.3.2 Setup Page

Current section describes the needed user procedures to modify global settings for
SmartGlue application, by means of the Setup Page.
The following topics are described:
– General information
– Softkeys description
– Object Page Description
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01/1111 27
4.3.2.1 General information

By pressing SETUP (L3) key, in the left menu the Home page of the SETUP
environment is activated which is used to operate on the system settings. (seeFig. 3.1).
To access the applications SETUP instead, select APPL: the system displays the
Uninstall icon and one icon for each installed application software showing a wrench
(seeFig. 4.5).
Fig. 4.5 - Application Setup
Select the icon of the desired application and press ENTER. The Setup page of the
application, in this specific case the one of the SmartStud application, is shown as in
Fig. 4.6.
Fig. 4.6 - Setup of the SmartGlue application
It presents as many panels (System, Doser, Pump, Vision) as the number of the object
pages, or sub-pages, that allow to modify the parameters of the application.
The access to the Object Pages menus depends on the performed login; the default is
no menus available.
There exist two login levels that enable different menu grade:
– Technology level 1 - enables only first type type menus (for example 'DOSER_X'),
in each Object Page
– Tecnology livello 2 - enables all high level menus (HI’) of the Object Pages (for
example 'SYSTEM X HI' )
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It is therefore needed to create a suitable Technology Login, to be able to access

the wished environment.
The user can use the Object Pages of the Setup environment, in order to modify the
application configuration parameters, only during the Programming status (status
selector in T1 position).
In general, to access any Object Page and their associated menus, perform the
following steps:
a. choose the wished Object Page, by means of the left/right arrow keys;
b. press ENTER again, or down arrow, to move the focus to the menu and press
ENTER to open it;
c. select the wished item and confirm with ENTER;
d. move focus onto the fields to be modified, using the arrow keys, perform the wished
modifications;
e. apply the modifications, using the available softkeys in the bottom menu, as
explained in the following par. 4.3.2.2 Softkeys description a pag. 29.
4.3.2.2 Softkeys description

In each application Setup Page, the following commands are available, which can be
activated by means of the four softkeys of the bottom menu (seeFig. 4.7):
– Save (F2)
– Apply (F3)
– Reload (F4)
– Close (F6).
Fig. 4.7 - Softkey description
In particular, Save, Apply, and Reload act on the adjustment made. When
adjustments are made on the displayed data, the new values are displayed in italics.
4.3.2.2.1 Save (F2)

Saves the performed modifications, both in the execution memory and to a file. The
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01/1111 29
Object Page still remains open. The new value is displayed in the default style again. If
some values are saved which are different than the default ones, the files gl_conf.var (*)
including the new configuration values are saved in UD:\data\glue directory.
(*) This file will be automatically generated by the application only when user
modifications are made on the SETUP page. Therefore after a first installation this
file may not be present. In case of software updating, this file will be preserved in
order not to risk to loose the user configuration.
4.3.2.2.2 Apply (F3)

Saves the adjustments made in execution memory. The object Page remains open, but
the adjustments are NOT reproduced on the file. The new value is displayed again in
default style.
4.3.2.2.3 Reload (F4)

Loads again, from the file, the application variables default values.
4.3.2.2.4 Close (F6)

Closes the Setup Page.
4.3.2.3 Object Page Description

The Setup page of the application SmartGlue makes available the following
sub-pages:
– SYSTEM
– DOSER
– PUMP
– VISION.
4.3.2.3.1 SYSTEM
In this sub-page the user can operate on the settings of the DOSERS.
The configurations of the doser are basically included in two menu entries
– SYSTEM X (configuration for non expert users) - it is required the login type
Technology 1
– SYSTEM X HI LEVEL (configuration for expert users) - it is required the login type
Technology 2
Where X is the number of sealant system.
SYSTEM X
PARAMETER DESCRIPTION RANGE

System alarms timeout It sets the timeout used for all the alarm signals of [ms] [0..10000]
the sealant system
Number of the sealant devices It sets the number of the sealant devices used with [1..4]
used the system
Linear speed I sets, as linear speed, the speed indicated in the [ON/OFF]
BEAD table
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Alarms during the process It enables the function to check faults also during the [ON/OFF]
technological process
Send reset to system It enables the transmission of the faults reset signal [ON/OFF]
also to the sealant system
SYSTEM X HI LEVEL

Minimum speed It sets the minimum linear speed [ms] [0..0.6]
Percentage minimum flux It sets the percentage minimum flux [%] [0..100]
Percentage maximum flux It sets the percentage maximum flux [%] [0..100]
Eco programs It enables the control of the eco of the sealant [ON/OFF]
system for the selected program
4.3.2.3.2 DOSER
In this Object Page, the user can operate on the settings of the DOSERS.
The configurations of the doser are basically included in two menu entries:
– DOSER X (configuration for non expert users) - it is required the login type
Technology 1
– DOSER X HI LEVEL (configuration for expert users) - it is required the login type
Technology 2
Where X is the doser number.
DOSER X

It allows to choose the doser to use among:
• Pneumatic
Doser type
• Electric
• Without doser
Pre-pressure check It enable pre-pressure check [ON/OFF]
Low level check It enable doser low level check [ON/OFF]
Doser filling It enables automatic filling function [ON/OFF]
Filling Timeout It sets in timeout for doser filling [ms] [0..15000]
Purge It enables the Purge function [ON/OFF]
Purge time It sets purge time [ms] [1..10000]
Purge flow It indicates the material requirement percentage [%] [0..100]
Doser alarm timeout It sets the timeout used for all the alarm signals of [ms] [0..100000]
the doser
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01/1111 31
DOSER X HI LEVEL

