NJ4 170 – 2.9
NJ4 220 – 2.4
NJ4 220 – 2.7
Rel. 1.0 / Rel. 2.0
Maintenance
CR00757650_en-04/2019.11
Instruction Handbook
The contents of this handbook are the property of COMAU S.p.A.
Any reproduction, even partial, is prohibited without prior written authorization from COMAU S.p.A.
COMAU reserves the right to modify, without notice, the features of the product presented in this handbook.
Copyright © 2019 by COMAU - Date of publication 11/2019
Comau Robotics Product Instruction
SUMMARY
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Documentation storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Limits on the handbook contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Symbols used in the handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Modification History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.
GENERAL SAFETY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Essential safety requirements applied and fulfilled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Aspects of particular attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.
HOW TO DISCONNECT THE ELECTRICAL POWER SUPPLY OF C5G CONTROL
UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...20
Precautions and risks associated to the electrical power supply disconnection . . . . . . . . . . . . 20
Disconnection of the electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.
HOW TO DISCONNECT THE ELECTRICAL POWER SUPPLY ON C5G PLUS
CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25
Precautions and risks associated to the electrical power supply disconnection . . . . . . . . . . . . 25
Disconnection of the electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...28
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Robot cleaning and general inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Precautions regarding the use of Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Robot lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Floor-mounted Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Oil change in axis 1 gearbox with Robot mounted on floor . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil change in axes 2 - 3 gearbox with Robot mounted on floor . . . . . . . . . . . . . . . . . . . . . . . 47
Inverted mounted Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3
Comau Robotics Product Instruction
SUMMARY
Oil change in axis 1 gearbox with Robot mounted inverted . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Oil change in axes 2 - 3 gearbox with Robot mounted inverted. . . . . . . . . . . . . . . . . . . . . . . 56
Oil change in axis 4 gear case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Oil change in axis 4 gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Oil change in axes 5 - 6 gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Axes 5 - 6 wrist gears compartment greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.
SPECIAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..66
Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Assembly notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Parts disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Use of the integrated brake releasing module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
AXIS 1 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
ROBOT:
SMART5 NJ4 170 – 2.9;
SMART5 NJ4 220 – 2.4;
SMART5 NJ4 220 – 2.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Floor mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Robot inverted mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
AXIS 2 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROBOT:
SMART5 NJ4 170 – 2.9; SMART-5 NJ4 220 – 2.4;
SMART5 NJ4 220 – 2.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Robot floor mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Robot inverted mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
81
81
83
AXIS 3 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ROBOT:
SMART5 NJ4 170 – 2.9; SMART5 NJ4 220 – 2.4;
SMART5 NJ4 220 – 2.7; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
AXIS 4 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
AXIS 5 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
AXIS 6 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
WRIST UNIT: complete replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
HANDLING dressing on robot NJ4 170-2.5 / NJ4 170-2.9 / NJ4 175-2.2 / NJ4 220-2.4 / NJ4
220-2.7:
Wiring installation/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Applicative dressings for SPOT WELDING on Robot NJ4 170-2.9 / NJ4 220-2.4 / 220-2.7:
Wiring installation/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Double Multibus dressing application: installation/replacement. . . . . . . . . . . . . . . . . . . . . . . . 131
ALU dressing on Robot NJ 220-2.7.
Wiring installation/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4
Comau Robotics Product Instruction
SUMMARY
6.
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...168
Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Axis 1 Workspace Partialization Unit: assembly (1 area Part No. 82343300 - 2 areas Part No.
82343200- 3 areas Part No. CR82342200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Axis 2 Work Area Partialization Unit: assembly
(Part No. CR82342300; Part No. CR82344900) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Axis 1 Adjustable Mechanical Hard Stop Unit: assembly
(Part No. CR82342400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Axis 2 Adjustable Mechanical Hard Stop Unit: assembly (Part No. CR82344800) . . . . . . . . . 185
Axis 1 On-Off Mechanical Hard Stop Unit (Part No. CR 82344300): assembly. . . . . . . . . . . . 187
Screws and Pins Assembly for Robot Fixing (Part No. CR82342700) . . . . . . . . . . . . . . . . . . 195
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Levelling Plate Assembly for Robot Fixing (Part No. CR82342800) . . . . . . . . . . . . . . . . . . . . 196
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Non-levelling plate assembly for Robot fixing (Part No. CR82343100) . . . . . . . . . . . . . . . . . . 198
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Fall-prevention Bracket Unit for Fixing on Ceiling: assembly (Part No. CR82348800) . . . . . . 199
NJ Fixing on Ceiling and Fall-prevention Unit - BRIC: assembly (Part No. CR82344700) . . . 202
Fork unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Calibration Tool (Part No. 82314100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Calibrated Tool Unit - Tool Master
(L= 200 Part No. 82109501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Distribution panel connections walkable protection unit
(Part No. CR 82352200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
7.
TURN-SET AND CALIBRATION BASIC CONCEPTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...213
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Turn-set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn-set on system calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn-set on user calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn-set for Robot axes with multi-turn stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
215
215
215
215
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
System calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
User calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
8.
TURN-SET AND CALIBRATION - OPERATING PROCEDURES . . . . . . . . . . . . . ...218
5
Comau Robotics Product Instruction
SUMMARY
General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Identification of Robot calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Turn-set procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
System calibration using tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements for axes positioning control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary operations and ordinary operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axes calibration procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
222
222
222
223
224
User calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
9.
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..238
10.
SETTING OUT OF WORK AND DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . ..253
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Personnel in charge of decommissioning and dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Decommissioning and dismantling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Disposal of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
6
Comau Robotics Product Instruction
PREFACE
PREFACE
This chapter contains:
–
Reference documentation
–
Documentation storage
–
Limits on the handbook contents
–
Symbols used in the handbook
–
Modification History
7
Comau Robotics Product Instruction
PREFACE
Reference documentation
For further technical information relating to the Robot maintenance and use, refer to the
specific SMART5 NJ4 base Robot handbooks listed in the following table
Comau
Robot
Set of Handbooks
Comau
SMART5 NJ4
–
–
Technical Specifications
Transport and installation
Comau
SMART5 NJ4 170 – 2.5
SMART5 NJ4 175 – 2.2
–
–
Maintenance
Electrical circuit diagram
Comau
SMART5 NJ4 170 – 2.9
SMART5 NJ4 220 – 2.4
SMART5 NJ4 220 – 2.7
–
–
Maintenance
Electrical circuit diagram
Comau
SMART5 NJ4 220 – 3.0
SMART5 NJ4 270 – 2.7
–
–
Maintenance
Electrical circuit diagram
These handbooks must be integrated with the following documents:
Comau
C5G Control Unit
–
–
–
–
–
Technical Specifications
Transport and installation
Maintenance
Use of Control Unit.
Electrical circuit diagram
Programming
–
–
–
–
EZ PDL2 Easy programming
environment
PDL2 Programming Language Manual
Motion programming
VP2 Visual PDL2
–
Stopping time
Modes and stopping
distance of the
Robot
8
Comau Robotics Product Instruction
PREFACE
Documentation storage
All the provided documents must be placed in close proximity to the area where the
Robotic System is installed, maintained available for all people that work on it and
preserved intact for the entire operational life of the Robotic System.
Limits on the handbook contents
The images included in the instructions handbook have the purpose to represent the
product
and can differ from what is actually visible on the Robotic System.
Some pictures inserted in the handbook, represent the Robot with the standard wrist,
but they are also valid for the other types of wrists available.
Symbols used in the handbook
Below are indicated the symbols that represent: WARNING, CAUTION and NOTES and
their meaning.
This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed may cause injuries to the personnel.
This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed may cause damage to the equipment.
This symbol indicates operating procedures, technical information and precautions that
must be underlined.
The symbol draws the attention to materials disposal that is regulated by the WEEE
Directive.
The symbol points out to avoid environmental contamination and to properly dismiss the
materials in the appropriate collection sites.
9
Comau Robotics Product Instruction
MODIFICATION HISTORY
Modification History
The following table shows the history of the Handbook release, with related changes /
improvements made.
Data
Edition of the
Handbook
2017-01
03/2017.01
Lubrication and calibration improvements.
2018-06
03/2018.06
Improvement of the handbook contents.
2018-12
03/2018.12
Insertion of alternative lubricants (see Chap. Preventive
maintenance).
2019-11
04/2019.11
–
Contents
–
–
10
Insertion of maintenance sheet:
•
Robot cleaning and general inspection (see Chap.
Preventive maintenance)
•
Axis 3 fulcrums lubrication and anti-tilt connecting rod
toggles (NJ4 220-3.0 - NJ4 270-2.7).
•
BALANCING SPRINGS ASSEMBLY: complete
replacement (NJ4 220-3.0 - NJ4 270-2.7).
•
Insertion of procedure for Spring guard assembly
mounting (Part No. CR82273500) - (NJ4 220-3.0 - NJ4
270-2.7).
Update of the procedure for the Oil change in axis 1 gearbox
(NJ4 220-3.0 - NJ4 270-2.7).
Insertion of additional information on the Foundations
preparation (see par. 7.3 on page 68).
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 importance, this chapter is referred to unconditionally in every instruction
handbook of the system.
This chapter contains the following topics:
–
Intended use
–
Improper use
–
Essential safety requirements applied and fulfilled
–
Operating modes
–
Aspects of particular attention
–
Responsibilities
1.1 Intended use
The Robot and the Control Unit (when present) represent a robotic system made in
compliance with EN ISO 10218-1. Its performance must be exploited in industrial or
comparable areas, subject to current regulations, also complementary to the
aforementioned standard.
Installation, use, maintenance and disposal of the robotic system must be carried out by
authorized and trained personnel.
1.2 Improper use
The robotic system or its parts must not be used in environments that do not comply with
the technical specifications indicated in the relative handbooks. The use in
non-compliant environments, different from those required, uses beyond the expected
performances can create risks both for people and for the Robot system or its parts.
A non-careful integration according to the laws and regulations in force can also incur
the integrator to legal and criminal complications.
1.3 Essential safety requirements applied and fulfilled
The robotic system composed of Control Unit and SMART5 Robot series considers as
applied and fulfilled the following Safety Fundamental Requirements, Annex I of
Machinery Directive 2006/42/EC: 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.
11
Comau Robotics Product Instruction
GENERAL SAFETY REQUIREMENTS
1.4 Operating modes
Installation and Start-up
12
–
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.
–
For Robots with no collaborative functionality:
•
the system installation and startup is only allowed exclusively inside a
Protected Zone 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 Zone ( e.g structural columns, power
supply lines, etc.) or with the barriers. If necessary, limit the Robot workspace
by means of mechanical stop buffers (see optional units);
•
any fixed Robot control protections are to be located outside the Protected
Zone and in a point where there is a full view of the Robot movements;
•
install the Control Unit outside the Protected Zone: the Control Unit should not
be used as part of the fence.
–
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 must be handled as described
in the relative Instruction Handbooks; if lifting is necessary, check that the eyebolts
are fixed correctly and use only adequate slings and equipment.
–
Fix the Robot to mount holder, with all the provided bolts and pins, tightened to the
tightening torques given in the related Instruction Handbooks.
–
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.
–
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.
–
The connection between the Control Unit and the power supply mains of the plant,
must be made through a cable of dimensions suitable for the power installed on the
Control Unit (for details refer to chapter “Power supply from the electric network:
features and connection” in the Control Unit Instruction Handbooks).
–
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 armor to the
ground.
–
Connect the signals and power cables between the Control Unit and the Robot.
Comau Robotics Product Instruction
GENERAL SAFETY REQUIREMENTS
–
Connect the Robot to the ground through the Control Unit or specific terminals,
according to the prearrangements present on Robot and/or Control Unit.
–
Where provided, check that the Control Unit door/s is/are closed with the
appropriate 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
push-buttons, 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, safety
fences etc.), i.e. the making 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
emergency stop push-buttons of the Control Unit available on the appropriate connector
(for details, refer to the electrical circuit diagrams and the specific Instruction Handbooks
according to the Unit Control model). 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 Robot emergency stop in AUTO/REMOTE mode is set in a controlled way
(IEC 60204-1, stop of category 1 or category 2*); it is also possible to set the stop
in category 0 by changing the related setting within the control logic of the Control
Unit safety aspects.
* the stop in category 2 is only possible for Robots with collaborative functionality
Setting the emergency stop in category 0 can result in mechanical damages to the tools
and loss of load if they are not properly designed.
–
When preparing protection barriers (when required), especially for light curtains
and access doors, take into consideration the Robot stopping times and distances
according to the stop category (according to IEC 60204-1) and the weight of the
Robot.
The stop circuit timer is normally set to 1.5 seconds. This parameter can be changed if
heavy-duty implements (e.g. rotary tables, positioners, etc.) are matched with the Robot.
The stop circuit timer can be modified by changing its setting within the control logic of
the Control Unit safety aspects. For further details, refer to the paragraph “Safety stop
circuit timer” in the Control Unit Instruction Handbooks.
–
Check that the environmental and operating conditions do not exceed the limits
specified in the specific Instruction Handbooks.
–
The calibration operations must be carried out with utmost attention, as indicated
in the Instruction Handbooks of the specific product, and must be concluded by
checking the correct position of the machine.
–
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 Instruction Handbooks supplied with
13
Comau Robotics Product Instruction
GENERAL SAFETY REQUIREMENTS
the specific product. After loading, always make some Robot motion tests at low
speed remaining outside the Robot action radius.
–
Check that the barriers of the Protected Zone (when present) are correctly
positioned.
Functioning in Programming mode
–
The Robot is only to be programmed by the authorised personnel.
–
Before proceeding with programming, the operator, remaining at the end of the
Protected Zone / Collaborative Zone, must:
•
make sure that all the necessary protective guards and safety devices are
present and in working conditions;
•
make sure that the Teach Pendant is functioning correctly (reduced speed,
enabling device, emergency stop device, etc.);
•
check the Robotic system (Robot and Control Unit) to make sure that there
are no potentially dangerous anomalous conditions and that no person is
present in the Protected Zone / Collaborative Zone.
–
As far as possible, the programming should be controlled from outside the
Protected Zone / Collaborative Zone.
–
During the programming phases, only the operator with the Teach Pendant is
allowed inside the Protected Zone / Collaborative Zone.
–
For Robots without collaborative functionality, if the presence of a second operator
is required in the workspace when checking the program, these people must have
their enabling device interlocked with the safety devices.
–
Activation of the motors (DRIVE ON) must always be controlled from a position
outside the Robot area of action, after having verified that there is nobody in the
area concerned. The Drive On operation is considered complete when the relevant
machine status indication is shown.
–
During programming the operator must remain at a distance from the Robot such
as to allow him to avoid any anomalous movements of the machine, and in any
case in a position to avoid possible risks of restraint between the Robot and parts
of the structure (columns, barrier, etc.), or between moving parts of the Robot itself,
including parts which, due to gravity, could perform movements downwards,
upwards or laterally (in the case of mounting on an inclined plane).
–
The test of a programmed cycle at working speed with the operator inside the
Protected Zone / Collaborative Zone, in some situations where a close visual check
is necessary, must be activated 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 execution of a new program or a varied sequence of instructions, make
sure that the movement of the Robot takes place along the intended path.
–
Check while remaining out of the Robot action area and test the cycle at low speed.
Functioning in Auto / Remote Mode
–
14
The activation of the automatic operation (AUTO and REMOTE statuses) is only
allowed with the Robotic system (Robot and Control Unit) integrated in a special
area with sufficient features to meet the needs of Protected Zone / Collaborative
Comau Robotics Product Instruction
GENERAL SAFETY REQUIREMENTS
Zone (depending on the Robot type) as prescribed by the Safety Regulations in
force in the country where the installation is carried out.
–
Before activating the automatic operation, the operator must check:
•
the Protected Zone / Collaborative Zone to ensure that there are no potentially
dangerous anomalous conditions;
•
that the Robot and Control System is not in a state of maintenance or repair
and that there are no potentially dangerous abnormal conditions;
•
that the protection barriers (when present) are correctly positioned;
•
that there is nobody inside the Protected Zone / Collaborative Zone;
•
that the Control Unit doors are closed and locked with the appropriate key;
•
that the safety devices are in working conditions;
–
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.
Functioning in Collaborative Mode
–
The Comau collaborative Robot requires an appropriate assessment of the risk of
the area in which it is integrated, combining the performances already available in
the AURA solution with additional safety devices.
The integrator is responsible for the correct integration of the AURA solution in the
complete cell/machine.
–
The integrator shall consider at least the following aspects:
•
tool connected to the Robot must be equipped with a sensorized skin
(comparable to the one already present on the Robot); this skin must be
connected to the existing electronics, as an additional node / sensor;
•
the impact force of the Robot against the person, proportional to the
movement speed of the Robot itself;
•
the Collaborative Zone, which must be sufficiently large, without edges or
structural parts that can block the operator without an escape route, possibly
trapped between the skin and a static structural element of the cell / machine;
•
the stopping distance and time of the Robot, which must include a reasonable
distance to avoid crushing (see details in “Robot Technical Specifications”
handbook, paragraph “Robot stop modes and space” and “Sensorized skin
on AURA Collaborative Robot” handbook, “paragraph Technical features”);
Robot axes brake release (where required)
–
The movement of the Robot axes is possible by means of suitable control devices
(integrated, where provided, on Robot base, or available as optional devices
-brake releasing module-) and adequate lifting means. Such devices only enable
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 forces generated by
the balancing system or by gravity.
Before using manual brake releasing devices, it is recommended to sling the Robot, or
hook it to an overhead traveling crane.
15
Comau Robotics Product Instruction
GENERAL SAFETY REQUIREMENTS
–
The brake releasing operation can generate crash risks caused by:
•
an incorrect reset after the brake release
•
resumption of movement after an interruption of an incomplete MOVE (whose
typical function of trajectory recovery can generate unpredictable paths);
•
subsequent resumption of the automatic cycle (similarly to what has been
described above, relating to the resumption of a not completed MOVE).
–
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.
–
The procedure for the correct use of the brake releasing devices (integrated on
Robot base and/or optional brake releasing module) is shown in the “Maintenance”
section of the Instruction Handbooks of the specific Robot.
Maintenance and Repair
–
The Robot (where required) 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 plenty of water; in case irritation persists, seek medical advice.
If swallowed, do not induce vomiting or administer anything by mouth; consult a
doctor as soon as possible.
–
Maintenance, troubleshooting and repair operations 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 replacement operations of the components or Control Unit must
be carried out (where provided and necessary) with the main switch in open
position and locked with a safety 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 (where provided and necessary).
–
Faulty components are to be replaced with others having the same Part No., or
equivalent components defined by COMAU.
Where required, the replaced safety components must be configured with the same
parameters as those removed.
–
16
Troubleshooting and maintenance activities:
•
must be performed, as far as possible, outside the Protected Zone /
Collaborative Zone;
•
on Control Units they must as far as possible be performed in the absence of
power;
•
on the Robot must be performed with power supply deactivated (DRIVE
OFF).
Comau Robotics Product Instruction
GENERAL SAFETY REQUIREMENTS
–
If necessary, during troubleshooting, intervene with the Control Unit powered; all
the precautions specified by Safety Standards must be observed when operating
in presence of dangerous voltages.
–
At the end of the maintenance and troubleshooting operations, all the deactivated
safety devices must be reset (panels, protection shields, interlocks, etc.).
–
The maintenance, repair and troubleshooting intervention must be completed by
verifying the correct operation of the Robotic system (Robot and Control Unit) and
all safety devices performed outside the Protected Zone / Collaborative Zone.
–
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 Instruction
Handbooks; after loading, always run a test cycle, remaining outside the Protected
Zone.
–
The disassembly of Robot components (e.g. motors, balancing cylinders, etc.) may
cause uncontrolled movements of the axes in different directions: before starting a
disassembly procedure, refer to the warning plates affixed on the Robot and to the
supplied Instruction Handbooks.
–
On Robots equipped with balancing springs, it is forbidden to remove the protection
cover of the springs.
–
Where fitted, always restore the protective casing if previously installed.
Decommissioning and Dismantling
–
The decommissioning and removal of the Robot and Control System is allowed
only to Authorized Personnel.
–
Move the Robot in transport position and mount the axes blocking brackets (when
required) referring to the plate affixed to the Robot and to the Instruction
Handbooks of the Robot itself.
–
Before proceeding with decommissioning it is mandatory, depending on the type of
Control Unit:
•
on the Control Unit with power cable wired directly to the terminals of the main
switch:
•
turn off the mains voltage at the Control Unit input, by disconnecting the
circuit breaker on the power mains and locking it in open position;
•
check with a suitable instrument that the terminals are disconnected;
•
disconnect the power supply cable from the circuit breaker on the power
mains, first disconnecting the power conductors and then the ground
conductor;
•
Disconnect the power supply cable from the Control Unit and remove it.
•
on Control Units equipped with a pre-assembled power cable, with a
“socket-plug” system:
•
disconnect the power supply cable.
–
First disconnect the connection cables between the Robot and the Control Unit,
then the earth cable.
–
If installed, disconnect the pneumatic system from the air supply and blow off the
residual air.
–
Check that the Robot is properly balanced and if necessary sling it correctly, then
remove the screws that fix the Robot to the supporting surface.
17
Comau Robotics Product Instruction
GENERAL SAFETY REQUIREMENTS
–
Remove the Robot and the Control Unit from the workspace, taking all the
requirements indicated in the products Instruction Handbooks; if lifting is
necessary, check the eyebolts proper fixing and use only suitable slings and
equipment.
The disposal operations must be carried out in compliance with the legislation in force
in the country where the Robotic system is installed; dispose of the batteries, oils and
other chemical liquids in an environmentally correct way and in accordance with the
regulations in force transferring them to specific waste collection centres.
–
18
Consign the Robot and the Control Unit to a centre responsible for the dismantling
and disposal.
Comau Robotics Product Instruction
GENERAL SAFETY REQUIREMENTS
1.5 Aspects of particular attention
The documentation of the robotic system required a subdivision of the contents into one
or more Instruction Handbooks. For this reason, the understanding of the functionalities
and the necessary attention to the requirements may require consultation of the entire
applicable documentation, always listed in the first pages of each handbook.
1.6 Responsibilities
The integrator is responsible for the correct integration of the robotic system or its parts
in accordance with the applicable legislation.
Comau is not responsible for any improper use of the robotic system or its parts.
19
Comau Robotics Product Instruction
HOW TO DISCONNECT THE ELECTRICAL POWER SUPPLY OF C5G CONTROL UNIT
2.
HOW TO DISCONNECT THE ELECTRICAL
POWER SUPPLY OF C5G CONTROL UNIT
This chapter contains the following topics:
–
Precautions and risks associated to the electrical power supply disconnection
–
Disconnection of the electrical power supply.
2.1 Precautions and risks associated to the electrical
power supply disconnection
–
After the Control Unit shutdown wait for at least 30 seconds before powering it
up again.
–
Before removing any connector wait for at least 30 seconds and make sure that
all the LED are turned off.
In case of non-compliance with these warnings it is possible to:
•
jamming one or more modules
•
jeopardizing one or more modules functionality.
–
In case of occurring blocking of one or more modules, shut down the system, wait
for at least 30 seconds and reconnect the power supply.
–
If installed, X120 connector shall not be used for the power supply
powering-off (C5G-MCK option).
–
To increase the battery life do not shut down the Control Unit before carrying out
the shutdown software procedure.
–
The shutdown software procedure ensures the files and applications closing
without requiring the using of the buffer battery.
Shutting down the Control Unit when the Robot is moving, forces the system and
consequently the Robot to immediately stop without deceleration ramps, with resulting
kinematic chain stress, trajectory direction deviation (unpredictable due to the force of
gravity) with consequent risks of impact. The constant repetition of this modality of
stopping can damage the Robotic System and/or the equipment connected to the
Robot.
Pay attention to the interconnected voltages, usually identified with orange coloured
conductors.
20
Comau Robotics Product Instruction
HOW TO DISCONNECT THE ELECTRICAL POWER SUPPLY OF C5G CONTROL UNIT
2.2 Disconnection of the electrical power supply
Status:
–
Before disconnecting the electrical
power supply, it is recommended to
disable the Robotic system by means
of shutdown software procedure.
Material:
–
Padlock (not supplied)
Europe: min. 4 mm / max 8 mm
(min. 0.15 in / max 0.31 in),
North America: external min. 5 mm /
max 8 mm (min. 0.20 in / max 0.31 in)
internal min. 1/4 in / max 0,31 in.
Equipment:
–
Not required
Preliminary procedures / notes
–
–
Most maintenance activities foreseen on the Control Unit are to be carried out
with the electrical power supply turned off. In those cases the maintenance sheet
bears the inscription “Main circuit breaker open (OFF)”.
Some activities, especially those related to cabinet main power supply
disconnecting, must be carried out only after having completely disconnected the
power supply of the electric mains. In these cases the maintenance sheet bears
the inscription “Electrical power supply turned off”.
The main circuit breaker located on the Control Unit disconnects the power
supply only of the Robot (or Robots) connected to it and occasionally of the
application.
–To verify the area or devices powered by a specific Control Unit it may be
necessary to refer also to the Instructions Handbook of the machine which
the Robotic System is integrated into.
21
Comau Robotics Product Instruction
HOW TO DISCONNECT THE ELECTRICAL POWER SUPPLY OF C5G CONTROL UNIT
Operating procedure
Main circuit breaker open (OFF)
Main circuit breaker on C5G Control Unit (Europe version)
Main circuit breaker on C5G Control Unit (North America version) - in case of
power supply disconnection for Robot maintenance purpose
A
A
Main circuit breaker on C5G Control Unit (North America version) - in case of
power supply disconnection for Control Unit maintenance purpose
A
22
A
a.
Carry out the software shutdown. Use the specific command on the Teach
Pendant.
b.
Wait for the ending of the shutdown procedure.
Comau Robotics Product Instruction
HOW TO DISCONNECT THE ELECTRICAL POWER SUPPLY OF C5G CONTROL UNIT
Operating procedure (Continued)
c.
