Handling System: Comau Robotics Instruction Handbook

Comau Robotics
Instruction Handbook
Handling System
SmartHand
Application Software Rel. 115.xx
CR00757621-en_01/2012.07
The information contained in this manual is the property of COMAU S.p.A.
Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A.
COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation.
Copyright © 2003 by COMAU - Date of publication 07/2012

Summary
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Implemented and respected essential health and safety requirements . . . . . . . . . . . . . . . . . . 7
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2. GENERAL DESCRIPTION OF SMARTHAND APPLICATION SOFTWARE . . . . . . ...17

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Basic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Basic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3. INSTALLING / ACTIVATING / UNINSTALLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Preparation for SmartHand installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Use of WinApplicationCreator tool for C5G (WAC5G). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Uninstall procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4. USER INTERFACE ON THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Process control keys (right menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Specific application environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Application Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Areas description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
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Summary
Object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Setup Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Softkeys description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Object Pages description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Integration of the application package with System environment . . . . . . . . . . . . . . . . . . . . . . . 36
Alarm page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Errors cause and remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
I/O Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
User Help I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Integration with IDE environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Technological Instruction insertion in IDE environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5. PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Technological Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Process routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Gripper_sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Gripper_vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Gripper_vacuum_blow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Gripper_chkpart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Grip_part_supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Grip_air_supervision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Advanced variables and routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Hnvb_smarthand_in_fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Hnru_user_fault_abort_enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Hnru_user_fault_abort_ack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Hnrb_get_user_fault_abort. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Handling RESET key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
hnru_tp_reset_in_remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Using the System shared resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6. CUSTOMIZATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..50
I/O configuration towards PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7. OPTIONAL SOFTWARE FUNCTIONALITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..51

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SmartVisualProcess. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Functioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Part Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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Preface
PREFACE
Symbols used in the manual

The symbols used for WARNING, CAUTION and NOTES and their relevant meanings
are given below
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 Handling System.
The complete set of Handling System manuals consists of:
Comau C5G Control Unit – Technical Specifications

– Transport and installation
– C5G Control Unit use.
Robot – Technical Specifications
– Transport and installation
– Maintenance
Programming – PDL2 Programming Language Manual
– 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.
1.1.1 Implemented and respected essential health and safety

requirements
The robotic system composed of C5G Control Unit series SMART 5 considers as
implemented and respected the following Essential health and sefety requirements of
the 2006/42/CE Machinery Directive: 1.1.3 – 1.1.5 – 1.2.1 – 1.2.2 – 1.2.3 – 1.2.4.3 –
1.2.5 – 1.2.6 – 1.3.2 – 1.3.4 – 1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4 – 1.5.6 – 1.5.8 – 1.5.9 –
1.5.10 – 1.5.11 – 1.5.13 – 1.6.3 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2 – 1.7.4.
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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.
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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.
– 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
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– 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.
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 stop pushbutton (red
mushroom-shaped one on WiTP) in category 0 (according to the standard
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 and enabling device inputs from 150 ms
the TP in wireless version, when the safety
T1 250 mm/s
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 automatic modality, under full extension, full load and
maximum 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 deceleration 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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General Description of SmartHand Application Software
2. GENERAL DESCRIPTION OF
SMARTHAND APPLICATION
SOFTWARE
2.1 Introduction
This chapter is the introduction to the COMAU Handling environment, with special
regard to SmartHand application software.
A Handling system can have different configurations according to the User’s specific
requirements. This manual only refers to:
– Basic System
– Basic Functions.
2.2 Basic System

This consists of the following basic components (see Fig. 2.1 - Basic System):
– Robot C5G Control Unit (1)
– SMART NJx, NS robots (2)
– One of the following Interface board
• Devicenet
• Profibus-DP
– SmartHand application software
– Users manual.
Fig. 2.1 - Basic System
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General Description of SmartHand Application Software
2.3 Basic Functions

The basic functions, always available on a handling system, are as follows:
– Integrated Programming Environment (IDE)
– Set of Technological Instructions for the handling
– Special functions
– Alarms management (Alarm page)
– A signals profile towards PLC, common to all the application Softwares provided
by Comau with standard signals (application inclusion, process activation, dry
cycle, anomaly reset, and corresponding status feedbacks towards PLC).
– A graphics environment composed by:
• main page (Application Page): it includes general information about the
process status, configuration information and application software version,
and an informational area available to the User;
• Process control keys (right menu): the most common functionalities are
associated to the process keys, together with the corresponding icons;
• setup environment (Setup Page): functionalities to modify and save general
setup values (not included in the technological instructions as parameters)
which control the application working modalities.
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Installing / Activating / Uninstalling
3. INSTALLING / ACTIVATING /
UNINSTALLING
3.1 Introduction
This chapter describes the installation procedure for the SmartHand application.
The following topics are dealt with:
– System requirements
– Preparation for SmartHand installation
– Use of WinApplicationCreator tool for C5G (WAC5G)
– Installation procedure
– Uninstall procedure
3.2 System requirements

3.2.1 Software
It is needed to enable the software option allowing to use the application itself.
Comau Code for SmartHand CR13612060
L'applicativo SmartHand può essere utilizzato con il Software di Sistema C5G la cui
versione corrisponde alle prime tre cifre presenti nella versione del software applicativo.
Ad esempio la versione 100.01 del software applicativo richiede una versione del
software di sistema che sia pari o superiore a 1.0x .
The SmartHand application software can be used in combination with the C5G System
Software, whose version is identified by the most significant three digits in the
application software version. For example version 100.01 of the application software,
requires a system software 1.0x or better.
3.2.2 Hardware
The following basic hardware components are necessary to use the SmartHand
application:
– C5G Robot Control Unit
– one of the following interface boards:
• C5G-Devicenet
• C5G-Profibus.
3.3 Preparation for SmartHand installation

Before starting the actual installation procedure, the C5G Control Unit has to be
prepared. The general installation preparations for the C5G Control Unit are contained
in the relevant C5G Control Unit- Transport and Installation manual.
It may be necessary to install the SmartHand application in one of these situations:
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– C5G Controller with SmartHand application package not present.

