WAC

WinApplCreator Program
Installing, activating, usage commands

CR00758151_en-01/2019.02

Instructions handbook
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 02/2019

 Comau Robotics Product Instruction

SUMMARY

SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Symbols in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1. GENERAL SAFETY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Fundamental Requirements Applied and Respected . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. WINAPPLCREATOR TOOL - WAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...18

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
How it works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
File types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19
System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Software installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4. ACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
First launch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operating directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Folders created by WAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5. COMMANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
File ................................................................... 28
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Import version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Delete current version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SaveAs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Comau Robotics Product Instruction

SUMMARY

Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Auto save after generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Stop at error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6. USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..32
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Selecting objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Generating and saving the configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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 Comau Robotics Product Instruction

PREFACE

PREFACE
– Symbols in the manual
– Reference documents

Symbols in the manual

Find below the symbols highlighting WARNING, CAUTION and NOTES together with
their meaning

This symbol applies to operating procedures, technical information and precautions that
are to be complied with and/or properly performed to prevent possible injuries.

This symbol applies to operating procedures, technical information and precautions that
are to be complied with and/or properly performed to prevent possible equipment
damages.

This symbol applies to operating procedures, technical information and precautions that
need necessarily to be highlighted.

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Comau Robotics Product Instruction

PREFACE

Reference documents
This document refers to the C5G Control Unit.
The C5G complete manual set consists of:

Comau C5G Control Unit – Technical specifications

– Transport and installation
– Maintenance
– Control Unit usage.

The above mentioned manuals shall be integrated by the following documents:

Comau Robot – Technical specifications

– Transport and installation
– Maintenance
Programming – PDL2 Programming Language
– VP2 - Visual PDL2
– Motion programming
Applications – According to the requested application
type.

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Comau Robotics Product Instruction

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

1. GENERAL SAFETY REQUIREMENTS

This chapter deals with general specifications that apply to the whole Robot System.
Considering its significance, this chapter is referred unreservedly in each system
instructions handbook.

This chapter deals with the following topics:

– Responsibilities
– Safety Requirements.

1.1 Responsibilities

– The system integrator is responsible for ensuring that the Robotic System (Robot
and Control Unit) is installed and handled in accordance with the Safety Standards
in in the country where the installation takes place. The application and use of the
necessary protection and safety devices, the issuing of declaration of conformity
and any EC marking of the system are the responsibility of the Integrator.

– COMAU refuses any responsibility for accidents caused by incorrect or improper

use of the Robotic System (Robot and Control Unit), by tampering with circuits,
components, software and with the use of spare parts that are not included in the
spare parts list.
– The application of these Safety Requirements is the responsibility of the persons
assigned to direct / supervise the activities indicated in the section Applicability,
which should make sure that the Authorised Personnel is aware of and
scrupulously follow the requirements contained in this document in addition to the
general Safety Standards applicable to Robotic System (Robot and Control Unit)
in in the Country where the system is installed.
– The non-observance of the Safety Standards may cause to the operators
permanent injuries or death and can damage the Robotic System (Robot and
Control Unit).

The installation shall be carried out by qualified Personnel and must conform to all
National and Local standards.

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 Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

1.1.1 Safety Fundamental Requirements Applied and

Respected
The robotic system is composed of Control Unit and Robot series SMART 5 considers
as applied and respected the following Safety Fundamental Requirements, Annex 1 of
Directive on Machinery 2006/42/CE: 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.
In case it is provided only the Robot series SMART 5 are to be considered as applied
the following requirements: 1.1.3 – 1.1.5 – 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 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2
– 1.7.4.

1.2 Safety Requirements

1.2.1 Purpose
These safety requirements are aimed to define the behaviour and obligations to be
observed when performing the activities listed in the Applicabilitysection.

1.2.2 Definitions
Robotic System (Robot and Control Unit)
Robotic system is the workable assembly composed of: Robot, Control Unit, Teach
Pendant and other possible options.