In case of Robot or Europe Control Unit maintenance:
c.1 With cabinet door closed, set the Q100 main circuit breaker handle (A) in 0 (OFF)
position.
c.2 Move the lever (B) to access the slot.
c.3 Insert the padlock into the slot (C) available on the external handle.
d.
In case of North America Control Unit maintenance:
d.1 With cabinet door closed, set the Q100 main circuit breaker handle (A) in 0 (OFF)
position.
d.2 Open the cabinet door
d.3 Insert the padlock into the slot (D) available on the external handle.
e.
On completion of maintenance
f.
Remove the padlock only at the end of the maintenance activity.
g.
The padlock is not supplied together with the electrical cabinet.
With main circuit breaker open, the X120 connector (when present) and the
cable upstream the main circuit breaker are live.
23
Comau Robotics Product Instruction
HOW TO DISCONNECT THE ELECTRICAL POWER SUPPLY OF C5G CONTROL UNIT
Operating procedure (Continued)
Electrical power supply turned off
(if the optional connector X120 is not installed)
a.
Perform the power supply off-switching as specified in Main circuit breaker open
(OFF).
b.
Open and padlock the main circuit breaker upstream the Control Unit. The
padlock is not supplied together with the Control Unit.
Electrical power supply turned off
(if the optional X120 connector is installed)
If available, X120 connector shall not be removed with Q100 main circuit
breaker closed.
a.
Disconnect the electrical power supply as indicated in the previous steps.
b.
This activity requires the removal of X120 connector, located in the box lower
area.
c.
Release the levers (D).
d.
Remove the
connector
X120
mating
Follow-up procedure
–
–
24
Not necessary on C5G Control Unit (Europe Version)
On C5G Control Unit (North America Version), when closing the door at the end
of the maintenance:
•
do not damage the control and extension shaft
•
carefully close the doors, avoiding excessive pressures.
•
secure the door acting on the lock.
Comau Robotics Product Instruction
HOW TO DISCONNECT THE ELECTRICAL POWER SUPPLY ON C5G PLUS CONTROL UNIT
3.
HOW TO DISCONNECT THE ELECTRICAL
POWER SUPPLY ON C5G PLUS CONTROL
UNIT
This chapter contains the following topics:
–
Precautions and risks associated to the electrical power supply disconnection
–
Disconnection of the electrical power supply
3.1 Precautions and risks associated to the electrical
power supply disconnection
–
After the Control Unit shutdown wait for at least 30 seconds before powering it
up again.
–
Before removing a connector wait for at least 30 seconds.
In case of non-compliance with these warnings it is possible to:
•
blocking of one or more internal modules of the Control Unit
•
impairing the functioning of one or more internal modules of the Control Unit
–
In case of occurring blocking of one or more modules, shut down the system, wait
for at least 30 seconds and reconnect the power supply.
–
To increase the battery life do not shut down the Control Unit before carrying out
the shutdown software procedure.
–
The shutdown software procedure ensures the files and applications closing
without requiring the using of the buffer battery.
Shutting down the Control Unit when the Robot is moving, forces the system and
consequently the Robot to immediately stop without deceleration ramps, with resulting
kinematic chain stress, trajectory direction deviation (unpredictable due to the force of
gravity) with consequent risks of impact. The constant repetition of this modality of
stopping can damage the Robotic System and/or the equipment connected to the
Robot.
25
Comau Robotics Product Instruction
HOW TO DISCONNECT THE ELECTRICAL POWER SUPPLY ON C5G PLUS CONTROL UNIT
3.2 Disconnection of the electrical power supply
Status:
–
Before disconnecting the electrical
power supply, it is recommended to
disable the Robotic system by means
of shutdown software procedure.
Material:
–
Not necessary
Equipment:
–
Not required
Preliminary procedures / notes
–
–
26
Most maintenance activities foreseen on the Control Unit are to be carried out
with the electrical power supply turned off. In those cases the maintenance sheet
bears the inscription “Main circuit breaker open (OFF)”.
Some activities, especially those related to cabinet main power supply
disconnecting, must be carried out only after having completely disconnected the
power supply of the electric mains. In these cases the maintenance sheet bears
the inscription “Electrical power supply turned off”.
The main circuit breaker located on the Control Unit disconnects the power
supply only of the Robot connected to it and occasionally of the application.
–To verify the area or devices powered by a specific Control Unit it may be
necessary to refer also to the Instructions Handbook of the machine which
the Robotic System is integrated into.
Comau Robotics Product Instruction
HOW TO DISCONNECT THE ELECTRICAL POWER SUPPLY ON C5G PLUS CONTROL UNIT
Operating procedure
Main circuit breaker open (OFF)
a.
Carry
out
the
software
shutdown. Use the specific
command on the Teach
Pendant.
b.
Wait for the ending of the
shutdown procedure.
c.
Position the main circuit
breaker in 0 (OFF) position.
With the main circuit breaker open the cables upstream the main circuit
breaker are energized.
Electrical power supply turned off
a.
Disconnect the electrical power supply as indicated in the previous steps.
b.
Disconnect the electrical power supply of the Control Unit directly from the supply
mains.
For details regarding the disconnection procedures of the power supply
from the mains, consult the complete handbook of the machine inside
which the Control Unit is integrated.
Follow-up procedure
–
Not necessary.
27
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.
PREVENTIVE MAINTENANCE
This chapter contains:
–
Overview
–
Robot cleaning and general inspection
–
Precautions regarding the use of Lubricants
–
Robot lubrication
–
Floor-mounted Robot
–
Inverted mounted Robot
4.1 Overview
The Robot requires very little maintenance, however, to keep it operating efficiently over
time, certain lubrication and checking operations indicated in the paragraphs that follow
are to be carried out periodically.
Before starting any type of operation, carefully read Chap.1. - General Safety
Requirements on page 11.
Robot maintenance operations must be carried out with the system powered off: the
main switch MUST be in OFF position (closed).
It is recommended to carry out accurate and precise preventive maintenance operations
in order to retain over the long term the Robot functional features.
28
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.2 Robot cleaning and general inspection
Status:
–
Power supplies (electrical and
pneumatic) cut off
Material:
–
Material and detergents for cleaning
If necessary:
–
warning signs (see Tab. 4.1)
Equipment:
–
Fixing
components:
–
Ratchet torque wrench with bits and
extension rods
–
Set of bits and sockets for torque
wrench
–
Pliers with rubber inserts
If necessary:
–
material and equipment for removing
and fixing the warning signs
---
Representative figure
Preliminary procedures / notes
–
–
The frequency of intervention is 90 days but may vary depending on the
environment and the type of application.
The procedure is divided into the following steps:
•
Robot cleaning
•
Check of the structure integrity and warning signs
•
Check of Robot fixing
Operating procedure
Robot cleaning
a.
Clean the Robot parts.
Check of the structure integrity and warning signs
b.
Check the integrity and good conservation state of all the Robot parts.
c.
Check the presence and proper fixing of the warning signs. The warning signs
location is given in Fig. 4.1.
d.
Check the integrity and good conservation state of the warning signs.
e.
If the warning signs were no longer legible, replace them with signs having the
same features. The warning signs part numbers are listed in Tab. 4.1
29
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Operating procedure (Continued)
Check of Robot fixing
f.
Check the proper tightening and integrity of connectors.
g.
Check the proper tightening and integrity of wiring power supply pipes.
h.
Check the proper locking of brackets and supports of the wiring.
i.
Check, by means of appropriate visual reference notches, the proper tightening
of the screws that fix the Robot to the floor or to the supporting structure.
j.
Check, using suitable visual reference notches, the proper tightening of the
screws that fix the equipment on the Robot flange.
Follow-up procedures
–
30
Not necessary
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.1
12
- Warning signs location
11
5
3
5
2
10
4
8
7
1
9
6
Tab. 4.1 - List of warning signs
Ref.
Description
Comau Part No.
CR82349101 *¹ /
CR82349701 *²
1
Lifting/transport warning sign
2
Company logo plate Ø140
82312504
3
Monitory sign (Hot parts) - q.ty 6
81784803
4
Monitory sign (Shearing) - q.ty 2
82206516
5
COMAU sign H=36 - q.ty 2
6
Lubricants identification plate
82312406
7
MTR 1 - SYN 1 warning sign
81827318
8
MTR 2 - SYN 2 warning sign
81827309
9
MTR 3 - SYN 3 warning sign
81827315
10
MTR 4 - SYN 4 warning sign
81827304
11
MTR 5 - SYN 5 warning sign
81636711
12
MTR 6 - SYN 6 warning sign
81807117
CR82396201
*¹: valid for NJ4 170-2.9-I and NJ4 220-2.7-TC
*²: valid for NJ4 220-2.4
31
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.3 Precautions regarding the use of Lubricants
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.
In case of contact with eyes or skin: rinse the affected areas with plenty of water; if
irritation persists, consult a doctor.
If swallowed, do not induce vomiting or administer anything by mouth; seek medical
advice immediately.
For more information, read promptly the lubricant safety data sheet.
The lubrication operations must be carried out respecting the type of lubricant indicated
on the lubricants identification plate installed in a clearly visible position on the Robot
body. The indication of the type of lubricant is represented with an “X” (see Fig. 4.2).
Do not mix different lubricants.
–
If the lubricant of the first filling is not available, it is possible to use an alternative
lubricant, choosing among those listed in Tab. 4.2, Tab. 4.3 but it must be taken
into account that in this case it is necessary to discharge completely the exhausted
lubricant and clean carefully the kinematic chains. Failure to apply this
procedure could compromise the effectiveness of the lubrication.
–
When filling, keep in mind that the amount of lubricant greater than that indicated,
can cause leakage or, in extreme cases, damage the seal gaskets.
–
To speed up the oil draining and filling, unscrew the plugs of the air vent holes
present in the gearboxes.
Fig. 4.2
32
- Lubricants identification plate
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.4 Robot lubrication
The summarising table of the lubricating points on the Robot and the frequency of
operations are shown in:
–
Tab. 4.2 - SMART5 NJ4 170–2.9; Lubrication Interventions on page 35
–
Tab. 4.3 - SMART5 NJ4 220–2.4; SMART5 NJ4 220–2.7 Lubrication Interventions
on page 38
The location of points on the robot for lubricants filling and draining is shown in the
figures:
–
Fig. 4.4 - SMART5 NJ4 170–2.9; Lubrication points with Robot mounted on floor
on page 36
–
Fig. 4.5 - SMART5 NJ4 170–2.9; Lubrication points with Robot mounted inverted
on page 37
–
Fig. 4.6 - SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7 Lubrication points with
Robot mounted on floor on page 39
–
Fig. 4.7 - SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7 Lubrication points with
Robot mounted inverted on page 40
The Robot can be fixed to the ground or on ceiling, and consequently, the function of the
plugs for lubricant filling/draining differs according to the mounting position as specified
in the following figures:
–
Fig. 4.8 - SMART5 NJ4 170–2.9; SMART5 NJ4 220–2.4; SMART5 NJ4 220-2.7
Floor mounting Location of lubricants filling and draining points for axes 1-2-3-4 on
Robot on page 41
–
Fig. 4.9 - SMART5 NJ4 170–2.9; Floor mounting Location of lubricants filling and
draining points for axes 5-6 on Robot on page 43
–
Fig. 4.10 - SMART5 NJ4 220–2.4; SMART5 NJ4 220–2.7 Floor mounting Location
of lubricants draining and filling points for axes 5-6 on Robot on page 44
–
Fig. 4.14 - SMART5 NJ4 220–2.4; SMART5 NJ4 220–2.7 Inverted mounting Location of lubricants filling and draining points on Robot on page 49
For lubrication of axes 4-5-6 gearboxes it is necessary to use a simple equipment
described in Fig. 4.3 that allows to drain and fill the oil easily.
33
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.3
34
- Required equipment for gearboxes lubrication
axes 4-5-6
–
Plastic pipe (1) for oil draining (∅ ext =12 mm; ∅ int = 8 mm)
–
Fitting (2) 1/8”(∅ est = 9,5 mm) for plastic tube
–
100 cc syringe for oil filling in axis 4 gearboxes
–
120 cc syringe for oil filling in axis 5-6 gearboxes
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Tab. 4.2 - SMART5 NJ4 170–2.9; Lubrication Interventions
Ref.
Lubrication points
Quantity
for 1st
filling
Quantity for
2nd filling
1
Axis 1 gearbox
4.9 kg
5.4 l
3.42 kg
3.8 l
2
Axis 2 gearbox
2.92 kg
3.2 l
2.42 kg
2.64 l
3
Axis 3 gearbox
1.98 kg
2.2 l
1.53 kg
1.7 l
4
Axis 4 gearbox
0.27 kg
0.30 l
0.24 kg
0.27 l
5
Axis 5 gearbox
0.068 kg
0.075 l
0.045 kg
0.05 l
6
Axis 6 gearbox
0.068 kg
0.075 l
0.045 kg
0.05 l
7
Axis 4 gears
3.42 kg
3.8 l
2.79 kg
3.1 l
8
Axis 5 wrist gears
compartment
0.6 kg
see
Chap.4.10 on
page 64, step
d.
9
Axis 6 wrist gears
compartment
0.1 kg
see
Chap.4.10 on
page 64, step
d.
Type of lubricant
(first filling)
Interval
hours
OIL - CASTROL OPTIGEAR
150
OIL - CASTROL OPTIGEAR
SYNTETIC X150
15000
OIL - PETRONAS GEAR MEP
320 *¹
GREASE - SHELL GADUS S3
V100 2 *²
Alternative lubricants
*¹
KLUBEROIL GEM 1-320 N
FUCHS Renolin CLP 320
TOTAL Carter EP 320
SHELL Omala 320
MOBIL Mobilgear 600 XP 320
TEXACO Meropa 320
*²
FUCHS Renolit LX EP2
ESSO Unirex N2
TEXACO Starplex EP2
MOBIL Mobilgrease XHP222
Pay attention to the Precautions
regarding the use of Lubricants
(see par. 4.3 on page 32).
The quantity of lubricant indicated for the first filling refers to a filling carried out after a
new unit has been assembled.
The quantity indicated for the second filling refers to the topping up of lubricant drained
from the unit, considering the indicative time to drain off between 10 and 15 minutes.
The time required to drain off the lubricant depends on its viscosity and the temperature
of the environment where the operation takes place.
35
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.4
- SMART5 NJ4 170–2.9; Lubrication points with Robot mounted
on floor
7
9
4
š
š
š
7
7
2
3
š
2
1
š
š
8
5
1
6
š
symbols used in the figure:
Oil filling plug
Oil drain plug
36
š
3
š
8
š
9
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
- SMART5 NJ4 170–2.9; Lubrication points with Robot mounted
inverted
1
2
š
š
1š
5
8
9
š
6
š
7
š
4š
8
9
š
7
7
3
š
2
3
š
Fig. 4.5
symbols used in the figure:
Oil filling plug
Oil drain plug
37
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Tab. 4.3 - SMART5 NJ4 220–2.4; SMART5 NJ4 220–2.7 Lubrication
Interventions
Ref.
Lubrication points
Quantity
for 1st
filling
Quantity for
2nd filling
1
Axis 1 gearbox
4.9 kg
5.4 l
3.42 kg
3.8 l
2
Axis 2 gearbox
2.92 kg
3.2 l
2.42 kg
2.64 l
3
Axis 3 gearbox
1.98kg
2.2 l
1.53 kg
1.7 l
4
Axis 4 gearbox
0.27 kg
0.30l
0.24 kg
0.27 l
5
Axis 5 gearbox
0.153 kg
0.17 l
0.110 kg
0.12 l
6
Axis 6 gearbox
0.153 kg
0.17 l
0.110 kg
0.12 l
7
Axis 4 gears
3.42 kg
3.8 l
2.79 kg
3.1 l
8
Axis 5 wrist gears
compartment
2.5 kg
see
Chap.4.10 on
page 64,
step d.
0.5 kg
see
Chap.4.10 on
page 64,
step d.
9
Axis 6 wrist gears
compartment
Type of lubricant
(first filling)
Interval
hours
OIL - CASTROL OPTIGEAR
150
15000
OIL - PETRONAS GEAR MEP
320 *¹
GREASE - SHELL GADUS S3
V100 2 *²
Alternative lubricants
*¹
KLUBEROIL GEM 1-320 N
FUCHS Renolin CLP 320
TOTAL Carter EP 320
SHELL Omala 320
MOBIL Mobilgear 600 XP 320
TEXACO Meropa 320
*²
FUCHS Renolit LX EP2
ESSO Unirex N2
TEXACO Starplex EP2
MOBIL Mobilgrease XHP222
Pay attention to the Precautions
regarding the use of Lubricants
(see par. 4.3 on page 32).
.
The quantity of lubricant indicated for the first filling refers to a filling carried out after the
assembly of a new unit.
The quantity indicated for the second filling refers to the topping up of lubricant drained
from the unit, considering the indicative time to drain off between 10 and 15 minutes.
The time required to drain off the lubricant depends on its viscosity and the temperature
of the environment where the operation takes place.
38
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.6
9
9
8
- SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7
Lubrication points with Robot mounted on floor
7
8
7
o
š
o4
2
3o
2
1
5
š6
3
o
o
1
symbols used in the figure:
Oil filling plug
Oil drain plug
39
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
- SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7
Lubrication points with Robot mounted inverted
1
3
1
o
7
8
6
9
š
o
4
š
5
symbols used in the figure:
Oil filling plug
Oil drain plug
40
o
8
9
7
3
o
2
2
o
Fig. 4.7
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.5 Floor-mounted Robot
Fig. 4.8
- SMART5 NJ4 170–2.9;
SMART5 NJ4 220–2.4;
SMART5 NJ4 220-2.7
Floor mounting
Location of lubricants filling and draining points for axes
1-2-3-4 on Robot
Ref.1 - Axis 1 gearbox filling
Ref.1 - Axis 1 gearbox draining
Ref.2 - Axis 2 gearbox filling (A) - draining (B)
Ref.3 - Axis 3 gearbox filling (A) - draining (B)
41
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.8
42
- SMART5 NJ4 170–2.9;
SMART5 NJ4 220–2.4;
SMART5 NJ4 220-2.7
Floor mounting
Location of lubricants filling and draining points for axes
1-2-3-4 on Robot (Continued)
Ref.4 - Oil filling for axis 4 gears compartment
Ref.4 - Oil drain for gears compartment axis 4
Ref.5 - Oil filling for axis 4 gearbox
Ref.5 - Oil draining for axis 4 gearbox
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.9
- SMART5 NJ4 170–2.9;
Floor mounting
Location of lubricants filling and draining points for axes 5-6
on Robot
Ref.5 - Oil filling - draining for axis 5 gearbox
Ref.6 - Oil draining - filling for axis 6 gearbox
Ref. 8 - Lubricant point for axis 5 gears compartment
Ref. 8 - Vent plug for axis 5 gears compartment
Ref. 9 - Lubricant point for axis 6 gears compartment
Ref. 9 - Vent plug for axis 6 gears compartment
43
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.10 - SMART5 NJ4 220–2.4; SMART5 NJ4 220–2.7 Floor mounting
Location of lubricants draining and filling points for axes 5-6
on Robot
44
Ref.5 - Oil filling - draining for axis 5 gearbox
Ref.6 - Oil draining - filling for axis 6 gearbox
Ref. 8 - Plug for axis 5 gears greasing
Ref. 8 - Vent plug for axis 5 gears compartment
Ref. 9 - Plug for axis 6 gears greasing
Ref. 9 - Vent plug for axis 6 gears compartment
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.5.1
Oil change in axis 1 gearbox with Robot mounted on floor
k.
Place a container under the oil drain plug, then apply a plastic protection on the
base as shown in figure Fig. 4.11 - Oil change in axis 1 gearbox on page 45 to
channel the oil into the underlying container.
Loosen the oil filling plug with an 27 mm open-end wrench to vent the compressed air
that may be present in the gearbox and to prevent the oil from coming out with high
pressure when removing the drain plug.
l.
Unscrew the oil drain plug (B) using a 10 mm Socket hex head wrench and drain
the oil.
To speed up the oil draining it is possible to unscrew the filling plug (A) and vent low
pressure air (0.5 bar max) in the gearbox (see Fig. 4.11 phase Oil draining)
m.
Completed the oil draining, close the drain plug and fill the slew gear compartment
with the required oil (see Tab. 4.3).
n.
Check the sealing gasket and apply the sealant on the plug thread (see Tab. 5.3
- Products for sealing and fixing on page 68).
o.
Screw with a 27 mm open-end wrench the plug in the oil filling hole (see Fig. 4.11
phase Oil filling).
Fig. 4.11 - Oil change in axis 1 gearbox
Oil draining
45
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.11 - Oil change in axis 1 gearbox (Continued)
Oil filling
46
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.5.2
Oil change in axes 2 - 3 gearbox with Robot mounted on
floor
Pay attention to reposition the filling plugs with vent valve and the drain plugs in the
correct foreseen mounting position.
Before starting the lubrication operations, carry out a general cleaning of the parts
surrounding the lubrication point, in order not to allow the possible insertion of dirt and/or
impurities inside the machine body.
a.
Use adhesive tape to retain the motor cables on one side, to avoid smearing them
with oil during the draining.
b.
Position a container under the drain plug (B), then unscrew the plug.
c.
Unscrew and remove the oil filling plug (A) of the axis 2 and the oil filling plug with
vent valve (A) of the axis 3.
d.
Completed the oil draining, thoroughly clean the drain hole and plug (B) from any
ferrous residues.
e.
Install a new gasket on the drain plug (B) and screw it applying the sealant Loctite
572 on the thread (see Tab. 5.3 - Products for sealing and fixing on page 68).
Tighten the drain plug (B) of the axis 2 up to 70 Nm and the drain plug (B) of the
axis 3 up to 60 Nm.
f.
Position a funnel with flexible extension with cutting (for air vent) in the filling hole
(A) and insert the required lubricant.
g.
Install a new gasket on the filling plug (A) of the axis 2 and loosely tighten it
applying the sealant Loctite 572 on the thread (see Tab. 5.3 - Products for sealing
and fixing on page 68).
h.
Install a new gasket on the filling plug (A) and on the vent valve of the filling plug
(A) of the axis 3 and loosely tighten it applying the sealant Loctite 572 on the thread
(see Tab. 5.3 - Products for sealing and fixing on page 68).
i.
Keeping the orientation of the vent valve upright, as shown in Fig. 4.13:
•
tighten the filling plug (A) of the axis 2 up to 60 Nm.
•
tighten the filling plug (A) of the axis 3 up to 60 Nm and the vent valve of the
filling plug up to 10 Nm.
47
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.12 - Oil change in axes 2 - 3 gearboxes
Axis 2 oil draining/filling
Necessary equipment:
container for oil draining;
funnel and tube for oil filling;
open-end wrenches set;
torque wrench with bits for open-end wrenches.
Axis 3 oil draining/filling
Necessary equipment:
container for oil draining;
funnel and tube for oil filling;
open-end wrenches set;
torque wrench with bits for open-end wrenches.
Fig. 4.13 - Vent valve orientation
48
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.6 Inverted mounted Robot
Fig. 4.14 - SMART5 NJ4 220–2.4; SMART5 NJ4 220–2.7 Inverted
mounting - Location of lubricants filling and draining points
on Robot
Ref.1 - Axis 1 gearbox filling
Ref.1 - Axis 1 gearbox draining
Ref.2 - Axis 2 gearbox filling (A) - draining (B)
Ref.3 - Axis 3 gearbox filling (A) - draining (B)
Ref.4 - Oil filling axis 4 gears compartment
Ref.4 - Oil draining axis 4 gears compartment
49
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.14 - SMART5 NJ4 220–2.4; SMART5 NJ4 220–2.7 Inverted
mounting - Location of lubricants filling and draining points
on Robot (Continued)
50
Ref.4 - Axis 4 gearbox oil filling
Ref.4 - Axis 4 gearbox oil draining
Ref.7 - Oil filling - draining for axis 5 gearbox
Ref.8 - Oil filling - draining for axis 6 gearbox
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.14 - SMART5 NJ4 220–2.4; SMART5 NJ4 220–2.7 Inverted
mounting - Location of lubricants filling and draining points
on Robot (Continued)
Ref. 8 - Lubricant point for axis 5 gears compartment
Ref. 8 - Vent hole for axis 5 gears compartment
Ref. 9 - Lubricant point for axis 6 gears compartment
Ref. 9 - Vent hole for axis 6 gears compartment
51
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.6.1
Oil change in axis 1 gearbox with Robot mounted inverted
For the oil change in the axis 1 gearbox with the Robot mounted inverted you will need
the equipment specified in Fig. 4.15.
Fig. 4.15 - Equipment for oil change in the axis 1 gearbox
on ceiling
52
1.
Fitting 3/4 “
2.
venturi meter device (6 bar)
3.
Pneumatic fitting 1/8 gas
4.
Plastic pipe for fitting with venturi meter device
5.
Male fitting 1/8 gas
6.
Plastic pipe (∅ est =12 mm; ∅ int = 8 mm)
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Oil Draining
a.
Get a suitable container to
collect the discharged oil from
the gearbox and apply a
protection for the motor as
shown in the figure to protect it
from oil.
b.
Loosen the oil filling plug (A) to
vent the compressed air that
may be present in the gearbox
and to avoid the oil coming out
with high pressure when the
drain plug is removed.
c.
Unscrew the oil drain plug (B)
using a 10 mm Allen wrench
and drain the oil.
d.
Once the oil draining has been
completed, close again the
plug.
53
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Oil Filling
54
a.
Remove the oil vent plug
installed on the Robot base with
a socket hex wrench.
b.
Screw in the air vent hole an
angle fitting (A) of 1/8gas.
c.
Connect to the fitting (A) the
suction pipe (B) of the venturi
meter unit (C) .
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Oil Filling (Continued)
d.
Connect the venturi meter to the
pipe for compressed air supply
of the establishment pneumatic
system.
e.
Screw a pipe with fitting 3/4” in
the oil drain hole.
f.
Fill an appropriate container
with the prescribed oil (see
Tab. 4.3) and immerse in it the
pipe screwed to the hole for oil
draining.
g.
Feed the venturi meter with
compressed air.