Material modulation It enables the flow modulation functions [ON/OFF]
Modulation type It selects the modulation type of the material,
choosing among:
• Actual speed
• Program speed
• Independent speed
Modulation delay It sets the modulation signal delay to the sealant [ms] [0..500]
system
Type of swirl modulation (*) It selects the modulation type for swirl choosing
among:
• Actual speed
• Program speed
• Independent speed
Modulation delay for swirl It sets the modulation signal delay for swirl [ms] [0..500]
Doser Selection It enables the doser selection (function managed by [ON/OFF]
special sealant systems)
(*) only if the swirl is enabled, that is only if the Flow air > 0 (seeTab BEAD)
4.3.2.3.3 PUMP
In this kind of Object Page, the user can operate on the settings of the PUMP.
In order to choose the pump to use, open the combobox PUMP 1, select the required
one and confirm with ENTER.
In order to modify the Pump sub-page parameters, it is necessary a login of

technology type level 1.

Heating alarm It enables the heating system fault check [ON/OFF]
End of drum alarm It enables end of drum check [ON/OFF]
Pump alarm timeout To enter the timeout used for all pump alarm signals [ms] [0..10000]
4.3.2.3.4 VISION
In this type of Object Page, the user can operate on the settings of the VISION.
NOTE - This object page is present only if the chosen hardware configuration
foresees the vision system (that is with SCA sealant system).
In order to choose the pump to use, open the combobox VISION 1, select the required
one and confirm with ENTER.
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In order to modify the Vision sub-page parameters, it is necessary a Login of

Technology type level 1.

Vision alarm timeout It sets the timeout used for all the alarm signals of [ms] [0..100000]
the vision system
Number of the connected doser It sets the number of the connected doser to this [1..4]
vision system
Min. speed It sets the minimum speed value for the scanning [ms] [0..0.5]
Max. speed It sets the maximum speed value for the scanning [ms] [0..0.5]
Minimum screen sampling It sets the minimum value, expressed in percentage, [%] [0..100]
of the screen sampling
Maximum screen sampling It sets the maximum value, expressed in [%] [0..100]
percentage, of the screen sampling
Start signal delay It sets the delay with whom the start signal is sent in [ms] [0..100]
order to activate the vision
Stop signal delay It sets the delay with whom the stop signal is sent in [ms] [0..100]
order to deactivate the vision
Modulation delay It sets the delay with whom the modulation is [ms] [0..500]
activated
4.3.3 DATA Page

In order to enter the DATA environment, it is necessary to press the L2 key. If among
the 6 displayed softkey the one related to DATA is not present, press the more key to
display all the available softkey.
Depending on the system configuration, it is possible to have two different DATA
environment:
– DATA Page for MODAL configuration
– DATA Page for NODAL configuration.
4.3.3.1 DATA Page for MODAL configuration

Entering the DATA environment the system displays a list of all the available tabs (ex.
BASE, TOOL, etc.)
The tab related to the SmartGlue application is the BEAD TAB: it will be used for the
glue bead characteristics .
Select the table (see Fig. 4.8) and press ENTER.
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Fig. 4.8 - DATA page home
This tab (seeFig. 4.9) contains 99 available beads.
Fig. 4.9 - Tab BEAD
The list below describes the columns of this table.
COLUMN DESCRIPTION RANGE

Prog The sealant system program code that we want to use [1..99]
in this bead
Sub Prog (*) The sealant system sub program code that we want to [1..99]
use
Flow Mat Flux material percentage we want to obtain at the [0..100]
indicated speed in the following column
Speed Lin Speed with whom we want to obtain the glue bead [m/sec] [0..0,6]
Recov Offset Distance in mm used by the robot to retrace back the [mm][-30..30]
trajectory, when it is interrupt during the process
Dist Opn Mat Distance in mm of the Material delivery gun opening [mm][0..100]
Dist Cls Mat Distance of the Material delivery gun closing [mm][0..100]
Flow Air (**) Air percentage we want to obtain at the indicated linear [0..100]
speed
Offset Tool Tool distance from the planned point [mm][-100..200]
(*) - Depending on the hardware configuration this field can be present or not
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(**) - If this value is 0, the swirl modulation is not activated.
4.3.3.2 DATA Page for NODAL configuration

Entering the DATA environment the system displays a list of all the available tabs (ex.
BASE, TOOL, etc.)
The The tab related to the SmartGlue application is the BEAD TAB, where the elements
are created by the User, it will be used for the glue bead characteristics.
Select that tab (see Fig. 4.8) and press ENTER.
Fig. 4.10 - DATA page home
In the displayed tab, the User has to insert the required glue beads.
In order to do this, press Modify (F2) and then choose the entry Insert: it will be required
to specify the name of the element and therefore it will be created a new line in the tab.
(seeFig. 4.11).
Fig. 4.11 - BEAD tab created by the User
4.4 Integration of the application package with

System environment
This section describes the System environment pages providing information about the
application.
Such pages are:
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– ALARM Page
– I/O Page
4.4.1 ALARM Page

This User page allows to manage the alarms and messages occurred in the system.
Fig. 4.12 - Alarm Page
For each message displayed, the following information are given:

– Alarm order number
– Error code and severity
– Message text
– Date and hour
If possible, when a determined alarm occurs, it is given the possibility to perform a reset
of the alarm itself (see Fig. 4.12):
– By-pass (F2) - it is present depending on the alarm type; it resets the alarm,
by-passing the cause that made it arose, and enables the next procedures carrying
out.
– Reset (F2) - it has the same function of the RESET key of the Teach Pendant. It
deletes the alarm and re-executes the control on the cause that generated it.
4.4.1.1 Error cause and remedy