– SmartHand updating - installation of a newer version with respect to the currently
installed on C5G; it is the situation in which either the SmartHand version must be
updated, keeping the existing configuration, or one or more SmartHand files have
been deleted from the User Directory, by fault.
In both cases the procedure is the same (see Installation procedure)
3.4 Use of WinApplicationCreator tool for C5G

(WAC5G)
SmartHand application Software supplied by Comau is distributed in a single file
(version file) with extension .wac5g (SmartHandVxxx.xx.waC5G): it includes all the
available configurations, i.e. all the allowed devices. As far as SmartHand, just one
configuration is available.
The filename refers to the application type and the version number (e.g.
SmartHandv10001.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 WAC5G is an archive file (.zip extension)
whose name is composed by
<version_file name><configuration name>.zip
The configuration name is asked by WAC5G before generating the installation file.
The User can choose any meaningful string, which could help 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

The following operations are necessary to install the application:
a. Activate the SETUP page on the Teach Pendant

(see Fig. 3.1).
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Fig. 3.1 - SETUP
b. Select the Install icon and press ENTER to confirm.
c. Press ENTER again, then down arrow to select the device (COMP:, XD:, UD:, TX:)
containing the being installed SmartHand application.
d. Confirm with ENTER. Down arrow to select the application to be installed, i.e.
SmartHand .
e. Confirm with ENTER (Fig. 3.2).
Fig. 3.2 - SETUP Application
f. Press the key for the Install command (F5) to carry out 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 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.
i. After the installation has been completed, re-start the system (Restart Cold).
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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 (see Fig. 3.3)
Fig. 3.3 - SETUP - Uninstall
d. In the displayed combobox, select the wished application to be uninstalled and

press ENTER.
Fig. 3.4 - SETUP - Uninstall - 2
e. At the end of the procedure the User is requested to restart the System (Restart
Cold).
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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, for the SmartHand
application.
The following topics are dealt with:
– Process control keys (right menu)
– Specific application environments
– Integration of the application package with System environment
– Integration with IDE environment.
As for the Teach Pendant use, please refer to the pertaining manual C5G Control
Unit use, chapter Teach Pendant.
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4.2 Process control keys (right menu)

The Right Menu displays the softkeys and “software led” for the process control.
Commands associated to the softkeys could be either enabled or disabled as shown by
the following icons in Tab. 4.1.
Tab. 4.1 - Meaning of the softkeys

Icon enabled / disabled - description
When the corresponding softkey is enabled, the icon representing the

functionality is displayed in colour.
When the corresponding softkey is disabled, the icon representing the

functionality is displayed in grey.
The software led always shows the component status.
The “software led” associated to each softkey indicates, depending on the displayed
colour, the status of the component represented by the icon. See the description in the
following Tab. 4.2.
Tab. 4.2 - Meaning of the software leds

LED colour - description
When the software led colour is yellow, it means that a command ($DOUT) has
been sent to the component, but the function performed confirmation ($DIN)
hasn’t been received yet.
In the case shown on the left, the softkey functionality is disabled (e.g. because
the command comes from remote) but the software LED still indicates the
component status: in this example, green means that the function has been
properly completed.
In particular, descriptions for all the softkeys are provided, for all the allowed positions
of the modal selector switch on C5G Controller Unit:
– T1 position (System in Prog state)
– AUTO position (System in Local state)
– REMOTE position (System in Remote state)
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Tab. 4.3 - Functionality and position of the modal selector switch

KEY ICON DESCRIPTION
Select the wished gripper. It only works if SmartHand has been configured as
a multigripper. Each pressure updates the icon depending on the total amount
R1 of configured grippers during the SETUP.
The only colour of the software led is grey.
The softkey is always enabled in all positions: T1, AUTO and REMOTE.
Select the type of component to be displayed/commanded (Vac/Seq). Each

pressure updates the icon depending on the the type of the configured
R2 component of the gripper indicated by R1.
Each pressure increases the R4 and R5 component number. The increment

value depends on the total amount of configured components.
R3
These softkeys control the component which is represented by the displayed

icon. Each softkey pressure causes the component to execute the
corresponding command (**).
The allowed colours for the led are:
– grey - after a Restart Cold it indicates the unknown state of the component
– yellow - a command ($DOUT) has been sent, but the confirmation ($DIN)
R4 ed R5
hasn’t been received yet.
– green - properly accomplished movement, thus each $DIN is in the
wished condition.
The softkeys are enabled in T1(*) and disabled both in AUTO and REMOTE,
but the corresponding icons still display the colour information in order to show
the component state.
It handles the DRY CYCLE command.
The allowed colours for the led are:
– grey (with the prohibition sign) - dry cycle disabled
R6 – green - dry cycle enabled
The key is enabled in either T1 or AUTO and disabled in REMOTE (because

the command comes from remote but the colour information is still provided).
(*) R4 and R5 keys are enabled only when the robot is in DRIVE ON for safety reasons.
(**) EXAMPLE 1: if R4 Seq 1 is used, the same key controls either opening the component when it is closed,
or closing the component when it is opened.
EXAMPLE 2: if R4 Vac 1 is used, the same key controls the intake of the suction devices unit if they are in
stop or vice-versa if they are operating. With the suction device in stop there is also a function of long pressure
to control the suction device blowing. When the key is released the suction device is locked.
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4.3 Specific application environments

The specific Application Pages are the following:
– Application Page
– Setup Page
A detailed description follows for each one of them, focused on their use for SmartHand
application.
4.3.1 Application Page