The pressure of the air
passing through the venturi
meter creates a depression in
the gear housing, which
draws the oil upwards from
the underlying container by
inserting it into the gearbox.
h.
Completed the oil filling, check
the sealing gasket and screw
with a 10 mm hex wrench the
cone-shaped
plug
without
forcing.
55
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.6.2
Oil change in axes 2 - 3 gearbox with Robot mounted
inverted
Pay attention to reposition the vent fill and drain plugs in the correct fixing position.
Before starting the lubrication operations, carry out a general cleaning of the parts
surrounding the lubrication point, in order not to allow the possible insertion of dirt and/or
impurities inside the machine body.
56
a.
Use adhesive tape to retain the motor cables on one side, to avoid smearing them
with oil during the draining.
b.
Position a container under the drain plug (B), then unscrew the plug.
c.
Unscrew and remove the oil vent filling plug (A).
d.
Completed the oil draining, thoroughly clean the drain hole and plug (B) from any
ferrous residues.
e.
Install a new gasket on the drain plug (B) and screw it applying the sealant Loctite
572 on the thread (see Tab. 5.3 - Products for sealing and fixing on page 68).
Tighten the drain plug (B) of the axis 2 up to 10 Nm and the drain plug (B) of the
axis 3 up to 60 Nm.
f.
Position a funnel with flexible extension with cutting (for air vent) in the filling hole
(A) and insert the required lubricant.
g.
Install a new gasket on the filling plug (A) of the axis 2 and loosely tighten it
applying the sealant Loctite 572 on the thread (see Tab. 5.3 - Products for sealing
and fixing on page 68).
h.
Install a new gasket on the filling plug (A) and on the vent valve of the filling plug
(A) of the axis 3 and loosely tighten it applying the sealant Loctite 572 on the thread
(see Tab. 5.3 - Products for sealing and fixing on page 68).
i.
Keeping the orientation of the vent valve upright, as shown in Fig. 4.17:
•
tighten the filling plug (A) of the axis 2 up to 70 Nm and the vent plug up to 10
Nm.
•
tighten the filling plug (A) of the axis 3 up to 60 Nm and the vent plug up to 10
Nm.
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.16 - Oil change in axes 2 and 3 gearboxes - Inverted mounted
Robot
Axis 2 oil draining/filling
Necessary equipment:
container for oil draining;
funnel and tube for oil filling;
open-end wrenches set;
torque wrench with bits for open-end wrenches.
Axis 3 oil draining/filling
Necessary equipment:
container for oil draining;
funnel and tube for oil filling;
open-end wrenches set;
torque wrench with bits for open-end wrenches.
Fig. 4.17 - Vent valve orientation
57
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.7
Oil change in axis 4 gear case
a.
Position the Robot as shown in Fig. 4.18 - Oil change in axis 4 gear case on
page 58 to facilitate the complete oil draining from the gear case.
Loosen the oil filling plug (B) to vent the compressed air possibly present in the gear
case and prevent the oil from coming out with high pressure when removing the drain
plug.
b.
Position the container under the wrist and unscrew with a 10 mm hex head socket
wrench the oil drain plug (A) and drain the oil Fig. 4.18 - Axis 4 oil draining.
c.
After oil draining, close again the drain plug (A)
d.
Rotate the axis 3 and 2 to position the forearm as shown in Fig. 4.18 - Axis 4 oil
filling (axis 3 rotated in positive direction and axis 2 rotated in negative direction) to
allow the air vent from the gearbox internal chamber.
e.
Refill the gearbox with prescribed oil (see Tab. 4.3)
f.
Check the sealing gasket and apply the sealant on the plug thread (see Tab. 5.3
- Products for sealing and fixing on page 68)
g.
Screw the plug in the oil filling hole.
Fig. 4.18 - Oil change in axis 4 gear case
Axis 4 oil draining
58
Axis 4 oil filling
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.8 Oil change in axis 4 gearbox
Oil Draining
a.
Get a suitable container to
collect the oil drained from the
gearbox and plastic piping with
drain nipple.
b.
Using a 5mm hex head wrench
, unscrew the oil drain plug and
screw the plastic fitting for the
draining.
c.
To speed up the draining
procedure, remove the oil filling
plug and blow air into the
gearbox up to its complete
emptying.
d.
Rotate the axis in positive and
negative direction to move the
internal kinematic chains and
drain completely the gearbox.
Make sure that the oil washers and the screws are stored.
Depending on the floor or inverted mounting, the position of the drain and filling holes
can be changed compared to what is shown in the following figures.
59
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Oil Filling
60
a.
Screw the plug (A) in the oil
drain hole
b.
Unscrew the air vent plug (B)
with a 5mm hex head wrench.
c.
By means of a 100cc syringe
(see
Fig. 4.3
- Required
equipment
for
gearboxes
lubrication axes 4-5-6 on
page 34) insert the oil in the
gearbox. See the Tab. 4.2 for
the type of lubricant and relative
amount.
d.
Before removing the syringe
from the filling hole, wait until
the air flows back in the syringe
to avoid pressured oil spillage
from the gearbox.
e.
If too much oil is delivered,
which pours out from the
vent hole, it is possible to
suck it using the syringe.
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Oil Filling (Continued)
f.
Check the seal gaskets and
close all vent and filling holes.
61
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.9 Oil change in axes 5 - 6 gearboxes
Oil Draining
a.
Using a 4mm hexagonal
wrench, unscrew the two
closing screws of the holes for
oil filling and draining
Axis 5
Axis 6
b.
Rotate axis 4 to position the
plugs downwards and drain the
oil from the gearbox
Axis 5
Axis 6
62
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Oil Filling
a.
Completed the oil draining,
rotate the axis 4 to position the
filling and drain holes upwards.
b.
By means of a 100 cc syringe
(see
Fig. 4.3
- Required
equipment
for
gearboxes
lubrication axes 4-5-6 on
page 34) refill the gearbox with
prescribed oil (see Tab. 4.3).
c.
Insert the proper oil quantity
and check that the oil does not
pour out from the vent hole. If
that happens, suck the excess
oil with the syringe by sucking
the air (10cc).
d.
Axis 5
Axis 6
Completed the oil filling, close
with a 4 mm hex head wrench
the two screws on the gearbox,
paying attention to interpose
the washer for sealing.
63
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
4.10 Axes 5 - 6 wrist gears compartment greasing
Before starting the lubrication operations, carry out a general cleaning of the
surrounding parts of the lubrication point, in order not to allow the possible insertion of
dirt and/or impurities inside the machine body.
To speed up the lubricant procedure, replace the greasers with suitable cone-shaped
plugs of 1/8” gas. After lubrication operations, carry out a general cleaning of the parts
surrounding the lubrication point, in order to remove possible lubricant residues.
a.
Unscrew and remove from the wrist body the plug from the air vent hole (see
Fig. 4.19).
b.
Unscrew and remove the plug screwed into the lubrication hole.
c.
Screw the pipe end of the grease gun into the lubrication hole.
d.
Insert the required grease (see Tab. 4.3) until clean grease comes out from the
vent hole.
64
e.
Do not reassemble the plug on the vent hole and move the Robot axis for a couple
of minutes in order to distribute equally the lubricant inside the unit.
f.
Completed the above mentioned operation, reassemble the plug on the vent hole.
g.
Unscrew and remove the pipe end of the greaser from the lubrication hole.
h.
Screw the plug in the lubrication hole.
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Fig. 4.19 - SMART5 NJ4 170-2.9
Wrist Lubricators and air vent plugs for axes 5 - 6 gears
compartmentSMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7
Wrist Lubricators and air vent plugs for axes 5 - 6 gears
compartment
Axis 5 gears
Hole for greasing
Vent plug
Axis 6 gears
Hole for greasing
Vent plug
Follow-up procedures
–
After 50/100 hours from the lubrication operations, carry out a general cleaning
of the parts surrounding the lubrication point, in order to remove any residual
lubricant.
65
Comau Robotics Product Instruction
SPECIAL MAINTENANCE
5.
SPECIAL MAINTENANCE
5.1 Generalities
The procedures of the main Robots spare parts replacement are to be carried out after
mechanical accidents or if the limit of wear has been reached, are described in the
maintenance sheets that follow.
Before starting any type of operation, carefully read Chap.1. - General Safety
Requirements on page 11.
Robot maintenance operations must be carried out with the system powered off: the
main switch MUST be in OFF position (closed).
It is recommended to carry out accurate and precise preventive maintenance operations
in order to retain over the long term the Robot functional features.
66
Comau Robotics Product Instruction
SPECIAL MAINTENANCE
5.2 Assembly notes
Special maintenance operations must be performed by specialized staff using
appropriate tools, applying the standard operating procedures even if not expressly
mentioned, including the following:
•
Check the O-rings, oil retaining rings and bearings wear condition and replace
them if necessary;
•
When reassembling, consider the following guidelines:
•
Apply the recommended threadlockers on the screw threads, see Tab. 5.2
- Threadlocker products on page 68.
•
Use recommended products on sealing surfaces and for components fixing,
see Tab. 5.3 - Products for sealing and fixing on page 68;
•
While disassembling and reassembling the components, comply with the
screw tightening torques. Unless otherwise specified, tighten to the tightening
torques required for the type of screws used and tighten the screws and/or
nuts to the required tightening torque, see Tab. 5.1 - Tightening torque for
Hex head screws and Socket hex head screws (Nm) on page 67.
An excessive tightening may impair the thread and consequently the maintaining in
position of the item.
An insufficient tightening can cause the item falling and/or overheating (and consequent
breaking) due to an incorrect adherence to the dissipating structure.
•
•
•
Apply AREXONS 52A22 or LOCTITE 222 to the outside diameter of the
gaskets for rotary shafts and rubber sealing plugs.
Use FUCHS ANTICORIT DFW to protect any exposed machined surfaces.
When assembling double-lipped rotary seals or in case of a double seal, fill
the gap between the two lips with "NLGI NR.2” grade grease.
Tab. 5.1 - Tightening torque for Hex head screws and Socket hex head
screws (Nm)
dxp
Class
8.8*¹ screws
Class 10.9*¹
screws
Class 12.9*¹
screws
Class 12.9 screws
(for NABTESCO
gearboxes only)
3 x 0.5
4 x 0.7
5 x 0.8
6x1
8 x 1.25
10 x 1.5
12 x 1.75
14 x 2
16 x 2
18 x 2.5
20 x 2.5
24 x 3
1.5
3.1
6
10.4
24.6
50.1
84.8
135
205
283
400
691
1.9
4.3
8.5
14.6
34.7
70.5
119
190
288
398
562
971
2.3
5.2
10.1
17.5
41.6
84.6
143
228
346
478
674
1170
9.01 ± 0.49
15.6 ± 0.78
37.2 ± 1.86
73.5 ± 3.43
129 ± 6.37
205 ± 10.2
319 ± 15.9
441 ± 22
539 ± 27
-
*¹ Admissible tolerance 0/-10%
67
Comau Robotics Product Instruction
SPECIAL MAINTENANCE
A tolerance of ± 10% is allowed on tightening torques of screws and lock nuts for
preloading of bearings.
Tab. 5.2 - Threadlocker products
Product *²
Material
Aluminium
Steel
Cast iron
Aluminium with Heli-coil
for screws
M5 or M6
for screws
M8 and
onwards
For
plugs and
fittings
Loctite 222
Loctite 222
Loctite 572
Loctite 243
-
For screws up to M4 do not use threadlocker.
*² As an alternative to the products indicated in the table Tab. 5.2 it's possible to use:
–
Arexons 52A22 (alternative for Loctite 222)
–
Arexons 52A43 (alternative for Loctite 243)
–
Arexons 35A72 (alternative for Loctite 572)
Tab. 5.3 - Products for sealing and fixing
Application
Product*³
Flat sealant
Loctite 518
Polyurethane sealant
BOSTIK MK2639
Bearing fasteners
Loctite 641
High strength retainers
Loctite 648
*³ As an alternative to the products indicated in the table Tab. 5.3 it's possible to use:
68
–
Arexons 35A73 (alternative for Loctite 518)
–
Arexons 56A41 (alternative for Loctite 641)
–
Arexons 56A48 (alternative for Loctite 648)
Comau Robotics Product Instruction
SPECIAL MAINTENANCE
5.3 Parts disposal
The disposal of used oils and greases MUST BE CARRIED OUT IN ACCORDANCE
WITH THE LEGISLATION IN FORCE IN THE COUNTRY WHERE THE ROBOT IS
INSTALLED.
Should it become necessary the Robot partial or total disposal, it MUST be carried out
a separate collection of the parts to be disposed (e.g. iron with iron and plastic with
plastic). The disposal of these parts also MUST be carried out in accordance with the
legislation in force in the country where the Robot has been installed.
69
Comau Robotics Product Instruction
USE OF THE INTEGRATED BRAKE RELEASING MODULE
5.4 Use of the integrated brake releasing module
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 that case, all system safety devices (including the
emergency stop and enabling push-button) are cut-off.
Status:
–
Power on, C5G on.
Material:
–
Integrated brake release device
installed on Robot.
Equipment:
–
Suitable lifting means to support the
Robot axes subject to gravity
Preliminary procedures / notes
During brake releasing operation the operator must avoid standing under
the Robot parts that can move upwards or downwards due to forces
generated by the balancing system or gravity.
Robot axes subjected to gravity must be held with suitable lifting means
(crane, overhead crane).
This operation requires at least 2 operators: one to control the crane or
overhead crane, the other to control the axes brake releasing operation.
The dynamic brake release function could be compromised by failures on
the C5G drive section having the same name or by the absence of motor
electrical connection: in this case the brake release provokes the axis free
fall.
In case of proper function of the dynamic brake, there exists the fall risk,
but with slower fall.
–
–
70
In order to be able to operate, the integrated brake releasing module requires
that:
•
the electric power is delivered to the Control Unit.
•
the Control Unit is ON with 24Vdc section available and operating.
•
Robot connected to the Control Unit.
•
Motors off (Drive OFF). With Drive ON motors, the push-button pressure is
not influential.
Motion freedom of axes is obstructed and slowed down by dynamic braking.
Comau Robotics Product Instruction
USE OF THE INTEGRATED BRAKE RELEASING MODULE
Operating procedure
a.
Support the Robot axes subject to gravity with crane or overhead crane. Use
ropes or bends. Do not use chains. See the Robot handbook to detect the most
suitable points to sling the Robot.
b.
To release the Robot axes:
•
Press each push-button (A).
•
On each push-button there is the word identifying the related axis.
c.
It is recommended to control the brake releasing by pressing the push-button
shortly and contemporaneously reducing gradually the pulling tension of the
ropes used to support the axes that are subject to gravity.
d.
The control is active for the time the action is performed: at the release, the
motion stops due to the brakes action.
Follow-up procedure
–
Not required.
71
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 1 MOTOR
5.5 AXIS 1 MOTOR: complete replacement
5.5.1
5.5.1.1
ROBOT:
SMART5 NJ4 170 – 2.9;
SMART5 NJ4 220 – 2.4;
SMART5 NJ4 220 – 2.7
Floor mounting
Status:
–
–
The procedure must be carried out with
the system powered off: the main circuit
breaker of the cell controller MUST be in
OFF position (closed).
Position the Robot axis 1 with the
accessible motor
Material:
–
Axis 1 motor: Part No. see Chap.9. Spare Parts List on page 238;
Equipment:
–
–
Hex male T-wrench of 10mm
Lever approx. length 400 mm
Fixing
components:
–
M12 socket hex head screws for motor
fixing, q.ty 4
Socket hex head screws M10 for pinion
fixing, q.ty 1
Flat sealant see Tab. 5.3
–
–
Preliminary procedures / notes
–
72
Remove the electrical connectors from the motor
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or knock on the motor during disassembly
and reassembly operations.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 1 MOTOR
Disassembly procedure
a.
Unscrew using a 10 mm wrench
the 4 socket hex head screws
M12 that fix the motor to the
Robot base.
b.
Lift the motor upward to remove
it from the flange of the axis 1
gearbox; if necessary insert a
lever in the notch of the gearbox
and apply a force on it to
remove the motor from the
gearbox flange.
Do not use a hammer or
knock on the motor during
disassembly
and
reassembly operations.
73
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 1 MOTOR
Disassembly procedure (Continued)
c.
Bring the motor on the
workbench and remove the
terminal flywheel unscrewing
the socket hex head screws
M12 (A) with the 10mm wrench,
then remove the gear and
washer unscrewing the socket
hex head screw M8 (B) with 6
mm wrench .
Reassembly
a.
Clean and lubricate the motor shaft, fit on the motor shaft the pinion and fasten
the pinion on the motor shaft with the fixing socket hex head screw M8 (B) cl 12.9
and the related washer. Tighten the screws to the specified torque (see Tab. 5.1
- Tightening torque for Hex head screws and Socket hex head screws (Nm) on
page 67)
b.
Fit the terminal flywheel tightening the socket hex head screws M12 (A) with a
10mm wrench. Tighten the screws to the specified torque (see Tab. 5.1
- Tightening torque for Hex head screws and Socket hex head screws (Nm) on
page 67).
c.
Clean the motor coupling flange and apply the required sealant to prevent
lubricant leakage (see Tab. 5.3 - Products for sealing and fixing on page 68)
d.
Reassemble the motor on the gearbox following the removal procedure in
reverse order.
Apply the prescribed sealant to the screws when reassembling and tighten
them to the prescribed torque (see
–Tab. 5.2 - Threadlocker products on page 68
–Tab. 5.1 - Tightening torque for Hex head screws and Socket hex head
screws (Nm) on page 67.
When tightening the screws, apply a radial force to the motor to remove any
meshing clearances.
Follow-up procedures
Procedure for Robot matched with Standard Control Unit
–
–
–
74
When restarting, the following message is displayed on the Teach Pendant:
“64054-11 Axis <<axis number>> New element drive-motor-transducer"
The signalling must be silenced with the function key “Confirmation” [F1] from the
screen page “Alarm”.
Carry out the calibration procedure as described in Tab. 8.3 - Axis 1 calibration
on page 225
Check the correct functioning of the Robot running a work program at low speed.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 1 MOTOR
Follow-up procedures (Continued)
Procedure for Robot matched with Safe Control Unit
–
–
–
The Safe Control Unit does not allow the restart if before there was not performed
a confirmation of a Safe (motor) component replacement and the calibration with
updating of the dimensions in Safe field.
Carry out the reset procedure as described in the “Use of RoboSAFE
functionality” handbook in the paragraph “Reset after a motor replacement”.
Subsequently, check the correct functioning of the Robot running a work program
at low speed.
75
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 1 MOTOR
5.5.2
Robot inverted mounting
Status:
–
–
The procedure must be carried out with
the system powered off: the main circuit
breaker of the cell controller MUST be in
OFF position (closed).
Position the Robot axis 1 with the
accessible motor
Material:
–
Axis 1 motor Part No.: see Chap.9. Spare Parts List on page 238;
Equipment:
–
–
Hex male T-wrench of 10mm
Lever approx. length 400 mm
Fixing
components:
–
M12 socket hex head screws for motor
fixing, q.ty 4
Socket hex head screws M10 for pinion
fixing, q.ty 1
Flat sealant see Tab. 5.3
–
–
Preliminary procedures / notes
–
76
If the Robot functionality allows it, move axis 2 in calibration position.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or knock on the motor during disassembly
and reassembly operations.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 1 MOTOR
Disassembly procedure
a.
Drain the oil from the gearbox
(see Chap.4.6.2 - Oil change in
axes 2 - 3 gearbox with Robot
mounted inverted on page 56)
b.
Remove
the
electrical
connectors from the motor
In order to guarantee the safety conditions, prepare suitable equipment to
support the motor taking into consideration that its weight is about 30 kg.
c.
With a 10 mm wrench unscrew one socket hex head screw M12 without
removing it so that it can support safely the motor when the other three
screws will be removed.
d.
Remove the other 3 socket hex head screws M12 mm that fix the motor to the
Robot base and remove the motor from the coupling flange.
If the motor remains attached to the gearbox flange because of the sealant
used during the installation, insert a lever into the notch on the gear
housing and apply a force on the lever to detach it from the gearbox flange.
77
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 1 MOTOR
Disassembly procedure (Continued)
To guarantee the safety
conditions, during the
disassembling procedure,
support and move the
motor
with
suitable
equipment taking into
consideration that the
motor weight is about 30
kg.
e.
Once the motor has been
removed from the gearbox
flange, remove the screw
foreseen to support it and bring
the motor on the workbench.
f.
Take the motor to the
workbench and remove the
terminal flywheel unscrewing
the socket hex head screws
M12 (A) using a 10mm wrench,
then remove the gear and
washer unscrewing the socket
hex head screw M8 (B) using a
6 mm wrench.
Reassembly
78
a.
Clean and lubricate the motor shaft, fit on the motor shaft the pinion and fasten
the pinion on the motor shaft with the fixing socket hex head screw M8 (B) cl 12.9
and the related washer. Tighten the screws to the specified torque (see Tab. 5.1
- Tightening torque for Hex head screws and Socket hex head screws (Nm) on
page 67)
b.
Fit the terminal flywheel tightening the socket hex head screws M12 (A) with a
10mm wrench. Tighten the screws to the specified torque (see Tab. 5.1
- Tightening torque for Hex head screws and Socket hex head screws (Nm) on
page 67).
Tighten the screws to the foreseen tightening torque (see Tab. 5.2
- Threadlocker products on page 68 and Tab. 5.1 - Tightening torque for
Hex head screws and Socket hex head screws (Nm) on page 67)
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 1 MOTOR
Reassembly (Continued)
c.
Clean the motor coupling flange
and apply the required sealant
to prevent lubricant leakage
(see Tab. 5.3 - Products for
sealing and fixing on page 68)
d.
Clean and lubricate the motor shaft and mount the flywheel by tightening the
screws M12 (A) with a 10 mm wrench. Fix the motor shaft to the pinion with
screws M6 interposing the washer. (See Disassembly procedure step f.).
Tighten the screws to the foreseen tightening torque (see Tab. 5.2
- Threadlocker products on page 68 and Tab. 5.1 - Tightening torque for
Hex head screws and Socket hex head screws (Nm) on page 67)
e.
Reassemble the motor on the gearbox following the removal procedure in
reverse order.
In order to guarantee the safety conditions, prepare suitable equipment to
support and move the motor taking into consideration that its weight is
about 30 kg.
Apply the foreseen sealant to the screws when reassembling and tighten
them to the foreseen tightening torque (see Tab. 5.2 - Prodotti frenafiletti
on page 74 and Tab. 5.1 - Coppia di serraggio viti T.E. e T.C.E.I. (Nm) on
page 73).
When tightening the screws, apply a radial force to the motor to remove any
meshing clearances.
f.
Fill the gearbox with the prescribed lubricating oil applying the specific procedure
for inverted mounting (see Tab. 4.2 - SMART5 NJ4 170–2.9; Lubrication
Interventions on page 35 )
Follow-up procedures
Procedure for Robot matched with Standard Control Unit
–
–
–
When restarting, the following message is displayed on the Teach Pendant:
“64054-11 Axis <<axis number>> New element drive-motor-transducer"
The signalling must be silenced with the function key “Confirmation” [F1] from the
screen page “Alarm”.
Carry out the calibration procedure as described in Tab. 8.3 - Axis 1 calibration
on page 225
Check the correct functioning of the Robot running a work program at low speed.
79
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 1 MOTOR
Follow-up procedures (Continued)
Procedure for Robot matched with Safe Control Unit
–
–
–
80
The Safe Control Unit does not allow the restart if before there was not performed
a confirmation of a Safe (motor) component replacement and the calibration with
updating of the dimensions in Safe field.
Carry out the reset procedure as described in the “Use of RoboSAFE
functionality” handbook in the paragraph “Reset after a motor replacement”.
Subsequently, check the correct functioning of the Robot running a work program
at low speed.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 2 MOTOR
5.6 AXIS 2 MOTOR: complete replacement
5.6.1
ROBOT:
SMART5 NJ4 170 – 2.9; SMART-5 NJ4 220 – 2.4;
SMART5 NJ4 220 – 2.7
5.6.2
Robot floor mounting
Status:
–
The procedure must be carried out
with the system powered off: the main
circuit breaker of the cell controller
MUST be in OFF position (closed).
The removal of the motor
releases the brake of axis 2,
therefore, before disassembling
the motor, lock the axis in safe
position
to
prevent
uncontrolled
upward
or
downward movements that
could injure the operators
that may be standing close to
the Robot.
Spare part:
–
Axis 2 motor: Part No.: see Chap.9. Spare Parts List on page 238;
Equipment:
–
–
–
–
Hex male T-wrench of 10 mm - 8 mm
- 6 mm
Male tool for M16 threads
Grub screw M16x40mm
Lifting ropes
–
–
Socket hex head screws M12-M10-M8
Flat sealant
Fixing
components:
Preliminary procedures / Notes
The removal of the motor involves the axis 2 brake release. Before starting
to remove the motor be sure that the axis is locked in a position that
prevents possible uncontrolled movements of the weights applied on the
Robot.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or knock on the motor during disassembly
and reassembly operations.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.
81
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 2 MOTOR
Preliminary procedures / Notes (Continued)
–
–
–
82
If the Robot functionality permits it,
move axes 2 and 3 to bring the
Robot in the position shown in the
figure on the side.
If it is not possible to move the
Robot axes, block the forearm to
prevent uncontrolled movements
during the motor removal.
Remove the electrical connectors
from the motor
Drain the oil from the gearbox (see )
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 2 MOTOR
5.6.3
Robot inverted mounting
Status:
–
The procedure must be carried out
with the system powered off: the main
circuit breaker of the cell controller
MUST be in OFF position (closed).
The removal of the motor
releases the brake of axis 2,
therefore, before disassembling
the motor, lock the axis in safe
position
to
prevent
uncontrolled
upward
or
downward movements that
could injure the operators
that may be standing close to
the Robot.
Spare part:
–
Axis 2 motor: Part No.: see Chap.9. Spare Parts List on page 238;
Equipment:
–
–
–
–
Hex male T-wrench of 10 mm - 8 mm
- 6 mm
Male tool for M16 threads
Grub screw M16x40mm
Lifting ropes
–
–
Socket hex head screws M12-M10-M8
Flat sealant
Fixing
components:
Preliminary procedures / Notes
The removal of the motor involves the axis 2 brake release. Before starting
to remove the motor be sure that the axis is locked in a position that
prevents possible uncontrolled movements of the weights applied on the
Robot.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or knock on the motor during disassembly
and reassembly operations.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.