To know the cause of an application alarm and the corresponding available remedy, it
is needed to type in the alarm number into the Cause and Remedy Window of WinC5G
interface, and issue Find command.
File gl_ms.crd, containing such information about SmartGlue application, must be
added to the errors list, by means of the WinC5G Property Window, in the CRD File
field, by first pressing Edit key, and then Add key as shown in the following figures:
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Fig. 4.13 - Property Window
Fig. 4.14 - Select the file CRD
The file gl_ms.crd is present:

– on the PC, in the installation directory of WinC5G together with System alarms crd
files
– on the Control Unit in UD:\sys\msg\gl_ms.crd, it is pasted in this directory of the
application SmartGlue during the installation.
If the alarm number typed in WinC5G Cause/Remedy Window is not found, the possible
reasons could be:
– the file gl_ms.crd has not been added to the WinC5G Properties Window
– the file gl_ms.crd is present, but it could be not up to date; in this case the file stored
on the Control Unit must be added.
For any other information on the sub-pages and the use of the general use
softkeys of the Alarm Page, please refer to the manual Use of the Control Unit,
chapter Use of the Teach Pendant - paragraph Alarm Page.
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4.4.2 I/O Page

The I/O signals handled by the application are grouped “by component” in a directory
called smartglue.
Press I/O (L5) (left menu) to access it, moving focus on Ports sub-page identified by the
tabsheet with this name, and selecting smartglue directory, it is possible to access to
the screen to choose the required component (seeFig. 4.15), among those that have
been previously set up through theSetup Page.
Fig. 4.15 - I/O Ports
By selecting the required component, it is possible to obtain the screen with the I/O
connected to it.
The Fig. 4.16 represents an example of how the I/O are displayed.
Fig. 4.16 - I/O display
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4.5 Integration with IDE

In this paragraph it is described how to insert the technological instruction in the
application program from the environment IDE. For a detailed analysis of those
instruction, please refer to par. 5.2 Technological instructions a pag. 43.
For a system configured as NODAL, please follow the description of par. 4.5.1
Entering technological instructions by NODAL system a pag. 41.
Inserting technological instructions from within the IDE environment, is made in the
following way:
a. select the wished holdable program by pressing Prog (L3) key;
b. press ENTER to open the program in IDE environment, in order to edit it and insert
the required Technological instructions;
c. move the cursor to the line in which the required instruction is to be added, press
PDL2 (F3) key, choose Empty Line and confirm with ENTER.
Fig. 4.17 - Insertion of Technological Instruction - example
d. Press Instructions (F1),
e. Select the directory Smartglue and confirm with ENTER, the Technological
Instruction of the application SmartGlue will be presented among them, to allow
the User to select the wished one which is to be inserted in the program.
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Fig. 4.18 - Selection of the Technological Instruction
f. In the following figure example the instruction glue_init is selected.
g. The System inserts the corresponding template (mask) for the required instruction
(seeFig. 4.19) and the User must fill all the fields in and press ENTER to confirm.
Fig. 4.19 - Insertion completion
The above described insertion procedure is the same for all Technological Instructions.
A functionality exists which makes inserting an application instruction faster, in IDE
environment.
Press SHIFT + '1' to activate such a functionality; a table is open, called Numeric
Keypad, which associates the numeric keys of the TP Alphanumeric Keypad, to the
application Technological Instructions. (see Fig. 4.20).
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Fig. 4.20 - Use of the numerical virtual keypad
By pressing any numeric key corresponding to an instruction, that same instruction will
be entered in the program.
It is possible to enter instructions in an even quicker way: in the IDE environment, press
SHIFT + the numeric key associated to the desired instruction, at the same time,
without opening the numeric Keypad; the system will add the instruction to the program.
For example, (refer to Fig. 4.20) if the user presses SHIFT and 5 at the same time,
without opening the keypad, glue_end technological instruction will be added to the
program.
Summarizing, the keys to control the numeric Keypad are the following ones:
– SHIFT + ‘1’ - opens the numeric Keypad
– ‘n’ - when the numeric Keypad IS OPEN, adds the instruction corresponding to ‘n’
key and closes the numeric Keypad.
– SHIFT + ‘n’ - when the numeric Keypad IS NOT OPEN, adds the instruction
corresponding to ‘n’ key, to the program.
– PAGE UP / PAGE DOWN - changes the page of the numeric Keypad.
– arrows up/down/r/l- for circular navigation in the numeric keypad.
– ESC - closes the numeric keypad without inserting any instruction in the program.
– ENTER - inserts the currently selected instruction on the numeric keypad into the
program and closes.
4.5.1 Entering technological instructions by NODAL system

In case of system featuring NODAL configuration, the technological instructions in the
IDE environment are entered through the REC Setup environment. Fig. 4.21 shows the
REC key configuration screen, to enter the ML Glue technological instruction.
For a detailed description of the entering modality of nodal movement

instructions, in the IDE environment, please refer to manual Nodal Move , chapter
Spot development/learning and Nodal Move changing environment (in IDE).
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Fig. 4.21 - REC setup environment - example
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Programming
5. PROGRAMMING
5.1 Introduction
This chapter gives detailed information for the User that has to write programs related
to the manipulation application. The instructions here described are classifiable as
PROCESS INSTRUCTIONS.
In particular, the following topics are detailed described:
– Technological instructions
– Use of shared System sources
– Cosmetic Sealer application.
5.2 Technological instructions