Protected Area
The protected area is the zone confined by the protection barriers and intended to be
used for the installation and operation of the Robot.

Authorised Personnel
Authorised personnel defines the group of persons who have been appropriately trained
and assigned to carry out the activities listed in the section Applicability.

Staff in Charge
The staff in charge defines the personnel who manage or supervise the activities of the
employed persons defined in the preceding point.

Installation and Startup

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.

Functioning in Programming Mode

Operating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual movement of Robot axes and programming
of work cycles at low speed, programmed cycle testing at low speed and, when allowed,

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

at working speed.

Functioning in Auto / Remote Mode

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

Maintenance and Repair

Maintenance and repair are activities that involve periodical checking and / or
replacement of Robot and Control System (mechanical, electrical, software) parts or
components, and trouble shooting, that ends when the Robot and Control System has
been reset to its original project functional conditions.

Decommissioning and Dismantling

Decommissioning 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 Robot and Control System
installation and startup.

Misuse
Misuse is defined as the use of the system outside the limits specified in the Technical
Documentation.

Action Area
The Robot action area is the enveloping volume of the area occupied by the Robot and
its equipment during movement in the area.

1.2.3 Applicability
These requirements must be applied when carrying out the following activities:
– Installation and Startup
– Functioning in Programming Mode
– Functioning in Auto / Remote Mode
– Robot Axes Brake Release (if present)
– Maintenance and Repair
– Decommissioning and Dismantling.

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GENERAL SAFETY REQUIREMENTS

1.2.4 Operating Modes

Installation and Startup
– The startup is only possible when the Robot and Control System has been correctly
and completely installed.
– The system installation and startup is exclusively the task of the authorised
personnel.
– The system installation and startup is only permitted exclusively inside a protected
area of an adequate size to house the Robot and the equipment it is outfitted with,
without passing beyond the protection barriers. It is also necessary to check that in
normal Robot movement conditions there is no collision with parts inside the
protected area ( e.g structural columns, power supply lines, etc.) or with the
barriers. If necessary, limit the Robot work area using mechanical hard stop (see
optional units).
– Any fixed Robot control stations must be located outside the protected area and in
a point such as to permit a full view of the Robot movements.
– The Robot installation area must be as free as possible from materials that could
impede or limit the visibility.
– During installation the Robot and the Control Unit must 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.
– Fix the Robot to mount holder, with all the provided bolts and pins, tightened to the
tightening torque indicated in the product Technical Documentation.
– If present, remove the fixing brackets of the axes and verify the proper fixing of the
equipment the Robot is outfitted with.
– Check that the Robot guards are correctly fixed and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– Install the Control Unit outside the protected area: the Control Unit should not be
used as part of the fencing.
– Check that the voltage value of the power mains is consistent with that indicated
on the nameplate of the Control Unit.
– Before electrically connect the Control Unit, check that the circuit breaker on the
power mains is locked in open position.
– Connection between the Control Unit and the supply mains at the works, is to be
with a cable dimensioned appropriately for the power installed on the Control Unit
(for further details see the Control Unit “Transport and Installation” manual).
– Connect the ground cable (PE) then connect the power conductors to the main
switch.
– Connect the power supply cable, first connecting the ground cable to the circuit
breaker on the power mains line, after checking with a tester that the circuit breaker
terminals are not powered. It is recommended to connect the cable armouring to
the earth.
– Connect the signals and power cables between the Control Unit and the Robot.

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

– Connect the Robot to earth through the Control Unit or by means of specific ground
terminal blocks, depending on the predispositions available on the Robot and/or on
the Control Unit.
– If present, check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors may cause permanent damage to the
Control Unit components.
– The Control Unit manages internally the main safety interlocks (gates, enabling
pushbuttons, etc.). Connect the 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 (emergency stop, gates
safety 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 it is necessary to include the contacts of the
Control Unit emergency stop push-buttons, available on X30. The push-buttons are not
interlocked inside the emergency stop circuit of the Control Unit.