83
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 2 MOTOR
Preliminary procedures / Notes (Continued)
–
–
–
If the Robot functionality allows it,
move axis 2 in calibration position as
shown in the side figure.
If it is not possible to move the
Robot axes, block the forearm to
prevent uncontrolled movements
during the motor removal.
Connect the brake release assembly
COMAU C5G-OBR and unlock the
axis 2 to discharge any forces of
gravity generated by the load applied
to the robot arm.
Disassembly procedure
a.
84
Drain the oil from the gearbox
(see
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 2 MOTOR
Disassembly procedure
b.
Remove
the
electrical
connectors from the motor
c.
With a 10 mm hex male
T-wrench loosen, without
removing it, a fixing screw of
the motor, then unscrew and
remove completely the other
three screws.
In order to guarantee the safety conditions, prepare suitable equipment to
support the motor taking into consideration that its weight is about 30 kg.
d.
With a 10 mm wrench unscrew one socket hex head screw M12 without
removing it so that it can support safely the motor when the other three
screws will be removed.
e.
Remove the other 3 socket hex head screws M12 mm that fix the motor to the
gearbox and remove the motor from the coupling flange.
If the motor remains attached to the gearbox flange because of the sealant
used during the installation, insert a lever into the notch on the gear
housing and apply a force on the lever to detach it from the gearbox flange.
To guarantee the safety conditions during the disassembly procedure,
support and move the motor with suitable equipment taking into
consideration that the motor weight is of 30 kg.
f.
Once the motor has been removed from the gearbox flange, remove the screw
foreseen to support it and bring the motor on the workbench.
85
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 2 MOTOR
Disassembly procedure
g.
With a 6 mm hex male
T-wrench, untighten the screw
(A) and remove the pinion from
the drive shaft.
Reassembly
a.
Apply on the motor coupling
flange the flat sealant that
prevents oil leaks (see Tab. 5.3
- Products for sealing and fixing
on page 68).
b.
Clean and lubricate the coupling
surfaces of the pinion on the
drive shaft
c.
Fit the pinion without knocking
on the drive shaft.
d.
Reassemble the motor on the
gearbox following the removal
procedure in reverse order.
When reassembling, apply the required sealant to the screws and tighten
them applying the appropriate tightening torque (see Tab. 5.2
- Threadlocker products on page 68 and Tab. 5.1 - Tightening torque for
Hex head screws and Socket hex head screws (Nm) on page 67).
e.
86
Fill the gearbox with prescribed lubricating oil applying the specific procedure for
inverted mounting (see Tab. 4.2 - SMART5 NJ4 170–2.9; Lubrication
Interventions on page 35 and Chap.4.6.2 - Oil change in axes 2 - 3 gearboxes
with Robot mounted inverted on page 52)
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 2 MOTOR
Follow-up procedures
Procedure for Robot matched with Standard Control Unit
–
–
–
When restarting, the following message is displayed on the Teach Pendant:
“64054-11 Axis <<axis number>> New element drive-motor-transducer"
The signalling must be silenced with the function key “Confirmation” [F1] from the
screen page “Alarm”.
Carry out the calibration procedure as described in Tab. 8.4 - Axis 2 calibration
on page 227
Check the correct functioning of the Robot running a work program at low speed.
Procedure for Robot matched with Safe Control Unit
–
–
–
The Safe Control Unit does not allow the restart if before there was not performed
a confirmation of a Safe (motor) component replacement and the calibration with
updating of the dimensions in Safe field.
Carry out the reset procedure as described in the “Use of RoboSAFE
functionality” handbook in the paragraph “Reset after a motor replacement”.
Subsequently, check the correct functioning of the Robot running a work program
at low speed.
87
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 3 MOTOR
5.7 AXIS 3 MOTOR: complete replacement
5.7.1
ROBOT:
SMART5 NJ4 170 – 2.9; SMART5 NJ4 220 – 2.4;
SMART5 NJ4 220 – 2.7;
Status:
–
The procedure must be carried out
with the system powered off: the main
circuit breaker of the cell controller
MUST be in OFF position (closed).
The removal of the motor
releases the brake of axis 3,
therefore, before disassembling
the motor, lock the axis in safe
position
to
prevent
uncontrolled
upward
or
downward movements that
could injure the operators
that may be standing close to
the Robot.
Material:
–
Axis 3 motor Part: Part No.: see
Chap.9. - Spare Parts List on
page 238
Equipment:
–
–
Hex male T-wrench of 10 mm - 8 mm
- 6 mm
Lever approx. length 400 mm
–
Socket hex head screws M12
Fixing
components:
Preliminary procedures / notes
The removal of the motor involves the axis 3 brake release. Before
starting to remove the motor be sure that the axis is locked in a position
that prevents possible uncontrolled movements of the weights applied on
the Robot.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or knock on the motor during disassembly
and reassembly operations.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.
88
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 3 MOTOR
Preliminary procedures / notes (Continued)
–
–
–
If the Robot functionality permits it,
move axes 2 and 3 to bring the Robot
in the position shown in the figure on
the side.
If it is not possible to move the
Robot axes, block the forearm to
prevent uncontrolled movements
during the motor removal.
Remove the electrical connectors
from the motor
Drain the oil from the gearbox (see
Chap.4.5.2 - Oil change in axis 2 - 3
gearbox with Robot mounted on floor
on page 41)
Operating procedure
a.
Sling the motor with a rope, to
support it during the removal
operations.
b.
With a 10 mm hex male
T-wrench loosen, without
removing it, a fixing screw of
the motor, then unscrew and
remove the other three
screws (A).
c.
C
C
D
E
Insert a lever in the notch
provided on the gearbox and
apply a force on the lever to
remove the motor from the
gearbox flange.
89
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 3 MOTOR
Operating procedure (Continued)
d.
Remove the motor from its
centring seat and bring it to the
bench.
e.
Unscrew the axial fixing screws
and use a puller to remove the
pinion from the drive shaft.
Reassembly
a.
Clean and lubricate the coupling surfaces of the pinion on the drive shaft
b.
Fit the pinion without knocking on the drive shaft.
c.
Apply on the motor coupling flange the flat sealant that prevents oil leaks (see
Tab. 5.3 - Products for sealing and fixing on page 68).
d.
Reassemble the motor on the gearbox following the removal procedure in
reverse order.
When reassembling tighten all the screws to the specified torque
(seeTab. 5.1 - Tightening torque for Hex head screws and Socket hex head
screws (Nm) on page 67)
e.
Fill the gearbox with the prescribed lubricating oil applying the procedure specific
for floor or inverted mounting (see and Chap.4.5.2 - Oil change in axis 2 - 3
gearbox with Robot mounted on floor on page 41)
Follow-up procedures
Procedure for Robot matched with Standard Control Unit
–
–
–
90
When restarting, the following message is displayed on the Teach Pendant:
“64054-11 Axis <<axis number>> New element drive-motor-transducer"
The signalling must be silenced with the function key “Confirmation” [F1] from the
screen page “Alarm”.
Carry out the calibration procedure as described in
Check the correct functioning of the Robot running a work program at low speed.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 3 MOTOR
Follow-up procedures (Continued)
Procedure for Robot matched with Safe Control Unit
–
–
–
The Safe Control Unit does not allow the restart if before there was not performed
a confirmation of a Safe (motor) component replacement and the calibration with
updating of the dimensions in Safe field.
Carry out the reset procedure as described in the “Use of RoboSAFE
functionality” handbook in the paragraph “Reset after a motor replacement”.
Subsequently, check the correct functioning of the Robot running a work program
at low speed.
91
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 4 MOTOR
5.8 AXIS 4 MOTOR: complete replacement
Status:
–
The procedure must be carried out with
the system powered off: the main switch
of the cell controller MUST be in OFF
position (closed).
The removal of the motor releases
the brake of axis 4, therefore, before
disassembling the motor, lock the
axis in safe position to prevent
uncontrolled
upward
or
downward movements that could
injure the operators that may be
standing close to the Robot.
Material:
–
Axis 4 motor; Part No.: Chap.9. - Spare
Parts List on page 238
Equipment:
–
–
Hex male T-wrench of 8 mm
Lever approx. length 400 mm
Fixing
components:
–
Socket hex head screws M10
Preliminary procedures / notes
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or knock on the motor during disassembly
and reassembly operations.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.
The detachment of the motor involves the axis brake release, therefore,
before starting the motor disassembly operation, lock the axes to avoid any
falls caused by the gravity.
–
–
–
92
Clamp the forearm to prevent
uncontrolled movement of the
masses applied to the Robot
when the motor is removed
If the Robot functionality allows
it, position the motor axis
vertically upward as shown in
the figure.
Remove the electrical
connectors from the motors
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 4 MOTOR
Disassembly procedure
a.
With a 8 mm male hex T wrench
loosen, but do not remove, a
fixing screw (M10 socket hex
head screw) of the motor,
then unscrew and remove the
other three screws.
b.
With a lever, detach the motor
from the gearbox flange.
c.
Take the
workbench.
motor
to
the
93
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 4 MOTOR
Reassembly
a.
Reassemble the motor on the gearbox following the removal procedure in
reverse order.
When reassembling, tighten all the screws applying the appropriate
tightening torque (see Tab. 5.1 - Tightening torque for Hex head screws and
Socket hex head screws (Nm) on page 67)
Follow-up procedures
Procedure for Robot matched with Standard Control Unit
–
–
–
When restarting, the following message is displayed on the Teach Pendant:
“64054-11 Axis <<axis number>> New element drive-motor-transducer"
The signalling must be silenced with the function key “Confirmation” [F1] from the
screen page “Alarm”.
Carry out the calibration procedure as described in Tab. 8.6 - Axis 4 calibration
on page 231
Check the correct functioning of the Robot running a work program at low speed.
Procedure for Robot matched with Safe Control Unit
–
–
–
94
The Safe Control Unit does not allow the restart if before there was not performed
a confirmation of a Safe (motor) component replacement and the calibration with
updating of the dimensions in Safe field.
Carry out the reset procedure as described in the “Use of RoboSAFE
functionality” handbook in the paragraph “Reset after a motor replacement”.
Subsequently, check the correct functioning of the Robot running a work program
at low speed.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 5 MOTOR
5.9 AXIS 5 MOTOR: complete replacement
Status:
–
The procedure must be carried out with
the system powered off: the main switch
of the cell controller MUST be in OFF
position (closed).
The removal of the motor releases
the axis. Block the axis in a safe
position before disassembling the
motor, to prevent any uncontrolled
movements of the load fixed to the
flange that could injure any
operators who may be standing
close to the robot.
Material:
–
Axis 5 motor; Part No.: Chap.9. - Spare
Parts List on page 238
Equipment:
–
–
Hex male T-wrench of 6mm
Lever
Fixing
–
components:
Socket hex head screws M8x25
Preliminary procedures / notes
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or knock on the motor during disassembly
and reassembly operations.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.
The detachment of the motor involves the axis brake release, therefore,
before starting the motor disassembly operation, lock the axes to avoid any
falls caused by the gravity.
–
–
Clamp the wrist to prevent
uncontrolled movement of the
masses applied to the Robot
flange when the motor is
removed.
Remove the electrical
connectors from the motors
95
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 5 MOTOR
Disassembly procedure
96
a.
With a 6 mm hex male
T-wrench loosen, without
removing it, a fixing screw of
the motor, then unscrew and
remove completely the other
three screws.
b.
With a lever, detach the motor
from the gearbox flange.
c.
Take the motor with the pinion
to the bench.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 5 MOTOR
Reassembly
a.
Clean and lubricate the coupling surfaces of the pinion on the drive shaft.
b.
Reassemble the motor on the gearbox following the removal procedure in
reverse order.
When reassembling, tighten all the screws applying the appropriate
tightening torque (see Tab. 5.1 - Tightening torque for Hex head screws and
Socket hex head screws (Nm) on page 67)
When reassembling the motor to facilitate the drive shaft fitting in the
gearbox, rotate the splined hole with a screwdriver in order to center the hole
and the shaft.
Follow-up procedures
Procedure for Robot matched with Standard Control Unit
–
–
–
When restarting, the following message is displayed on the Teach Pendant:
“64054-11 Axis <<axis number>> New element drive-motor-transducer"
The signalling must be silenced with the function key “Confirmation” [F1] from the
screen page “Alarm”.
Carry out the calibration procedure as described in Tab. 8.7 - Axis 5 calibration
on page 233
Check the correct functioning of the Robot running a work program at low speed.
Procedure for Robot matched with Safe Control Unit
–
–
–
The Safe Control Unit does not allow the restart if before there was not performed
a confirmation of a Safe (motor) component replacement and the calibration with
updating of the dimensions in Safe field.
Carry out the reset procedure as described in the “Use of RoboSAFE
functionality” handbook in the paragraph “Reset after a motor replacement”.
Subsequently, check the correct functioning of the Robot running a work program
at low speed.
97
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 6 MOTOR
5.10 AXIS 6 MOTOR: complete replacement
Status:
–
The procedure must be carried out with the
system powered off: the main switch of the
cell controller MUST be in OFF position
(closed).
The removal of the motor releases
the axis. Block the axis in a safe
position before disassembling the
motor, to prevent any uncontrolled
movements of the load fixed to the
flange that could injure any operators
who may be standing close to the
robot.
Material:
–
Axis 6 motor Part: Part No.: see Chap.9. Spare Parts List on page 238
Equipment:
–
–
Hex male T-wrench of 6mm
Lever
Fixing
–
components:
Socket hex head screws M8x25
Preliminary procedures / notes
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or knock on the motor during disassembly
and reassembly operations.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.
The detachment of the motor involves the axis brake release, therefore,
before starting the motor disassembly operation, lock the axes to avoid any
falls caused by the gravity.
–
–
98
Lock the equipment installed on
the flange in order to prevent
uncontrolled motions during the
motor removal.
Remove the electrical
connectors from the motors
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 6 MOTOR
Preliminary procedures / notes (Continued)
–
Remove the protection roll-bar
of the motor
Disassembly procedure
a.
With a 6 mm male hex T wrench
loosen a fixing screw of the
motor, but do not remove it,
then unscrew and remove
completely the other three
screws.
b.
With a lever, detach the motor
from the gearbox flange.
c.
Take the motor with the pinion
to the bench.
99
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - AXIS 6 MOTOR
Reassembly
a.
Clean and lubricate the coupling surfaces of the pinion on the drive shaft.
b.
Reassemble the motor on the gearbox following the removal procedure in
reverse order.
When reassembling, tighten all the screws applying the appropriate
tightening torque (see Tab. 5.1 - Tightening torque for Hex head screws and
Socket hex head screws (Nm) on page 67).
Follow-up procedures
Procedure for Robot matched with Standard Control Unit
–
–
–
When restarting, the following message is displayed on the Teach Pendant:
“64054-11 Axis <<axis number>> New element drive-motor-transducer"
The signalling must be silenced with the function key “Confirmation” [F1] from the
screen page “Alarm”.
Carry out the calibration procedure as described in Tab. 8.8 - Axis 6 calibration
on page 235
Check the correct functioning of the Robot running a work program at low speed.
Procedure for Robot matched with Safe Control Unit
–
–
–
100
The Safe Control Unit does not allow the restart if before there was not performed
a confirmation of a Safe (motor) component replacement and the calibration with
updating of the dimensions in Safe field.
Carry out the reset procedure as described in the “Use of RoboSAFE
functionality” handbook in the paragraph “Reset after a motor replacement”.
Subsequently, check the correct functioning of the Robot running a work program
at low speed.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WRIST UNIT
5.11 WRIST UNIT: complete replacement
Status:
–
The procedure must be carried out
with the system powered off: the main
circuit breaker of the cell controller
MUST be in OFF position (closed).
Material:
–
Wrist unit Part No.: see Chap.9. Spare Parts List on page 238
Equipment:
–
–
Hex male T wrenches 8 mm
Ø 10 mm pin extraction tool
Fixing
components:
–
–
M10 x 30 socket hex head screws
Dowel pin Ø 10x24 mm type B-H
Preliminary procedures / notes
–
–
–
Position the Robot wrist in an adequate position with accessible fixing screws.
Remove the equipment installed on the wrist.
Disconnect the electrical connectors from the axis 5-6 motors
Disassembly procedure
a.
Unscrew the screws (1) and
remove the cover (2).
b.
Unscrew the screws (3) and
remove the wrist flange.
c.
Remove the dressing fittings
from the distributor device
body.
101
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WRIST UNIT
Disassembly procedure
102
d.
Move backwards the wiring
inside the forearm spacer (see
the MANUAL of the robot
dressing).
e.
Hold the wrist by means of
ropes hooked to the protection
rollbar of the axis 6 motor.
f.
Remove the dowel pin Ø10x24
mm.
g.
Use a 8 mm hexagonal male T
wrench unscrew the 10 M10
hex head screws the wrist
spacer
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WRIST UNIT
Disassembly procedure
h.
Remove the wrist from the
centring on the forearm spacer,
lift it and put in on the bench.
i.
Rest the wrist on the bench.
j.
Unscrew the screws and remove the complete axis 5 motor (see Chap.5.9 - AXIS
5 MOTOR: complete replacement on page 95).
k.
Unscrew the screws and remove the complete axis 6 motor (see Chap.5.10 AXIS 6 MOTOR: complete replacement on page 98).
Reassembly
Make sure the wiring is
placed properly inside the
spacer, with cable and
pipe ends positioned by
the
wrist
connecting
flange.
a.
Position the spacer for axis 5
gearbox assembly inside the
wrist body.
103
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WRIST UNIT
Reassembly
104
b.
Reassemble the reduces holder
to the axis 5 motor.
c.
Fit the spacer for axis 5 gearbox
assembly inside the wrist body.
d.
Screw the axis 5 gearbox holder
fixing screws to the wrist body.
e.
Reassemble the motor support,
gearbox and axis 6 motor on the
wrist performing the same
procedure described for axis 5
(see procedure described in the
previous steps c., d.)
f.
Using a lifting mean lower the
wrist on the spacer placing axis
5 motor in its seat.
Be careful not to interfere
with the wiring inside the
spacer
g.
Fit the wrist on the spacer and
centre the holes for the fixing
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WRIST UNIT
Reassembly
h.
Fit the dowel pin Ø10x24 mm
type B-H
i.
Screw to the required torque, the
wrist fixing M10x30 socket hex
head screws to the spacer.
j.
Carry out the robot wiring inside the forearm and wrist
k.
Complete the fixing of the fittings to the distributor body
l.
Reassemble the ISO flange and the front cover of the distributor device body.
When reassembling, apply the prescribed sealant to the screws (see
Tab. 5.2 - Threadlocker products on page 68 and tighten them to the
appropriate tightening torque (see Tab. 5.1 - Tightening torque for Hex
head screws and Socket hex head screws (Nm) on page 67).
Follow-up procedures
Procedure for Robot matched with Standard Control Unit
–
–
–
When restarting, the following message is displayed on the Teach Pendant:
“64054-11 Axis <<axis number>> New element drive-motor-transducer"
The signalling must be silenced with the function key “Confirmation” [F1] from the
screen page “Alarm”.
Carry out the calibration procedure, as described in Tab. 8.6 - Axis 4 calibration
on page 231, Tab. 8.7 - Axis 5 calibration on page 233, Tab. 8.8 - Axis 6
calibration on page 235
Check the correct functioning of the Robot running a work program at low speed.
Procedure for Robot matched with Safe Control Unit
–
–
–
The Safe Control Unit does not allow the restart if before there was not performed
a confirmation of a Safe (motor) component replacement and the calibration with
updating of the dimensions in Safe field.
Carry out the reset procedure as described in the “Use of RoboSAFE
functionality” handbook in the paragraph “Reset after a motor replacement”.
Subsequently, check the correct functioning of the Robot running a work program
at low speed.
105
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
5.12 HANDLING dressing on robot NJ4 170-2.5 /
NJ4 170-2.9 / NJ4 175-2.2 / NJ4 220-2.4 / NJ4
220-2.7:
Wiring installation/replacement
This paragraph provides detailed information on the assembly of HANDLING dressing.
Status:
–
The procedure must be carried out
with the system powered off: the main
switch of the cell controller MUST be
in OFF position (closed).
Spare part:
–
Tab. 9.9 - SMART5 NJ4 - Rel. 2.0
Robot dressing spare parts on
page 251
Equipment:
–
Set of allen wrenches;
13 mm open-end wrench;
Cross-head screwdriver;
A pair of scissors;
Torque wrench.
Fixing
components:
–
Supplied with the assembling kit.
Preliminary procedures / notes
The cables are not to be twisted and the connectors are to be protected
against impacts.
Apply the foreseen sealant to the screws when reassembling and tighten
them to the foreseen tightening torque (see Tab. 5.1 - Tightening torque for
Hex head screws and Socket hex head screws (Nm) on page 67, Tab. 5.2
- Threadlocker products on page 68 and Tab. 5.3 - Products for sealing
and fixing on page 68).
Lubricate with one of the following lubricants:
- OPTIMOL OPTITEMP LG2
- KLUBER POLYLUB GLY801.
Assembly procedure
a.
106
If the Robot functionality allows it, set the axes in calibration position to replace
the cables harness.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
b.
Install the buffers using screws (M8x25) as indicated in the figures.
c.
Fasten the cestilene cover (CR82009276) A, to the Robot on axis 2 using 3
socket hex head screws M6x12.
d.
Fasten the cestilene cover
(CR82009255) C, to the Robot
on axis 3 using 2 socket hex
head screws M6x12 D.
107
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
[1] Wiring passage and assembly from axis 1 to axis 2
[2] Wiring passage and assembly from axis 2 to axis 3
[3] Axis 3 wiring passage and assembly
[1] Wiring passage and assembly from axis 1 to axis 2
e.
Stretch out the base wiring on
the ground and tape the cables
as shown in figure.
f.
Pass the wiring through the Robot base E, making it come out from the axis 1
cavity F.
g.
Fix the panel to the Robot base
distribution panel G, using 4
screws H (Socket hex head
screws M6x16).
Apply the prescribed
Thread Lock sealant on all
the screws used for
assembly.
h.
108
Connect the ground wire to the
screw J (only on this screw do
not use Thread Lock sealant).
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
i.
Stretch the Handling dressing
as indicated in figure.
j.
Pass the Handling dressing through the Robot base K, by making it come out
from the axis 1 cavity L.
k.
Pass the Handling dressing
through the Robot column by
making it come out from axis 3
M.
l.
Fix the X90 N multibus
connector to the distribution
panel using 4 slotted pan head
screws M3x10.
m.
Connect the air tube AIR1
(yellow)
to
the
Robot
distribution panel, P.
109
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
110
n.
Fix the panel to the Robot base
distribution panel using 4
screws (Socket hex head
screws M6x16).
o.
Pass two axis 2 motor cables,
through the passage on the
column Robot left side, Q.
p.
Pass two axis 2 motor cables,
through the hole on the bracket
AX1, (CR82341602) R.
q.
Through the passage on the Robot column right side S clamp the cables using a
cable tie (L=125 Width 4.6).
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
r.
Fasten the cables locking
bracket of Handling dressing on
the axis 1 bracket using 4
screws (Socket hex head
screws M5x8) as indicated in
figure.
s.
Fasten the STAUFF cables
locking of the Handling dressing
on the axis 1 bracket U, using 2
screws (Socket hex head
screws M6x12).
t.
The result of all the assemblies
carried out until now should
result as indicated in the figure.
u.
Fasten the axis 1 bracket to the
Robot base using 2 screws V
(Socket hex head screws
M6x18).
111
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
[2] Wiring passage and assembly from axis 2 to axis 3
112
v.
Clamp 2 cables of axis 2 motor
using a clamp, W (L=125 Width
4.6).
w.
Clamp 2 cables of axis 3 motor
using a clamp, X (L=125 Width
4.6).
x.
Pass the base wiring, through
the Robot column by making it
come out from axis 3.
y.
Connect the XMTR1 - XSYN1
connectors Y to the axis 1
motor.
z.
Connect the XMTR2 - XSYN2
connectors Z to the axis 2
motor.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
a.
Connect the XMTR3 - XSYN3
connectors AA to the axis 3
motor.
b.
Clamp the AB motor cables
using 4 cable ties (L=128 Width
4.6).
c.
Fasten the supplied bracket AC
(CR82009235) to the cables
STAUFF locking device of the
Handling dressing using 2
screws (Socket hex head
screws M6x12).
d.
Fasten 2 brackets to the Robot
column using 4 screws (Socket
hex head screws 6x16) as
shown in figure.
e.
Fasten the pivoting support
bracket AD (CR822009237) to
the robot using the fixing of the
base wiring bracket.
113
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
f.
Fasten the revolving flange AE
(CR19186007) to the locking of
Handling dressing using 2
self-locking nuts AF (M8). Give
an ounce of fat on the mobile
part.
g.
Fasten the rotary base with Handling dressing AG to the pivoting support bracket
using 4 screws (Socket hex head screws M6x12) and 2 washers (D6).
[3] Axis 3 wiring passage and assembly
114
h.
Connect the XMTR4 - XSYN4
connectors AJ to the axis 4
motor.
i.
Assemble the axis 4 cap using 4
screws (Socket hex head
screws M6x20) AK.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
j.
Insert the rear bushing into the Robot casing.
k.
Fix the bushing on the Robot casing using 2 spacers and 2 screws (Socket hex
head screws M8x25) AL.
l.
Fasten the cables adequately,
using two cable ties.
m.
Pull out the whole pipes and
cables harness from axis 6.
115
Comau Robotics Product Instruction
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Assembly procedure (Continued)
116
n.
Thread the axis 6 motor cables,
without crossing the cables of
Handling dressing.
o.
Insert the protective sheath and
fix the cables with the cables
locking bracket.
p.
Connect the XMTR6 - XSYN6
connectors to the axis 6 motor.
q.
Remove the cable ties AM and
the iron cable tie AN from the
pipes and cable harness (keep
the latter).
