Documente Academic
Documente Profesional
Documente Cultură
Rel. 1.0
Technical Specifications,
Transport and Installation and
Maintenance
CR00758126-en_00/2016.11
Instructions 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.
SUMMARY
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Documents storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Limits on the handbook contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Symbols used in the handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MODIFICATION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3
Comau Robotics Product Instruction
SUMMARY
4
Comau Robotics Product Instruction
SUMMARY
Suggestions for the construction of a tool suitable for ISO tool coupling flange ISO 9409 - 1 -
A40 (CR82392149). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Suggestions for the construction of the flange, to be carried out by the Integrator . . . . . . . 100
Modifications in the Robot Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Robot connection with R1C-4 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Preliminary precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Connection with the R1C-4 Control Unit (main motors and encoder cables). . . . . . . . . . . . 104
Connection of I/O signals cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Operations related to the first startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Precautions before the first power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Control Unit power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Floor / ceiling / wall installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Load auto-determination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Safety functional verifications of the robotic system integrated in the production cell . . . . . 107
4. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...108
General requirements for the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Precautions during the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Precautions at the end of the maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Maintenance staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Assembly notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Parts disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Assistance for troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Problem analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Diagnostic messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Traceability for replacement purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Components replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Robot wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Comau service centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
How to disconnect the electrical power supply on R1C-4 Control Unit . . . . . . . . . . . . . . . . . . 116
Precautions and risks associated with the electrical power supply disconnection . . . . . . . . 116
Disconnection of the electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
How to move the Robot in case of emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Use of the brake releasing device integrated on Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Risks deriving from Robot axes releasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Usage procedure of the integrated brake release device. . . . . . . . . . . . . . . . . . . . . . . . . .120
Maintenance structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Summary diagram of the maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Preventive maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Robot cleaning and general inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Encoder batteries: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5
Comau Robotics Product Instruction
SUMMARY
6
Comau Robotics Product Instruction
PREFACE
PREFACE
This chapter contains:
– Reference documentation
– Documents storage
– Limits on the handbook contents
– Symbols used in the handbook
– Modification History.
Reference documentation
This document refers to the Robot in standard outfitting indicated below:
– Rebel-S6-0.45 - Rel. 1.0
– Rebel-S6-0.60 - Rel. 1.0
– Rebel-S6-0.75 - Rel. 1.0
– Rebel-S6-0.60c - Rel. 1.0
– Rebel-S6-0.75c - Rel. 1.0
The structure of the complete set of handbooks describing the Robot and Control Unit
is detailed in the following table:
7
Comau Robotics Product Instruction
PREFACE
Documents storage
All provided documentation must be placed in close proximity to the area where is
installed the robotic system, maintained available for all people that work on it and
preserved intact for the entire operational life of the robotic system.
This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed may cause injuries to the staff.
This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed may cause equipment damage.
The 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.
8
Comau Robotics Product Instruction
MODIFICATION HISTORY
MODIFICATION HISTORY
The following table shows the history of the Handbook release, with related changes /
improvements made.
Edition of the
Date Contents
Handbook
2016-09 00/2016.09 First release of the Handbook.
2016-11 00/2016.11 Added Chap.4. - Maintenance on page 108
9
Comau Robotics Product Instruction
This chapter deals with general specifications that apply to the whole Robot System.
Considering its significance, this chapter is referred unreservedly in each system
instructions handbook.
1.1 Responsibilities
– The system integrator is responsible for ensuring that the Robotic system (Robot
and Control Unit) is installed and handled in accordance with the Safety Standards
in force in the country where the installation takes place. The application and use
of the necessary protection and safety devices, the issuing of declaration of
conformity and any EC marking of the system are the responsibility of the
Integrator.
The installation shall be carried out by qualified Personnel and must conform to all
National and Local standards.
10
Comau Robotics Product Instruction
1.2.1 Purpose
These safety requirements are aimed to define the behaviour and obligations to be
observed when performing the activities listed in the Applicabilitysection.
1.2.2 Definitions
Robotic system (Robot and Control Unit)
Robotic system is the workable assembly composed of: Robot, Control Unit, Teach
Pendant and other possible options.
Protected Area
The protected area is the zone confined by the protection barriers and intended to be
used for the installation and operation of the Robot.
Authorised Personnel
Authorised personnel defines the group of persons who have been appropriately trained
and assigned to carry out the activities listed in the section Applicability.
Staff in Charge
The staff in charge defines the personnel who manage or supervise the activities of the
employed persons defined in the preceding point.
11
Comau Robotics Product Instruction
Integrator
The integrator is the professional expert responsible for the Robot and Control System
installation and startup.
Misuse
Misuse is defined as the use of the system outside the limits specified in the Technical
Documentation.
Action Area
The Robot action area is the enveloping volume of the area occupied by the Robot and
its equipment during movement in the area.
1.2.3 Applicability
These requirements must be applied when carrying out the following activities:
– Installation and Startup
– Functioning in Programming Mode
– Functioning in Auto / Remote Mode
– Maintenance and Repair
– Decommissioning and Dismantling.
12
Comau Robotics Product Instruction
13
Comau Robotics Product Instruction
In the cell/line emergency stop circuit it is necessary to include the contacts of the
Control Unit emergency stop push-buttons, available on X30. The push-buttons are not
interlocked inside the emergency stop circuit of the Control Unit.
14
Comau Robotics Product Instruction
– To load or update the system software (for example after boards replacing), use
only the original software handed over by COMAU. Scrupulously follow the system
software loading procedure described in the Technical Documentation supplied
with the specific product. After loading, always make some Robot moving tests at
low speed remaining outside the protected area.
– Check that the barriers of the protected area are correctly positioned.
15
Comau Robotics Product Instruction
– In both cases operate cautiously, always remaining out of the Robot range of action
and test the cycle at low speed.
16
Comau Robotics Product Instruction
17
Comau Robotics Product Instruction
18
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
2. TECHNICAL SPECIFICATIONS
This chapter contains:
– Robot general description
– Robot axes identification
– Declaration of incorporation of partly completed machinery
– Name and address of the manufacturer.
– Available versions and technical features
– Robot wrist features
– Description of the Robot mechanics
– Matching with the Control Unit and user customizations
– Robot integration principles
– Devices for calibration and maintenance
– Options
19
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
20
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Robot Rebel-S6-0.xx
Ax1
Ax4
Mtr2
Mtr1
Ax2
Ax Robot axis
Mtr Motor axis
Ax3
Mtr4
Mtr3
Ax4
Mtr2 Mtr1
Ax1
21
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
It is forbidden to startup the assembly consisting of the Robot and Control Unit before
the machine in which it will be incorporated has been declared in compliance with the
regulations stated in the 2006/42/EC Machinery Directive.
A xxxx
xxxxxxx
xxxxxxxxxx
C CRxxxxxxxx
E xx lb / xx kg
22
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Reach (to
Maximum Nominal
the wrist Assemblin Part No.