– The safety of the system cannot be guaranteed in case of interlocks erroneous,

incomplete or missing execution.
– 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 mode; in Programming mode the power is disabled
immediately.
– When preparing protection barriers, especially light curtains and access doors,
take into consideration the Robot stopping times and distances according to the
stop category (0 or 1) and the weight of the Robot.

If present, on the Control Unit, make sure that the setting of the stop circuit timer is
consistent with the type of Robot connected (for further details see the Control Unit
“Transport and Installation” manual)

– Check that the environmental and operating conditions do not exceed the limits
specified in the Technical Documentation of the specific product.
– The calibration operations must be carried out with great care, as indicated in the
Technical Documentation of the specific product, and should be concluded by
checking the correct position of the machine.

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 Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

– To load or update the system software (for example after boards replacing), use
only the original software handed over by COMAU. Scrupulously follow the system
software loading procedure described in the Technical Documentation supplied
with the specific product. After loading, always make some Robot moving tests at
low speed remaining outside the protected area.
– Check that the barriers of the protected area are correctly positioned.

Functioning in Programming Mode

– The programming of the Robot is exclusively the task of the authorized personnel.
– Before starting to program, the operator must check the Robotic System (Robot
and Control Unit) to make sure that there are no potentially dangerous irregular
conditions, and that there is nobody inside the protected area.
– The programming should be controlled from outside the protected area whenever
possible.
– 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 Teach Pendant is working properly (low
speed, emergency stop device, enabling device, etc.).
– During the programming phases, only the operator with the Teach Pendant 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) always must be controlled from a position
outside the operating range of the Robot, after checking that there is nobody in the
area involved. The Drive On operation is considered complete when the relevant
machine status indication is shown.
– When programming, the operator must remain at an appropriate distance from the
Robot to be able to avoid any irregular machine movements, and in any case in a
suitable position to avoid the risk of being trapped between the Robot and
structural parts (columns, barriers, etc.), or between movable parts of the Robot.
– When programming, the operator must avoid to remain in a position where parts of
the Robot, pulled by gravity, could move downwards, upwards or sideways (when
installed on a inclined 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 low speed has been carried out. The
test must be controlled from a safe distance.
– Special attention is to be paid when programming using the Teach Pendant: 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.

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

– In both cases operate cautiously, always remaining out of the Robot range of action
and test the cycle at low speed.

Functioning in Auto / Remote Mode

– The activation of the automatic operation (AUTO and REMOTE states) is permitted
only with the Robotic System (Robot and Control Unit) integrated inside an area
with protection barriers properly interlocked, as required by the Safety Standards
currently in in the Country where the installation takes place.
– Before starting the automatic mode the operator must check the Robot and Control
System and the protected area to make sure there are no potentially dangerous
irregular conditions.
– The operator can activate automatic operation only after having checked:
• that the Robot and Control System is not in maintenance or repair status;
• that the protection barriers are correctly positioned;
• that there is nobody inside the protected area;
• that the Control Unit doors are closed and locked with the appropriate key;
• that the safety devices (emergency stop, protection barrier safety devices)
are functioning;
– Special attention is to be paid when selecting the remote mode, in which the line
PLC can perform automatic operations of motors power up and program starting.

Robot Axes Brake Release (if present)

– In the absence of motive power, the Robot axes repositioning is possible by means
of optional brake release devices and suitable lifting devices. Such devices only
allow the brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enabling push-button) are disabled; also the
Robot axes can move upwards or downwards because of the s generated by the
balancing system or by the gravity .

Before using the manual brake release devices, it is recommended to sling the Robot,
or hook it to an overhead travelling crane.

– The use of brake releasing device may cause the axes falling due to gravity, as well
as possible impacts due to an incorrect reset, 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
handbooks.

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GENERAL SAFETY REQUIREMENTS

– When after the interruption of an unfinished MOVE the motion is enabled again, the
typical function of trajectory recuperation may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next restart of the
automatic cycle. Avoid moving the Robot in positions that are distant from the ones
required for the motion restarting; alternatively disable the outstanding MOVE
programmes and/or instructions.