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
r.
Mount the aluminium bushing
(CR82344206) AP, using 4
screws (M6x25) respecting the
position of the reference pin
AQ.
s.
Fasten the aluminium bushing
to the distribution panel,
centering the reference pin,
using 4 screws (Socket hex
head screws M5x12).
t.
Fasten the two flanges to the
distributor with closing torque
equal to 17,5 Nm using 10
screws (M6x55).
u.
Screw the X200 connector, AR, to the connector support bracket, CR82344202,
using screws AS (Socket head flat-tip screws M3x10).
117
Comau Robotics Product Instruction
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Assembly procedure (Continued)
v.
Fasten the bracket with the
connector to the distributor
panel using 2 screws AT
(Socket hex head screws
M5x12).
w.
Fasten the flange to the
distributor with a closing torque
equal to 35 Nm using 12 screws
(M8x25).
x.
Fix the frame to the distributor
using 7 screws (Socket hex
head screws 34x8).
Disassembly procedure
To assemble the pipes and cables harness carry out on reverse order the
operations described previously.
118
Comau Robotics Product Instruction
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5.13 Applicative dressings for SPOT WELDING on
Robot NJ4 170-2.9 / NJ4 220-2.4 / 220-2.7:
Wiring installation/replacement
This paragraph provides detailed information on the SPOT WELDING assembly with
electric welding gun.
The procedure is valid also in case of spot welding application with pneumatic welding
gun, except for details on assembly of the motor cables (XMTR8) and encoder (XSYN8)
of the welding gun because they are not present.
Status:
–
The procedure must be carried out
with the system powered off: the main
circuit breaker of the cell controller
MUST be in OFF position (closed).
Spare part:
–
Tab. 9.7 - SMART5 NJ4 - Rel. 1.0
Robot wiring on page 249
Equipment:
–
Hex Allen wrench of 5 mm;
Hex Allen wrench of 10 mm;
Open-end wrench of 13 mm;
Open-end wrench of 22 mm;
Cross-head screwdriver;
5 mm extractor;
A pair of scissors;
Torque wrench.
Fixing
components:
–
Supplied with the assembling kit.
Preliminary procedures / notes
The cables are not to be twisted and the connectors are to be protected
against impacts.
Apply the foreseen sealant to the screws when reassembling and tighten
them to the foreseen tightening torque (see Tab. 5.1 - Tightening torque for
Hex head screws and Socket hex head screws (Nm) on page 67, Tab. 5.2
- Threadlocker products on page 68 and Tab. 5.3 - Products for sealing
and fixing on page 68).
Lubricate with one of the following lubricants:
- OPTIMOL OPTITEMP LG2
- KLUBER POLYLUB GLY801.
119
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure
a.
If the Robot functionality allows
it, set the axes in calibration
position to replace the cables
harness.
b.
Lay the wiring out on the ground and cut the locking plastic cable ties of the
cables.
1) Cables locking bracket
2) (STAUFF) cables locking with the supplied bracket
3) (STAUFF) cables locking with the supplied pivoting bracket
4) (STAUFF) cables locking with the supplied pivoting bracket
120
Comau Robotics Product Instruction
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Assembly procedure (Continued)
c.
Insert the wiring for welding
inside the arm and pull it from
the lower part.
Be careful not to rotate in
an unusual way the pipes
and cables harness and
avoid overlaps.
d.
Remove the support bracket from the Robot base and insert in the upper bushing
the Harting connector, the power connector and the water pipes.
Pull out the cables and pipes from the distribution panel on Robot base.
e.
Fasten the connectors and pipes on panel provided with the kit.
To fasten the X90 multibus connector use 4 socket head flat-tip screws M3x10,
respecting the position shown in the figure.
To fasten the X28 Harting connector motor axis 8, use 4 socket head cross-tip
screws M4x10.
To fasten the X9 power connector use 2 socket head cross-tip screws M5x30,
respecting the position indicated in the figure.
121
Comau Robotics Product Instruction
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Assembly procedure (Continued)
f.
Fix the upper panel on Robot
base as indicated in the figure.
Use 4 socket hex head screws
M6x16.
Check that the pipes are
not constricted and the
cables have adequate
curvatures.
122
Comau Robotics Product Instruction
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Assembly procedure (Continued)
g.
Reassemble
the
support
bracket A on the Robot base,
previously removed and fix the
cables locking bracket of the
spot dressing, using 4 socket
hex head screws M5x8, as
shown in the figure.
h.
Fasten the cables locking
bracket B of the spot dressing,
using 2 socket hex head screws
M6x12, as shown in the figure.
i.
Fasten the cables locking device on the supplied bracket using 2 C screws
(Socket hex head screws M6x12).
Fix the bracket to the robot column with 2 screws D (Socket hex head screws
M6x16).
j.
Fix the pivoting support bracket
E, to the Robot using the
bracket fixing of the basic
wiring, as indicated in the figure.
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Comau Robotics Product Instruction
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Assembly procedure (Continued)
k.
Fasten the STAUFF fixing
bracket on the rotary plate,
including the cables locking,
using two self-locking nuts M8,
F.
l.
Fasten the rotary plate on the
pivoting support bracket, using
4 socket hex head screws
M6x12 and 4 toothed washers.
Before fixing it, grease the
movable part of the
flange.
124
m.
Connect the mobile connectors
X26 and X56 to the related
connectors of the motor cables
and axis 6 encoder, available in
the wiring of Spot dressing .
n.
Insert the draw tape into the hole of the Robot flange and pull out from the rear
hole of the Robot arm.
Tie the draw tape to the spot dressing wiring. Insert the wiring cable inside the
Robot arm.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
Protect with a cellophane film the connectors to avoid crashes and dirt
during the pipes and cables harness insertion in the Robot arm. Check that
there are any obstructions of the connectors along their path. Lubricate the
pipes and cables harness appropriately with one of the following lubricants:
- OPTIMOL OPTITEMP LG2
- KLUBER POLYLUB GLY801.
o.
Pull
the
draw
tape
accompanying the pipes and
cables harness until it comes
out from the flange side hole, so
as to allow the capture of the
axis 6 motor cables and
encoder.
p.
Pass the XMTR5 and XSYN5
cables in the bushing seat (G)
shown in the figure.
q.
Lock the two cables on the
special seat by using the two
cable ties.
r.
Clamp the wiring as shown in
the picture.
s.
Insert the bushing in the seat
and fasten it using 2 socket hex
head screws M8x16.
Check at the end of
assembly that the bushing
is free to move.
125
Comau Robotics Product Instruction
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Assembly procedure (Continued)
126
t.
Remove the wrist lower guard
and pull out the axis 6 motor
cables and encoder, as
indicated in the figure. Reinsert
the cables in the wrist and
extract them from the upper
opening of the wrist.
u.
Insert the protective guards supplied with the dressing, connect the XMTR6 and
XSYN6 connectors to the axis 6 motor, fix the closing plate (H) and the guard of
the wrist lower opening (J) previously removed.
v.
Disconnect two axis 5 motor cables and encoder and insert the protective guards
supplied with the dressing.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
w.
Remove the cellophane film from the cable package, the metal clamp and cut the
remaining plastic cable ties.
x.
Install the bushing (K) on the wiring and fix to the flange (L) using 4 socket hex
head screws M5x12, respecting the position of the reference dowel pin (M).
y.
Fasten two brackets (N) using 10 socket hex head screws M6x55. Using a torque
wrench tighten with closing torque of 17.5 Nm.
Fasten the pipes to the bulkhead fittings on the flange.
127
Comau Robotics Product Instruction
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Assembly procedure (Continued)
128
z.
Fasten the XMTR8 motor connectors and XSYN8 encoder on the flange using
the supplied plate and 2 socket hex head screws M5x12.
The connector is fixed to the plate using 8 socket head cross-tip screws M3x10.
Assemble the connectors with the polarisers arranged as shown in figure.
a.
Fasten the X200 connectors on the flange using the supplied plate and 2 socket
hex head screws M5x12. The connector is fixed to the plate using 4 socket head
cross-tip screws M3x10. Assemble the connector with the polariser arranged as
shown in figure.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
b.
Fasten the power connector to the support bracket using 2 countersunk hex head
screws M5x10.
Fasten the support bracket to the distributor using 2 socket hex head screws
M6x12.
129
Comau Robotics Product Instruction
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Assembly procedure (Continued)
c.
Fasten the plate using 13
socket hex head screws
M8x25. Using a torque wrench
tighten with a closing torque of
35 Nm.
d.
Fasten the cover casing using 7
socket hex head screws M4x8.
The connectors and fittings features are listed in par. Spot welding service connectors
on Robot SMART5 NJ4 in the Transport, Installation and Integration handbook.
Disassembly procedure
To assemble the pipes and cables harness carry out on reverse order the
operations described previously.
130
Comau Robotics Product Instruction
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5.14 Double Multibus dressing application:
installation/replacement
This paragraph provides detailed information on the assembly of Double multibus
dressing.
Status:
–
The procedure must be carried out
with the system powered off: the main
switch of the cell controller MUST be
in OFF position (closed).
Spare part:
–
Tab. 9.9 - SMART5 NJ4 - Rel. 2.0
Robot dressing spare parts on
page 251
Equipment:
–
5 mm hex Allen wrench;
10 mm hex Allen wrench;
13 mm open-end wrench;
22 mm open-end wrench;
Cross-head screwdriver;
5 mm extractor;
A pair of scissors;
Torque wrench
Fixing
components:
–
Supplied with the assembly kit
Preliminary procedures / notes
The cables are not to be twisted and the connectors are to be protected
against impacts.
Apply the foreseen sealant to the screws when reassembling and tighten
them to the foreseen tightening torque (see Tab. 5.1 - Tightening torque for
Hex head screws and Socket hex head screws (Nm) on page 67Tab. 5.1
- Tightening torque for Hex head screws and Socket hex head screws (Nm)
on page 67, Tab. 5.2 - Threadlocker products on page 68Tab. 5.2
- Threadlocker products on page 68andTab. 5.3 - Products for sealing and
fixing on page 68Tab. 5.3 - Products for sealing and fixing on page 68).
Lubricate with one of the following lubricants:
- OPTIMOL OPTITEMP LG2
- KLUBER POLYLUB GLY801.
131
Comau Robotics Product Instruction
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Assembly procedure
a.
If the Robot functionality allows
it, set the axes in calibration
position to replace the cables
harness.
b.
Lay the wiring out on the ground and cut the locking plastic cable ties of the
cables.
c.
Introduce the cables in the arm
and draw it out from the lower
side.
Take care not to rotate in
an unusual way the
bundle of pipes and
cables
and
avoid
overlaps.
132
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Assembly procedure (Continued)
d.
Remove the support bracket from the robot base and insert the cables and pipes
in the upper bushing.
Pull out the cables and pipes from the distribution panel on Robot base.
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Assembly procedure (Continued)
e.
Fasten the connectors and pipes on panel provided with the kit.
To fasten the X90 and X42 multibus connector (B and C), use 4 socket head
flat-tip screws M3x10, respecting the position shown in the figure.
f.
Fix the upper panel on Robot
base as indicated in the figure.
Use 4 screws C (socket hex
head screws M6x16).
Make sure the pipes are
not constricted and cables
have
the
adequate
bendings.
134
Comau Robotics Product Instruction
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Assembly procedure (Continued)
g.
Reassemble the support bracket D previously removed on the Robot base and
fix the cables locking bracket E of the Double Multibus dressing, using 4 socket
hex head screws M5x8, as shown in the figure.
h.
Fasten the cables locking bracket F of the Double Multibus dressing, using 2
socket hex head screws M6x8, as shown in the figure.
i.
Fasten the cables locking device G on the supplied bracket with 2 socket hex
screws M6x12 H.
Fasten the bracket to the Robot column, unscrewing 2 screws J (socket hex head
screws M6x16) and 2 washers M6.
135
Comau Robotics Product Instruction
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Assembly procedure (Continued)
j.
Fasten the pivoting support
bracket K to the Robot, using
the bracket fixing (L) of the
basic wiring, as indicated in the
figure.
k.
Fasten the bracket with the
locking device on the rotary
plate, using two self-locking
nuts M8, M.
l.
Fasten the rotary plate on the
pivoting support bracket, using
4 screws N (socket hex head
screws M6x12) and 4 toothed
washers.
Before fixing it, grease the
movable part of the
flange.
m.
136
Connect the X26 and X56
mobile connectors P to the
related connectors of the axis 6
motor cables and encoder.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
n.
Insert the draw tape into the hole of the Robot flange and pull out from the rear
hole of the Robot arm.
Tie the draw tape to the Double Multibus dressing wiring. Insert the wiring cable
inside the Robot arm.
Protect with a cellophane film the connectors to avoid crashes and dirt
during the pipes and cables harness insertion in the Robot arm. Check that
there are any obstructions of the connectors along their path. Lubricate the
pipes and cables harness appropriately with one of the following lubricants:
- OPTIMOL OPTITEMP LG2
- KLUBER POLYLUB GLY801.
o.
Pass the XMTR5 and XSYN5
cables in the bushing seat Q
shown in the figure.
p.
Lock the two cables on the
special seat by using the two
cable ties.
137
Comau Robotics Product Instruction
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Assembly procedure (Continued)
138
q.
Remove the wrist lower guard
and pull out the axis 6 motor
cables and encoder, as
indicated in the figure. Reinsert
the cables in the wrist and
extract them from the upper
opening of the wrist.
r.
Insert the protective sheaths supplied with the dressing, connect the XMTR6 and
XSYN6 connectors to the axis 6 motor, fix the closing plate R and the guard of
the wrist lower opening S previously removed.
s.
Disconnect two axis 5 motor cables and encoder and insert the protective guards
supplied with the dressing.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
t.
Remove the cellophane film from the cable package, the metal clamp and cut the
remaining plastic cable ties.
u.
Install the bushing T on the wiring, in correspondence of the protection U,
respecting the position of the reference dowel pin V.
v.
Fasten the bushing W to the
flange Y using 4 socket hex
head screws M5x12, respecting
the position of the reference
dowel pin X.
139
Comau Robotics Product Instruction
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Assembly procedure (Continued)
w.
Fasten two brackets Z using 10
socket hex head screws
M6x55. Using a torque wrench
tighten with a closing torque of
17.5 Nm.
Fasten the pipes to the
bulkhead fittings on the flange.
140
x.
Fasten the X200 connectors on the flange using the supplied plate and 2 socket
hex head screws M5x12. The connector is fixed to the plate using 4 socket head
cross-tip screws M3x10. Assemble the connector with the polariser arranged as
shown in figure.
y.
Fasten the X300 connectors on the flange using the supplied plate and 2 socket
hex head screws M5x12. The connector is fixed to the plate using 4 socket head
cross-tip screws M3x10. Assemble the connector with the polariser arranged as
shown in figure.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
z.
Fasten the plate using 13
socket hex head screws
M8x25. Using a torque wrench
tighten with a closing torque of
35 Nm.
a.
Fasten the cover casing using 7
socket hex head screws M4x8.
Disassembly procedure
To assemble the pipes and cables harness carry out on reverse order the
operations described previously.
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5.15 ALU dressing on Robot NJ 220-2.7.
Wiring installation/replacement
This paragraph provides detailed information on the assembly of SPOT WELDING ALU
dressing with electric welding gun.
The procedure is valid also in case of spot welding application with pneumatic welding
gun, except for details on assembly of the motor cables (XMTR8) and encoder (XSYN8)
of the welding gun because they are not present.
Status:
–
The procedure must be carried out
with the system powered off: the main
switch of the cell controller MUST be
in OFF position (closed).
Spare part:
–
Tab. 9.9 - SMART5 NJ4 - Rel. 2.0
Robot dressing spare parts on
page 251
Equipment:
–
5 mm hex Allen wrench;
10 mm hex Allen wrench;
13 mm open-end wrench;
22 mm open-end wrench;
Cross-head screwdriver;
5 mm extractor;
A pair of scissors;
Torque wrench.
Fixing
components:
–
Supplied with the assembling kit.
Preliminary procedures / notes
The cables are not to be twisted and the connectors are to be protected
against impacts.
Apply the foreseen sealant to the screws when reassembling and tighten
them to the foreseen tightening torque (see Tab. 5.1 - Tightening torque for
Hex head screws and Socket hex head screws (Nm) on page 67, Tab. 5.2
- Threadlocker products on page 68 and Tab. 5.3 - Products for sealing
and fixing on page 68).
Lubricate with one of the following lubricants:
- OPTIMOL OPTITEMP LG2
- KLUBER POLYLUB GLY801.
142
Comau Robotics Product Instruction
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Disassembly procedure
b.
Remove the cover casing
unscrewing 7 socket hex head
screws M4x8 (A).
c.
Remove the plate unscrewing
13 socket hex head screws
M8x25 (B) using a torque
wrench.
d.
Remove the support bracket from the distributor unscrewing 2 socket hex head
screws M6x12 (D).
e.
Remove the power connector to the support bracket using 2 socket hex head
screws M5x10 (C).
143
Comau Robotics Product Instruction
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Disassembly procedure (Continued)
f.
144
Remove the connector from the plate, unscrewing 4 socket head flat-tip screws
M3x10.
Remove the X200 connector from the flange, unscrewing 2 socket hex head
screws M5x12 and removing the supplied plate.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Disassembly procedure (Continued)
g.
Remove the connector fixed to the plate using 8 socket head cross-tip screws
M3x10.
Remove the XMTR8 motor connectors and XSYN8 encoder from the flange,
unscrewing 2 socket hex head screws M5x12 from the supplied plate.
145
Comau Robotics Product Instruction
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Disassembly procedure (Continued)
h.
146
Remove the pipes fixed to the bulkhead fittings from the flange.
Remove two brackets (E) unscrewing 10 socket hex head screws M6x55.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Disassembly procedure (Continued)
i.
Remove the plug on the X9B
connector.
j.
Remove the panel on the robot
base as indicated in the figure
unscrewing 4 socket hex head
screws M6x16 (F).
k.
Remove the connectors and
pipes on panel provided with
the kit.
Remove the X28 Harting
connector (G) of the axis 8
motor, using 4 socket head
flat-tip screws M4x10.
Remove the X9A and X9B
power connectors unscrewing 4
socket head cross-tip screws
M5x30.
l.
Disconnect the green water
pipes H2O cold (green collar)
and H2O hot (red collar) from
the bulkhead pipe fittings.
m.
Remove the plug on the axis 4
(H).
147
Comau Robotics Product Instruction
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Disassembly procedure (Continued)
148
n.
Remove the bushing from the
flange unscrewing 4 socket hex
head screws M6x25, then
remove it from the wiring.
o.
Remove the metal cable tie (K),
clamp and cover the pipes and
cables
harness
with
cellophane.
p.
Remove the 2 screws M8x25
and spacers (L) and pull out the
bushing from its seat.
q.
Cut the
dressing.
r.
Remove two locking cable ties.
s.
Pull out the XMTR5 and XSYN5
cables from the bushing seat
(M) shown in the figure.
cable
ties
from
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Disassembly procedure (Continued)
t.
Disconnect the X26, X56, X200
mobile connectors and the
black air pipe AIR2 (yellow
collar) to the base wiring.
u.
Disconnect the connectors
XMTR5 and XSYN5 to the axis
5 motor of the Robot as shown
in the figure.
It is necessary to insert the
rubber gasket (N) to protect the
output hole of the cables from
the Robot arm.
After
disconnecting
the
connectors remove the sheath
from the cables supplied with
the dressing.
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Comau Robotics Product Instruction
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Disassembly procedure (Continued)
v.
150
Protect with a cellophane
film the connectors to
avoid impacts and dirt
during the pipes and
cables harness removal
from the Robot arm.
Check that there are any
obstructions
of
the
connectors along their
path. Lubricate the pipes
and
cables
harness
appropriately with one of
the following lubricants:
- OPTIMOL OPTITEMP
LG2
- KLUBER POLYLUB
GLY801.
w.
Remove the closing plate (P) and disconnect the XMTR6 and XSYN6 from the
axis 6 motor. Remove the sheath from the cables supplied with the dressing.
x.
Pull out the axis 6 motor cables
and encoder as indicated in the
figure. Reinsert the cables in
the wrist and extract them from
the upper opening of the wrist.
y.
Pull out the axis 6 motor cables
and encoder from the wrist,
previously inserted into the
upper opening.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Disassembly procedure (Continued)
z.
Pull out the wiring from the
bushing of axis 4.
a.
Remove the rotary plate (R)
from the pivoting support
bracket, unscrewing 4 socket
hex head screws M6x12 (S).
b.
Remove the rotary flange from
the locking device unscrewing 2
self-locking nuts M8 (T).
151
Comau Robotics Product Instruction
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Disassembly procedure (Continued)
152
c.
Release the bracket from the
robot arm unscrewing 2 socket
hex head screws M6x16 (U).
d.
Remove the bracket (V) from
the cables locking unscrewing 2
screws M6x12 (W).
e.
Remove the cables locking (Z)
of the spot dressing unscrewing
2 socket hex head screws M6x8
(AA).
f.
Remove the cables locking
bracket (Y) of the spot dressing,
unscrewing 4 socket hex head
screws M5x8.
g.
Loosen the support bracket (X)
from the robot base.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Disassembly procedure (Continued)
h.
Pull cables and pipes from the upper bushing accompanying them from the base
robot sorting.
The connectors and fittings features are listed in par. Spot welding service connectors
on Robot SMART5 NJ4 in the Transport, Installation and Integration handbook.
153
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Assembly procedure
154
a.
If the Robot functionality allows
it, set the axes in calibration
position to replace the cables
harness.
b.
Lay the wiring out on the ground
and cut the locking plastic cable
ties of the cables.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
c.
Insert the wiring inside the arm
and pull it from the lower part of
the axis 1.
Be careful not to rotate in
an unusual way the pipes
and cables harness and
avoid overlaps.
d.
Loosen the support bracket on the Robot base to facilitate the passage of the
dressing cables.
e.
Insert the Harting connector, power connectors and the water pipes in the upper
bushing.
Pull out the cables and pipes from the distribution panel on Robot base.
155
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
156
f.
Fasten the cables locking
bracket (Y) of the spot dressing,
unscrewing 4 socket hex head
screws M5x8 and 4 hex nuts
M4.
g.
Fasten the cables locking (Z)
using 2 socket hex head screws
M6x8 (AA).
h.
Fix the support bracket (X) on
the Robot base.
i.
Fasten the cables locking (V) to
the bracket using 2 screws
M6x12 (U).
j.
Fasten the bracket on the robot
arm, using 2 screws (socket hex
head screws M6x16) and 2
washers M6 (W).
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
k.
Fasten the rotary flange to the
locking device unscrewing 2
self-locking nuts M8 (T).
l.
Fasten the rotary plate (R)on
the pivoting support bracket,
using 4 socket hex head screws
M6x12 and 4 toothed washers
(S).
Before fixing it, grease the
movable part of the
flange.
157
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
158
m.
Insert the draw tape into the
hole of the Robot flange and
pull out from the rear hole of the
Robot arm.
n.
Clamp the wiring.
o.
Pull back the 6 axis motor cable
(Q) and insulate it from the
opposite side to the green
pipes.
Protect with a cellophane
film the connectors to
avoid impacts and dirt
during the pipes and
cables harness insertion
in the Robot arm. Check
that
there
are any
obstructions
of
the
connectors along their
path. Lubricate the pipes
and
cables
harness
appropriately with one of
the following lubricants:
- OPTIMOL OPTITEMP
LG2
- KLUBER POLYLUB
GLY801.
p.
Tie the draw tape to the spot
dressing wiring. Insert the
wiring inside the Robot arm with
the power connector facing
towards the left side.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
q.
Pull
the
draw
tape
accompanying the pipes and
cables harness until it comes
out from the flange side hole, so
as to allow the capture of the
axis 6 motor cables and
encoder.
r.
Pull out the XMTR6 and XSYN6
cables as shown in the picture.
s.
Reinsert the XMTR6 and
XSYN6 cables in the wrist and
extract them from the upper
opening of the wrist.
159
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
160
t.
Connect the XMTR6 and XSYN6 connectors to axis 6 motors and fasten the
closing plate (P). Before connecting the connectors insert on the cables the
sheath provided with the dressing.
u.
Connect the XMTR5 and
XSYN5 connectors to the axis 5
motor of the Robot as shown in
the figure.
It is necessary to insert the
rubber gasket (N) to protect the
output hole of the cables from
the Robot arm.
Before
connecting
the
connectors insert on the cables
the sheath provided with the
dressing.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
v.
Connect the X26, X56, X200
mobile connectors and the
AIR2 black air pipe to the base
wiring.
w.
Pass the XMTR5 and XSYN5
cables in the bushing seat (M)
shown in the figure.
x.
Lock the two cables on the
special seat by using the two
cable ties.
y.
Clamp
the
dressing
indicated in figure.
z.
Insert the bushing in the seat
and fasten it with 2 socket hex
head screws M8x25 and
spacers (L).
as
Check at the end of
assembly that the bushing
is free to move.
a.
Remove the protective film from
the pipes and cables harness.
161
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
162
b.
Remove the plastic cable ties
and fix the metal cable tie (K).
c.
Install the bushing on the wiring
using 4 socket hex head screws
M6x25, respecting the position
of the reference dowel pin.
d.
Fasten the aluminium bushing
to the robot wrist centering the
reference dowel pin (J).
e.
Fasten the plug on the axis 4
previously removed (H).
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
f.
Fasten the connectors and
pipes on panel provided with
the kit.
Fasten
the
X28
Harting
connector (C) of the motor axis
8 using 4 socket head cross-tip
screws M4x10.
Fasten the X9A and X9B power
connectors using 4 socket head
cross-tip
screws
M5x30,
respecting
the
position
indicated in figure.
g.
Connect the green water pipes
H2O cold (green collar) and
H2O hot (red collar) to the
bulkhead pipe fittings.
h.
Fix the upper panel on the
Robot base as indicated in the
figure. Use 4 socket hex head
screws M6x16 (F).
i.
Ensure that on the X9B
connector is present the plug.
163
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
j.