Robot type wrist load wrist load Application type
centre) g position Robot
(kg) (lb) (kg) (lb)
(mm) (ft)
Rebel-S6-0.45 450
CR82412300
Rel. 1.0 (17.71)
Rebel-S6-0.60 600
Floor / Wall CR82412400
Rel. 1.0 (23.62)
Handling,
Rebel-S6-0.75 6 1 750
CR82412500 Assemblies, Pick
Rel. 1.0 (13.22) (2.2) (29.52)
& Place
Rebel-S6-0.60c 600
CR82415700
Rel. 1.0 (23.62)
Ceiling
Rebel-S6-0.75c 750
CR82415800
Rel. 1.0 (29.52)
Rebel-S6-0.45 Rebel-S6-0.60c
23
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
24
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
25
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
(450)
275 175 162
STROKE +150
560 MAX
0
57
STROKE -50
506,95
450
Maximum space
175
290
°
° -132
-150
115
0
0
115
506,95
+15
Center of joint #3
R33
450
0°
R2 1,95
+132 75
°
R15
50
R4
1,31
449,05
392,1
5
,9
450
06
R5
506,95
Dimensions in millimetres
26
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
27
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
(600)
275 325 162
stroke +150
560 max
0
57
stroke -50
656,95
Maximum space
600
-150° -132°
240
115
0
115
Center of joint #3
+150 +13
° 2°
656,95
R331,95
600
R162
R2
75
,628
00
R6
549,42
492,47
5
,9
56
600
R6
656,95
Dimensions in millimetres
28
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
29
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
(600)
275 325 162
239
57
819
Maximum space
656,95
600
275
°
-150° -132 4 3
150
0
2
7
+15 +13 5 6 150
Center of joint #3
0°
600
2°
656,95
R331,95
R162,6
R2
75
3
00
R6
492,47
549,42
95
,
56
600
R6
656,95
Dimensions in millimetres
30
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
31
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
(750)
275 475 162
stroke +150
560 max
0
stroke -50
806,95
750
Maximum space
317,84
-150° °
-132
0 77,994
0
77,994
+150 +132
° °
Center of joint #3
1,95
806,95
R33
R273
R275
,9
750
50
R7
592,84
649,79
5
,9
06
R8
750
806,95
Dimensions in millimetres
32
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
33
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
(750)
275 475 162
-265 145 MAX
239
57
STROKE+465
969
0
806,95
750
Maximum space
1
273,86
317,84
°
-150 -132°
2
0
+150 +132 3
° °
Center of joint #3
1,95
806,95
R33
R273
R275
,9
750
50
R7 4
649,79
592,84
, 95
06
750
R8
806,95
Dimensions in millimetres
34
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
35
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
36
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Robot
Rebel-S6
The area defined by the loading curves defines the barycentre distances admissible for
load application specified on the area.
In the following Fig. 2.7 is shown the diagram of Max load capacity on the Robot
Rebel-S6 flange.
The inertia specified in the graph curves refers to the centre of gravity of the load applied
on the flange.
When applying loads different from the values specified in the graphs, check the Robot
use limitations by means of the SMART Payload software function.
6 5 4 3 2 1 [kg]
37
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Detail a
View from A
B B
40
+90°
10
15
10
ø3
ø 14
ø 20 h7
A
a
8,5
87,2
17
174,4 B-B
Dimensions in millimetres
38
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Purpose
The ISO flange allows the proper fixing of the machining tool on the Robot wrist.
Fixing components
– Socket hex head screws M5x16 (q.ty 2)
– Cone point grub screw M4x10 (q.ty 1).
Limitations
– Do not install tool weighing more than the Robot capacity.
For details, see the Robot par. 2.5.2 Technical features on page 24 .
39
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
40
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
A B
41
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Degrees of freedom
The Robot is of SCARA type with 4 degrees of freedom.
Rebel-S6-0.45
A- Base unit
B- Wrist unit
A
B
42
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Rebel-S6-0.60
A- Base unit
B- Spacer
C- Wrist unit
Rebel-S6-0.60c
A- Base unit
B- Spacer
C- Wrist unit
C
B
A
43
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Rebel-S6-0.75
A- Base unit
B- Spacer
C- Wrist unit
C
B
Rebel-S6-0.75c
A- Base unit
B- Spacer
C- Wrist unit C
44
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Spacer
The spacer is made of aluminum alloy and has a standard length of 150 mm. The spacer
is provided with centering dowel pins and screws for precise fixing on the base unit and
on the wrist unit or on any additional spacer. Depending on the needs, the User may
require Comau to provide for the additional installation* of spacers (up to two
consecutive, as shown in Fig. 2.11) obtaining an increase of up to 300 mm of the length
of the reach.
For further details see par. 3.5.3 Modifications in the Robot Reach on page 101.
45
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Ball screw
The Robot wrist is equipped with ball screw with spline shaft to ensure a high positioning
accuracy.
The vertical motion (Ax 3) and rotation (Ax 4) of the ball screw are controlled by two
specific motors through belt drive.
At the end of the screw, two mechanical limit switches are fixed.
Inside the ball screw it is possible to insert cables and pipes to bring on the tool installed
on the wrist, possible customer's installations (see Fig. 2.8).
46
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
The batteries have a duration of five years; any anomalies or malfunctions are signalled
to the operator by alarm on the Teach Pendant page (optional) or on PC (via WinR1C
software).
The verification and replacement procedures are indicated in the Maintenance chapter
of this handbook.
47
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
A Robot
B R1C-4 Control Unit
B
C Connection cables kit
R1C-4 Control Unit (B) and the connection cables (C) are described in the Technical
specifications, Transport and Installation and Maintenance handbook of R1C-4 Control
Unit.
48
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Robot Rebel-S6-0.xx
Robot Rebel-S6-0.xxc
On Robot Rebel-S6-0.60c and Rebel-S6-0.75c the Base plate (A) the plate Wrist
applications connection (B) are rotated 180°.
49
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
AIR1 AIR2
AIR3
X50
A
A
X1 X2
Code
Function Description
Base plate Wrist body
X1 --- Encoder signals cable gland ---
Motor and Brakes signals
X2 --- ---
cable gland
Quick coupling fitting for air pipe Ø 6 mm. The
AIR1 AIR1 AIR1 fitting for air delivery internal pipe reaches up to the AIR1 fitting on
Robot wrist body.
Quick coupling fitting for air pipe Ø 6 mm. The
AIR2
AIR2 AIR2 fitting for air delivery internal pipe reaches up to the AIR2 fitting on
Robot wrist body.
Quick coupling fitting for air pipe Ø 4 mm. The
AIR3 AIR3 AIR3 fitting for air delivery internal pipe reaches up to the AIR3 fitting on
Robot wrist body.
The X50 connector is connected to the X70
Connector for I/O signals connector in the wrist body area, by means of a
X50 X70
cable. cable inside the Robot that connects all the pins.
For further details see par. 2.8.2.2.
50
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Code
Function Description
Wrist body
The X70 connector is connected to X50
X70 I/O signals connector connector on Robot base with specific cable. For
further details see par. 2.8.2.2.
Quick coupling fitting for air pipe Ø 6 mm. The
AIR1 AIR fitting for air passage pipe starts at the Robot base (AIR1) and reaches
up to the Robot wrist body without interruptions.
Quick coupling fitting for air pipe Ø 6 mm. The
AIR2 AIR fitting for air passage pipe starts at the Robot base (AIR2) and reaches
up to the Robot wrist body without interruptions.
Quick coupling fitting for air pipe Ø 4mm. The
AIR3 AIR fitting for air passage pipe starts at the Robot base (AIR3) and reaches
up to the Robot wrist body without interruptions.
51
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
*Pinout valid only when using the optional connection cable between Control Unit and Robot (Services cable).
In the absence of such a cable, the X50 connector is available to the User and can be used according to the
specific needs. The X50 connector is connected pin-to-pin to X70 connector on Robot wrist body, through
internal cable.