Maintenance and Repair

– When assembled in COMAU the Robot is supplied with lubricants that do not
contain any harmful to health substances, however, in some cases, repeated and
prolonged exposure to the product may cause skin irritation, or if swallowed,
sickness.
First Aid Measures. In case of contact with the eyes or skin: rinse the affected
areas with copious amounts of water; should irritation persist, seek medical advice.
If swallowed, do not induce vomiting or administer anything by mouth; consult a
doctor as soon as possible.
– Maintenance, trouble-shooting and repair are only to be carried out by authorised
personnel.
– When carrying out maintenance and repair operations, the specific warning sign
stating the maintenance status must be placed on the control panel of the Control
Unit, until the end of the operation, even if it should be temporarily suspended.
– Maintenance and components or Control Unit replacement operations must 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 deriving from connection to peripheral units or external
power sources (e.g. 24 Vdc input/output). Power off the external sources when
operating on involved system parts.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Defective components must be replaced with others having the same Part
Number, or equivalent components defined by COMAU.

If present, the safety components, in case of replacement, must be configured using the
same parameters of the components just removed.

– Trouble-shooting and maintenance activities must be carried out, whenever

possible, outside the protected area.
– Trouble-shooting executed on the control is to be carried out, whenever 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 must be observed
when operating in presence of dangerous voltages.
– Trouble-shooting on the Robot must be carried out with the power supply turned
off (DRIVE OFF).
– At the end of the maintenance and trouble-shooting operations, all the deactivated
safeties must be reset (panels, protection shields, interlocks, etc.).

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

– Maintenance, repair and trouble-shooting operations must be concluded with the

check of the correct functioning of the Robotic System (Robot and Control Unit)
and all the safety devices, executed from outside the protected area.
– During the software loading phases (for example after replacement of electronic
boards) use only the original software handed over by COMAU. Scrupulously
follow the system software loading procedure described in the specific product
Technical Documentation; after loading, to be sure, always run a test cycle,
remaining outside the protected area
– Disassembly of Robot components (e.g. motors, balancing cylinders, etc.) may
cause uncontrolled movements of the axes in any direction: before starting a
disassembly procedure, consult the warning plates applied on the Robot and the
Technical Documentation supplied.
– If present, always restore the protective covering where previously installed.

Decommissioning and Dismantling

– The decommissioning and removal of the Robot and Control System is exclusively
the task of Authorised Personnel.
– Move the Robot in transport position and assemble the axes locking brackets
(when required) following the instructions on the plate on the Robot and its
Technical Documents.
– Before decommissioning initiation, the mains voltage at the Control Unit inlet must
be powered off (switch off the circuit breaker on the power mains 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 power mains,
first disconnecting the power conductors, then the earth one. 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 ground cable.
– If present, disconnect the Robot pneumatic system from the air distribution mains.
– Check that the Robot is properly balanced and if necessary sling it correctly, then
remove the Robot securing bolts from the mount holder.
– Remove the Robot and Control Unit from the work area, following all the
requirements indicated in the products Technical Documents; if lifting is necessary,
check the eyebolts proper fixing and use only suitable slinging devices and
equipment.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU, 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 environment
safeguarding.

Disposal operations must be carried out in accordance with the legislation of the country
where the Robot System is installed; dispose the batteries, oils and other chemical
liquids respecting the environment and in accordance with the legislative standarts in ,
transfering them to the appropriate waste collection sites.

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GENERAL SAFETY REQUIREMENTS

– 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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WINAPPLCREATOR TOOL - WAC

2. WINAPPLCREATOR TOOL - WAC

2.1 Introduction
The WinApplCreator tool known as WAC, is used to create an installation file for
applications on C5GPlus Control Unit, using the Hardware configuration requested by
the Customer.
Note that, anyway, this application can be used on C5G Control Unit too.
The goal of this manual is to describe the tool functionalities and all modalities to
properly configure it.
Due to the C5GPlus Control Unit applications structures, the tool is able to
self-configure according to the applications requirements.