164
Fasten two brackets (E) using 10 socket hex head screws M6x55. Using a torque
wrench tighten with a closing torque of 17.5 Nm.
Fasten the pipes to the bulkhead fittings on the flange.
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
k.
Fasten the XMTR8 motor connectors and XSYN8 encoder on the flange using
the supplied plate and 2 socket hex head screws M5x12.
The connector is fixed to the plate using 8 socket head cross-tip screws M3x10.
Assemble the connectors with the polarisers arranged as shown in figure.
165
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
166
l.
Fasten the X200 connectors on the flange using the supplied plate and 2 socket
hex head screws M5x12. The connector is fixed to the plate using 4 socket head
cross-tip screws M3x10. Assemble the connector with the polariser arranged as
shown in figure.
m.
Fasten the power connector to the support bracket using 2 socket hex head
screws M5x10 (C).
Fasten the support bracket to the distributor using 2 socket hex head screws
M6x12 (D).
Comau Robotics Product Instruction
SPECIAL MAINTENANCE - WIRING INSTALLATION/REPLACEMENT
Assembly procedure (Continued)
n.
Fasten the plate using 13
socket hex head screws M8x25
(A) by means of a torque
wrench tighten with a closing
torque of 35 Nm.
o.
Fasten the cover casing using 7
socket hex head screws M4x8
(B).
The connectors and fittings features are listed in par. Spot welding service connectors
on Robot SMART5 NJ4 in the Transport, Installation and Integration handbook.
167
Comau Robotics Product Instruction
OPTIONS
6.
OPTIONS
6.1 Generalities
The mechanical option list and the quantity that can be installed on the Robot is
described in the following table, in this chapter some options requiring a more detailed
installation procedure are described.
Before starting any operation, read carefully the Chap.1. - General Safety Requirements
on page 11 and the Chap.5.2 - Assembly notes on page 67 in order to be aware of the
general requirements and specific fixing components.
Robot maintenance operations must be carried out with the system powered off: the
main switch MUST be in OFF position (closed).
Tab. 6.1 - Available options
COMAU Part No.
SMART5
Description
NJ4 170-2.5
NJ4 175-2.2
NJ4 170-2.9
NJ4 220-2.4
NJ4 220-2.7
CR82343300
CR82343200
CR82342200
Axis 1 Workspace Partialization Unit: assembly (1 area Part No. 82343300 - 2
areas Part No. 82343200- 3 areas Part No. CR82342200)-
CR82342300 CR82344900
Axis 2 Work Area Partialization Unit: assembly (Part No. CR82342300; Part No.
CR82344900)
CR82342400
Axis 1 Adjustable Mechanical Hard Stop Unit: assembly (Part No. CR82342400)
-
CR82344800 Axis 2 Adjustable Mechanical Hard Stop Unit: assembly (Part No. CR82344800)
-
CR82344800 Axis 2 Adjustable Mechanical Hard Stop Unit: assembly (Part No. CR82344800)
CR82342700
Screws and Pins Assembly for Robot Fixing (Part No. CR82342700)
CR82342800
Levelling Plate Assembly for Robot Fixing (Part No. CR82342800)
CR82343100
Non-levelling plate assembly for Robot fixing (Part No. CR82343100)
CR82344300
Axis 1 On-Off Mechanical Hard Stop Unit (Part No. CR 82344300): assembly
CR82348800
Fall-prevention Bracket Unit for Fixing on Ceiling: assembly (Part No.
CR82348800)
CR82344700
NJ Fixing on Ceiling and Fall-prevention Unit - BRIC: assembly (Part No.
CR82344700)
82314100
Calibration Tool (Part No. 82314100)
82109501
Calibrated Tool Unit - Tool Master (L= 200 Part No. 82109501)
CR82342200
-
168
Distribution panel connections walkable protection unit (Part No. CR 82352200)
CR82274800 Fork unit
Comau Robotics Product Instruction
OPTIONS - AXIS 1 WORKSPACE PARTIALIZATION UNIT
6.2 Axis 1 Workspace Partialization Unit:
assembly (1 area Part No. 82343300 - 2 areas
Part No. 82343200- 3 areas Part No.
CR82342200)
Workspace partialization unit
1- 2 areas axis 1
Status:
–
The procedure must be carried out
with the system powered off: the main
circuit breaker of the cell controller
MUST be in OFF position (closed).
Material:
–
Axis 1 workspace partialization unit - 1
area (Part No. 82343300).
Axis 1 workspace partialization unit - 2
areas (Part No. 82343200).
–
Workspace partialization unit
3 areas axis 1
Status:
–
The procedure must be carried out
with the system powered off: the main
circuit breaker of the cell controller
MUST be in OFF position (closed).
Material:
–
Axis 1 workspace partialization unit - 3
areas (Part No. 82342200).
Equipment:
–
T-wrench with hex male for socket hex
head screws.
Fixing
components:
–
–
–
Stub socket hex head screws M6x10;
Socket hex grub screws M6x8;
Low hex nut M6-0.5-FE/ZN;
Partialization device 1 - 2 areas
–
Socket hex head screws M6x45
–
Pin ∅ = 4x40
Partialization device 3 areas
–
Socket hex head screws M6x20
–
Pin ∅ 4x20
169
Comau Robotics Product Instruction
OPTIONS - AXIS 1 WORKSPACE PARTIALIZATION UNIT
Preliminary procedures / Notes
The installation of the unit is the task of the integrator and is to be carried
out observing the safety precautions contained at the beginning of this
handbook.
The possible assembling positions are indicated in the diagram of the
Robot Technical Specifications handbook.
Remember that the installation positions shall be established according to
safety criteria foreseen in the cell.
Apply the prescribed sealant to the screws when reassembling and tighten
them to the prescribed tightening torque (see Tab. 5.2 - Threadlocker
products on page 68 and Tab. 5.1 - Tightening torque for Hex head screws
and Socket hex head screws (Nm) on page 67).
In case of maintenance interventions it is necessary to verify the proper
functioning of the unit and the lock of the fixing screws:
–
–
–
Avoid the overhaul and/or replacement of some unit items; it is recommended to
replace always the entire unit.
Remove any equipment/piping installed on the Robot that interfere with the fixing
seats of the cam holders.
The installation position must be coherent with what has been required by the cell
projecting.
Assembly
170
Comau Robotics Product Instruction
OPTIONS - AXIS 1 WORKSPACE PARTIALIZATION UNIT
Assembly (Continued)
Cams customization
a.
Customise the plastic cams cutting them to the required by the working cycle
length and chamfer the ends considering the following indications:
–
the “A” type cut is required if the cam end (Y) is not positioned in the space Z (cam
holder milling provided for insertion).
–
the “B” type cut is required if one end of the cam remains positioned above the
milling on the cams guide Z.
Measurement “K” is to be defined when assembling, to allow the cam
locking on the adjacent guide overcoming the guide milling.
Cams installation
b.
Insert into the cam groove the
low hex nut M6 with the grub
screw M6 (A) moving them
where the cam end will be
presumably installed.
c.
Insert the cams into the cam
holder by sliding them through
the milling in the direction
indicated by the arrow.
171
Comau Robotics Product Instruction
OPTIONS - AXIS 1 WORKSPACE PARTIALIZATION UNIT
Assembly (Continued)
d.
Position the cams accurately in
the cam holder taking into
consideration the working cycle
strokes, then tighten the fixing
grub screws.
e.
For 1 and 2 areas partialization
unit, proceed as follows:
e.1 Fix the interface plate (1) and
the limit switch (2) to the Robot
base using two socket hex head
screws M6x45 and lock by two
pins D = 4x40.
172
f.
For 3 areas partialization unit,
proceed as follows:
f.1
Position the limit switch on the
seat of the Robot base using
the two dowel pins (B) M4x20.
f.2
Fix the limit switch using the two
socket hex head screws (A)
M6x20.
g.
For the electrical connection to
the user line of the 1 and 2
areas limit switch assembly,
there is available a 19-pin
female mating connector (A)
90° cable 14-60.
Comau Robotics Product Instruction
OPTIONS - AXIS 1 WORKSPACE PARTIALIZATION UNIT
Assembly (Continued)
h.
For the electrical connection to
the user line on the limit switch
of the 3 areas limit switch
assembly, there is available a
Harting connector (B).
For further information regarding the connector pinout, see the Robot
Circuit Diagram.
173
Comau Robotics Product Instruction
OPTIONS - AXIS 2 WORKSPACE PARTIALIZATION UNIT
6.3 Axis 2 Work Area Partialization Unit:
assembly
(Part No. CR82342300; Part No. CR82344900)
Status:
–
The procedure must be carried out with
the system powered off: the main circuit
breaker of the cell controller MUST be in
OFF position (closed).
Material:
–
Axis 2 work area partialization unit Part
No. see Tab. 6.1 - Available options on
page 168
Equipment:
–
Hex male T-wrench for socket hex head
screws;
Hammer and punch for pin.
–
Fixing
–
components: –
–
–
–
Socket hex head screws M6x20; q.ty 6
Stub socket hex head screws M6x8; q.ty 4
Socket hex grub screws M6x8;
q.ty 6
Low hex nut M6-05-FE/ZN; q.ty 8
Pin ∅ 4x20 with extraction hole; q.ty 2
Preliminary procedures / Notes
The installation of the unit is the task of the integrator and is to be carried
out observing the safety precautions contained at the beginning of this
handbook.
The possible assembling positions are indicated in the diagram of the
Robot Technical Specifications handbook.
Remember that the installation positions shall be established according to
safety criteria foreseen in the cell.
Apply the prescribed sealant to the screws when reassembling and tighten
them to the prescribed tightening torque (see Tab. 5.2 - Threadlocker
products on page 68 and Tab. 5.1 - Tightening torque for Hex head screws
and Socket hex head screws (Nm) on page 67).
In case of maintenance interventions it is necessary to verify the proper
functioning of the unit and the lock of the fixing screws:
–
–
–
174
Avoid the overhaul and/or replacement of some unit items; it is recommended to
replace always the entire unit.
Remove any equipment/piping installed on the Robot that interfere with the fixing
seats of the cam holders.
The installation position must be coherent with what has been required by the cell
projecting.
Comau Robotics Product Instruction
OPTIONS - AXIS 2 WORKSPACE PARTIALIZATION UNIT
Assembly
a.
Insert the cable in the Robot
base from the free wire ferrules
side. If the limit switch unit is
installed on a Robot dressed for
Spot welding, it is necessary to
remove the right side panel on
the Robot base.
It is recommended to bound
together all wire end ferrules, in
order to facilitate the passage.
b.
Draw out the cable end from the
central hole of the base.
The figure represents a Robot
with Spot welding dressing.
175
Comau Robotics Product Instruction
OPTIONS - AXIS 2 WORKSPACE PARTIALIZATION UNIT
Assembly (Continued)
c.
176
Pass the cable through the
support bracket hole and fasten
it with a cable tie to the other
cables.
The figures represent a Robot
in Handling configuration and a
Robot in Spot configuration
respectively.
Comau Robotics Product Instruction
OPTIONS - AXIS 2 WORKSPACE PARTIALIZATION UNIT
Assembly (Continued)
d.
Remove the adhesive tape from
the wire ferrules.
e.
Mount the cable gland on the
cable.
177
Comau Robotics Product Instruction
OPTIONS - AXIS 2 WORKSPACE PARTIALIZATION UNIT
Assembly (Continued)
f.
Insert the wire end ferrules in
the limit switch and screw the
cable gland on the metal
casing.
g.
Connect the wire end ferrules
as shown in figure.
h.
Close the limit switch with a
cover.
S4-13 S4-21
S3-13 S3-21
S2-13 S2-21
S1-13 S1-21
i.
178
Disassemble the cable clamp
on the connector on the
opposite side of the cable, so as
to unscrew the connector body.
Loosen the connector body to
pass the connector in the plate
on Robot base.
S4
S3
S2
S1
S4-22 S4-14
S3-22 S3-14
S2-22 S2-14
S1-22 S1-14
Comau Robotics Product Instruction
OPTIONS - AXIS 2 WORKSPACE PARTIALIZATION UNIT
Assembly (Continued)
j.
Insert the connector in the plate.
k.
Reassemble the connector
body and the cable clamp
l.
Fix the connector on the panel
(in the indicated position) with 4
provided cross head screws
M3.
The panel in the figure is in Spot
configuration. The procedure is
the same for the Robots in
Handling configuration.
179
Comau Robotics Product Instruction
OPTIONS - AXIS 2 WORKSPACE PARTIALIZATION UNIT
Assembly (Continued)
m.
Fix partially the cam holders to
the castings and screw without
tightening the 4 socket hex
head screws M6x20.
n.
Fix the cam holders to the
support by means of stub
socket hex head screws M6x10
(C)
o.
Insert into the cam groove the
low hex nut M6 with the socket
hex grub screw M6x8 moving
them where the cam end will be
presumably installed.
The maximum length of the cam must be such as to allow proper
positioning and fixing of the hexagonal nuts for blocking the cam to the 2
ends.
p.
180
Customise the plastic cams cutting them to the length required by the working
cycle and chamfer the ends Y.
Comau Robotics Product Instruction
OPTIONS - AXIS 2 WORKSPACE PARTIALIZATION UNIT
Assembly (Continued)
q.
Insert the cams in the cam
holder by sliding them in the
milling.
r.
Fix the cams in the required by
the working cycle position,
locking the socket hex grub
screws M6x8.
s.
Insert the two pins ∅ 4x20 (A) to
centre the limit switch in the
foreseen seats on the Robot
column.
t.
Fit the limit switch unit on the
pins and fix it to the Robot
column with 2 socket hex head
screws M6x20 (B)
u.
Tighten the fixing screws of the
cams support (see step m.).
v.
Follow the X42 connector pinout for connection with safety circuits of the
production line. The counterpart (female mating connector) is provided with the
kit.
The Robot safety limit switch signals must be integrated in safety
circuits able to guarantee the safety levels required by the existing
standards.
181
Comau Robotics Product Instruction
OPTIONS - AXIS 2 WORKSPACE PARTIALIZATION UNIT
Assembly (Continued)
S4
S3
S2
S1
Tab. 6.2 - Pin connector X42 on Robot base
182
X42 Pin
Plugger No.
Contact No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
1
N.O. 13
N.O. 14
N.C. 21
N.C. 22
N.O. 13
N.O. 14
N.C. 21
N.C. 22
N.O. 13
N.O. 14
N.C. 21
N.C. 22
N.O. 13
N.O. 14
N.C. 21
N.C. 22
-
2
3
4
GROUND
Comau Robotics Product Instruction
OPTIONS - AXIS 1 ADJUSTABLE MECHANICAL HARD STOP UNIT
6.4 Axis 1 Adjustable Mechanical Hard Stop Unit:
assembly
(Part No. CR82342400)
Status:
–
The procedure must be carried out
with the system powered off: the main
circuit breaker of the cell controller
MUST be in OFF position (closed).
Material:
–
Axis 1 adjustable mechanical hard
stop unit: CR82342400
Equipment:
–
Hex wrenches for socket hex head
screws
Fixing
components:
–
Socket hex head screws M20x
90-12.9 q.ty 4.
Preliminary procedures / Notes
–
–
Remove any equipment/piping installed on the Robot that interfere with the fixing
seat of the mechanical stoppers
The axis 1 adjustable mechanical hard stop unit allows to limit the axis 1 stroke
in the two working directions with steps of 15°, if necessary to limit the stroke only
in one direction, use only one of the two stoppers.
183
Comau Robotics Product Instruction
OPTIONS - AXIS 1 ADJUSTABLE MECHANICAL HARD STOP UNIT
Assembly
a.
Position
the
mechanical
stoppers in the base seats in
relation to the stroke limits to be
obtained.
-
+
1
2
b.
184
Lock on the base the
mechanical stoppers by means
of the screws M20x90 (A).
Stopper ax.1 (q.ty 2)
Socket hex head screw M20 x
90-12.9
Comau Robotics Product Instruction
OPTIONS - AXIS 2 ADJUSTABLE MECHANICAL HARD STOP UNIT
6.5 Axis 2 Adjustable Mechanical Hard Stop Unit:
assembly (Part No. CR82344800)
Front stopper ax.2 -
Status:
–
The procedure must be carried out
with the system powered off: the main
circuit breaker of the cell controller
MUST be in OFF position (closed).
Material:
–
Axis 2 adjustable mechanical hard
stop unit: CR82344800
Equipment:
–
Hex male T-wrench for socket hex
head screws
Fixing
components:
–
Socket hex head screws M12x45 (q.ty
12)
Rear stopper ax.2 -
Preliminary procedures / Notes
–
–
Remove any equipment/piping installed on the Robot that interfere with the fixing
seat of the mechanical stoppers
The unit allows to limit the axis 2 stroke in the two working directions with steps
of 12°; if necessary to limit the stroke only in one direction, use only one of the
two stoppers.
185
Comau Robotics Product Instruction
OPTIONS - AXIS 2 ADJUSTABLE MECHANICAL HARD STOP UNIT
Assembly
186
a.
Set in the column seats the mechanical stoppers on the front side and the rear
side depending on the stroke reduction to be obtained.
1
2
3
Rear stopper ax.2
Front stopper ax.2
Socket hex head screw M12 x 45 -12.9 (Q.ty 12)
b.
Lock the mechanical stoppers
to the column by means of
M12x45 screws.
Comau Robotics Product Instruction
OPTIONS - AXIS 1 ON-OFF MECHANICAL HARD STOP UNIT
6.6 Axis 1 On-Off Mechanical Hard Stop Unit
(Part No. CR 82344300): assembly
Status:
–
Maintenance operations on the Robot
shall be carried out with the system
powered off: the main switch MUST be
in OFF position (closed) and locked
(e.g. with a padlock); in the same way
cut off and lock the pneumatic line.
Material:
–
Axis 1 on-off mechanical hard stop
unit: CR 82344300
Equipment:
–
17 and 19 mm hex male T-wrenches
Fixing
components:
–
Socket hex head screw M20x70 (for
unit fixing from upper side of the base)
Socket hex head screw M24x90 (for
unit fixing from lower side of the base)
–
–
–
–
–
–
–
–
The installation of the ON-OFF mechanical had stop is the responsibility of
the integrator and must be performed in compliance with the safety
requirements given at the beginning of this handbook.
During the lay-out definition, to identify the areas occupied by the Robot
inside the partialized sector, consider the maximum overall position reached
both by loads moved by the wrist, and by the equipment installed on the
forearm. THE ACCESS TO THE ABOVE-MENTIONED AREAS MUST BE
PROHIBITED TO THE OPERATORS.
The integrator must guarantee that the equipment mounted on the Robot in
case of hard stop intervention (impact) does not enter the partialized area.
THE INSTALLATION OF THE ON-OFF MECHANICAL HARD STOP MUST
FORESEE THE CONTEMPORANEOUS PRESENCE OF THE WORKSPACE
PARTIALIZATION UNIT which allows to determine the Robot presence in a
determined zone of the workspace, and therefore exclude its presence in the
partialized area.
After maintenance interventions or mechanical impacts it is necessary to
check the proper functioning of the unit and the lock of the fixing screws.
For the overhaul and/or replacement of some elements of the unit, it is
recommended to contact the COMAU Service Center.
Before starting any type of operation, carefully read Chap.1. - General Safety
Requirements on page 11.
Technical features and requirements for the unit installation are listed in the chapter
Options of the TECHNICAL SPECIFICATIONS handbook.
187
Comau Robotics Product Instruction
OPTIONS - AXIS 1 ON-OFF MECHANICAL HARD STOP UNIT
.
Assembly
188
a.
Clean the Robot base in the
fixing seat of the unit, chosen
depending on the required axis
1 stroke
b.
If
present,
remove
the
protections from the threaded
holes on the base foreseen for
fixing the unit to the base.
c.
Screw two eyebolts M10 in the
holes on the hard stop body.
d.
Hook a rope to the two eyebolts
and handle the unit using a
lifter.
e.
By means of the lifter, take the
hard stop unit to the Robot base
positioning it in the seat
foreseen for assembly.
f.
Fix the hard stop to the Robot
base by means of two socket
hex head screws M20x70 (1).
Comau Robotics Product Instruction
OPTIONS - AXIS 1 ON-OFF MECHANICAL HARD STOP UNIT
Assembly
g.
Connect to the fitting (1) one
pipe of int. Ø 4mm and out. Ø
6mm for pneumatic power
supply of the unit
h.
Connect the Harting connector
(2) of the interconnection cable
to the corresponding connector
on the hard stop unit.
The lockout pin motion can cause danger of crushing between the lockout pin and Robot
base seat; therefore, pay attention during lockout pin motion phases.
Micro limit switch SG3 replacement
a.
Detach
the
HARTING
connector from the unit.
b.
Unscrew the 4 screws M4x10
(2) and remove the guard 1
paying
attention
to
the
pneumatic
and
electrical
connections of the servo
valves.
c.
Unscrew the two socket hex
head screws M6x16 (2) and
remove the bracket (1) with the
micro limit switch from the unit.
d.
Remove the micro limit switch
from the bracket, unscrewing
the two screws M6x16 and
disconnect
the
electrical
connections.
189
Comau Robotics Product Instruction
OPTIONS - AXIS 1 ON-OFF MECHANICAL HARD STOP UNIT
Micro limit switch SG3 replacement
e.
Fix the new limit switch to the
bracket (1) with the screws (2)
M6x16 precisely aligning the
front profile to the bracket.
f.
In the position described in step
e. bore on the limit switch base
the plugs seat (3) to Ø4mm H7.
g.
Insert the pins Ø 4 x 12 mm and
tighten the screws (2).
h.
Reassemble the limit switch
and bracket onto the unit and
complete the reassembly.
Maintenance
a.
Every 5000 hours, inject 10gr of
grease ALBIDA RL2 to lubricate
the internal components of the
assembly using the manual
grease pump shown in the
figure.
Tab. 6.3 - Spare parts
COMAU PART
NO.
CR82344300
190
Description
Q.ty
Axis 1 on-off mechanical hard stop complete unit
1
82315809
Multiple micro limit switch SG3
1
82315813
VD1-VD2 solenoid valve
2
82315820
Connector for solenoid valve
2
Comau Robotics Product Instruction
OPTIONS - AXIS 1 ON-OFF MECHANICAL HARD STOP UNIT
Fig. 6.1
- Location of components
Fig. 6.2
- Pneumatic diagram
191
Comau Robotics Product Instruction
OPTIONS - AXIS 1 ON-OFF MECHANICAL HARD STOP UNIT
Fig. 6.3
192
- Electrical circuit diagram
Comau Robotics Product Instruction
OPTIONS - AXIS 1 ON-OFF MECHANICAL HARD STOP UNIT
Fig. 6.4
- Lockout pin connected
OFF ON
Fig. 6.5
ON
OFF
- Lockout pin disconnected
ON OFF
OFF
ON
193
Comau Robotics Product Instruction
OPTIONS - AXIS 1 ON-OFF MECHANICAL HARD STOP UNIT
Tab. 6.4 - Lockout pin status
VD1
VD2
SG1
SG2
SG3/1
SG3/2
Lockout pin connected
OFF
ON
ON
OFF
Released
Activated
Lockout pin disconnected
ON
OFF
OFF
ON
Activated
Released
194
Comau Robotics Product Instruction
OPTIONS - ASSEMBLIES FOR ROBOT FIXING
6.7 Screws and Pins Assembly for Robot Fixing
(Part No. CR82342700)
1.
2.
3.
4.
5.
6.
7.
Centring pin Ø = 30 mm L = 80 mm (q.ty = 1)
Centring pin Ø = 30 mm L = 60 mm (q.ty = 1)
Socket hex head screw M 10 x 90 (8.8) (q.ty = 1)
Socket hex head screw M 10 x 70 (8.8) (q.ty = 1)
Partially threaded hex head screw M 24 x 100 (8.8.) (q.ty = 4)
Split spring washer Ø = 24mm (q.ty = 4)
Flat washer Ø = 24 mm (q.ty = 4)
195
Comau Robotics Product Instruction
OPTIONS - ASSEMBLIES FOR ROBOT FIXING
6.7.1
Description
The assembly consists of screws and pins needed to fix the Robot to a steel plate fitted
with appropriate holes.
The steel plate and its arrangement for the Robot fixing must be carried out by the
installer referring to the figure presented in this paragraph.
6.8 Levelling Plate Assembly for Robot Fixing
(Part No. CR82342800)
1
1
1.
2.
3.
4.
5.
Levelling plate (q.ty = 1)
Plate (q.ty = 4)
Straight edge (q.ty = 8)
Fully threaded hex head screw M20x100-8.8 (q.ty = 4)
Hex nut M20 -8 FE/ZN 12 (q.ty = 4)
The figure illustrates an example of fixing the plate to the floor. Other solutions may be
carried out by the installer, on condition that the stresses produced by the Robot and the
resistance conditions of fixing surface are verified.
196
Comau Robotics Product Instruction
OPTIONS - ASSEMBLIES FOR ROBOT FIXING
6.8.1
Description
The levelling plate assembly for Robot fixing allows the correct anchoring of the Robot
to the floor. The assembly allows to meet the following requirements:
–
ensure a good flatness of the supporting surface in order to avoid abnormal
stresses on the Robot base structure;
–
possibility to assemble the Robot plumb and level in order to facilitate "off-line
programming" applications
The assembly consists of:
–
four steel plates to be fixed to the floor by means of chemical sleeve anchors (for
a total of 16 sleeve anchors, not included in the supply).
–
a levelling plate to be welded on the plates specified above after having reached
the optimal Robot levelling condition, operating on the specific levelling screws.
197
Comau Robotics Product Instruction
OPTIONS - ASSEMBLIES FOR ROBOT FIXING
6.9 Non-levelling plate assembly for Robot fixing
(Part No. CR82343100)
1.
Robot fixing plate
The figure illustrates an example of fixing the plate to the floor. Other solutions may be
carried out by the installer, on condition that the stresses produced by the Robot and the
resistance conditions of fixing surface are verified.
6.9.1
Description
The unit consists of a steel plate with holes for chemical sleeve anchors for fixing on the
floor (for a total of 12 sleeve anchors not included in the supply) and with holes for fixing
the Robot on the plate.