52
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
*Pinout valid only when using the optional connection cable between Control Unit and Robot (Services cable).
In the absence of such a cable, the X50 connector is available to the User and can be used according to the
specific needs. The X50 connector is connected pin-to-pin to X70 connector on Robot wrist body, through
internal cable.
53
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
54
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Purpose
The fixing screws and pins unit allows to properly fix the Robot on the floor, to the wall
and on ceiling.
Limitations
– Use 1 unit to fix 1 Robot.
Fixing components
– Socket hex head screw M8x25 8.8 ISO 4762-A3K (q.ty 4) (A)
– Plain washer, internal Ø 8 mm (q.ty 4) (B)
– Split spring washer 8x14,8x2 DIN127B (q.ty 4) (C)
– Dowel pin with extraction hole Ø 6x20 (q.ty 2) (D)
55
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Fig. 2.14 - Robot floor and ceiling fixing option method of use diagram
1 1
3 4 Detail A 3
2 2
Dimensions in millimetres
1. Socket hex head screw M8x25 8.8 ISO 4762-A3K
2. Plain washer, internal Ø 8 mm
3. Split spring washer 8x14,8x2 DIN127B
4. Dowel pin with extraction hole Ø 6x20
56
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
1 Detail A
3
1
3 4
Dimensions in millimetres
1. Socket hex head screw M8x25 8.8 ISO 4762-A3K
2. Plain washer, internal Ø 8 mm
3. Split spring washer 8x14,8x2 DIN127B
4. Dowel pin with extraction hole Ø 6x20
57
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Because of the considerable stress discharged on the ground by the Robot and the need
to have appropriate backing plans, direct fixing on the floor is not foreseen.
The values of stresses created by the Robot on the supporting structure are indicated in
he following Fig. 2.16 - Stresses on the supporting structure on page 59.
58
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Mk
Fv
Mr
Fo
Mk
Fv
Mr
Fo
59
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
The figures represent the Robot installed on the floor / ceiling but are valid also for Robot
installed in other positions (e.g. to wall).
60
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Type of
Available solutions for areas limitation Supply Application
intervention
Axis 1
Axis 2
Software limit switch Standard Software*¹
Axis 3
Axis 4
Type of
Available solutions for safety areas partialization Supply Application
intervention
Axis 1 mechanical limit switch (CR82417400) Optional Axis 1 Mechanical*²
61
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Purpose
The mechanical stop block option (mechanical limit switch) axis 1 allows to limit the
stroke of the Robot axis 1.
It is possible to mount, in all configurations, one or both of the stop screws (A) thus
obtaining the following stroke limitations:
– negative limit switch ÷ 0° / 0° ÷ + 100°
– negative limit switch ÷ 0° / 0° ÷ + 115°
– -100° ÷ 0 / 0 ÷ positive limit switch
– -115° ÷ 0 / 0 ÷ positive limit switch
– -100° ÷ 0 / 0 ÷ +100°
– -100° ÷ 0 / 0 ÷ +115°
– -115° ÷ 0 / 0 ÷ +100°
– -115° ÷ 0 / 0 ÷ + 115°
The axis 1 mechanical limit switch it is able to absorb all the axis kinetic energy.
62
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
After the impact of the axis 1 on the set screws, the stop screws must be replaced.
Also the integrity of the parts involved in the impact is to be checked, such as:
– Robot arm in the fixing area of the stop screw
– Robot base in the vicinity of the impact area
– equipment moved by Robot
The failed replacement in case of impact will undermine the correct functioning (and
therefore the Robot stopping) in case of later interventions.
Limitations
– Use max 2 mechanical limit switches for each Robot (to limit the axis 1 stroke in
both rotation directions).
63
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
1 1
1. Axis 1 mechanical limit switch (q.ty 2 socket hex head screws - ISO 4762 - M10X25 - 12.9 - A3K)
64
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
1 1
1. Axis 1 mechanical limit switch (q.ty 2 socket hex head screws - ISO 4762 - M10X25 - 12.9 - A3K)
65
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
66
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Purpose
In absence of motive power, the Robot axes 3 and 4 movement is possible by means of
brake releasing devices.
The integrated brake releasing device allows the brake deactivation of the axis 3 and 4
by pressing the button A (provided with identification logo as shown in figure) on the
Robot wrist plate.
During the axes brake release activity, all the system safety devices (including the
emergency stop and the enabling push-button) are cut-off.
Limitations
– Motion freedom of axes is conflicted and slowed down by dynamic braking.
Refer also to the R1C-4 Control Unit “Technical Specifications, Transport and
Installation, Maintenance” handbook.
For details, see the Robot Maintenance Chapter.
67
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Purpose
The calibrated tool unit (A) is used to calculate the TCP (Tool Centre Point) in relation
to the Robot flange.
Limitations
– It requires the presence of the ISO tool coupling flange ISO 9409 - 1 - A40
(CR82392149) option.
68
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
AX 3 and 4 AX 1 and 2
Purpose
The calibration tool option consists of a mechanical key, a flange and a bracket.
The option allows to manually carry out a proper calibration of each Robot axis.
Limitations
– None
1. Mechanical key
69
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
1. Bracket
2. Flange
3. Mechanical key
70
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Purpose
The tool allows the assembly of the axis 3 and 4 pulleys on the ball screw, in case of
replacement of the screw itself.
71
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
Purpose
The plate allows to perform the tensioning of the axis 4 first belt after the replacement
of the axis 4 motor.
72
Comau Robotics Product Instruction
TECHNICAL SPECIFICATIONS
2.11 Options
The Robot can be integrated with additional options to better adapt to the installation
requirement. These options, if not differently specified, can be chosen among the
available ones, combining them. All possible limitations to the mutual incompatibility or
maximum quantity that can be installed are clearly defined.
For a better finding, the options are listed below organised according to the topic and
application field, while the details are directly described in the related chapter.
73
Comau Robotics Product Instruction
74
Comau Robotics Product Instruction
75
Comau Robotics Product Instruction
Before carrying out any type of installation operation carefully read the Chap.1. -
General Safety Requirements on page 10.
The Robot has to be matched with Comau Control Unit. Any other use is prohibited.
Possible exceptions must be expressly authorised by COMAU.
76
Comau Robotics Product Instruction
For further information see the par. 2.5.2 Technical features on page 24 of the Robot.
77
Comau Robotics Product Instruction
The maximum overall dimension of the Robot operating area is indicated in the graphs
Operational areas and Robot overall dimensions (see par. 2.5.3 on page 25) in the
chapter “Technical Specifications” of the Robot.
Because of the considerable stress discharged on the ground by the Robot and the need
to have appropriate backing plans, direct fixing on the floor is not foreseen.
The Robot must be fixed on a horizontal flat surface with flatness tolerance of:
0,2 .
When choosing the place of installation, make sure that there is an adequate space
(approximately 50 cm) next to the Robot base, in order to allow easy access to the Robot
distribution panel (e.g. for maintenance operations).
The graphs and the values of the stress generated by the Robot are listed in the
paragraph Stresses on the supporting structure (see par. 2.9.2 on page 58) in the
chapter “Technical Specifications” of the Robot.
78
Comau Robotics Product Instruction
79
Comau Robotics Product Instruction
The Robot is stable only in transport position and without the installed equipment.
Any movement of the Robot axes made when the Robot is not fixed to the floor can
cause overturning.