The Application Page, on the Teach Pendant, is the Main Page of the installed
application; in this case the application is SmartHand.
On the Teach Pendant, when Appl (L6) key of the Left Menu is pressed, the Main Page
of the application is activated.
Such a page (see Fig. 4.1) is divided into four parts, also called areas, showing
differente information related to the installed application. If more than one application
are installed on the Controller, 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 Controller, to display the
corresponding pages.
Fig. 4.1 - Application Page - start page
A detailed description follows, about all the Application Page topics:

– Areas description
– About
– Object
4.3.1.1 Areas description

The four areas of the Application Page subdivision, are as follows (see Fig. 4.1):
– the first one (top left - (1)) identifies the selected application, specifying its
installation version
– the second one (top right - (2)), called Dynamic Data, includes 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 one (bottom left - (3)), called Device Status, includes the hardware
configuration information, related to the selected application
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– Finally, the fourth one (bottom right - (4)) is the User dedicated area, so it is called
User Area. It is a table in which the User is allowed to display some wished
information (with a maximum o four), with string format.
The SmartHand application strings are:
hnxs_user_1 : ARRAY [ki_row] OF STRING [19] EXPORTED FROM sh_dd
hnxs_user_2 : ARRAY [ki_row] OF STRING [19] EXPORTED FROM sh_dd
where:
– ki_row, is the maximum number of rows, i.e. 4
– hnxs_user_1 is the reference variable of the first column
– hnxs_user_2 is the reference variable of the second column
In the Application Page bottom menu, two softkeys are available, related to the following
functions:
– About (F5)
– Object (F1)
A detailed description for each of them, follows.
4.3.1.2 About
Displays a menu containing the following information related to 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 WAC5G tool) and the application
hardware configuration.
For further information, please refer to the WAC5G tool 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, used by the 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).
SmartHand application includes some more pages in addition to the Application Page
4.3.2 Setup Page

Current section describes the needed user procedures to modify global settings for
SmartHand application, by means of the Setup Page.
In particular, the following topics are described:
– General information
– Softkeys description
– Object Pages description
4.3.2.1 General information

When SETUP (L3) softkey of the Left Menu is pressed, the SETUP Home Page, useful
to act on the System settings, is activated (see Fig. 3.1).
To access the applications SETUP instead, select APPL: several icons are displayed,
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showing a monkey wrench, with the installed applications names (see Fig. 4.5).
Fig. 4.5 - Application Setup
Select the wished application icon and press ENTER. The application Setup Page is
shown in Fig. 4.6.
Fig. 4.6 - Setup of SmartHand application
It displays as many panes (Gripper_1, Gripper_2, Gripper_3, Config, Air) as the object
pages and sub-pages are, allowing to modify the application parameters.
The access to the Object Pages menus depends on the performed login; the default is
no menus available.
There are two login levels, enabling different levels of menu:
– Technology level 1 - only 'General' menus are enabled, in each Object Page
– Technology level 2 - all the menus are enabled in all Object Pages (e.g. Alarms
'Reset from TP/PLC')
It is therefore needed to create a suitable Technology Login, to be able to access

the wished environment.
The User can use the Setup environment Object Pages, to modify the application
configuration parameters, in Programming state only (modal selector switch in T1
position).
To access any Object Page and their associated menus, perform the following steps:
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a. choose the wished page, by means of the left/right arrow keys;
b. press either ENTER or down arrow, to move the focus to the menus selection and
press ENTER to open the list;
c. select the wished menu and confirm with ENTER;
d. move focus onto the fields to be modified, using the arrow keys, perform the wished
modifications;
e. save the modifications, using the available softkeys in the bottom menu, as
explained in the following par. 4.3.2.2 Softkeys description on page 30.
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 (see Fig. 4.7):
– Save (F2)
– Apply (F3)
– Reload (F4)
– Close (F6).
Fig. 4.7 - Softkeys description
Note that, Save, Apply, and Reload act on the performed modifications. During the
modifications, the being modified values are displayed in Italic style.
4.3.2.2.1 Save (F2)

Saves the performed modifications, both in the execution memory and to a file. The
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, hn_conf.var (*) file,
containing the new configuration values, is saved in UD:\data\hand.
(*) This file is automatically generated by the application, only if User

modifications are performed in the SETUP page. So, after the first installation, it
can be not present yet. In case of software updating, this file is preserved in order
not to lose the user configuration.
4.3.2.2.2 Apply (F3)

Saves the performed modifications, in the execution memory. The Object Page still
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remains open but the new values are NOT saved to a file. The new value is displayed
in the default style again.
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 Pages description

The SmartHand application Setup page makes available the following sub-pages:
– Gripper_X (from 1 to MAX_GRIPPER (3))
– Config
– Air.
4.3.2.3.1 Gripper
In this type of Object Page, the user has to enter all the devices to be used in the
process.
Each Object Page is similar to the others: the only difference is the gripper which it refers
to.
The possible choices (in the menu list) in the current Object Page are:
– Enable devices
– Sequence 1..6
– Vacuum 1..6
– Part_present 1..5.
GRIPPER : ENABLE DEVICES

It shows the list of the devices to be enabled/disabled, as in the following table
PARAMETER DESCRIPTION RANGE

Allows enabling/disabling Sequences (1…6) to be
Sequence 1…..6 [ON/OFF]
used in the process
Allows enabling Vacuum (1…6) to be used in the
Vacuum 1…6 [ON/OFF]
process
Allows enabling the control to handle the part
Part_present 1…5 [ON/OFF]
presence
GRIPPER : Sequence 1….6

After the device has been enabled, it is allowed to access its subpage, by selectin the
wished component in the menu list.
In this environment $DIN inputs and $DOUT outputs can be inserted in order to handle
the componentne.
Each sequence can handle a maximum amount of
– 5 inputs for the open sequence
– 5 inputs for the close sequence
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– 5 outputs for the open sequence

– 5 outputs for the close sequence.
The parameters description and the corresponding range are shown in the following
table.