Technological Instructions dedicated to the seal process welding are available for the
User, they are clustered as follows:
– General routines
– Service routine
– General routines of the NODAL system
– Service routines NODAL system.
5.2.1 General routines

In this group the following routines are included:
– Glue_init
– Glue_prepara
– Glue_prepara_set
– Glue_prepara_check
– Glue_opengun
– Glue_switchpara
– Glue_closegun
– Glue_end
– Vision_prepara
– Vision_end.
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Programming
5.2.1.1 Glue_init
Syntax: glue_init (ai_sys_id<, ai_num_gun>)
This routine starts the application depending on the doser.
Parameters Range
ai_sys_id: Number of the system we want to use (INTEGER) 1..4
ai_num_gun: optional parameter that shows the number of (INTEGER) 1..4
the gun to be used to seal. It is used when more sealant
devices are used (dosers, nozzles) for a system.
Call example:
ROUTINE glue_init (ai_tool:INTEGER) EXPORTED FROM h_glue GLOBAL

BEGIN
glue_init(1)
...
END prog_1
5.2.1.2 Glue_prepara
Syntax: glue_prepara (ai_bead_type)
It prepares the sealant system using the selected bead. After setting the values, the
application software waits for it to be ready.
It shall be recalled any time the user wishes to glue a new stretch using a different bead.
Parameters Range
ai_bead_type: index of the bead to be used (Tab BEAD of the [1..99] (INTEGER)
DATA Pageenvironmen)
Call example:
ROUTINE glue_prepara (ai_bead:INTEGER) EXPORTED FROM h_glue GLOBAL

BEGIN
...
glue_prepara(4)
...
END prog_1
5.2.1.3 Glue_prepara_set
Syntax: glue_prepara_set (ai_bead)
This routine prepares the sealant system using the selected bead. After having set the
values, it does NOT wait for it to be ready: it is very useful to reduce the cycle time.
Parameters Range
ai_bead: index of the bead to be used (Tab BEAD of the [1..99] (INTEGER)
DATA Pageenvironment)
Call example:
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Programming
ROUTINE glue_prepara_set (ai_bead:INTEGER) EXPORTED FROM h_glue GLOBAL

BEGIN
...
glue_prepara_set(45)
...
END prog_1
5.2.1.4 Glue_prepara_check
Syntax: Glue_prepara_check
This routine waits for the system to be active and ready, for the selected bead.
Call example:
ROUTINE glue_prepara_check EXPORTED FROM h_glue GLOBAL

BEGIN
...
Glue_prepara_check
...
END prog_1
5.2.1.5 Glue_opengun
Syntax: glue_opengun
This routine controls the selected doser opening, at the motion Start.
Call example:
ROUTINE glue_opengun : INTEGER EXPORTED FROM h_glue GLOBAL

BEGIN
...
MOVEFLY LINEAR TO pnt0003p ADVANCE
WITH CONDITION[glue_opengun],
ENDMOVE
...
END prog_1
5.2.1.6 Glue_switchpara
Syntax: glue_switchpara (ai_bead, ai_dist)
It enables the bead parameters modification during the gluing procedure It must be used
in a motion instruction, through the clause WITH CONDITION.
Parameters Range
ai_bead: index of the bead to be enabled (Tab BEAD of the [1..99] (INTEGER)
DATA Pageenvironment)
ai_dist: distance at which the new bead shall be enabled, [1..200] (INTEGER)
during the MOVE in progress
Call example:
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Programming
ROUTINE glue_switchpara : glue_switchpara (ai_bead, ai_dist)

INTEGER EXPORTED FROM h_glue GLOBAL
BEGIN
...
glue_switchpara (3,100)
...
END prog_1
5.2.1.7 Glue_closegun
Syntax: glue_closegun
It controls the doser closing. The closing is performed at the END of the corresponding
motion. It must be used in a motion instruction, through the clause WITH CONDITION.
Call example:
ROUTINE glue_closegun : INTEGER EXPORTED FROM h_glue GLOBAL

BEGIN
...
MOVEFLY LINEAR TO pnt0003p ADVANCE
WITH CONDITION[glue_opengun],
ENDMOVE
...
END prog_1
5.2.1.8 Glue_end
Syntax: glue_end
This routine checks whether the gluing bead has been carried out properly.
Call example:
ROUTINE glue_end : INTEGER EXPORTED FROM h_glue GLOBAL

BEGIN
...
glue_end
...
END prog_1
5.2.1.9 Vision_prepara
Syntax: vision_prepara (ai_prog_idx, ai_vision_system)
It prepares the vision system to capture the images by using the specified program.
The application waits that the system is ready, and then it sends to the system the trigger
signal.
Parameters Range
ai_prog_idx: program code [1..15] (INTEGER)
ai_vision_system: it indicates the vision system [1..3] (INTEGER)
Call example:
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Programming
ROUTINE vision_prepara (ai_prog_idx, ai_vision_system : INTEGER) EXPORTED FROM

GLH_vision
BEGIN
...
vison_prepara (2, 2)
...
END prog_1
5.2.1.10 Vision_end
Syntax: vision_end
This routine waits that the vision system accomplishes the measurement and controls
that no errors occurred.
Call example:
ROUTINE vision_end : INTEGER EXPORTED FROM GLH_vision