For details on lifting and transport procedures of various Robot models, see the next
par. 3.3.3 Robot lifting and transport on page 81.
80
Comau Robotics Product Instruction
If it would be necessary to lift the Robot after the installation (lifting from fixing surface),
the lifting shall always be carried out by means of a translation perpendicular to the fixing
surface until obtaining the extraction of the pins from the seats on Robot base, in order
to avoid damages to the centering pins.
Operative notes: Move the Robot in transport position (see Tab. 3.2).
81
Comau Robotics Product Instruction
A A
Operative notes: Move the Robot in transport position (see Tab. 3.2).
82
Comau Robotics Product Instruction
83
Comau Robotics Product Instruction
Because of the considerable stress discharged on the ground by the Robot and the need
to have appropriate backing plans:
– direct fixing on the floor is not foreseen.
– the Robot must be fixed on a horizontal flat surface with flatness tolerance of:
0,2 .
It should be noted that in order to use the load auto-determination option it is necessary
to have some cubic meters of free space to allow the Robot axes to move while
performing the function.
The Robot must be fixed: to a metal backing surface (plate / structure) fitted with
drillings, see Fig. 3.1, for screws and pins (for the main dimensions of the fixing points
see Screws and pins unit for Robot fixing (CR82417300) in the Technical Specifications
chapter).
The backing surface must be realised by the integrator and made of S235JR steel.
The integrator must check the stresses discharged by the Robot and the resistance
conditions on the backing surface / structure (see par. 2.9.2 Stresses on the supporting
structure on page 58) and fix properly the backing surface / structure of the Robot to the
floor or on any specific equipment / supporting stand.
84
Comau Robotics Product Instruction
85
Comau Robotics Product Instruction
Fig. 3.1 - Drilling diagram on backing plan for Robot floor fixing
B A A
CL
A
A
B
A A
Tolerance only
on pins
Section A - A
N° 2 holes N° 4 holes
ø6H7 - thru M8 - thru
Dimensions in millimetres
A: threaded holes for Robot fixing (details on Screws and pins unit for Robot fixing (CR82417300))
B: centring holes (details on Screws and pins unit for Robot fixing (CR82417300))
86
Comau Robotics Product Instruction
Operating procedure
C C
B A
B C
87
Comau Robotics Product Instruction
Follow-up procedures
None
88
Comau Robotics Product Instruction
89
Comau Robotics Product Instruction
Fig. 3.2 - Drilling diagram on backing plan for Robot wall fixing
A A
B B
A
CL
A A
Section A - A
N° 4 holes N° 2 holes
M8 - thru ø6H7 - thru
Dimensions in millimetres
A: threaded holes for Robot fixing (details on Screws and pins unit for Robot fixing (CR82417300))
B: centring holes (details on Screws and pins unit for Robot fixing (CR82417300))
90
Comau Robotics Product Instruction
Operating procedure
C C
B B
C CL C
91
Comau Robotics Product Instruction
J HG D
Follow-up procedures
None
92
Comau Robotics Product Instruction
The drilling diagram for Robot ceiling fixing is identical to the drilling diagram for Robot
floor fixing. Please refer to par. 3.4.3.1.
93
Comau Robotics Product Instruction
Operating procedure
C C
B A
B D
C
C
94
Comau Robotics Product Instruction
Follow-up procedures
None
95
Comau Robotics Product Instruction
96
Comau Robotics Product Instruction
Operating procedure
a. Clean the seat of the axis 3 shaft A on which will be installed the flange.
b. Position the flange B on the
shaft.
97
Comau Robotics Product Instruction
Follow-up procedures
None
98
Comau Robotics Product Instruction
3.5.1.1 Suggestions for the construction of a tool suitable for ISO tool
coupling flange ISO 9409 - 1 - A40 (CR82392149)
When using the option ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149), the
Integrator must provide for the construction of a machining tool suitable for the flange
itself. In the following Fig. 3.3 and Fig. 3.4 are given the drilling diagrams and
mechanical drawings of the flange, useful for the construction of the machining tool.
R25
M6 - 6H
4x
A
A
8
+0,012
10
20
6 H7 0
25 ±0,025 25
D
5,50
13
8
0.04 B
SECTION A-A
1.6
1.6
6 H7
63 h8 -0,046
0
99
Comau Robotics Product Instruction
R
2
A 1.6 1 X 45°
1.6
SECTION D-D
B
+0,025
31,50 H7 0
0.03 A
100
Comau Robotics Product Instruction
The modifications of the Robot Reach must be carried out exclusively by Comau staff.
101
Comau Robotics Product Instruction
102
Comau Robotics Product Instruction
103
Comau Robotics Product Instruction
3.6.2 Connection with the R1C-4 Control Unit (main motors and
encoder cables)
Operating procedure
a. Carry out the cables connection through X10, X60 connectors on the connectors
panel of the R1C-4 Control Unit.
Encoder cable
Follow-up procedure
– Not necessary
104
Comau Robotics Product Instruction
The following procedure describes only the I/O signals cable connection.
For other users connection, see the specific application handbook.
Operating procedure
a. Carry out the cable connection through X55 connector on the connectors panel
of the R1C-4 Control Unit.
b. Carry out the cable connection through X50 connector on Robot base.
X55 X50
Service cable
Follow-up procedure
– Not necessary
105
Comau Robotics Product Instruction
For the proper interfacing refer to the principle diagrams given in the "Transport and
Installation" chapter of the Control Unit.
The vastness of the topics related to the Control Unit power up, motion and
programming and other necessary topics, requires the consultation of additional
handbooks.
Depending on requirements, the following documents are recommended:
– for Robotic system power up, use: Use of the Control Unit
– for specific applications: various handbooks of the applications.
106
Comau Robotics Product Instruction
The following procedure indicates the necessary operations in case of Robot ceiling or
wall installation, with reference to the pages of the Teach Pendant (optional).
In the absence of the Teach Pendant, the same operations can be performed through
Virtual TP interface on WinR1C software.
In case of Robot ceiling / wall installation, ensure the proper configuration of the Robot
ceiling installation position:
1. Go to the “Mounting” page accessed by selecting “Setup” and “Motion”.
2. According to need select:
• “On ceiling” option in case of ceiling installation
• “On floor” option in case of floor or wall installation.
3. Save the configuration by touching the “Apply” key (remaining on the Mounting
page) or the OK key (exiting). In both cases the user is asked whether he wants to
save the system configuration.
107
Comau Robotics Product Instruction
MAINTENANCE
4. MAINTENANCE
This chapter deals with the following topics:
– General requirements for the maintenance
– Assistance for troubleshooting
– How to disconnect the electrical power supply on R1C-4 Control Unit
– How to move the Robot in case of emergency
– Maintenance structure
– Preventive maintenance
– Special maintenance
– Robot calibration
– Spare parts list
The maintenance activities that are not expressly mentioned in this handbook are not
authorized. If necessary, require the manufacturer intervention.
108
Comau Robotics Product Instruction
MAINTENANCE
If maintenance and/or troubleshooting activities are carried out on the safety circuits, do
not stand near the Robot and move in jog at a suitable distance.
At the end of each maintenance operation, the first machine power up shall be regarded
as a test for the whole system. During this phase the operator must stand outside the
Robot range of action but in a position that allows to observe its movements. It must also
have a Teach Pendant (optional, if any) or other safety shutdown device in the
immediate vicinity.
109
Comau Robotics Product Instruction
MAINTENANCE
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.