Sequence_open_input_1
Allows inserting the input signal ($DIN) for the
.... $DIN[0…512]
reference sequence opening
Sequence_open_input_5
Sequence_close_input_1
Allows inserting the output signal ($DIN) for the
.... $DIN[0…512]
reference sequence closing
Sequence_close_input_5
Open_sequence_output_1
Allows inserting the input signal ($DOUT) for the
.... $DOUT[0…512]
reference sequence opening
Open_sequence_output_5
Close_sequence_output_1
Allows inserting the output signal ($DOUT) for the
.... $DOUT[0…512]
reference sequence closing
Close_sequence_output_5
Examples of devices that can be used by the sequences group:

– Clamping / Centering with 2-input bi-stable valves
• Sequence_open_input_1 --> Enter $DIN open index
• Sequence_close_input_1 -> Enter $DIN close index
• Sequence_open_output_1 -> Enter $DOUT open index
• Sequence_close_output_1 ->Enter $DOUT close index
– Clamping / Centering with 1-input bistable valves
• Sequence_open_input_1 -> enter the $DIN if it is an open input, otherwise
leave 0
• Sequence_close_input_1 -> enter the $DIN if it is a close input, otherwise
leave 0
• Sequence_open_output_1 ' enter the $DOUT opening index
• Sequence_close_output_1 ' enter the closing $DOUT index
– Clamping / Centering with 2-input monostable valves
• Sequence_open_input_1 -> enter the $DIN opening index
• Sequence_close_input_1 -> enter the $DIN closed index
• Sequence_open_output_1 -> enter the $DOUT if it is an opening output,
otherwise leave 0
• Sequence_close_output_1 -> enter the $DOUT if it is a closing output,
otherwise leave 0
– Clamping / Centering with 1-input monostable valves
• Sequence_open_input_1 -> enter the $DIN if it is an open output, otherwise
leave 0
• Sequence_close_input_1 ->enter the $DIN if it is a close output, otherwise
leave 0
• Sequence_open_output_1 -> enter the $DOUT if it is an opening output,
otherwise leave 0
• Sequence_close_output_1 -> enter the $DOUT if it is a closing output,
otherwise leave 0
– Clamping / Centering without inputs
In this case no $DIN is to be entered and the process routine has to be called with
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control flag at FALSE.
GRIPPER : Vacuum 1….6

Also for vacuums, as for Sequences, it is possible to insert Input and Output signals
($DIN, $DOUT), to handle the component just after enabling it.
For each vacuum it is possible to enter a maximum of:
– 5 inputs for the vacuum meters
– 5 outputs for aspiration
– 5 outputs for clamping
– 5 outputs for blowing.
The parameters description and the corresponding range are shown in the following
table.

Vacuum_active_input_1
Allows inserting the input signal ($DIN) to activate
.... $DIN[0…512]
the corresponding vacuum
Vacuum_active_input_5
Release_vacuum_output_1
Allows inserting the output signal ($DOUT) to stop
.... $DOUT[0…512]
aspiration
Release_vacuum_output_5
Active_vacuum_output_1
Allows inserting the output signal ($DOUT) to
.... $DOUT[0…512]
activate aspiration
Active_vacuum_output_5
Blow_vacuum_output_1
Allows inserting the output signal ($DOUT) to
.... $DOUT[0…512]
enable blowing
Blow_vacuum_output_5
Examples of devices that can be used in the vacuum group:

– suction devices with bi-stable valves for aspiration and monostable for
blowing and a vacuum meter
• Vacuum_active_input_1 -> Enter the vacuum meter $DIN index
• Release_vacuum_output_1 -> Enter the $DOUT index to stop aspiration
• Active_vacuum_output_1 -> Enter the $DOUT index to activate aspiration
• Blow_vacuum_output_1 -> Enter the $DOUT index to activate blowing
– suction devices with mono-stable valves for aspiration and monostable for
blowing and a vacuum meter
• Vacuum_active_input_1 -> Enter the vacuum meter $DIN index
• Release_vacuum_output_1 -> Leave 0
• Active_vacuum_output_1 -> Enter the $DOUT index to activate aspiration
• Blow_vacuum_output_1 -> Enter the $DOUT index to activate blowing
– suction devices only one mono-stable valve and a vacuum meter
• Vacuum_active_input_1 ->Enter the vacuum meter $DIN index
• Release_vacuum_output_1 -> Leave 0
• Active_vacuum_output_1 -> enter the $DOUT if the output activates
aspiration, otherwise leave 0
• Blow_vacuum_output_1 -> enter the $DOUT if the output enables blowing,
otherwise leave 0
– suction devices without information from vacuum meter
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In this case no $DIN is to be entered and the process routine is to be called with
the FALSE control flag.
GRIPPER : Part Present 1….5

To check the part presence on robot board
– 3 inputs for presence microswitches
The parameters are the same for each device checking the part presence.

Part_present_input_1
.... Allows inserting the part input signal ($DIN) $DIN[0…512]
Part_present_input_3
NOTE THAT to use $DIN and $DOUT signals, please refer to Tab. 5.1 showing the
provided User shared resources.
4.3.2.3.2 Config
In this sub-page the user can act on the GLOBAL Parameters settings, that operate in
real time on the handling process.
The corresponding menus are:
– Application program setting
– Reset alarms for TP/PLC.
The parameters corresponding to these two subpages are shown in the following tables
(Tab. 4.4 e Tab. 4.5), as well as their meaning and range of values.
Tab. 4.4 - Config - Application program settings
PARAMETRO DESCRIZIONE RANGE

Enables the outputs reset after the motion
Clear output [ON/OFF]
completion
Drive off fault Enables drive off during anomalies [ON/OFF]
Indicates the status of the anomaly output towards
Status Output fault [ON/OFF]
PLC
Timeout after a movement before a fault is
Timeout alarm [1000..5000] [ms]
generated
Waiting time used before exiting from a routine, if
Waiting Time [500..3000] [ms]
the process is called without inputs check
Time used in the dynamic part present check to filter
any vibrations of the part during the movement; if
Timeout supervision the part present input is missing for the time [100…1000] [ms]
included in the filter, the application will not signal a
lost part
Time used for the blowing pulse. If the indicated
Time blowing time is 0 the application will not use the PULSE [0…3000] [ms]
mode, but will directly set the output
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Tab. 4.5 - Config - Reset alarms from TP/ PLC