BEGIN
...
vision_end
...
END prog_1
5.2.2 Service routine

In this group the following routines are included:
– Glue_fill
– Glue_fill_wait
– Glue_purge
– Glue_fix_purge
– Glue_fix_purge_wait.
5.2.2.1 Glue_fill
Syntax: glue_fill (ai_tool, ab_wait_check)
This routine fills the specified doser, and controls the request by the sealant system.
Parameters Range
ai_tool: it shows the required doser [1..4] (INTEGER)
ab_wait_check: it is a flag that indicates whether during the filling, the [TRUE/FALSE] BOOLEAN
application must wait until the doser is full
– TRUE =it waits,
– FALSE = it does not wait. In this case, in order to check if the doser is
full, it is necessary to run the routine Glue_fill_wait.
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Programming
ROUTINE glue_fill (ai_tool : INTEGER, ab_wait_check : BOOLEAN) EXPORTED FROM

h_glue GLOBAL
BEGIN
...
glue_fill (1, TRUE)
...
END prog_1
5.2.2.2 Glue_fill_wait
Syntax: glue_fill_wait (ai_tool)
When the routine Glue_fill is called but the application does not stop to wait the doser
refilling in order to reduce the cycle time, it is necessary to call this routine to check
whether the doser is still full.
Parameters Range
ROUTINE glue_fill (ai_tool : INTEGER, ab_wait_check : BOOLEAN) EXPORTED FROM

h_glue GLOBAL
ROUTINE glue_fill_wait (ai_tool : INTEGER) EXPORTED FROM h_glue GLOBAL
BEGIN
...
glue_fill (3, FALSE)
...
glue_fill_wait (3)
...
END prog_1
5.2.2.3 Glue_purge
Syntax: glue_purge (ai_tool)
This routine manages the purge of the specified doser and controls the request by the
sealant system.
Parameters Range
ROUTINE glue_purge (ai_tool : INTEGER) EXPORTED FROM h_glue GLOBAL

BEGIN
...
glue_purge (3)
...
END prog_1
5.2.2.4 Glue_fix_purge
Syntax: glue_fix_purge (ai_tool)
This routine manages the specified fix doser purge, and controls the request by the
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Programming
sealant system.
Parameters Range
ROUTINE glue_fix_purge (ai_tool : INTEGER) EXPORTED FROM h_glue GLOBAL

BEGIN
...
glue_fix_purge (1)
...
END prog_1
5.2.2.5 Glue_fix_purge_wait
Syntax: glue_fix_purge_wait (ai_tool)
When the routine Glue_fix_purge is called but the application, in order to reduce the
cycle time, does not stop to wait cycle completion, it is necessary to call this routine in
order to check whether the purge operation is finished.
Parameters Range
ROUTINE glue_fix_purge_wait (ai_tool : INTEGER) EXPORTED FROM h_glue GLOBAL

BEGIN
...
glue_fix_purge_wait (1)
...
END prog_1
5.2.3 General routines of the NODAL system

To insert this type of routines, please refer to par. 4.5.1 Entering technological
instructions by NODAL system a pag. 41.
– Glue_init (nodal system)

– Glue_prepara_check (nodal system)
– GlueOn (nodal system)
– Glue (nodal system)
– GlueCh (nodal system)
– GlueOff (nodal system)
– Glue_end (nodal system).
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Programming
5.2.3.1 Glue_init (nodal system)

Syntax: glue_init (ei_syst_id, ai_num_gun)
It has to be recalled at the programme start, by NODAL configured system; it initialises
the application software based on the doser, for the entire programme (therefore it
delivers a MODAL effect), until the next glue_init is launched.
It prepares the user programme to properly carry out the gluing procedures.
The SmartGlue software routine statements can be omitted if the instruction

IMPORT 'H_GLUE' is available on top of the user programme
Parameters Range
ei_syst_id: index of the system to use, it is the index of the ToolMap that TOOLMAP
the User has to modify.
ai_num_gun: optional parameter that shows the number of the gun to be 1..4
used to seal. It is used when more sealant devices are available for a
system (dosers, nozzles). (INTEGER).
ROUTINE glue_init(ei_syst_id : ToolMap; ai_num_gun : INTEGER(0)) EXPORTED FROM

h_glue GLOBAL
BEGIN
...
glue_init(TM1)...
...
END prog_1

Syntax: glue_prepara (ei_bead_id)
This routine prepares the system to glue using the selected bead. After setting the
values, the application software waits for it to be active and ready. It delivers a MODAL
effect, also by a NODAL configured system.
Glue_prepara shall be recalled any time the user wishes to glue a new stretch using a
different bead.

Parameters Range
ei_bead_id: bead index to use. BEAD_DATA
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Programming
ROUTINE glue_prepara(ei_bead_id : INTEGER) EXPORTED FROM h_glue GLOBAL

BEGIN
...
glue_prepara(BEAD_1)...
...
END prog_1

Syntax: glue_prepara_set (ei_bead_id)
This routine prepares the sealant system using the selected bead. After having set the
values, it does NOT wait for it to be ready: it is very useful to reduce the cycle time.

Parameters Range
ei_bead_id: bead index to use. BEAD_DATA
ROUTINE glue_prepara_set(ei_bead_id : INTEGER) EXPORTED FROM h_glue GLOBAL

BEGIN
...
glue_prepara_set(BEAD_1)...
...
END prog_1
5.2.3.4 Glue_prepara_check (nodal system)

Syntax: Glue_prepara_check
It waits for the system to be ready, for the selected bead in the previous routine Glue_init
(nodal system), is active and ready.