110
Comau Robotics Product Instruction
MAINTENANCE
Tab. 4.1 - Tightening torque for Hex head screws and Socket hex head
screws (Nm)
A tolerance of ± 10% is allowed on tightening torques of screws and lock nuts for
preloading of bearings.
Product
As an alternative to the products indicated in the table Tab. 4.2 it's possible to use:
– Arexons 52A22 (alternative for Loctite 222)
– Arexons 52A43 (alternative for Loctite 243)
– Arexons 35A72 (alternative for Loctite 257)
111
Comau Robotics Product Instruction
MAINTENANCE
Application Product
Flat sealant Arexons 35A73
Polyurethane sealant BOSTIK MK2639
Bearing fasteners Arexons 56A41
High strength fasteners Arexons 56A48
As an alternative to the products indicated in the table Tab. 4.3 it's possible to use:
– Loctite 518 (alternative for Arexons 35A73)
– Loctite 641 (alternative for Arexons 56A41)
– Loctite 648 (alternative for Arexons 56A48)
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 is installed.
112
Comau Robotics Product Instruction
MAINTENANCE
113
Comau Robotics Product Instruction
MAINTENANCE
A B
For further information on Win R1C software, error messages and recovery mode
consult the "Use of Control Unit" handbook.
114
Comau Robotics Product Instruction
MAINTENANCE
Do not carry out autonomous or not authorized repairs on the damaged modules.
Repairs can be carried out only by Comau.
For further details see the Robot electrical diagram and connection details.
115
Comau Robotics Product Instruction
MAINTENANCE
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.
116
Comau Robotics Product Instruction
MAINTENANCE
117
Comau Robotics Product Instruction
MAINTENANCE
Operating procedure
Main switch open (OFF)
a. Carry out the software
shutdown. Use the specific
command on the Teach
Pendant (when present) or on
Virtual TP interface on WinR1C
interface.
With main switch open, the X120 connector and the upstream cables of the
main switch are under voltage.
Follow-up procedure
– Not necessary.
118
Comau Robotics Product Instruction
MAINTENANCE
The functionality of the integrated brake releasing device is always available with the
Control Unit powered on and the motor cables connected.
– The axes brake release generates the risk of falling of the axes subject to gravity.
– During the brake releasing operation, the operator must avoid being alongside the
Robot parts that can move downwards due to gravity. During the operations, any
operator can stand in the working area and in particular under the Robot.
– The dynamic brake release function could be compromised by failures occurred on
the Control Unit 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.
119
Comau Robotics Product Instruction
MAINTENANCE
120
Comau Robotics Product Instruction
MAINTENANCE
Operating procedure
a. Manually support the axes of the Robot subject to gravity.
b. Press the push-button (A) to
obtain the axis 3 and 4 brake
release.
A
c. Manually move the required
axis (or axes).
121
Comau Robotics Product Instruction
MAINTENANCE
4.6.1 Overview
The Robot maintenance is divided in:
– Summary diagram of the maintenance operations
– Preventive maintenance
– Special maintenance
122
Comau Robotics Product Instruction
MAINTENANCE
Frequency
---** L2 L1 ---**
SW D.* P1 SW D.*
180 d L3 180 d
h = hours 90 d P2 90 d
d = days
Frequency
Failure
S6 S5 S3 S4 S2 S1 S7 Failure
h = hours
d = days
Pn = Preventive Maintenance
Ln = Lubrication
Sn = Special Maintenance
123
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Poor or missing preventive maintenance activities during the warranty period, will be
regarded as prejudicial to the warranty itself.
124
Comau Robotics Product Instruction
PREVENTIVE MAINTENANCE
Pn = Preventive Maintenance
Ln = Lubrication
125
Comau Robotics Product Instruction
Operating procedure
Robot cleaning
a. Clean the Robot parts.
Check the structure and warning signs integrity
b. Check integrity and good conservation state of all the Robot parts.
c. Check the presence and proper fixing of the warning signs. The warning signs
position is given in Fig. 4.3.
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. 4.6
126
Comau Robotics Product Instruction
g. Check the proper tightening and integrity of wiring power supply pipes.
i. Check, using suitable visual reference notches, the proper tightening of the
screws that fix the equipment on the Robot flange.
Follow-up procedures
– Not necessary
13 3 2 7 8 10 1 2 4 13
6
12 11
5
9
127
Comau Robotics Product Instruction
128
Comau Robotics Product Instruction
Operating procedure
a. Unscrew and remove the six
fixing hex socket button head A
screws M5x10 (A).
129
Comau Robotics Product Instruction
C
c. Disconnect the two connectors
(D) of the batteries.
G E F
g. Reposition the new batteries (G) in the corresponding holder (F).
h. Reposition and fix the battery holder, fixing it with the hex socket button head
screws M5 (E) and M5 nuts to the proper tightening torque.
The batteries' cables must come out on the left side, as shown in figure.
j. Clamp using cable ties the batteries' cables to the cables harness already
present inside the Robot wrist.
130
Comau Robotics Product Instruction
C
l. Tighten the six fixing hex socket
button head screws M5x10 (A) A
to the proper tightening torque.
Follow-up procedures
– After the batteries replacement, carry out the Encoder recognition procedure as
described in par. 4.9 Software procedures following the maintenance on
page 214.
– Carry out the Robot calibration, as described in par. 4.10 Robot calibration on
page 219.
131
Comau Robotics Product Instruction
In case of contact with eyes or skin: rinse the affected areas with copious amount of
water; if irritation persists, consult a doctor.
If swallowed, do not induce vomiting or administer anything by mouth; seek medical
advice immediately.
The lubrication operations shall be carried out with the lubricant type advised on the
label applied on the Robot.
It is forbidden to mix lubricants of different qualities.
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.
After lubrication operations, carry out a general cleaning of the parts surrounding the
lubrication point, in order to remove possible lubricant residues.
The quantity of lubricant indicated for the “first intervention” refers to filling after a new
unit has been installed.
The quantity indicated for “subsequent interventions” concerns the replenishment of the
lubricant.
The disposal of used oils and greases is to be carried out according to the legislation in
force in the country where the Robot is installed.
132
Comau Robotics Product Instruction
Frequency
1 1
---* L2 L1 ---*
180 d L3 180 d
h = hours
d = days
Intervention point L1 L2 L3
Type of lubricant
HARMONIC GREASE SK-1A THK AFB-LF
used
Identification
symbol
* Recommended frequency. The necessity of lubrication is also signaled by the System Software through the Virtual TP interface, on WinR1C
or on the Teach Pendant (if present).
*¹ Lubricated for life; check the presence of grease in case of motor replacement
*² Quantity concerning a filling carried out after a new unit assembly
*³ Quantity concerning the replenishment of the lubricant
133
Comau Robotics Product Instruction
Operating procedure
a. Unscrew and remove the six
hex socket button head screws A
M5x10 (A).
134
Comau Robotics Product Instruction
C
c. Using a brush, manually apply a
thin layer of grease THK
AFB-LF ( 9.18 total grams) on D
the outer surface of the screw
(D).
d. At the end of the lubrication operations, carry out a general cleaning of the parts
surrounding the lubrication point, in order to remove possible lubricant residues.
e. Reposition the cover (B).
135
Comau Robotics Product Instruction
136
Comau Robotics Product Instruction
SPECIAL MAINTENANCE
137
Comau Robotics Product Instruction
SPECIAL MAINTENANCE
138
Comau Robotics Product Instruction
139
Comau Robotics Product Instruction
Operating procedure
a. Unscrew and remove the four
socket hex head screws M6x20
(A) with the corresponding
washers Ø6.