198
Comau Robotics Product Instruction
OPTIONS - FALL-PREVENTION BRACKETS UNIT FOR FIXING ON CEILING
6.10 Fall-prevention Bracket Unit for Fixing on
Ceiling: assembly (Part No. CR82348800)
Status:
–
The procedure must be carried out
with the system powered off: the main
circuit breaker of the cell controller
MUST be in OFF position (closed).
Material:
–
Fall-prevention brackets unit for fixing
on ceiling - (Part No. CR82348800)
Screws and pins unit for Robot fixing
(Part No. CR82342700)
5 mm, 17mm hex head wrenches
24mm, 36 mm wrenches
–
–
–
Preliminary procedures / Notes
–
–
The assembly of the Brackets Unit requires the use of the unit Screws and Pins
Unit for Robot Fixing (Part No. CR82342700) or components equivalent to those
included in that unit.
Remove any fixtures / piping installed on the Robot that interfere with the fixing
seats of the brackets.
See the chapter Options in the TECHNICAL SPECIFICATIONS handbook
to determine centre distances and diameters of the holes in the Robot
fixing plate.
Apply the foreseen sealant to the screws when reassembling and tighten them to the
foreseen tightening torque (see Tab. 5.2 - Threadlocker products on page 68 and
Tab. 5.1 - Tightening torque for Hex head screws and Socket hex head screws (Nm)
on page 67).
199
Comau Robotics Product Instruction
OPTIONS - FALL-PREVENTION BRACKETS UNIT FOR FIXING ON CEILING
Assembly
200
a.
Fix the two front brackets using
the socket hex head screws
M20x40 (1) with a hex head
wrench of 17 mm on the front
side of the Robot base
b.
Fix the rear bracket using the
two socket hex head screws
M6x16 (2) with a hex head
wrench of 5mm above the lower
distribution panel compartment
In
this
phase
of
preliminary
assembly
maintain al the loose
screws. The fixing will be
done at the end of the
procedure with Robot
installed on the ceiling.
c.
Assemble the fork unit (3) at the
two sides of the of the Robot
base with the socket hex head
screws M20 x 40 and hex head
wrench of 17mm.
Fix the fork to the Robot
base as indicated in
figure, positioning with
the fastening brackets
facing downwards.
d.
Using a lifting equipment of
appropriate capacity, turn the
Robot 180° and lift it up to
ceiling in proximity of the
mounting plate.
e.
Center the pins of the mounting
plate (4) in the seat of the Robot
base
For lifting the Robot and
centering at the base,
adopt the procedure given
in TRANSPORT AND
INSTALLATION
handbook.
Comau Robotics Product Instruction
OPTIONS - FALL-PREVENTION BRACKETS UNIT FOR FIXING ON CEILING
Assembly (Continued)
f.
Screw the hex head screws
M16 x 40 (4) with wrench of 24
mm to fix the brackets to the
plate
g.
Screw the hex head screws M24 x100 (5) with wrench of 36mm to fix the Robot
to the plate (see Fig. 6.6 - Robot fixing screws on page 201)
Fig. 6.6
- Robot fixing screws
After having assembled the brackets, check and tighten all the screws (see
Tab. 5.1 - Tightening torque for Hex head screws and Socket hex head
screws (Nm) on page 67)
201
Comau Robotics Product Instruction
OPTIONS - NJ FIXING ON CEILING AND FALL-PREVENTION UNIT - BRIC
6.11 NJ Fixing on Ceiling and Fall-prevention Unit
- BRIC: assembly (Part No. CR82344700)
Status:
–
The procedure must be carried out
with the system powered off: the main
circuit breaker of the cell controller
MUST be in OFF position (closed).
Material:
–
NJ fixing on ceiling and fall-prevention
unit - BRIC (Part No. CR82344700)
Wrenches with hex head of 5mm,
14mm, 17mm.
Wrenches for screws with hex head of
10mm, 30 mm, 36 mm.
–
–
Preliminary procedures / Notes
When reassembling, apply the foreseen sealant to the screws and tighten
them applying the appropriate tightening torque (see Tab. 5.2
- Threadlocker products on page 68 and Tab. 5.1 - Tightening torque for
Hex head screws and Socket hex head screws (Nm) on page 67)
See the chapter Options in the TECHNICAL SPECIFICATIONS handbook to
determine centre distances and diameters of the holes in the Robot fixing plate.
–
Remove any fixtures / piping installed on the Robot that interfere with the fixing
seats of the brackets.
Assembly
a.
202
Fix on the front side of the
Robot base the two anti-tilt
brackets using the socket hex
head screws M20X40 (1) and a
wrench of 30 mm.
In
this
phase
of
preliminary
assembly
maintain al the loose
screws. The fixing will be
done at the end of the
procedure with Robot
installed on the ceiling.
Comau Robotics Product Instruction
OPTIONS - NJ FIXING ON CEILING AND FALL-PREVENTION UNIT - BRIC
Assembly (Continued)
b.
Fix the rear bracket above the
lower distribution
panel
compartment using the two
socket hex head screws M6x30
(2) with a hex head wrench of 5
mm.
c.
Assemble the fork unit (3) at the
two sides of the Robot base for
Robot tilting at 180° with the
socket hex head screws
M20x40 and hex head wrench
of 17mm.
Fix the fork to the Robot
base as indicated in
figure, positioning with
the fastening brackets
facing downwards.
d.
Using a lifting equipment of
appropriate capacity, turn the
Robot 180° and lift it up to
ceiling in proximity of the
mounting plate.
e.
Center the pins of the mounting
plate (4) in the seat of the Robot
base
For lifting the Robot and
centering at the base,
adopt the procedure given
in TRANSPORT AND
INSTALLATION
handbook.
203
Comau Robotics Product Instruction
OPTIONS - NJ FIXING ON CEILING AND FALL-PREVENTION UNIT - BRIC
Assembly (Continued)
f.
Complete the fixing of the rear
fall-prevention bracket of the
Robot by inserting screws from
the upper side of the base plate
(see Fig. 6.7 - Robot fixing
screws and fall-prevention
brackets to the base plate on
page 205).
f.1
Position the angle brackets (5)
against the supporting surfaces
of the Robot base and lock with
hex head screws M6x16 (7) and
10mm wrench.
f.2
Screw the two hex head screws
M24x140 (6) with a wrench of
36 mm for the Robot fixing
passing from the upper side of
the fixing plate and screw in the
nuts welded to the angle
brackets
g.
Complete the assembly of the
fall-prevention brackets on the
Robot front side by inserting
screws from the upper side of
the base plate (see Fig. 6.7
- Robot fixing screws and
fall-prevention brackets to the
base plate on page 205).
g.1 Position the angle brackets
against the supporting surfaces
of the Robot base and lock with
hex head screws M6x16 (10)
and 10mm wrench.
g.2 Screw with hex head wrench by
24mm the hex head screws
M16x80 (8) through the plate for
the fixing of the fall-prevention
brackets on the Robot base.
g.3 Screw with hex head wrench of
36mm the hex head screws
M24x140 (9) through the plate
for the Robot fixing to the base.
204
Comau Robotics Product Instruction
OPTIONS - NJ FIXING ON CEILING AND FALL-PREVENTION UNIT - BRIC
Assembly (Continued)
Fig. 6.7
–
–
- Robot fixing screws and
fall-prevention brackets to the base
plate
A: Hex head screws M24x140 (q.ty 4) passing for robot base fixing to the plate.
B: Hex head screws M16x80 (q.ty 6) for brackets fixing to the plate.
After having assembled the brackets, check and tighten all screws (see
Tab. 5.1 - Tightening torque for Hex head screws and Socket hex head
screws (Nm) on page 67)
205
Comau Robotics Product Instruction
OPTIONS - FORK UNIT
6.12 Fork unit
6.12.1
Description
The fork unit is an essential option for the Robot lifting using a lift truck. The unit consists
of two rectangular electro-welded steel sections, that are fixed to the Robot column
sides. Inside the section bars are inserted the lift truck forks.
Before using the fork unit, see the usage information in the specific handbook provided
with the unit.
206
Comau Robotics Product Instruction
OPTIONS - CALIBRATION TOOL
6.13 Calibration Tool (Part No. 82314100)
1.
2.
3.
4.
6.13.1
Dial gauge holder
Conical ring nut
Probe
Dial gauge
Description
The calibration tool unit with dial gauge allows to carry out a correct manual calibration
of each Robot axis.
The kit consists of a dial gauge holder that is screwed into the specific seats on each of
the Robot axes and a centesimal dial gauge to find the correct calibration position.
207
Comau Robotics Product Instruction
OPTIONS - CALIBRATION TOOL
Tab. 6.5 - Example of use of the calibration tool
a.
Remove the protections from the
calibration reference notch and
from the seat for dial gauge
holder equipment.
b.
Visual alignment of the calibration
reference notches.
c.
Assembly of dial gauge holder
equipment.
d.
Search for axis calibration point
on dial gauge
208
Comau Robotics Product Instruction
OPTIONS - CALIBRATED TOOL UNIT - TOOL MASTER
6.14 Calibrated Tool Unit - Tool Master
(L= 200 Part No. 82109501)
6.14.1
Description
The calibrated tool unit is used to calculate the TCP (Tool Centre Point) related to the
Robot flange.
This unit consists of a cylindrical push rod whose length is defined such as that the end
is positioned in a given point in relation to the wrist centre.
The push rod is screwed directly on axis 6 outlet flange in radial position to it and does
not require the disassembly of the equipment possibly mounted on the flange itself.
209
Comau Robotics Product Instruction
OPTIONS - CALIBRATED TOOL UNIT - TOOL MASTER
210
Comau Robotics Product Instruction
OPTIONS - CALIBRATED TOOL UNIT - TOOL MASTER
211
Comau Robotics Product Instruction
OPTIONS - DISTRIBUTION PANEL CONNECTIONS WALKABLE PROTECTION UNIT
6.15 Distribution panel connections walkable
protection unit
(Part No. CR 82352200)
6.15.1
Description
The unit consists of a robust sheet guard that is fixed to the Robot base to protect the
Robot distribution panel unit and the cables connections.
212
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - BASIC CONCEPTS
7.
TURN-SET AND CALIBRATION BASIC CONCEPTS
7.1 Introduction
The purpose of this chapter is to provide basic concepts and terms related to the position
information management of Robot axes. For the description of the operating
procedures, see chapter TURN-SET AND CALIBRATION - OPERATING
PROCEDURES, specific for the Robot used.
In this chapter is provided basic information on the following topics:
–
used Terminology
–
Turn-set
–
Calibration.
213
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - BASIC CONCEPTS
7.2 Terminology
214
–
TRANSDUCER: Two types of position transducer are supported: encoder and
resolver.
–
NUMBER OF TRANSDUCER ROTATIONS: during the Robot axis motion, the
transducer can perform more rotations; the rotation number is initialized by the
calibration or turn-set operation.
–
AXIS DIMENSIONS: the dimensions of an axis contains all the information
required to define the proper position of an axis in the space;
–
DIMENSION RECONSTRUCTION: when the Control Unit is turned on, the system
software, among the other initialization processes, reconstructs the Robot axes
dimension.
The system software checks this dimensions; it checks if the difference between
the restored position and the position before the shutdown is below a threshold. If
the threshold is exceeded, the Control Unit displays the error 59411 - 08 Ax
<axis_numb> Arm <arm_numb> motion after shutdown and leaves to the
operator the responsibility to check that the Robot physical position corresponds to
the new dimension.
–
CALIBRATION POSITION: it is a pre-set position that can be checked by means
of suitable tools (dial gauges, supports, calibration tools). The calibration position
is a reference position in the Robot workspace that is used to univocally initialize
the dimension of each single axis and to calculate and assign the corresponding
Cartesian position of the Robot.
–
CALIBRATION CONSTANTS: the calibration constant is the difference between
the datum read by the transducer and the theoretical position that the transducer
should assume in that particular position of the Robot axis. In fact, since the
transducer positioning in relation to the Robot joint is random (as it depends on how
the transducer has been assembled), it is necessary to correct the real position of
the transducer depending on the theoretical position required by the Robot axis.
The calibration constant is expressed within a transducer rotation and is stored in
the $ARM_DATA[].CAL_DATA variable. It is represented in motor rotations and it
is a value included between -0.5 (excluded) and +0.5 (included). The calibration
constant described in the $ARM_DATA[].CAL_DATA variable can be read from the
Teach Pendant, page SETUP, sub-page Calib.
–
ASCII
CALIBRATION
FILE:
the
calibration
file
UD:\SYS\<$SYS_ID>_CAL<arm_numb>.PDL (where $SYS_ID indicates the
system identification label, as for example NJ4_001) is an ASCII file with syntax of
a
PDL2
file
in
which
are
stored
the
calibration
constants
($ARM_DATA[arm_numb].CAL_DATA[n]) and other Robot typical data.
–
RETENTIVE MEMORY: is a memory used to save featuring information of the
Robot matched with the Control Unit, the calibration constants and the axes length.
It can be found in the Controller CPU board.
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - BASIC CONCEPTS
7.3 Turn-set
The purpose of the turn-set operation is to update only the number of rotations of
the transducer in case the Control Unit has lost that value when restarting.
The operation consists of setting the interested axis in calibration position, by means of
the reference notches, and give the proper command. It does not require any specific
equipment because, the only one initialized value is the number of transducer
rotations.
The turn-set operation is required when
–
axes motion occur when the controller is powered off (e.g. when the error 59411 08 Ax <axis_numb> Arm <arm_numb> motion after shutdown is signaled)
–
occur some events that lead to the loss of the number of rotations, and therefore
the calibration procedure is not required. On the Teach Pendant status windows or
the PC screen it is shown the message Ar:TURN.
If the turn set is carried out with the Robot in system calibration position or user
calibration position, you will have:
7.3.1
–
Turn-set on system calibration position
–
Turn-set on user calibration position
–
Turn-set for Robot axes with multi-turn stroke
Turn-set on system calibration position
It allows to initialize the number of transducer rotations of each Robot axes in the
system calibration position (calibration position pre-defined by COMAU).
For further information see
($ARM_DATA[].CAL_SYS).
7.3.2
par. 7.4.1
System
calibration
on
page 217
Turn-set on user calibration position
It allows to initialize the number of transducer rotations of each Robot axes in the user
calibration position (“out of work area” calibration position defined by the user).
For further information see
($ARM_DATA[].CAL_USER).
7.3.3
par. 7.4.2
User
calibration
on
page 217
Turn-set for Robot axes with multi-turn stroke
In the Robot axes having the possibility to accomplish the multi-turn stroke, it may occur
that during the Turn-set procedure, the mechanical calibration notches are out of
alignment (such condition can occur when the Robot axis, having completed one or
more complete rotations, is positioned in a different mechanical rotation than that of the
original calibration).
215
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - BASIC CONCEPTS
Fig. 7.1
- Wrong Axis Position in TURN SET
Representative figure
In the wrong condition specified above, when moving the axis to align the notches, on
the Teach Pendant is displayed the following position error message:
5409 - 02
accurate
Ax <axis_numb> Arm <arm_numb> joints position not sufficiently
In case of wrong conditions specified above, do not send the Turn set command but
rotate the axis until reaching the axis turn position where the initial calibration was
performed. Restart the notches alignment and give the TURN SET command. Once the
proper position has been restored, the message Completed Command is displayed on
the Teach Pendant.
216
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - BASIC CONCEPTS
7.4 Calibration
The purpose of the calibration is to define the axes position of a Robot, referring it to an
ideal Robot. That allows to initialize the Robot axes dimensions and to make universal
the position variables used in the Robot programs.
During the calibration procedure, when the required axis is in the calibration position, the
deviation is stored (within a transducer rotation) between the value in the real position
and that in the theoretical position of the axis.
The notches available on each axis will allow to carry out future turn-set operations of a
Robot already installed.
Remember that carrying out the calibration operation (from Teach Pendant, SETUP
page, Calib sub-page, Calibra command) by simply positioning the Robot axes on the
reference notches, without using suitable tools, is an operation that does not guarantee
the required precision when positioning the Robot.
The calibration recovery (performed by COMAU), if necessary, must be carried out at
the first commissioning of the Robot.
Then, the calibration will not have to be carried out, unless a mechanical failure
occurs, that implies the replacement of a component of the kinematic chain, or
unless crashes damaging the Robot structure.
Find below the basic concepts on:
7.4.1
–
System calibration
–
User calibration
System calibration
It allows to initialize the Robot axes dimensions in the system calibration position
(calibration position pre-defined by COMAU - $ARM_DATA[].CAL_SYS).
To define the correct calibration position, special tools have to be used (dial gauges,
supports, etc.) able to determine with the required precision the position of each single
axis.
7.4.2
User calibration
The user calibration allows to define a new calibration position different from the one
of the system.
This type of calibration (usually defined as out of work area calibration) can be used
if the system position is hardly reachable once the Robot is included in the final
application, and therefore it is necessary to define a different calibration position,
defined as user calibration position ($ARM_DATA[].CAL_USER).
It will be the task of the user to find suitable tools to check the proper Robot positioning
in possible user recalibration, in particular as far as the reference notches position are
regarded.
217
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
8.
TURN-SET AND CALIBRATION - OPERATING
PROCEDURES
The purpose of this chapter is to provide the turn-set and calibration operating
procedures; particularly it contains the following topics:
218
–
General requirements
–
Identification of Robot calibration position
–
Turn-set procedure
–
System calibration using tools
–
User calibration
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
8.1 General requirements
WARNING:
Intrusion risk of not foreseen areas: a faulty or performed with poor accuracy calibration
alters the originally programmed workspace of the Robot, with the consequent risk
(even severe) to the operator.
The System calibration using tools must be performed following mechanical
disassembly operations that alter the geometry of the Robot.
The accuracy level achieved during the calibration affects the positioning: if a new
calibration is performed with poor accuracy, the Tool Center Point and the equipment
installed may reach technological points of the working cycle in a different position with
respect to that obtained with the previous calibration.
It is necessary to remember that:
–
it is recommended to perform the calibration in axes progressive sequence,
starting from the axis on which the calibration is required and continuing
with the subsequent axes;
–
the calibration of a single wrist axis (axes 4, 5 and 6) requires the positioning
on the calibration notches of the other wrist axes not involved in the
calibration, and their sequential calibration.
The theoretical aspects and functional description of the calibration and turn-set can be
found in Chap.7. - Turn-set and Calibration - Basic Concepts on page 213.
The calibration position of the Robot, defined by the alignment of all reference notches
of the axes, is illustrated in Fig. 8.1 - Robot: SMART5 NJ4 170 – 2.9; SMART5 NJ4 220
– 2.4; SMART5 NJ4 220 – 2.7; Calibration position on page 220
219
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
8.2 Identification of Robot calibration position
The Robot calibration positions are listed in Tab. 8.1, but may differ if a different
calibration position has been differently defined by the integrator (see par. 8.5 User
calibration on page 237)
Fig. 8.1
1.
2.
3.
4.
5.
6.
- Robot:
SMART5 NJ4 170 – 2.9;
SMART5 NJ4 220 – 2.4;
SMART5 NJ4 220 – 2.7;
Calibration position
Axis 1 calibration reference notch
Axis 2 calibration reference notch
Axis 3 calibration reference notch
Axis 4 calibration reference notch
Axis 5 calibration reference notch
Axis 6 calibration reference notch
Tab. 8.1 - Joints position in calibration ($ARM_DATA[].CAL_SYS)
220
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
0°
0°
-90°
0°
0°
0°
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
8.3 Turn-set procedure
This procedure is performed upon the system software request, if the Control Unit knows
the calibration constants, but have lost the information regarding the number of
revolutions of the transducer, for example due to an electrical disconnection of the
motors.
Bring the Robot axes on the reference notches to the most visually accurate position
possible: the system signals the operator the error 59409 SAX: joints position not
sufficiently accurate and subsequently showing the error 59421 SAX: a positive
registration is required and/or showing the error 59422 SAX: a negative registration
is required to reach the correct position.
Perform the Turn-set operations according to one of the indicated methods, depending
on the available software version:
1.
through CAT system command (Configure Arm Turn_set)
–
If the arm number is not specified, the default arm is used, while the axis
number shall always be specified. To show all the arm axes, specify an
asterisk (*).
–
Set the command CAT (Configure Arm Turn-set) with the Robot properly
positioned as specified in the Fig. 8.1 - Robot: SMART5 NJ4 170 – 2.9;
SMART5 NJ4 220 – 2.4; SMART5 NJ4 220 – 2.7; Calibration position on
page 220)
The Turn-set command implies the option: /User that allows to recalculate the
transducer
revolutions
number
referring
to
the
user
calibration
($ARM_DATA[].$CAL_USER).
2.
through specific video pages of the Teach Pendant
–
If the arm number is not specified, the default arm is used, while the axis
number shall always be specified. The current arm can be changed in the
“Motion” page, “General” sub-page.
–
Select in the following order the “Setup”, “Motion”, “Calib” pages
–
Carry out the “Turn Set” command:
–
short press for Turn set on standard calibration position;
–
press and hold for Turn set on user calibration position previously
acquired, then press “User”.
Afterwards, the system recalculates the correct number of revolutions of the transducer
depending on the calibration position ($ARM_DATA[].CAL_SYS). The operation shall
be performed only on the axis on which the count has been lost; if more than one axes
are in the situation described above it is advisable to carry out the turn-set of each axis
separately.
221
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
8.4 System calibration using tools
This paragraph describes the system calibration using tools considering the position of
the Robot corresponding to the $ARM_DATA[].$CAL_SYS function and is divided in the
following points:
8.4.1
–
Requirements for axes positioning control
–
Required equipment
–
Preliminary operations and ordinary operations
–
Axes calibration procedure
Requirements for axes positioning control
Release of the enabling button on the Teach Pendant (DRIVE OFF) may cause slight
movements of the axes generated by the gravity of the masses applied, and made more
evident if the drives activation functions are carried out in quick succession.
–
During the calibration it is necessary to limit to a minimum the number of
activations/deactivations of the drives to avoid possible slight movements of the
axes. The system recovers automatically the motions bringing the axes in the
proper calibration position under the condition that they have been previously
calibrated.
–
The axes repositioning can be checked on the teach pendant by registering the
joints position values through the commands Display - Arm - Joint (F2; F1; F4).
After every system drives activation command, check on the Teach Pendant that the
axes return to the correct calibration position.
If the axes do not return in the proper position, it is necessary to start again from the
beginning the calibration procedure.
8.4.2
Required equipment
The following is the minimum necessary equipment and the fixing components for
calibration operations:
Tab. 8.2 - Required equipment
–
–
–
–
–
222
Calibration tool (see Fig. 8.2)
Cross-head screwdrivers set
Flat-tip screwdrivers set
Set of Allen wrenches
Screws for holes protection for dial gauge (to be stored)
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
8.4.3
Preliminary operations and ordinary operations
Calibration shall be carried out with Robot without loads applied to the axes (tool,
grippers, etc.) excluded axis 1.
Remove the Tool from the wrist before starting the calibration operations.
a.
Activate on the Control Unit the programming functioning mode
(PROG).
b.
When required in the calibration procedure of the single axis, follow the steps
below for the correct calibration tool assembly.
–
Use the appropriate tool (see Fig. 8.2).
–
The threaded seat and the reference notch are protected by specific covers.
Remove the covers and store them for the subsequent reassembly.
–
Screw in the seat provided in each axis of the Robot the dial gauge holder.
–
Screw the dial gauge in the dial gauge holder: the dial gauge is used to detect
the minimum point with respect to the underlying fixed "V" notch. The position
of the Robot in the minimum point is the calibration position.
Fig. 8.2
1.
2.
3.
4.
- Calibration tool (optional)
Dial gauge holder
Conical ring nut
Probe
Dial gauge
When assembling the calibration tool, stick to the diagram below
Fig. 8.3
- Calibration tool assembly diagram
223
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
8.4.4
Axes calibration procedure
The operational procedures for the Robot single axes calibration are described below:
224
–
Axis 1 calibration
–
Axis 2 calibration
–
Axis 3 calibration
–
Axis 4 calibration
–
Axis 5 calibration
–
Axis 6 calibration
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
Tab. 8.3 - Axis 1 calibration
a.
Remove the protection covers
from the reference notch (B) and
from the seat (A) to fix the dial
gauge holder equipment.
b.
Using the Teach Pendant, move
the Robot axes to the calibration
position until the movable
reference notch C coincides with
the fixed reference notch.
c.
Screw the dial gauge holder
equipment (D) in the seat, and
screw the dial gauge in the
equipment up to preload the rod
of the dial gauge of a few
millimetres (about 2.5 mm).
For further information
on
calibration
tool
assembly, see par. 8.4.3
from step b.
d.
Move
at
low
speed
(recommended at 1% and, in any
case, not exceeding 5% GEN-OVR < 5%) the axis to be
calibrated,
moving
from
negative to positive direction
(as shown in the figure below),
until detecting on the dial gauge
the minimum point.
225
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
If the minimum point has
been passed, return to
the start position and
repeat the measurement,
always moving the Robot
axis from negative to
positive direction so as to
compensate
possible
mechanical clearance of
the axis.
e.
On the Teach Pendant keyboard select CAC (Configure Arm Calibrate) command.
f.
Select the arm to be calibrated and confirm with ENTER.
g.
Select the axis to be calibrated and confirm with ENTER.
h.
Remove the dial gauge and reassemble the protection covers in the seats for fixing the dial gauge holder
equipment and in the reference notches for calibration.
226
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
Tab. 8.4 - Axis 2 calibration
a.
Remove the protection covers
from the reference notch (A) and
from the seat (B) to fix the dial
gauge holder equipment.
b.
Using the Teach Pendant, move
the Robot axes to the calibration
position until the movable
reference notch C coincides with
the fixed reference notch.
c.
Screw the dial gauge holder
equipment (D) in the seat, and
screw the dial gauge in the
equipment up to preload the rod
of the dial gauge of a few
millimetres (about 2.5 mm).
For further information
on
calibration
tool
assembly, see par. 8.4.3
from step b.
d.
Move
at
low
speed
(recommended at 1% and, in any
case, not exceeding 5% GEN-OVR < 5%) the axis to be
calibrated,
moving
from
negative to positive direction
(as shown in the figure below),
until detecting on the dial gauge
the minimum point.