ROUTINE glue_prepara_check EXPORTED FROM h_glue GLOBAL

BEGIN
...
Glue_prepara_check
...
END prog_1
5.2.3.5 GlueOn (nodal system)

Syntax: ML GlueOn, Target, Speed, Zone, Tool, Frame, BeadD, /L=Load, /O=OrnD
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Programming
MC GlueOn, Target, TargetVia, Speed, Zone, Tool, Frame, BeadD, /L=Load,

/O=OrnD
This function, that is associated to the nodal motion instruction (ML or MC), carries out
the doser opening at the END of the motion.

Compulsory Parameters
Obbligatori:
– Target : position, jointpos, xtndpos
– TargetVia: name of Via position (for MC only) - position, jointpos, xtndpos
– Speed: variable created in the Speed table of the Data environment or stated in the
– Zone: variable created in the Zone table of the Data environment or stated in the User programme as zone
data type variable.
– Tool: variable created in the Tool table of the Data environment or stated in the user programme as
ttye_tool_table type variable
– Frame: variable created in the Uframe table of the Data environment or stated in the user programme as
tuye_frame_table type variable
– BeadD: variable created in the Bead table of the Data environment or stated in the user programme as
bead_data type variable.
Optional:
– Load: variable created in the Payload table of the Data environment or stated in the user programme as
ttye_payload_table type variable.
– OrnD: variable created in the Orient table of the Data environment or stated in the user programme as ornd
type variable.
ROUTINE GlueOn : INTEGER EXPORTED FROM h_glue GLOBAL

....
BEGIN
...
ML GlueOn, pnt0004p, VJ25, Z100, T0, F0, BEAD_1
...
END prog_1
5.2.3.6 Glue (nodal system)

Syntax: ML Glue, Target, Speed, Zone, Tool, Frame, BeadD, /L=Load, /O=OrnD
MC Glue, Target, TargetVia, Speed, Zone, Tool, Frame, BeadD, /L=Load,
/O=OrnD
the doser opening at the END of the motion.

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Programming
Obbligatori:
– TargetVia: nome della Via position (only for MC) - position, jointpos, xtndpos
– Zone: variable created in the Zone table of the Data environment or stated in the user programme as zone
data type variable.
Optional:
type variable.
ROUTINE Glue : INTEGER EXPORTED FROM h_glue GLOBAL

....
BEGIN
...
ML Glue, pnt0004p, VJ25, Z100, T0, F0, BEAD_1
...
END prog_1
5.2.3.7 GlueCh (nodal system)

Syntax: ML GlueCh, Target, Speed, Zone, Tool, Frame, BeadD, /L=Load, /O=OrnD
MC GlueCh, Target, TargetVia, Speed, Zone, Tool, Frame, BeadD, /L=Load,
/O=OrnD
This function, that is associated to the nodal motion instruction (ML or MC), enables to
change the bead parameters during the gluing procedure.
It delivers a NODAL effect, therefore the changes carried out will apply to this
programme line only

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Programming
Obbligatori:
data type variable.
Optional:
type variable.
ROUTINE GlueCh : INTEGER EXPORTED FROM h_glue GLOBAL

....
BEGIN
...
ML GlueCh, pnt0008p, VJ25, Z100, T0, F0, BEAD_2
...
END prog_1
5.2.3.8 GlueOff (nodal system)

Syntax: ML GlueOff, Target, Speed, Zone, Tool, Frame, BeadD, /L=Load, /O=OrnD
MC GlueOff, Target, TargetVia, Speed, Zone, Tool, Frame, BeadD, /L=Load,
/O=OrnD
the doser closing at the END of the motion.

Obbligatori:
data type variable.
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Programming
Optional:
– ttye_payload_table variable type.
type variable.
ROUTINE GlueOff : INTEGER EXPORTED FROM h_glue GLOBAL

....
BEGIN
...
ML GlueOff, pnt0010p, VJ25, Z100, T0, F0, BEAD_2
...
END prog_1
5.2.3.9 Glue_end (nodal system)

Syntax: glue_end
This routine checks whether the gluing bead has been carried out properly.

ROUTINE glue_end : INTEGER EXPORTED FROM h_glue GLOBAL

BEGIN
...
glue_end
...
END prog_1
5.2.4 Service routines NODAL system

– Glue_fill (nodal system)
– Glue_purge (nodal system)
– Glue_fix_purge (nodal system)
– Glue_fix_purge_wait (nodal system)
5.2.4.1 Glue_fill (nodal system)

Syntax: glue_fill (ei_tool_id, ab_wait_check)
This routine fulfils the specified doser, and controls the request by the sealant system.
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Programming

Parameters Range
ai_tool : indicates the required doser TOOLMAP
ab_wait_check: flag - TRUE indicates that the application waits until the FALSE / TRUE
doser is full; FALSE indicates that during the filling the application does not
wait. In this case, in order to check if the doser is full, it is necessary to run
the routine Glue_fill_wait.
ROUTINE glue_fill(ei_tool_id : ToolMap; ab_wait_check : BOOLEAN) EXPORTED FROM

h_glue GLOBAL
BEGIN
...
glue_fill(TM1,ON)
...
END prog_1
5.2.4.2 Glue_purge (nodal system)

Syntax: glue_purge (ei_tool_id)
This routine manages the purge of the specified doser and controls the request by the
sealant system.