140
Comau Robotics Product Instruction
F E
H
i. Lift the flange (K), including the
motor (M), from the Robot base. K
141
Comau Robotics Product Instruction
P
n. Disassemble the motor (M) with
the corresponding flange (Q) M
from the gearbox (R).
142
Comau Robotics Product Instruction
143
Comau Robotics Product Instruction
V W
When reassembling, on all the fixing screws with M5 size onwards, apply
Loctite 222 threadlocker.
M U V
u. Pre-screw the two socket hex
grub screws M3 (S) on the
internal part of the gearbox (T). T
144
Comau Robotics Product Instruction
12 mm
S
w. Position the internal part of the X
gearbox (T) of the driving shaft,
matching the fixing socket hex
grub screws (S) with the milling
present on the driving shaft.
145
Comau Robotics Product Instruction
P
c. Clean any grease residues.
146
Comau Robotics Product Instruction
147
Comau Robotics Product Instruction
Top view
148
Comau Robotics Product Instruction
Follow-up procedures
– After the motor replacement, carry out the Encoder recognition procedure as
described in par. 4.9 Software procedures following the maintenance on
page 214.
– Carry out the calibration procedure, as described in par. 4.10.2 Calibration -
Operating procedures on page 223
– Check the correct functioning of the Robot running a slow speed work program.
149
Comau Robotics Product Instruction
– Disconnect the electrical power supply (details in par. 4.4 How to disconnect the
electrical power supply on R1C-4 Control Unit on page 116).
– Disconnect and discharge the pneumatic power supply.
150
Comau Robotics Product Instruction
Operating procedure
a. Unscrew and remove the six
fixing hex socket button head A
screws M5x10 (A).
C
c. Cut the cable ties that fix the
cables to the axis 3 and 4
motors.
E D
151
Comau Robotics Product Instruction
152
Comau Robotics Product Instruction
153
Comau Robotics Product Instruction
154
Comau Robotics Product Instruction
Top view, with the wrist free of top cover (B) and bracket
(E).
x. Tighten the four socket hex
head screws M5x12 (J) that fix
the axis 2 motor (H) to 6 Nm.
H
torque, using a torque wrench
with extension.
155
Comau Robotics Product Instruction
156
Comau Robotics Product Instruction
C
f. Tighten the six fixing hex socket
button head screws M5x10 (A) A
to the proper tightening torque.
Follow-up procedures
– After the motor replacement, carry out the Encoder recognition procedure as
described in par. 4.9 Software procedures following the maintenance on
page 214.
– Carry out the calibration procedure, as described in par. 4.10.2 Calibration -
Operating procedures on page 223
– Check the correct functioning of the Robot running a slow speed work program.
157
Comau Robotics Product Instruction
– Disconnect the electrical power supply (details in par. 4.4 How to disconnect the
electrical power supply on R1C-4 Control Unit on page 116).
– Disconnect and discharge the pneumatic power supply.
158
Comau Robotics Product Instruction
Operating procedure
a. Unscrew and remove the six
fixing hex socket button head A
screws M5x10 (A).
C
c. Cut the cable ties that fix the
cables to the axis 3 and 4
motors.
E D
159
Comau Robotics Product Instruction
F
i. Unscrew and remove the 3
socket hex head screws M4x12
(J) that fix the plate (K) and
related blank washers, using an
Allen wrench with extension.
160
Comau Robotics Product Instruction
The pulley (L) is fixed on the driving shaft with 2 pairs of socket hex grub
screws M4, set at 90° to one another.
161
Comau Robotics Product Instruction
When reassembling, on all the fixing screws with M5 size onwards, apply
Loctite 222 threadlocker.
162
Comau Robotics Product Instruction
L
x. Tighten the two internal socket
hex grub screws M4 (N) to 3.1
Nm. torque.
N M
163
Comau Robotics Product Instruction
S
e. Maintain the pressure, then
tighten the fixing screws M4x12
(J) to 3.1 Nm. torque.
164
Comau Robotics Product Instruction
165
Comau Robotics Product Instruction
D
s. Reposition the cover (B).
C
t. Tighten the six fixing hex socket
button head screws M5x10 (A) A
to the proper tightening torque.
166
Comau Robotics Product Instruction
Follow-up procedures
– After the motor replacement, carry out the Encoder recognition procedure as
described in par. 4.9 Software procedures following the maintenance on
page 214.
– Carry out the calibration procedure, as described in par. 4.10.2 Calibration -
Operating procedures on page 223
– Check the correct functioning of the Robot running a slow speed work program.
167
Comau Robotics Product Instruction
– Disconnect the electrical power supply (details in par. 4.4 How to disconnect the
electrical power supply on R1C-4 Control Unit on page 116).
– Disconnect and discharge the pneumatic power supply.
168
Comau Robotics Product Instruction
Operating procedure
a. Unscrew and remove the six
fixing hex socket button head A
screws M5x10 (A).
C
c. Cut the cable ties that fix the
cables to the axis 3 and 4
motors.
E D
169
Comau Robotics Product Instruction
F
i. Unscrew and remove the 3
socket hex head screws M4x12
(J) that fix the plate (K) and
related blank washers, using an
Allen wrench with extension.
170
Comau Robotics Product Instruction
The pulley (L) is fixed on the driving shaft with 2 pairs of socket hex grub
screws M4, set at 90° to one another.
N
M
o. Remove the pulley (L) from the
axis 3 driving shaft (H).
H
p. Clean the driving shaft seat
within the pulley.
171
Comau Robotics Product Instruction
P
r. Unscrew and remove the two
socket hex head screws M4x8
(Q).
H
s. Remove the plate (K) from the
motor (H).
Q
When reassembling, on all the fixing screws with M5 size onwards, apply
Loctite 222 threadlocker.
172
Comau Robotics Product Instruction
L
x. Tighten the two internal socket
hex grub screws M4 (N) to 3.1
Nm. torque.
M
N
y. Tighten the two external socket
hex grub screws M4 (M) to 3.1
Nm. torque.
L
z. Remove the shim (R) previously
used.
N
M
a. Insert the motor (H) inside the
related seat, manually fitting the
belt on the pulley (L).
H
K
173
Comau Robotics Product Instruction
S
d. Position a compression
dynamometer (U) on the plate
side (S).
S
U
f. Maintain the pressure, then
tighten the screws (J) to 3.1
Nm. torque.
174
Comau Robotics Product Instruction
175
Comau Robotics Product Instruction
C
n. Tighten the six fixing hex socket
button head screws M5x10 (A) A
to the proper tightening torque.
Follow-up procedures
– After the motor replacement, carry out the Encoder recognition procedure as
described in par. 4.9 Software procedures following the maintenance on
page 214.
– Carry out the calibration procedure, as described in par. 4.10.2 Calibration -
Operating procedures on page 223
– Check the correct functioning of the Robot running a slow speed work program.
176
Comau Robotics Product Instruction
Operating procedure
a. Unscrew and remove the six
fixing hex socket button head A
screws M5x10 (A).
177
Comau Robotics Product Instruction
C
c. Cut the cable ties that fix the
cables to the axis 3 and 4
motors.
E D
e. Lift the holder (E) being careful
not to over-pull the cables. E
178
Comau Robotics Product Instruction
m. Carry out the tensioning of the axis 3 belt as indicated from point c. to point l.3 of
the par. 4.8.6 AXIS 3 MOTOR: complete replacement on page 158.