227
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
If the minimum point has
been passed, return to
the start position and
repeat the measurement,
always moving the Robot
axis from negative to
positive direction so as to
compensate
possible
mechanical clearance of
the axis.
e.
On the Teach Pendant keyboard select CAC (Configure Arm Calibrate) command.
f.
Select the arm to be calibrated and confirm with ENTER.
g.
Select the axis to be calibrated and confirm with ENTER.
h.
Remove the dial gauge and reassemble the protection covers in the seats for fixing the dial gauge holder
equipment and in the reference notches for calibration.
228
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
Tab. 8.5 - Axis 3 calibration
a.
Remove the protection covers from
the reference notch (A) and from the
seat (B) to fix the dial gauge holder
equipment.
b.
Using the Teach Pendant, move the
Robot axes to the calibration position
until the movable reference notch C
coincides with the fixed reference
notch.
c.
Screw the dial gauge holder
equipment (D) in the seat, and screw
the dial gauge in the equipment up to
preload the rod of the dial gauge of a
few millimetres (about 2.5 mm).
For further information on
calibration tool assembly,
see par. 8.4.3 from step b.
d.
Move at low speed (recommended at
1% and, in any case, not exceeding
5% - GEN-OVR < 5%) the axis to be
calibrated, moving from negative to
positive direction (as shown in the
figure below), until detecting on the
dial gauge the minimum point.
229
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
If the minimum point has
been passed, return to the
start position and repeat the
measurement,
always
moving the Robot axis from
negative to positive direction
so as to compensate possible
mechanical clearance of the
axis.
e.
On the Teach Pendant keyboard select CAC (Configure Arm Calibrate) command.
f.
Select the arm to be calibrated and confirm with ENTER.
g.
Select the axis to be calibrated and confirm with ENTER.
h.
Remove the dial gauge and reassemble the protection covers in the seats for fixing the dial gauge holder
equipment and in the reference notches for calibration.
230
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
Tab. 8.6 - Axis 4 calibration
a.
Remove the protection covers from
the reference notch (A) and from the
seat (B) to fix the dial gauge holder
equipment.
b.
Using the Teach Pendant, move the
Robot axes to the calibration position
until the movable reference notch (C)
coincides with the fixed reference
notch.
c.
Screw the dial gauge holder
equipment (D) in the seat, and screw
the dial gauge in the equipment up to
preload the rod of the dial gauge of a
few millimetres (about 2.5 mm).
For further information on
calibration tool assembly,
see par. 8.4.3 from step b.
d.
Move at low speed (recommended at
1% and, in any case, not exceeding
5% - GEN-OVR < 5%) the axis to be
calibrated, moving from negative
to positive direction until detecting
on the dial gauge the minimum point.
231
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
If the minimum point has
been passed, return to the
start position and repeat the
measurement,
always
moving the Robot axis from
negative
to
positive
direction
so
as
to
compensate
possible
mechanical clearance of the
axis.
e.
On the Teach Pendant keyboard select CAC (Configure Arm Calibrate) command.
f.
Select the arm to be calibrated and confirm with ENTER.
g.
Select the axis to be calibrated and confirm with ENTER.
h.
Remove the dial gauge and reassemble the protection covers in the seats for fixing the dial gauge holder
equipment and in the reference notches for calibration.
232
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
Tab. 8.7 - Axis 5 calibration
a.
Remove the protection covers from the
reference notch (A) and from the seat (B)
to fix the dial gauge holder equipment.
b.
Using the Teach Pendant, move the
Robot axes to the calibration position
until the movable reference notch (C)
coincides with the fixed reference notch.
c.
Screw the dial gauge holder equipment
(D) in the seat, and screw the dial gauge
in the equipment up to preload the rod of
the dial gauge of a few millimetres (about
2.5 mm).
For further information on
calibration tool assembly, see
par. 8.4.3 from step b.
d.
Move at low speed (recommended at 1%
and, in any case, not exceeding 5% GEN-OVR < 5%) the axis to be
calibrated, moving from negative to
positive direction until detecting on the
dial gauge the minimum point.
233
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
Tab. 8.7 - Axis 5 calibration (Continued)
If the minimum point has been
passed, return to the start
position
and
repeat
the
measurement, always moving
the Robot axis from negative to
positive direction so as to
compensate
possible
mechanical clearance of the
axis.
e.
On the Teach Pendant keyboard select CAC (Configure Arm Calibrate) command.
f.
Select the arm to be calibrated and confirm with ENTER.
g.
Select the axis to be calibrated and confirm with ENTER.
h.
Remove the dial gauge and reassemble the protection covers in the seats for fixing the dial gauge holder
equipment and in the reference notches for calibration.
234
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
Tab. 8.8 - Axis 6 calibration
a.
Remove the protection covers from
the reference notch (A) and from the
seat (B) to fix the dial gauge holder
equipment.
b.
Using the Teach Pendant, move the
Robot axes to the calibration position
until the movable reference notch (C)
coincides with the fixed reference
notch.
c.
Screw the dial gauge holder
equipment (D) in the seat, and screw
the dial gauge in the equipment up to
preload the rod of the dial gauge of a
few millimetres (about 2.5 mm).
For further information on
calibration tool assembly, see
par. 8.4.3 from step b.
d.
Move at low speed (recommended at
1% and, in any case, not exceeding
5% - GEN-OVR < 5%) the axis to be
calibrated, moving from negative to
positive direction until detecting on
the dial gauge the minimum point.
235
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
Tab. 8.8 - Axis 6 calibration (Continued)
If the minimum point has
been passed, return to the
start position and repeat the
measurement, always moving
the Robot axis from negative
to positive direction so as to
compensate
possible
mechanical clearance of the
axis.
e.
On the Teach Pendant keyboard select CAC (Configure Arm Calibrate) command.
f.
Select the arm to be calibrated and confirm with ENTER.
g.
Select the axis to be calibrated and confirm with ENTER.
h.
Remove the dial gauge and reassemble the protection covers in the seats for fixing the dial gauge holder
equipment and in the reference notches for calibration.
236
Comau Robotics Product Instruction
TURN-SET AND CALIBRATION - OPERATING PROCEDURES
8.5 User calibration
The calibration command allows specific options (which can be activated by pressing
contemporaneously the keys SHIFT and 9, / on the Teach Pendant) that allow to define
a Robot calibration position different from the system one (out of work area calibration)
illustrated in Fig. 8.1 - Robot: SMART5 NJ4 170 – 2.9; SMART5 NJ4 220 – 2.4;
SMART5 NJ4 220 – 2.7; Calibration position on page 220.
In particular can be used the following functions:
–
/Learn
used to move the Robot in the desired position and set the command CAC/L. So
the
Robot
position
is
stored
in
the
system
variable
$ARM_DATA[num_arm].CAL_USER.
To be able to carry out this operation, it is necessary that a system calibration
(Configure Arm Calibrate without options) must first be performed.
–
/User
can be used to carry out the calibration on the position stored in the system variable
$ARM_DATA[arm_num].CAL_USER as described in the previous point. After this
operation, the calibration constant is stored in the same system variable dedicated
to the system calibration constant ($ARM_DATA[].CAL_DATA).
237
Comau Robotics Product Instruction
SPARE PARTS LIST
9.
SPARE PARTS LIST
This section contains the lists of spare parts for Robot divided into:
238
–
Tab. 9.1 - SMART5 NJ4 170-2.9 - Rel. 1.0 Mechanical spare parts on page 239
–
Tab. 9.2 - SMART5 NJ4 170-2.9 - Rel. 2.0 Mechanical spare parts on page 241
–
Tab. 9.3 - SMART5 NJ4 220-2.4 - Rel. 1.0; SMART5 NJ4 220-2.7 - Rel. 1.0 on
page 243
–
Tab. 9.4 - SMART5 NJ4 220-2.4 - Rel. 2.0; SMART5 NJ4 220-2.7 - Rel. 2.0 on
page 245
–
Tab. 9.5 - SMART5 NJ4 - Rel. 1.0 Options spare parts on page 247
–
Tab. 9.6 - SMART5 NJ4 - Rel. 2.0 Options spare parts on page 248
–
Tab. 9.7 - SMART5 NJ4 - Rel. 1.0 Robot wiring on page 249
–
Tab. 9.8 - SMART5 NJ4 - Rel. 2.0 Robot wiring on page 250
–
Tab. 9.9 - SMART5 NJ4 - Rel. 2.0 Robot dressing spare parts on page 251
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.1 - SMART5 NJ4 170-2.9 - Rel. 1.0
Mechanical spare parts
14,15,17,18,19,20,21
23
16
22
24
9,10,11,12,13
6
7,8,9
2,3,4,5
1
Ref.
COMAU Part No.
SMART5
1
CR82309133
2
CR82341107
Gear z = 24; m=2
3
CR82350080
Motor 25 Nm - C5G - IP67
4
CR82341111
5
00300654
6
CR82309155
7
00301274
OR gasket No. 382 (5.33 x 329.6)
8
00300651
OR gasket No. 278 (3.53 x 304.3)
9
CR82350090
10
00300783
OR gasket No. 379 (5.33 x 278.8)
11
00300708
OR gasket No. 178 (2.62 x 247.3)
Robot
axis
Q.ty
Weight
1
94 kg
(207.23 lb)
1
-
1
32 kg
(70.54 lb)
Radial shaft seal TYPE 4 -Ø138x160x15 NBR
1
-
Toroidal seal No. 281 (3.53 x 380.6)
OR-O/200
1
-
Gearbox assembly
1
95 kg
(209.43 lb)
1
-
1
-
2
36 kg
(79.36 lb)
1
-
1
-
2
0.19 kg
(0.41 lb)
4
-
Description
Gearbox assembly
Motor 33 Nm - C5G - IP67
12
82100421
Roller bearing NKI 35/30
13
00345573
Single lip sealing ring 35x42x4
1
2
2-3
3
239
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.1 - SMART5 NJ4 170-2.9 - Rel. 1.0
Mechanical spare parts (Continued)
Ref.
COMAU Part No.
SMART5
14
00301240
15
CR82347304
16
82315010
17
82316580
240
Robot
axis
Q.ty
Weight
OR gasket No. 158
1
-
z=42; m=3 pinion
1
3 kg
(6.61 lb)
Slew Gear
1
17 kg
(37.47 lb)
1
3.4 kg
(7.49 lb)
1
-
Description
Gearbox assembly
4
18
CR82347316
Radial shaft seal Type 4-85x120x12 DIN
3760
19
82265927
Sealing ring AS DIN 3760 (150x180 x15)
1
-
20
CR82347318
Reinforced seal rubber plug int. steel 110
1
-
21
CR82350050
Motor 9 Nm - IP65 - C5G
1
10 kg
(22.04 lb)
22
CR82350041
Motor 5 Nm - IP65 - C5G SPLINE SHAFT
5
1
6.5 kg
(14.33 lb)
23
CR82350031
Motor 3.5 Nm - IP65 - C5G SPLINE
SHAFT
6
1
5.2 kg
(11.46 lb)
24
CR82343800
Hollow wrist
5-6
1
52 kg
(114.64 lb)
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.2 - SMART5 NJ4 170-2.9 - Rel. 2.0
Mechanical spare parts
14,15,17,18,19,20,21
23
16
22
24
9,10,11,12,13
6
7,8,9
2,3,4,5
1
Ref.
COMAU Part No.
SMART5
1
CR82309133
2
CR82341107
Gear z = 24; m=2
3
CR82370082
Motor 25 Nm - C5G - IP67
4
CR82341111
5
00300654
6
CR82309155
7
00301274
OR gasket No. 382 (5.33 x 329.6)
8
00300651
OR gasket No. 278 (3.53 x 304.3)
9
CR82370092
10
00300783
OR gasket No. 379 (5.33 x 278.8)
11
00300708
OR gasket No. 178 (2.62 x 247.3)
Robot
axis
Q.ty
Weight
1
94 kg
(207.23 lb)
1
-
1
32 kg
(70.54 lb)
Radial shaft seal TYPE 4 -Ø138x160x15 NBR
1
-
Toroidal seal No. 281 (3.53 x 380.6)
OR-O/200
1
-
Gearbox assembly
1
95 kg
(209.43 lb)
1
-
1
-
2
36 kg
(79.36 lb)
1
-
1
-
2
0.19 kg
(0.41 lb)
4
-
Description
Gearbox assembly
Motor 33 Nm - C5G - IP67
12
82100421
Roller bearing NKI 35/30
13
00345573
Single lip sealing ring 35x42x4
1
2
2-3
3
241
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.2 - SMART5 NJ4 170-2.9 - Rel. 2.0
Mechanical spare parts (Continued)
Ref.
COMAU Part No.
SMART5
14
00301240
15
CR82347304
16
82315010
17
82316580
242
Robot
axis
Q.ty
Weight
OR gasket No. 158
1
-
z=42; m=3 pinion
1
3 kg
(6.61 lb)
Slew Gear
1
17 kg
(37.47 lb)
1
3.4 kg
(7.49 lb)
1
-
Description
Gearbox assembly
4
18
CR82347316
Radial shaft seal Type 4-85x120x12 DIN
3760
19
82265927
Sealing ring AS DIN 3760 (150x180 x15)
1
-
20
CR82347318
Reinforced seal rubber plug int. steel 110
1
-
21
CR82370052
Motor 9 Nm - C5G - IP67
1
10 kg
(22.04 lb)
22
CR82370044
Motor 5 Nm - C5G Spline Shaft - IP67
5
1
6.5 kg
(14.33 lb)
23
CR82370031
Motor 3.5 Nm - C5G Spline Shaft - IP67
6
1
5.2 kg
(11.46 lb)
24
CR82343800
Hollow wrist
5-6
1
52 kg
(114.64 lb)
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.3 - SMART5 NJ4 220-2.4 - Rel. 1.0;
SMART5 NJ4 220-2.7 - Rel. 1.0
15,16,19,20,21,22
23
17
23
24
6
9,11,12,13,14
10
7,8,9
2,3,4,5
1
Ref.
COMAU Part No.
SMART5
1
CR82309133
2
CR82341107
Gear z = 24; m=2
3
CR82350080
Motor 25 Nm - C5G - IP67
4
CR82341111
5
00300654
6
CR82309155
7
00301274
OR gasket No. 382 (5.33 x 329.6)
8
00300651
OR gasket No. 278 (3.53 x 304.3)
9
CR82350090
10
82309141
11
00300783
OR gasket No. 379 (5.33 x 278.8)
12
00300708
OR gasket No. 178 (2.62 x 247.3)
13
82100421
14
00345573
Robot
axis
Q.ty
Weight
1
94 kg
(207.23)
1
-
1
32 kg
(70.54 lb)
Radial shaft seal TYPE 4
-Ø138x160x15 - NBR
1
-
Toroidal seal No. 281 (3.53 x 380.6)
OR-O/200
1
-
1
95 kg
(209.43 lb)
1
-
1
-
2
36 kg
(79.36 lb)
1
53 kg
(116.84 lb)
1
-
1
-
Roller bearing NKI 35/30
2
0.19 kg
(0.41 lb)
Single lip sealing ring 35x42x4
4
-
Description
Gearbox assembly
1
Gearbox assembly
Motor 33 Nm - C5G - IP67
2
2-3
Gearbox assembly
3
243
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.3 - SMART5 NJ4 220-2.4 - Rel. 1.0;
SMART5 NJ4 220-2.7 - Rel. 1.0
Ref.
COMAU Part No.
SMART5
15
00301240
16
CR82347304
17
82315010
18
82316580
19
CR82347316
Radial shaft seal Type 4-85x120x12
DIN 3760
20
82265927
21
Weight
OR gasket No. 158
1
-
z=42; m=3 pinion
1
3 kg
(6.61 lb)
Slew Gear
1
17 kg
(37.47 lb)
1
3.4 kg
(7.49 lb)
1
-
Sealing ring AS DIN 3760 (150x180
x15)
1
-
CR82347318
Reinforced seal rubber plug int. steel
130
1
-
22
CR82350050
Motor 9 Nm - IP65 - C5G
1
10 kg
(22.04 lb)
23
CR82350051
Motor 9 Nm - IP65 - C5G SPLINE
SHAFT
2
10 kg
(22.04 lb)
1
120 kg
(264.55 lb)
24
244
Robot
axis
Q.ty
CR82273900
Description
Gearbox assembly
Hollow wrist
4
5-6
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.4 - SMART5 NJ4 220-2.4 - Rel. 2.0;
SMART5 NJ4 220-2.7 - Rel. 2.0
15,16,19,20,21,22
23
17
23
24
6
9,11,12,13,14
10
7,8,9
2,3,4,5
1
Ref.
COMAU Part No.
SMART5
1
CR82309133
2
CR82341107
Gear z = 24; m=2
3
CR82370082
Motor 25 Nm - C5G - IP67
4
CR82341111
5
00300654
6
CR82309155
7
00301274
OR gasket No. 382 (5.33 x 329.6)
8
00300651
OR gasket No. 278 (3.53 x 304.3)
9
CR82370092
10
82309141
11
00300783
OR gasket No. 379 (5.33 x 278.8)
12
00300708
OR gasket No. 178 (2.62 x 247.3)
13
82100421
14
00345573
Robot
axis
Q.ty
Weight
1
94 kg
(207.23)
1
-
1
32 kg
(70.54 lb)
Radial shaft seal TYPE 4
-Ø138x160x15 - NBR
1
-
Toroidal seal No. 281 (3.53 x 380.6)
OR-O/200
1
-
1
95 kg
(209.43 lb)
1
-
1
-
2
36 kg
(79.36 lb)
1
53 kg
(116.84 lb)
1
-
1
-
Roller bearing NKI 35/30
2
0.19 kg
(0.41 lb)
Single lip sealing ring 35x42x4
4
-
Description
Gearbox assembly
1
Gearbox assembly
Motor 33 Nm - C5G - IP67
2
2-3
Gearbox assembly x
3
245
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.4 - SMART5 NJ4 220-2.4 - Rel. 2.0;
SMART5 NJ4 220-2.7 - Rel. 2.0 (Continued)
Ref.
COMAU Part No.
SMART5
15
00301240
16
CR82347304
17
82315010
18
82316580
19
CR82347316
Radial shaft seal Type 4-85x120x12
DIN 3760
20
82265927
21
Weight
OR gasket No. 158
1
-
z=42; m=3 pinion
1
3 kg
(6.61 lb)
Slew Gear
1
17 kg
(37.47 lb)
1
3.4 kg
(7.49 lb)
1
-
Sealing ring AS DIN 3760 (150x180
x15)
1
-
CR82347318
Reinforced seal rubber plug int. steel
130
1
-
22
CR82370052
Motor 9 Nm - C5G - IP67
1
10 kg
(22.04 lb)
23
CR82370051
Motor 9 Nm - C5G - IP67 - SPLINE
SHAFT
2
10 kg
(22.04 lb)
1
120 kg
(264.55 lb)
24
246
Robot
axis
Q.ty
CR82273900
Description
Gearbox assembly
Hollow wrist
4
5-6
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.5 - SMART5 NJ4 - Rel. 1.0
Options spare parts
1
2
Ref.
COMAU Part No. Rel.
1.0
1
CR82344300
Ax 1 ON/OFF mechanical hard stop unit
1
CR82325801
Multiple position switch 2 Roll Plungers
1
CR82325702
Multiple position limit switch 4Roll Plungers
1
CR82342204
Multiple position limit switch 6Roll Plungers
1
CR82325902
Multiple position limit switch 4Roll Plungers
1
2
Description
Q.ty
247
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.6 - SMART5 NJ4 - Rel. 2.0
Options spare parts
1
2
Ref.
COMAU Part No. Rel.
2.0
1
CR82344300
Ax 1 ON/OFF mechanical hard stop unit
1
CR82325801
Multiple position switch 2 Roll Plungers
1
CR82325702
Multiple position limit switch 4Roll Plungers
1
CR82342204
Multiple position limit switch 6Roll Plungers
1
CR82325902
Multiple position limit switch 4Roll Plungers
1
2
248
Description
Q.ty
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.7 - SMART5 NJ4 - Rel. 1.0
Robot wiring
1
Ref.
ROBOT
COMAU Part No.
Rel. 1.0
1
NJ4 170 - 2.9
CR18904280
1
Description
Wiring on machine
1
Q.ty
Weight
1
20 kg
(44.09 lb)
1
1
Ref.
ROBOT
COMAU Part No.
Rel. 1.0
NJ4 220 - 2.4
CR18904380
NJ4 220 - 2.7
CR18903680
Description
Q.ty
Weight
Wiring on machine
1
20 kg
(44.09 lb)
Wiring on machine
1
20 kg
(44.09 lb)
1
249
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.8 - SMART5 NJ4 - Rel. 2.0
Robot wiring
1
Ref.
ROBOT
COMAU Part No.
Rel. 2.0
1
NJ4 170 - 2.9
CR18904280
1
Description
Wiring on machine
1
Q.ty
Weight
1
20 kg
(44.09 lb)
1
1
Ref.
ROBOT
COMAU Part No.
Rel. 2.0
NJ4 220 - 2.4
CR18904380
NJ4 220 - 2.7
CR18903680
Description
Q.ty
Weight
Wiring on machine
1
20 kg
(44.09 lb)
Wiring on machine
1
20 kg
(44.09 lb)
1
250
Comau Robotics Product Instruction
SPARE PARTS LIST
Tab. 9.9 - SMART5 NJ4 - Rel. 2.0
Robot dressing spare parts
1
Ref.
ROBOT
COMAU Part No.
Rel. 2.0
1
NJ4 170 - 2.9
CR18542080
1
NJ4 170 - 2.9
1
1
1
Description
Q.ty
Weight
Dressing spot for electric gun
1
---
CR18501280
Dressing spot for air gun
1
---
NJ4 170 - 2.9
CR18561080
Handling Dressing
1
---
NJ4 170 - 2.9
CR18667380
Double Multibus Dressing
1
---
251
Comau Robotics Product Instruction
SPARE PARTS LIST
1
1
1
Ref.
1
1
252
ROBOT
COMAU Part No.
Rel. 2.0
NJ4 220 - 2.4
CR18542180
NJ4 220 - 2.4
Description
Q.ty
Weight
Dressing spot for electric gun
1
---
CR18501380
Dressing spot for air gun
1
---
NJ4 220 - 2.4
CR18560980
Handling Dressing
1
---
NJ4 220 - 2.7
CR18542280
Dressing spot for electric gun
1
---
NJ4 220 - 2.7
CR18501480
Dressing spot for air gun
1
---
NJ4 220 - 2.7
CR18560680
Handling Dressing
1
---
NJ4 220 - 2.7
CR18669780
Double Multibus Dressing
1
---
NJ4 220 - 2.7
CR18670680
ALU Dressing
1
---
Comau Robotics Product Instruction
SETTING OUT OF WORK AND DISMANTLING
10.
SETTING OUT OF WORK AND
DISMANTLING
This chapter contains the following topics:
–
Precautions before starting
–
Personnel in charge of decommissioning and dismantling
–
Required equipment
–
Decommissioning and dismantling procedure
–
Disposal of parts
10.1 Precautions before starting
The robotic system (consisting of Robot and Control Unit) must be disposed of in an
environmentally correct way and according to the specific methodologies of the nation
where installed.
Prepare different containers to collect the different materials separately.
10.2 Personnel in charge of decommissioning and
dismantling
Personnel in charge of dismantling should be trained to operate correctly with lifting
means.
Furthermore, the personnel must be trained (in electrical and mechanical fields) and
therefore aware of the dangers deriving from the electrical power supply and of the
precautions to be taken when working on electrical connections.
253
Comau Robotics Product Instruction
SETTING OUT OF WORK AND DISMANTLING
10.3 Required equipment
–
Standard mechanical and electrical equipment.
–
Various containers.
10.4 Decommissioning and dismantling procedure
In this section are described the main steps to perform the robot system dismantling at
the end of its operating life.
The activities below are to be carried out only by the Personnel in charge of
decommissioning and dismantling:
254
a.
create around the Robotic system enough space to perform all the motions without
risks for the personnel;
b.
move the Robot in transport position and assemble the axes locking brackets
(when required) referring to the instructions on the plate affixed on the Robot and
to Technical Documentation of the Robot itself;
c.
open the Control Unit main switch and lock it in open position;
d.
disconnect the electrical power at the power distribution point and lock the switch
in open position;
e.
disconnect the multipolar connectors on the Robot side;
f.
if present, disconnect the pneumatic system from the distribution network and
remove the residual air;
g.
remove the present oil and grease:
•
carefully empty the oil from the gearboxes following the specific lubrication
procedures given in the handbook;
•
it is possible that some compartments may not completely empty, in this case
manually aspirate the remaining lubricant;
•
the grease must be removed by removal or washing with specific detergents;
•
carry out a general cleaning of the parts surrounding the lubrication point, in
order to remove possible lubricant residues;
h.
read carefully and follow the instructions given in the chemicals safety sheets in
order to not endanger the operator and avoid environmental contamination;
i.
remove the Robot from the workspace taking all the precautions indicated in the
products Technical Documentation; in case of lifting, check the eyebolts proper
fixing and use only suitable slings and equipment;
j.
bring the Robot to the area intended for the dismantling and disposal procedures;
Comau Robotics Product Instruction
SETTING OUT OF WORK AND DISMANTLING
k.
if the procedure is to be carried out independently, disassemble the components
from top to bottom and paying particular attention to machine units/parts that may
fall due to gravity:
Act carefully, to avoid possible parts or components falling during the
removal phase, as this could severely endanger the operators.
l.
remove the parts and separate as much as possible the different components
based on the materials (plastic, metal, etc.) that shall be disposed of applying the
waste separation principle.
10.5 Disposal of parts
The disposal operations must be carried out in compliance with the law in force in the
country where the machine is installed: ferrous / plastic materials, the oil and grease
must be disposed of in accordance with the regulations in force transferring them to the
appropriate waste collection centres.
Assign the disposal of the materials resulting from the dismantling to the responsible
companies.
255
Comau Robotics Product Instruction
SETTING OUT OF WORK AND DISMANTLING
256
Original instructions
Made in Comau