Parameters Range
ai_tool: indicates the required doser TOOLMAP
ROUTINE glue_purge(ei_tool_id : ToolMap) EXPORTED FROM h_glue GLOBAL
BEGIN
...
glue_purge(TM1,ON)
...
END prog_1
5.2.4.3 Glue_fix_purge (nodal system)

Syntax: glue_fix_purge (ei_tool_id)
This routine manages the specified fix doser purge, and controls the request by the
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Programming
sealant system.
Parameters Range
ai_tool: indicates the required doser TOOLMAP
ROUTINE glue_fix_purge (ei_tool_id : ToolMap) EXPORTED FROM h_glue GLOBAL

BEGIN
...
glue_fix_purge (TM1)
...
END prog_1
5.2.4.4 Glue_fix_purge_wait (nodal system)

Syntax: glue_fix_purge_wait (ei_tool_id)
When the routine Glue_fix_purge (nodal system) is called but the application, in order
to reduce the cycle time, does not stop to wait cycle completion, it is necessary to call
this routine in order to check whether the purge operation is finished.
Parameters Range
ai_tool : indicates the required doser TOOLMAP
ROUTINE glue_fix_purge_wait (ei_tool_id: ToolMap)EXPORTED FROM Gl_glue_nod GLOBAL

BEGIN
...
glue_fix_purge_wait (TM1)
...
END prog_1
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Programming
5.3 Use of shared System sources

The system offers to the User some common resources, listed in the following tabs:
– Tab. 5.1 - $DIN e $DOUT
– Tab. 5.2 - $FMI e $FMO
– Tab. 5.3 - Errors, events, conditions
– Tab. 5.4 - Name of the user Fieldbus modules
– Tab. 5.5 - Application modules addresses.
Tab. 5.1 - $DIN e $DOUT
$DIN
RANGE OWNER NOTE
1 -- 16 SPOT Weld pincer

17 -- 34 GLUE / NUT Not assigned for Glue
35 -- 50 STUD Weld head
179 -- 199 ARC
To map on the Fieldbus Master or CAN Interface (if not
200 -- 255 USER
already mapped by the application package)
256 -- 512 USER To map on the Fieldbus Slave Interface (line PLC)
$DOUT
RANGE OWNER NOTE

1 -- 16 SPOT Welding gun
17 -- 34 GLUE / NUT Not assigned for Glue
35 -- 50 STUD Weld head
51 -- 178 HAND Gripper Clamps
179 -- 199 ARC
To map on the Fieldbus Master or CAN Interface (if not
200 -- 255 USER
already mapped by the application package)
256 -- 512 USER To map on the Fieldbus Slave Interface (line PLC)
Tab. 5.2 - $FMI e $FMO
$FMI
Quantity RANGE OWNER NOTE

32 1--32 USER
$FMO
Quantity RANGE OWNER NOTE

31 1--32 USER
ap-gl-0-sw_06bis.fm
58 01/1111
Programming
Tab. 5.3 - Errors, events, conditions
NUMBER OF ERR_POST
RANGE OWNER NOTE
43008 -- 44031 USER used in err_post
EVENTI PRIVILEGIATI DEL TP
RANGE OWNER NOTE

(Err_Post2 // Rignt Menu when it is not managed by
5120 -- 5169 USER
the application software)
CONDITION HANDLERS (declared in the user program)
RANGE OWNER NOTE
1 -- 24 USER
EVENTS PDL2
RANGE OWNER NOTE
49152 --> 50175 USER
Tab. 5.4 - Name of the user Fieldbus modules
MODULE NAME ADDRESS

TOOL STAND 1 TC_STAND_numStand_PhysAddr 16
TOOL STAND4 TC_STAND_numStand_PhysAddr 19
WELDING GUN/NUT/BOLT 1 SW_GUN_numGun_PhysAddr 22
GEOGRIPPER IDENTIFICATION GEO_ID_PhysAddr 60
GRIPPER 1 HN_GRIP_numGrip_PhysAddr 54
GRIPPER 2 / GRIPPER 1 NODO 2 HN_GRIP_numGrip_PhysAddr 55
GRIPPER 3 / GRIPPER 1 NODO 3 HN_GRIP_numGrip_PhysAddr 56
GRIPPER 4 / ... HN_GRIP_numGrip_PhysAddr 57
GRIPPER 5 / ... HN_GRIP_numGrip_PhysAddr 58
ap-gl-0-sw_06bis.fm
01/1111 59
Programming
Tab. 5.5 - Application modules addresses
MODULE APPLICATION NAME ADDRESS

WELDING TIMER 1 SMARTSPOT 27
APPLICATION BOX 1 SMARTSPOT 32
MEDIA PANEL 1 SMARTSPOT 37
TOOL CHANGER SMARTTCHANGE 21
GLUE SYSTEM 1 SMARTGLUE 46
GLUE VISION 1 SMARTGLUE 50
ap-gl-0-sw_06bis.fm
60 01/1111
Programming
5.4 Cosmetic Sealer application

If the application used is Cosmetic Sealer, in order to obtain the best performance from
the system, some programming rules have to be borne in mind.
The more closely these rules are followed, the better the results will be, both in
maintaining constant velocity and adherence to the trajectory.
The most important rules are:
1. The value of the $STRESS_PER variable is to be set only once and is not to be
changed any more during the program.
2. The value of $STRESS_PER is to be within the range of 20 and 30 according to
the variation in orientation. If there are considerable variations in the orientation, it
is advised to initialize the variable at a value of 22.
3. If possible, keep a linear distance between the ends of a MOVE (start point and
end point) greater than 120 mm. The recommended value to reach a speed of 0.5
m/s is 160 mm.
4. If it is necessary to make a big orientation variation, distribute it over the greatest
number of moves possible.
5. SPD_OPT is to be always set as SPD_LIN for this application.
Set these initial settings:
– FLY_TYPE := FLY_CART,
– FLY_TRAJ :=FLY_TOL and
– FLY_DIST to the necessary distance.
If the angles between 2 FLY trajectories are more than 120 degrees, set
FLY_DIST at sufficiently high values (5 mm). If the angle is less than 20
degrees, set FLY_DIST at low values (not less than 2 mm).
ap-gl-0-sw_06bis.fm
01/1111 61
Customizations
6. CUSTOMIZATIONS
6.1 Configuration I/O towards PLC