In case of belt replacement, tension the belt until obtaining a frequency
value between 75 Hz and 85 Hz.
n. Loosen the fixing screws of the axis 4 motor and of the axis 4 bearing holder.
o. Carry out the tensioning of the axis 4 belts as indicated from point z. to point k.
of the par. 4.8.10 AXIS 3 RECIRCULATING BALL SCREW: complete
replacement on page 187.
179
Comau Robotics Product Instruction
D
s. Reposition the cover (B).
C
t. Tighten the six fixing hex socket
button head screws M5x10 (A) A
to the proper tightening torque.
180
Comau Robotics Product Instruction
Follow-up procedures
– After the belt replacement, carry out the Encoder recognition procedure as
described in par. 4.9 Software procedures following the maintenance on
page 214.
– Carry out the calibration procedure, as described in par. 4.10.2 Calibration -
Operating procedures on page 223
– Check the correct functioning of the Robot running a slow speed work program.
181
Comau Robotics Product Instruction
Operating procedure
a. Unscrew and remove the six
fixing hex socket button head A
screws M5x10 (A).
182
Comau Robotics Product Instruction
C
c. Cut the cable ties that fix the
cables to the axis 3 and 4
motors.
E D
e. Lift the holder (E) being careful
not to over-pull the cables. E
183
Comau Robotics Product Instruction
When reassembling, on all the fixing screws with M5 size onwards, apply
Loctite 222 threadlocker.
184
Comau Robotics Product Instruction
p. Carry out the tensioning of the axis 3 belt as indicated from point c. to point l.3 of
the par. 4.8.6 AXIS 3 MOTOR: complete replacement on page 158.
q. Carry out the tensioning of the axis 4 second belt as indicated from point y. to
point j. of the par. 4.8.10 AXIS 3 RECIRCULATING BALL SCREW: complete
replacement on page 187.
r. Carry out the tensioning of the axis 4 first belt as indicated from point c. to point
f. of the par. 4.8.7 AXIS 4 MOTOR: complete replacement on page 168.
s. Block the axis 3 and 4 motor
cables to the corresponding E
motor, using a plastic cable tie.
185
Comau Robotics Product Instruction
D
v. Reposition the cover (B).
C
w. Tighten the six fixing hex socket
button head screws M5x10 (A) A
to the proper tightening torque.
Follow-up procedures
– After the belt replacement, carry out the Encoder recognition procedure as
described in par. 4.9 Software procedures following the maintenance on
page 214.
– Carry out the calibration procedure, as described in par. 4.10.2 Calibration -
Operating procedures on page 223
– Check the correct functioning of the Robot running a slow speed work program.
186
Comau Robotics Product Instruction
187
Comau Robotics Product Instruction
– Disconnect the electrical power supply (details in par. 4.4 How to disconnect the
electrical power supply on R1C-4 Control Unit on page 116).
– Disconnect and discharge the pneumatic power supply.
Operating procedure
a. Unscrew and remove the six
fixing hex socket button head A
screws M5x10 (A).
188
Comau Robotics Product Instruction
F F
f. Unscrew the four socket hex
head screws M4x12 (G). G G
189
Comau Robotics Product Instruction
M L
j. Position the appropriate Tool
for ball screw disassembly
(CR82392144) (N), inserting it
from the upper side of the
screw.
N
k. Move upwards the axis 3
bearing / pulley unit (P), until it N
is fully positioned on the P N
appropriate tool (N) previously
installed (free screw). P
190
Comau Robotics Product Instruction
191
Comau Robotics Product Instruction
U
T T
192
Comau Robotics Product Instruction
M L
40
c. Position and fix the second
mechanical limit switch (M) 40
mm from the lower edge of the
screw.
193
Comau Robotics Product Instruction
h. Remove the lubrication ring and the O-ring gasket, then repeat the operations
from point e. to point g. also on the axis 4 bearing.
i. At the end of the operations, remove the lubrication ring and the O-ring gasket
from the axis 4 bearing.
j. Manually apply a thin layer of THK AFB-LF grease (about 12.7 grams) on the
external surface of the screw.
k. Manually move the axis 3 and axis 4 bearing / pulley units, in order to obtain an
even distribution of the grease all along the screw and inside the nut screw.
l. Reposition the screw (J) in the
corresponding seat on the J
Robot wrist, by manually fitting
the axis 3 and axis 4 belts on
the respective pulleys.
Position the screw (J) in
the correct direction, so
as to match the fixing
holes with the holes on
the Robot wrist.
F F
194
Comau Robotics Product Instruction
H
q. Tighten the four socket hex
head screws M4x12 (G) to 3.1 G G
Nm. torque.
r. Check the correct tensioning of the axis 3 belt and, if necessary, adjust it as
indicated in the procedure AXIS 3 MOTOR: complete replacement (see par.
4.8.6 on page 158).
s. Check the correct tensioning of
the axis 4 second belt (AA), as
indicated below:
195
Comau Robotics Product Instruction
b. Maintain the pressure, then Representative image illustrating only the axis 4
tighten the three socket hex transmission, without guards.
head screws M4x12 (AE) to 3.1
Nm. torque.
196
Comau Robotics Product Instruction
197
Comau Robotics Product Instruction
AA
p. Reposition the lower guard (E).
C
s. Tighten the six fixing hex socket
button head screws M5x10 (A) A
to the proper tightening torque.
198
Comau Robotics Product Instruction
Follow-up procedures
– After the recirculating ball screw replacement, carry out the Encoder recognition
procedure as described in par. 4.9 Software procedures following the
maintenance on page 214.
– Carry out the calibration procedure, as described in par. 4.10.2 Calibration -
Operating procedures on page 223
– Check the correct functioning of the Robot running a slow speed work program.
199
Comau Robotics Product Instruction
Before proceeding with the wiring disassembly, make sure that the
pneumatic power supply is disconnected and the compressed air circuit is
discharged.
– Disconnect the electrical power supply (details in par. 4.4 How to disconnect the
electrical power supply on R1C-4 Control Unit on page 116).
– Disconnect and discharge the pneumatic power supply.
The following are the operations needed to carry out:
• Operating procedure - Wiring disassembly
• Operating procedure - Wiring assembly
200
Comau Robotics Product Instruction
201
Comau Robotics Product Instruction
202
Comau Robotics Product Instruction
203
Comau Robotics Product Instruction
204
Comau Robotics Product Instruction
205
Comau Robotics Product Instruction
206
Comau Robotics Product Instruction
207
Comau Robotics Product Instruction
208
Comau Robotics Product Instruction
209
Comau Robotics Product Instruction
210
Comau Robotics Product Instruction
211
Comau Robotics Product Instruction
212
Comau Robotics Product Instruction
If previously removed,
reassemble the Robot
lower plate, indicated in
figure (in case of wall
installation, reassemble
the side plate).
Follow-up procedures
– At the end of the activity, make sure the pipes and cables are not constricted or
inadequately curved.
– After the wiring replacement, carry out the Encoder recognition procedure as
described in par. 4.9 Software procedures following the maintenance on
page 214.
– Before restarting the production cycle, move the Robot at low speed, in order to
check the proper positioning of the wiring.
213
Comau Robotics Product Instruction
The need for any consequent Software procedures is indicated at the end of each
maintenance sheet of the Robot.
214
Comau Robotics Product Instruction
The encoder recognition procedure must be performed following the disconnection and
reconnection of the encoder cable from the motor, or following the replacement of
encoder batteries.