The Teach Pendant reset is enabled with the mode
Reset from TP in T1 $DIN[0…512]
selector switch on T1 (Prog mode)
Reset form TP in AUTO [ON/OFF]
selector switch on AUTO (Local mode)
Reset from TP in REMOTE [ON/OFF]
selector switch on REMOTE (Remote mode)
Reset from PLC is enabled with the mode selector
Reset form PLC in T1 [ON/OFF]
switch on T1 (Prog mode)
Reset from PLC in AUTO [ON/OFF]
switch on AUTO (Local mode)
Reset from PLC in REMOTE [ON/OFF]
switch on REMOTE Remote mode)
4.3.2.3.3 Air
This subpage allows enabling/disabling the pressure switches the User wishes to use in
the process, defining parameters needed to their handling.
The available menus in this Object page are:
– Enable pressure switches
– Air check 1..3
– Media Panel
Tab. 4.6 - Air - enable pressure switches

Air check 1 Enable pressure switch 1 [ON/OFF]
Air : Air check 1..3

It is allowed to access these subpages for defining each pressure switch
values/parameters, just after enabling such a device. Each subpage is similar to the
others: the only difference is the referenced device.

Enter the number of the $DIN port to be used to
Input Number $DIN[0…512]
control the pressure switch
Choose the gripper where the pressure switch is
installed. If the pressure switch is not mounted on
the gripper, but on a station, enter No Gripper. This
is because if there is the tool changer application, if [No Gripper/Gripper 1/
Gripper Index
the pressure switch is mounted on the gripper, Gripper 2/ Gripper 3]
during the release procedure the application
package will have to mask the air control so that it
does not become connected again
Enter the filter time in ms to mask any pressure
Timeout Air [100…1000] [ms]
fluctuations in the system
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Air : Media Panel

This subpage is always visible, but it is just enabled at the application package
installation creation time.
When enabled, it allows enabling/disabling the air pressure switch control on the Media
Panel

Enable/disable monitoring. Enabling this flag, the
Present state of a $DIN (previously configured by the [ON/OFF]
application software), will be monitored
it is the Filter Time; insert the waiting time to be used
Filter by the application software, before issuing an alarm [0..1000] [ms]
message
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:
– Alarm page
– I/O Page
4.4.1 Alarm page

This User Page (which is the System Alarm Page) the issued application alarms are
displayed.
Fig. 4.8 - Alarm Page
The following information is displayed for each message i:

– alarm order number
– error code and severity
– message text
– date and time.
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An ALARM MESSAGE is displayed when SmartHand detects an anomalous condition

that requires the interruption of the process and the intervention of the operator. These
messages are only displayed following an operation performed by an instruction that
belongs to the Technological Instructions group. The message remains displayed until
SmartHand receives an alarm reset command.
The allowed Reset capabilities of the alarm can be:
– Retry (F1) - it is present depending on the alarm type; usually it is available when
an action is expected only. It repeats such an action
– Skip (F2) - it is present depending on the alarm type; it resets the alarm bypassing
its cause and goes ahead with the next operations.
– Reset (F3) - it has exactely the same functionality of the Teach Pendant RESET
key. The alarm is deleted and the event causing the alarm is checked again.
4.4.1.1 Errors 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 hn_ms.crd, containing such information about SmartHand application, must be
added to the errors list, by means of the WinC5G Property Window, in the CRD File
field, byfirst pressing Edit key, and then Add key as shown in the following figures:
Fig. 4.9 - Property Window
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Fig. 4.10 - CRD file selection
File hn_ms.crd is present:

– on the PC, in the installation directory of WinC5G together with System alarms crd
files
– on the Controller in UD:\sys\msg\hn_ms.crd; it is copied in this directory during
SmartHand application installation.
If the alarm number typed in WinC5G Cause/Remedy Window is not found, the possible
reasons could be:
– file hn_ms.crd has not been added in WinC5G Property Window
– file hn_ms.crd is present but it could be not up to date; in this case the file stored
on the Controller must be added.
For any further details about subpages and the use of the Alarm Page general
purpose softkeys, please refer to C5G Control Unit use manual, chap.Teach
Pendant - par. Alarm Page.
4.4.2 I/O Page

The I/Os handled by the application are grouped “by component” in a directory called
SMARTHAND.
Press I/O (L5) (left menu) to access it, moving focus on Ports subpage identified by the
tabsheet with this name, and selecting smarthand directory.
A list is displayed of all already configured (by means of the Setup Page) components.
Fig. 4.11 - I/O Ports
Fig. 4.12 shows an example of how I/Os are displayed.
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Fig. 4.12 - Displaying I/Os
4.4.2.1 User Help I/Os

The I/Os comments, describing signals of each component configured on the GRIPPER
X ( where 'X' is the gripper number), are string variables included in hn_help_gripX.var
file.
The I/Os comments, describing inputs of the pressure switches which are NOT mounted
onto the gripper(s), are string variables included in hn_help_station_air.var file,
instead.
Such files, placed in UD:\\appl\\hio directory, are automatically generated by the
application only when the User modifies any values in the Setup Page. Depending on
the performed modification, the application will either generate a new var file or will
update the already existing one.
At the first installation, it is then possible that they are not present yet.
The help strings aare never changed depending on the selected language; this allows
the User to directly customize them.
Let us suppose of modifying the configuration of sequence 1, input open 2, referred to
gripper 1, automatically generated by the application within hn_help_grip1.var file; it it
then:
hnvs_din_11_help STR Len: 128 Priv 'Grip 1 Seq 1 Input Open 2'
NOTE THAT such strings are always and only generated in English language.
The item in Italic style is the string type variable name for the configured input: in this
case it is $DIN [11].
The item in bold style is the being modified string instead.
Example:
hnvs_din_11_help STR Len: 128 Priv 'Second input open of seq. 1, gripper 1'
To activate the new help string, it is necessary to perform a Restart Cold operation if
the string variable has been created for the first time; otherwise, if it was already exixting
and it has just been updated, issuing command 'ML/V'(Memory Load / Variables) of
the modified var file, is enough.
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Fig. 4.13 - Example of Help I/O
NOTE THAT to configure input and output signals ($DIN and $DOUT), it is needed
to use IO_MAP program, available on the Teach Pendant in the SETUP age; please
refer to C5G Control Unit use manual, chap. SETUP Page, for further details.
4.5 Integration with IDE environment