As far as the communication with the PLC, some standard signals are needed
(application exclusion, process activation, dry cycle, anomaly reset, active application
code and corresponding status feedbacks towards PLC) which are shared by the
several application Softwares provided by COMAU.
Such signals are configured during installation, as belonging to the virtual module called
PPL_PLC_VIRT.
When the User performs any configuration for the signals towards PLC, these virtual
signals must be associated to the physical signals which are mapped in the
communication area towards PLC. This operation is performed by means of the
IO_MAP program.
For a detailed description of I/O modules and I/O ports configuration programs,
IO_CNFG and IO_MAP programs, please refer to C5G Control Unit use manual,
chap. 11 - I/O Configuration Programs.
Summarizing you will need to:

– configure the fieldbus network towards PLC (by means of IO_CNFG program)
– define a range of input and output signals in the communication area towards PLC
(by means of IO_MAP program). A list of available ports to this purpose, is shown
in par. 5.3 Utilizzo delle risorse di Sistema condivise a pag. 45
– associate the just configured signals, to the virtual PLC module signals IO_MAP
program).
The signals association can be performed:
– globally - using a single command to agree with the suggested profile (standard
profile), in terms of position (byte - bit), for all signals in the PLC communication
area
– for each port - defining the position (byte e bit) of each single signal.
A description follows of the suggested standard profile:
INPUTS (SIGNALS FROM PLC) Position (byte-bit)

Application alarm reset $IN[413] 1-7
Process YES/NO command $IN[412] 1-6
Application exclusion command $IN[411] 1-5
Vision exclusion command $IN[416] 2-7
OUTPUT (SIGNALS TOWARDS PLC)
Application not alarm $OUT[413] 1-8
Process YES/NO $OUT[412] 1-7
Application included $OUT[411] 1-6
Vision included $OUT[416] 2-7
Application cycle activated $FMO[128] 2-3
ap-gl-0-sw_07.fm
62 00/0211
COMAU Robotics services
Repair: [email protected]
Training: [email protected]
Spare parts: [email protected]
Technical service: [email protected]
comau.com/robotics Original instructions

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SMART NH1 - Manuals list

Copyright © 2003 by COMAU - Date of publication 11/2011

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.5

2. DESCRIPTION OF SEALANT APPLICATION SYSTEM . . . . . . . . . . . . . . . . . . . . ..2.15

3. INSTALLING / ACTIVATING / DEACTIVATING . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3.17

4. USER INTERFACE ON THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . ..4.22

Symbols used in the manual

This symbol indicates operating procedures, technical information and

This symbol indicates operating procedures, technical information and

This symbol indicates operating procedures, technical information and

Comau C5GControl Unit – Technical specifications

1. GENERAL SAFETY PRECAUTIONS

This specification deals with the following topics:

– The application of these Safety Precautions is the responsibility of the persons

The installation shall be made by qualified installation Personnel and should

1.2 Safety Precautions

Installation and Putting into Service

Auto / Remote Automatic Mode

Maintenance and Repairs

Putting Out of Service and Dismantling

1.2.4 Operating Modes

Auto / Remote Automatic Mode

Robot axes release

Maintenance and Repairs

– Maintenance, trouble-shooting and repairs are only to be carried out by authorised

– Trouble-shooting and maintenance activities are to be executed, when possible,

Putting Out of Service and Dismantling

Tab. 1.1 - Stop spaces in programming modality (T1)

Tab. 1.2 - Safety electronics reaction time in programming

Mission time (typ. case)

Fig. 2.1 - Example of configuration

3.2 System requirements

3.3 Preparation for installation

It is possible to distinguish two different cases of configuration:

Application configuration generated by the user through WAC5G tool

Application configuration generated by COMAU Robotics

3.4 Use of the WinApplicationCreator tool for

<name of the version file>< name of the configuration>.zip

3.5 Installation procedure

a. Activate the SETUP page on the Teach Pendant

Fig. 3.1 - SETUP - Installation

b. Selection the Install icon and push ENTER to confirm

d. Press ENTER to confirm. Press down arrow to select the application to be

Fig. 3.2 - SETUP - Install - Application

Fig. 3.3 - Installation of customer projects - example

e. Confirm with ENTER.

3.6 Uninstall procedure

a. Activate SETUP page (see Fig. 3.1) on the Teach Pendant

b. Select APPL icon and press ENTER

c. Select Uninstall icon and press ENTER (seeFig. 3.4)

Fig. 3.4 - SETUP - Uninstall

d. In the displayed combobox, select the wished application to be uninstalled, if

Fig. 3.5 - SETUP - Uninstall - 2

4. USER INTERFACE ON THE TEACH

As for the use of the Teach Pendant, please refer to

4.2 Process control keys (menu on the right)

Tab. 4.1 - Meaning of softkey

Tab. 4.2 - Meaning of the led software

Tab. 4.3 - Function and status selector position

Vision (inclusion/exclusion) or Purge (in purge / not in purge)

4.3 Specific application environments

4.3.1 Application Page

Fig. 4.1 - Application Page - starting screen

4.3.1.1 Areas Description