NOTE - A configuration installation is always subject to the actual enabling of the

software options required by such a configuration.

2.2 How it works

The tool creates a suitably named version file:
Smart<ApplName>xxxxx.wac5g
where Smart<ApplName> is the name of the being imported application and xxxxx is
the application version number.
Inside the .wac5g file an xml type file is available that “builds” the interface composed
of different hardware and software items the user can select.

2.3 File types

The files types involved in WAC tool usage, are as follows:
– .wac5g - it is the compressed file of WAC application, delivered by Comau: a file
of such a type is available for each application package and each version. It is to
be used to perform the IMPORT version procedure (see par. 5.3.2 Auto save after
generation on page 30)
– .w5c - it is a file including a previously saved configuration.
– .cf5 - it is the configuration file that will be loaded into the Control Unit. It can be
used to read the already existing configuration on a Control Unit and clone it to
create an updated one or copy it to a different Control Unit. WAC can read this file
type and display the contained configuration, online too.
– .zip - it is the configuration file created by WAC tool (see par. 6.3 Generating and
saving the configuration on page 35). It includes the chosen hardware
configuration files; more specifically file .cf5.

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INSTALLATION

3. INSTALLATION

3.1 System requirements

The WAC software package can be installed on a Personal Computer and works
properly in Windows environment, either 32 or 64 bit.
It can be run on Microsoft® Windows®, XP version and subsequent ones.

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INSTALLATION

3.2 Software installation

The installation software is provided by COMAU.
The user is guided by the described below installation wizard.

Note that a profile with administrator priviledges is required to install the WAC tool.

a. Run the installation program

b. Choose the wished language to be used during the installation

c. Choose the wished installation folder

d. Choose the wished Start menu folder, for the program shortcut

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INSTALLATION

e. Click Install key to actually start the installation

f. A progress bar shows the installation development; when finished, the installation
wizard displays a page with a suitable message of installation completed.

CAUTION
The PC could automatically restart at the end of the Visual C++ libraries loading.

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INSTALLATION

g. Click Finish key to exit from the installation procedure. The WAC tool can be run
by using the corresponding icon (figure below) made available on the Desktop.

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ACTIVATION

4. ACTIVATION

4.1 Introduction
The tool interface is shown in the figure below:

The following topics are described in current chapter:

– First launch
– Operating directory
– Folders created by WAC.

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ACTIVATION

4.2 First launch

The first time WAC is launched, it is empty.
Before starting to import a version and create the corresponding installation package, it
is needed to properly configure the WAC tool in order to customize it, according to the
user’s wishes.
In next Chap.5. - Commands on page 27, all Setup menu options are described.

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ACTIVATION

4.3 Operating directory

The Operating Directory (Home), by default is set to the same directory which includes
the executable file.
It is anyway allowed to modify such a setting by means of the corresponding menu
(par. 5.3 Setup on page 30), shown in the figure below.

NOTE
WAC program must be allowed to write the HOME directory, even with no administrator
priviledges. Therefore the user must choose the proper position for such a folder. Refer
to the example below.

Example
Create a new folder (e.g. called “WAC”) on the Desktop.
Issue the Setup-Home command (figure above) to set the new folder as the Home
directory (figure below).
The WAC tool is definitely allowed to write such a folder.

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ACTIVATION

4.4 Folders created by WAC

While importing *.wac5g files and generating *.zip installation file, the Tool uses the
HOME directory (selected in par. 4.3 Operating directory on page 25) to automatically
create the following folders:
– .\<Home>\Config including .w5c files of the created configurations, provided that
the corresponding option is active (see par. 5.3.2 Auto save after generation on
page 30)
– .\<Home>\Versions including .wac5c files of the imported configurations
– .\<Home>\Working operating folder used by the Tool to create the installation
package.