In this section a detailed description is given on how to insert Technological Instructions
in the application program in IDE environment. A full analysis of such instructions is
given in par. 5.2 Technological Instructions on page 43.
4.5.1 Technological Instruction insertion in IDE environment

To insert Technological Instructions from within IDE environment, act as follows:
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. 4.14 - Inserting a Technological Instruction - example
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40 00/0410
d. Press Statement (F1),
e. select SMARTHAND directory and confirm with ENTER; SmartHand application

Technological instructions are displayed and the User is requested to select the
wished one to be inserted in the program
Fig. 4.15 - Selecting the Technological instruction
f. In the shown above example (see Fig. 4.15), gripper_sequence instruction is

selected when pressing ENTER.
g. The System inserts the corresponding template (mask) for the required instruction
and the User must fill in all the fields and press ENTER to confirm.
Fig. 4.16 - Insertion completion
The above described insertion procedure is the same for each Technological
Instruction.
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. 4.17).
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Fig. 4.17 - Use of the Numeric 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. 4.17) if the user presses SHIFT and 2 at the same time,
without opening the keypad, gripper_sequence 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 numertic 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 numeric Keypad pages.
– up/down/right/left arrows - allows moving within the numeric Kaypad.
– ESC - closes the numeric Keypad without adding any instruction to the program.
– ENTER - adds the currently selected instruction (in the numeric keypad) to the
program and closes the numeric Keypad.
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Programming
5. PROGRAMMING
5.1 Introduction
This chapter gives detailed information to the user who has to write programs for the
Handling application.
The following topics are dealt with in detail:
– Technological Instructions
– Handling RESET key
– Using the System shared resources.
5.2 Technological Instructions

The user has several technological instructions available, dedicated to the handling
process. They are grouped in the following classes:
– Process routines
– Advanced variables and routines.
5.2.1 Process routines

– Gripper_sequence
– Gripper_vacuum
– Gripper_vacuum_blow
– Gripper_chkpart
– Grip_part_supervision
– Grip_air_supervision.
Find below a detailed description of each Technological Instruction related to the
SmartHand application software.
5.2.1.1 Gripper_sequence
Name Gripper_sequence
Function/Usage Manages the clamps opening and closing command. Used to command a clamping.
– ai_grip: gripper to be used - 1 .. 3 (INTEGER)
– ai_seq: sequence to be used - 1 .. 6 (INTEGER)
– ab_state: ON -> calls the sequence closure
Parameters
OFF -> calls the sequence opening ON / OFF(BOOLEAN)
– ab_check (optional parameter): ON -> inputs checked
OFF -> inputs check excluded - ON / OFF(BOOLEAN)
gripper_sequence (ai_grip, ai_seq:INTEGER; ab_state,
Statement
ab_check:BOOLEAN) EXPORTED FROM H_hand GLOBAL
Entering from IDE NO
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Programming
ROUTINE gripper_sequence (ai_grip, ai_seq:INTEGER; ab_state,

ab_check:BOOLEAN) EXPORTED FROM H_hand GLOBAL
BEGIN
Calling example
Gripper_sequence( 1, 1, ON, ON)
...
END prog_1
5.2.1.2 Gripper_vacuum
Name Gripper_vacuum
Manages the vacuum work and idle command. Used when a vacuum is to be
Function/Usage
controlled.
– ai_seq: suction device to be used - 1 .. 6 (INTEGER)
– ab_state: ON -> calls aspiration
Parameters
OFF -> stops aspiration - ON / OFF(BOOLEAN)
– ab_check (optional parameter): ON -> vacuum meter check
OFF -> vacuum meter check off - ON / OFF(BOOLEAN)
gripper_vacuum (ai_grip, ai_vac : INTEGER; ab_state, ab_check :
Statement
BOOLEAN)EXPORTED FROM H_hand GLOBAL
ROUTINE gripper_vacuum (ai_grip, ai_vac : INTEGER; ab_state,

ab_check : BOOLEAN)EXPORTED FROM H_hand GLOBAL
BEGIN
Calling example
Gripper_vacuum( 1, 1, ON, ON)
...
END prog_1
5.2.1.3 Gripper_vacuum_blow
Name Gripper_vacuum_blow
Function/Usage Manages the vacuum blowing. Used issue vacuum blowing.

– ai_seq: suction device to be used - 1 .. 6 (INTEGER)
– ab_state: ON -> calls blowing
Parameters
OFF -> stops blowing - ON / OFF(BOOLEAN)
– ab_check (optional parameter): ON -> vacuum meter check
OFF -> vacuum meter check off - ON / OFF(BOOLEAN)
gripper_vacuum_blow(ai_grip, ai_vac:INTEGER; ab_state,
Statement
ab_check:BOOLEAN)EXPORTED FROM H_hand GLOBAL
ROUTINE gripper_vacuum_blow(ai_grip, ai_vac:INTEGER; ab_state,