215
Comau Robotics Product Instruction
216
Comau Robotics Product Instruction
i. Repeat the operations from point b. to point h. for each axis. Select every time the desired axis from the
related “Axis” drop down menu.
j. From the “Function” drop down menu, select
the “AbsEnc ResetError” item.
m. Repeat the operations from point j. to point l. for each axis. Select every time the desired axis from the
related “Axis” drop down menu.
217
Comau Robotics Product Instruction
218
Comau Robotics Product Instruction
AX 3 and 4 B AX 1 and 2
219
Comau Robotics Product Instruction
By means of the Virtual TP on WinR1C (or on Teach Pendant, if present), move at low
speed the Robot axes up to coincide the movable notch with the fixed notch.
Insert the calibration mechanical key in the seat of the aligned reference notch. The
insertion must occur easily, without forcing. In case of even a minimum jam, remove the
calibration mechanical key, move the axis that is to be calibrated and try to insert again.
AX 3 and 4 B AX 1 and 2
The following Tab. 4.9 are the points where it is necessary to insert the mechanical key
(T1) to perform the calibration of the various axes of the Robot.
220
Comau Robotics Product Instruction
T1
T1
T1
221
Comau Robotics Product Instruction
T1
The T1 key for axis 4 calibration can be installed without distinction in one of the two positions indicated in
figure
222
Comau Robotics Product Instruction
The calibration must be carried out on Robot free of loads applied to the axes, following
the sequence:
– Robot axis 1
– Axis 2 calibration
– Axis 4 calibration
– Axis 3 calibration.
To carry out the calibration it is necessary also to have the “SERVICE” access
privileges.
The following paragraphs describe the calibration procedures of the Robot axes, using
as reference the video pages displayed on the Teach Pendant (optional). If there is no
a Teach Pendant, the operations can be performed through similar commands
available on Virtual TP interface of the WinR1C software.
223
Comau Robotics Product Instruction
224
Comau Robotics Product Instruction
Operating procedure
a. Unscrew the two socket hex
head screws M4x12 (A) present
on the bracket (B), so as to C
make the two dowel pins to
completely come out (C).
Section
Front view
A-A
D
c. Fix the bracket (B) to the Robot
wrist manually tightening the
four screws (F), two for each
side.
225
Comau Robotics Product Instruction
G
f. Center and fix the flange (G) to
the axis 3 screw inserting and
tightening the screw (J).
J
226
Comau Robotics Product Instruction
227
Comau Robotics Product Instruction
n. Select “Calib”.
228
Comau Robotics Product Instruction
229
Comau Robotics Product Instruction
n. Select “Calib”.
230
Comau Robotics Product Instruction
231
Comau Robotics Product Instruction
n. Select “Calib”.
232
Comau Robotics Product Instruction
233
Comau Robotics Product Instruction
o. Select “Calib”.
234
Comau Robotics Product Instruction
235
Comau Robotics Product Instruction
g. At the end of the operations, the Robot will have to be placed in calibration position.
i. Insert the calibration mechanical key in each calibration notch (see Tab. 4.9 - Robot calibration notches
location on page 221); it must be possible to insert the calibration key without forcing.
j. Otherwise, repeat the calibration procedures, as described in par. 4.10.2 and the following.
k. Remove from the Robot wrist the Calibration tool (CR82415200), by reversing the steps indicated in the
Axis 3 and 4 calibration tool assembly (see par. 4.10.2.1 on page 224) procedure.
236
Comau Robotics Product Instruction
237
Comau Robotics Product Instruction
e. Assemble the ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149) on the Robot, as indicated in
the related procedure in par. 3.5.1.
f. Screw the Calibrated Tool Unit - Tool Master L=117 mm (81783801) on the ISO tool coupling flange ISO
9409 - 1 - A40 (CR82392149) using an open-end wrench of 10 mm.
g. Manually move the Robot up to bring the tip
of the Tool Master (A) in contact with the tip
of the mechanical reference (B) on which to
perform the verification.
238
Comau Robotics Product Instruction
k. Manually move the Robot axis 3 in order to move away of 2 mm the tip of the Tool Master from the tip of
the mechanical reference.
m. Press the “COORD” button on the Teach Pendant in order to select the TOOL mode. The mode selection
is indicated in the related field of the Status Bar.
n. On the Status Bar, select the GenOVR field
to access the quick setup of the General
Override value.
20%
p. Rotate the Tool Center Point (TCP hereinafter) around the mechanical reference point by 45° on Z axis,
pressing the JOG “6Z+” key.
q. During the rotation of the Tool around the mechanical reference point, observe the distance between the
TCP and the center of the mechanical reference. The maximum permitted deviation is ±3 mm in all
directions.
r. Rotate the TCP around the mechanical reference point until bringing it to the starting position, by pressing
the JOG “6Z-” key.
s. Rotate the TCP around the mechanical reference point by -45° on Z axis, pressing the JOG “6Z-” key.
t. During the rotation of the Tool around the mechanical reference point, observe the distance between the
TCP and the center of the mechanical reference. The maximum permitted deviation is ±3 mm in all
directions.
239
Comau Robotics Product Instruction
240
Comau Robotics Product Instruction
l. At the end of the calibration operations, perform a low-speed work program in order to verify the correct
operation of the Robot.
241
Comau Robotics Product Instruction
R
K M
Q
L
P
2
is
Ax
D
Axi
F
s4
E
H
C
A
is 3
Ax
B
J L Ax
is 1
Axis
Pos. Comau Part No. Description Q.ty Weight
Robot
O-RING gasket
A 00301289 Ax 1 1 ---
AS 568 - Ø60.05xØ1.78 (N°036)
O-RING gasket
B 00301287 Ax 1 1 ---
AS 568 - Ø50.52xØ1.78 (N°033)
O-RING gasket
C 00301215 Ax 1 1 ---
AS 568 - Ø88.62xØ1.78 (N°043)
O-RING gasket
D 00301287 Ax 2 1 ---
AS 568 - Ø50.52xØ1.78
O-RING gasket
E 00300765 Ax 2 1 ---
AS 568 - Ø69.57XØ1.78 (N°039)
242
Comau Robotics Product Instruction
Axis
Pos. Comau Part No. Description Q.ty Weight
Robot
O-RING gasket
F 00301215 Ax 2 1 ---
AS 568 - Ø88.62xØ1.78
Driving toothed belt
G CR82399630 Ax 3 1 ---
100S3M573
Driving toothed belt
H CR82399631 Ax 4 1 ---
100MTS3M231G
Driving toothed belt
J CR82399632 Ax 4 1 ---
200MTS3M459G
Recirculating ball screw 0.55 Kg
K CR82399610 Ax 3-4 1
2020A+410LC5 (THK) (1.21 lb)
0.7 Kg
L CR82397901 Motor 0.32 NM - 100W Ax 3-4 2
(1.54 lb)
0.9 Kg
M CR82397911 Motor 0.64 NM - 200W Ax 2 1
(1.98 lb)
1.2 Kg
N CR82397915 Motor 1.27 NM - 400W Ax 1 1
(2.64 lb)
CR82416900 Wiring for Rebel S6-0.45 --- 1 ---
243
Comau Robotics Product Instruction
Tab. 4.11 - Robot Rebel-S6 - Rel. 1.0 plates unit spare parts
N C B G H K A B D N
F
M L
E
J
244
Original instructions
Made
in
Comau