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COMMANDS

5. COMMANDS

5.1 Introduction
Current chapter describes WAC tool commands provided to the User.
More in detail, the following topics are dealt with:
– File
– Setup
– Help.

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COMMANDS

5.2 File

– New
– Open
– Import version
– Delete current version
– SaveAs
– Close.

5.2.1 New
This command allows the user to delete all the currently made selections and go back
to the starting scenario (i.e. no selections).

5.2.2 Open
This command allows the user to open .w5c and .cf5 file types containing user
configurations (as described in par. 2.3 File types on page 18)

5.2.3 Import version

This command allows to import a new or already existing Application, to the WAC tool
structure. The displayed page allows selecting .wac5g files only.

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COMMANDS

Fig. 5.1 - Successfully imported

If the import operation is successful, the tool inserts the application name and the
version number into the top leftmost comboboxes (Fig. 5.1, highlighted in red) and
issues a message in the bottom panel (Fig. 5.1, highlighted in green). In such an
Information and Warnings panel, import errors are displayed, if any.

5.2.4 Delete current version

This command allows deleting an already existing Application version, in the WAC tool
structure. The user is asked for confirmation before deleting, in the displayed page.
If confirmed, WAC cancels the current version, as well as the associated data, from
.\<Home>\Versions folder.

5.2.5 SaveAs
This command allows saving the currently selected hardware configuration, to a .w5c
file.

5.2.6 Close
This command closes the application. In order to help the user and save the previous
customization for later usages, the following user’s choices are saved before closing, to
%AppData%\Roaming\WAC\ini.dat file:
– Home Directory
– Open Directory
– Import Directory
– Save Directory
– Auto save after generation setup option.

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COMMANDS

5.3 Setup

Fig. 5.2 - Setup menu

– Home
– Auto save after generation
– Stop at error.

5.3.1 Home
Home command sets the Home Directory, i.e. the Operating Directory, as already
described in par. 4.3 Operating directory on page 25.

5.3.2 Auto save after generation

This command allows the user to automatically save *.w5g configuration file for each
generation.
The name of the self-generated file is composed in the following way:

<appname><version><user_defined_name>.w5g

5.3.3 Stop at error

This command allows to stop the generation phase if an error occurs.
This is especially useful to developers, in case of errors, to check the files situation in
.\<Home>\Working directory.
The generation phase continues upon pressing the ok button on the error message.

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COMMANDS

5.4 Help

Fig. 5.3 - Help menu

– About.

5.4.1 About
This command displays additional information about the WAC tool.

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USAGE

6. USAGE

6.1 Introduction
This chapter describes how to use the WAC tool: objects selecting modalities to put
together the wished hardware/software configuration, and application final generation.
The main steps to create the wished application installation file, are as follows:

a. Selecting objects

b. Generating and saving the configuration.

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USAGE

6.2 Selecting objects

To be able to activate the Generate button (figure above), the user must select the listed
objects, as shown in Fig. 6.1.
For each selected object, all the compatible choices are highlighted in green, the
incompatible ones are in red, instead.
In case an incompatible selection has been made, WAC disables the Generate button
and highlights the error/errors by means of red borders, as shown in Fig. 6.2.
Further information about the selected object can be displayed (Fig. 6.3), by clicking the
mouse right button.
The viewable information is:
– Fullname - is a wider description about the selected object
– <filename>.pdf - is the link to a help file (related to such a version) which provides
detailed information about the specific object.

Fig. 6.1 - Example of good selection

Fig. 6.2 - Example of incompatible selection

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USAGE

Fig. 6.3 - Further information about the selected object

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USAGE

6.3 Generating and saving the configuration

When all the needed selections have been performed and no red background objects
are displayed, the configuration generation (meaning creating the .zip installation file)
can take place, by pressing the Generate button.
If Auto save after generation flag is selected, the generated configuration is also saved
to the PC.

NOTE - A configuration installation is always subject to the actual enabling of the

software options required by such a configuration.

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USAGE

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