ab_check:BOOLEAN)EXPORTED FROM H_hand GLOBAL
BEGIN
Calling example
Gripper_vacuum_blow( 1, 1, ON, OFF)
...
END prog_1
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Programming
5.2.1.4 Gripper_chkpart
Name gripper_chkpart
Manages the part presence or absence check. Used to check the presence or absence
Function/Usage
of the part.
– ai_part : part presence to be used - 1 .. 5 (INTEGER)
Parameters
– ab_state: ON -> check presence
OFF -> check absence - ON / OFF(BOOLEAN)
gripper_chkpart(ai_grip, ai_part : INTEGER; ab_state :
Statement
ROUTINE gripper_chkpart(ai_grip, ai_part : INTEGER; ab_state :
BOOLEAN) EXPORTED FROM H_hand GLOBAL
BEGIN
Calling example
gripper_chkpart( 1, 1, ON)
...
END prog_1
5.2.1.5 Grip_part_supervision
Name grip_part_supervision
Manages the part presence or absence dynamic check. Used to activate or deactivate
Function/Usage
the part presence dynamic check.
– ai_part : part presence to be used - 1 .. 5 (INTEGER)
Parameters
– ab_state: ON -> enable dynamic check
OFF -> disable dynamic check - ON / OFF(BOOLEAN)
grip_part_supervision(ai_grip, ai_part : INTEGER; ab_state :
Statement
ROUTINE grip_part_supervision(ai_grip, ai_part : INTEGER;

ab_state : BOOLEAN)EXPORTED FROM H_hand GLOBAL
BEGIN
Calling example
Grip_part_supervision( 1, 1, ON)
...
END prog_1
5.2.1.6 Grip_air_supervision
Name grip_air_supervision
Manages the air pressure dynamic control. Used to activate or deactivate the air
Function/Usage
pressure dynamic control.
– ai_grip: gripper to be used - 1 .. 3 (INTEGER) or 0 if no gripper is mounted
Parameters – ab_state: ON -> enable dynamic check
OFF -> disable dynamic check - ON / OFF(BOOLEAN)
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Programming
grip_air_supervision(ai_grip : INTEGER; ab_state :

Statement
ROUTINE grip_air_supervision(ai_grip : INTEGER; ab_state :

BEGIN
Calling example
Grip_air_supervision( 1,ON)
...
END prog_1
5.2.2 Advanced variables and routines

– Hnvb_smarthand_in_fault
– Hnru_user_fault_abort_enable
– Hnru_user_fault_abort_ack
– Hnrb_get_user_fault_abort.
5.2.2.1 Hnvb_smarthand_in_fault
Name hnvb_smarthand_in_fault
This varible indicates that SmartHand application is in fault (e.g. it could be used to
Function/Usage
activate ABORT keys from right menu, if available)
Statement VAR hnvb_smarthand_in_fault : BOOLEAN EXPORTED FROM sh_dd NOSAVE
Example
5.2.2.2 Hnru_user_fault_abort_enable
Name hnru_user_fault_abort_enable
This routine indicates to SmartHand application, that ABORT key has been pressed
Function/Usage from the Right Menu (if available) and allows to reset the alarm (to be called upon
ABORT key pressure from Right Menu, if available)
Parameters none
Statement hnru_user_fault_abort_enable EXPORTED FROM H_hand GLOBAL
Calling example
5.2.2.3 Hnru_user_fault_abort_ack
Name hnru_user_fault_abort_ack
Function/Usage This routine indicates to SmartHand application, that the ABORT phase is finished.
Parameters none
Statement hnru_user_fault_abort_ack EXPORTED FROM H_hand GLOBAL
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Programming
Entering from IDE
Calling example
5.2.2.4 Hnrb_get_user_fault_abort
Name hnru_user_fault_abort_abort
This routine allows to understand whether or not a SmartHand application fault has
Function/Usage
been reset by means of the ABORT key, from Right Menu (if available).
Parameters none
Statement hnrb_get_user_fault_abort : BOOLEAN EXPORTED FROM H_hand GLOBAL
Entering from IDE

Calling example
5.3 Handling RESET key

These routines handle the TP RESET key.
– hnru_tp_reset_in_remote.
5.3.1 hnru_tp_reset_in_remote
Name hnru_tp_reset_in_remote
Enables/disables the RESET key on the Teach Pendant, when the system is in
Function/Usage
REMOTE state.
– ab_enable: Boolean parameter which value indicates whether enabling
Parameters (TRUE) or disabling (FALSE) the TP RESET key when the system is in
REMOTE state.
ROUTINE hnru_tp_reset_in_remote(ab_enable : BOOLEAN) EXPORTED
Statement
FROM H_hand GLOBAL
hnru_tp_reset_in_remote (ON) -- enables RESET key in REMOTE

Calling example
-- state
5.4 Using the System shared resources

The System provides the User with some shared resources, listed in the following
tables:
– Tab. 5.1 - $DIN e $DOUT
– Tab. 5.2 - $FMI e $FMO
– Tab. 5.3 - Errors, events, conditions
– Tab. 5.4 - User Fieldbus modules naming.
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Programming
Tab. 5.1 - $DIN e $DOUT
$DIN
RANGE OWNER NOTE
1 -- 16 SPOT Welding Gun

17 -- 34 GLUE / NUT Not Assigned for Glue
35 -- 50 STUD Welding Headn
51 -- 178 HAND Gripper Clamps
179 -- 199 ARC
To be mapped on fieldbus master Interface or CAN (if not
200 -- 255 USER
already mapped by application package)
256 -- 512 USER To be mapped on fieldbus Slave Interface (Line PLC)
200 -- 255 USER
$DOUT
RANGE OWNER NOTE

1 -- 16 SPOT Welding Gun
17 -- 34 GLUE / NUT Not Assigned for Glue
35 -- 50 STUD Welding Head
51 -- 178 HAND Gripper Clamps
179 -- 199 ARC
200 -- 255 USER
Tab. 5.2 - $FMI e $FMO
$FMI
How Many RANGE OWNER NOTE
32 1--32 USER
$FMO
How Many RANGE OWNER NOTE
$FMO[21] IS USED FOR ACTIVE

APPLICATION TOWARDS PLC.
31 1--32 USER
SEE THE U_ATTACH SHEET, FOR THE
MEANING OF THE $FMO[21] VALUES.
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Tab. 5.3 - Errors, events, conditions
ERR_POST NUMBER
RANGE OWNER NOTE
43008 -- 44031 USER used in err_post
TP PRIVILEGED EVENTS
RANGE OWNER NOTE

(Err_Post2 // Right menu when not managed by
5120 -- 5169 USER
application software)
CONDITION HANDLERS (declared in used program)
RANGE OWNER NOTE
1 -- 24 USER
PDL2 EVENTS
RANGE OWNER NOTE
50342 --> 50687 USER
Tab. 5.4 - User Fieldbus modules naming
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
GRIPPER 1 HN_GRIP_numGrip_PhysAddr 54
GRIPPER 2 / GRIPPER 1 NODE 2 HN_GRIP_numGrip_PhysAddr 55
GRIPPER 3 / GRIPPER 1 NODE 3 HN_GRIP_numGrip_PhysAddr 56
GRIPPER 4 / ... HN_GRIP_numGrip_PhysAddr 57
GRIPPER 5 / ... HN_GRIP_numGrip_PhysAddr 58
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Customizations
6. CUSTOMIZATIONS
6.1 I/O configuration 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
APPL_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 IO_CONFIG and IO_MAP programs, please refer to

C5G Control Unit use manual, chap. 11 - I/O Configuration Programs.
Summarizing, perform the following operations:

– configure the fieldbus network towards PLC (by means of IO_CONFIG 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. 5.4 Using the System shared resources on page 47
– 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:
INPUT (SIGNALS FROM PLC) Position (byte-bit)

Application fault Reset $IN[413] 1-7
Dry cycle command $IN[414] 3-8
OUTPUT (SIGNALS TOWARDS PLC)
Not Application fault $OUT[413] 1-8
Dry cycle active $OUT[414] 4-8
Active Application code $FMO[21] 2-3
ap-hn-0-hnd_07.fm
50 00/0410
Optional Software Functionalities
7. OPTIONAL SOFTWARE
FUNCTIONALITIES
7.1 Introduction
Current chapter contains descriptions and part codes for the Handing Systems available
software options:
– SmartVisualProcess.
7.2 SmartVisualProcess
– Introduction
– Functioning
– Part Code.
7.2.1 Introduction
Fig. 7.1 - Activating SmartVisualProcess
SmartVisualProcess is a SmartHand application option, allowing runtime graphical

display of some components, such as gripper inputs.
The associated leds to each input, may have the following four states:
1. GREEN LED - input open state is ON;
2. BLUE LED - input close state is ON
3. GREY LED - input open/close state is OFF;
4. RED LED - state is ERROR; this state applies when a
sequence/vacuum/part_presence is called.
7.2.2 Functioning
When the SmartHand Setup Page settings are saved, a file is created called
SmartHnSVP.xmd , in the following directory:
ap-hn-0-hnd_14.fm
01/0712 51
Optional Software Functionalities
UD:\DATA\HAND\SVP
Such a file contains all the positions of each LED (label) among the XML tag parameters
<POS_X>....</POS_X> <POS_Y>....</POS_Y>
as shown below.
After the labels positions are modified, save and rename the file to .xml extension
(e.g. SmartHnSVP.xml), and issue a RESTART COLD command.
Calling syntax from IDE environment:
hnru_change_part(ai_part_id)
routine for gripper changing in VisualProcess page.

The "ai_part_id" parameter indicates the being displayed gripper number.
Fig. 7.2 - SmartVisualProcess
7.2.3 Part Code
Comau Code Description

CR13621860 SmartVisualProcess
ap-hn-0-hnd_14.fm
52 01/0712
COMAU Robotics services
Repair: repairs.robotics@comau.com
Training: training.robotics@comau.com
Spare parts: spares.robotics@comau.com
Technical service: service.robotics@comau.com
comau.com/robotics Original instructions

Handling System: Comau Robotics Instruction Handbook

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Handling System: Comau Robotics Instruction Handbook

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Comau Robotics

Copyright © 2003 by COMAU - Date of publication 07/2012

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

2. GENERAL DESCRIPTION OF SMARTHAND APPLICATION SOFTWARE . . . . . . ...17

3. INSTALLING / ACTIVATING / UNINSTALLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

4. USER INTERFACE ON THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23

7. OPTIONAL SOFTWARE FUNCTIONALITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..51

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 C5G Control 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

1.1.1 Implemented and respected essential health and safety

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

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

– Disassembly of robot components (motors, balancing cylinders, etc.) may cause

Putting Out of Service and Dismantling

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

Expected Stopping Stopping

Tab. 1.2 - Safety electronics reaction time in programming modality (T1)

Mission time (typ. case)

2.2 Basic System

Fig. 2.1 - Basic System

2.3 Basic Functions

3.2 System requirements

3.3 Preparation for SmartHand installation

– C5G Controller with SmartHand application package not present.

3.4 Use of WinApplicationCreator tool for C5G

<version_file name><configuration name>.zip

3.5 Installation procedure

a. Activate the SETUP page on the Teach Pendant

Fig. 3.1 - SETUP

b. Select the Install icon and press ENTER to confirm.

e. Confirm with ENTER (Fig. 3.2).

Fig. 3.2 - SETUP Application

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 (see Fig. 3.3)

Fig. 3.3 - SETUP - Uninstall

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

Fig. 3.4 - SETUP - Uninstall - 2

4. USER INTERFACE ON THE TEACH

4.2 Process control keys (right menu)

Tab. 4.1 - Meaning of the softkeys

When the corresponding softkey is enabled, the icon representing the

When the corresponding softkey is disabled, the icon representing the

Tab. 4.2 - Meaning of the software leds

Tab. 4.3 - Functionality and position of the modal selector switch

Select the type of component to be displayed/commanded (Vac/Seq). Each

Each pressure increases the R4 and R5 component number. The increment

These softkeys control the component which is represented by the displayed