Racer5 Robot

Rel. 1.0

Technical Specifications,
Transport and Installation and
Maintenance

Description of the available versions and technical

features of the application
Integration principles of the application and
description of the available options
Information on the preparations and necessary
requirements for installation of the application
Maintenance procedures

CR00758077-en_01/2017.01

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.

Copyright © 2008-2017 by COMAU - Published on 01/2017

 Comau Robotics Product Instruction

SUMMARY

SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Documents storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Limitations on the handbook contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Symbols used in the handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

MODIFICATION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1. GENERAL SAFETY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10

Information on Robot supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Essential safety requirements applied and fulfilled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...20

Robot general description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Robot axes identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Declaration of incorporation of partly completed machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Name and address of the manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Available versions and technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Available versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operational areas and Robot overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Robot wrist features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Robot wrist flange diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Wrist loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Description of the Robot mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Matching with Control Unit and user customizations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Management and control through Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connections overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Robot connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
X50 Connector pinout on Robot base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Ethernet Connector pinout on Robot wrist base / body . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
X70 Connector pinout on Robot wrist body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

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Comau Robotics Product Instruction

SUMMARY

AIR fitting features on Robot wrist base/body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Features of the solenoid valves unit on Robot wrist body . . . . . . . . . . . . . . . . . . . . . . . . . .44
Mating connectors kit for I/O (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Robot integration principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Available solutions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Screws and pins unit for Robot fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Stresses on the supporting structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Integration of the Robot in production cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Mechanical hard stop (CR82392900). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Devices for calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Calibration tool (CR82392800). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Calibrated tool unit - Tool Master L=117 mm (CR82392146) . . . . . . . . . . . . . . . . . . . . . . . . 57

3. TRANSPORT AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..59

Installation summarizing table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Preparation for Robot installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Staff in charge of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Working environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Installation environment requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Environment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Operating space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Operating environment prearrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Foundations preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Stresses on the supporting structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Robot transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Robot weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Robot overall dimensions and transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Robot motion methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Robot Racer5-0.63 lifting by means of crane or overhead traveling crane . . . . . . . . . . . . .67
Robot Racer5-0.80 lifting by means of crane or overhead traveling crane . . . . . . . . . . . . .68
Robot Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Preliminary Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Diagram of drilling on plate for fixing the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Robot fixing on the backing plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Robot connection with Control Unit R1C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Preliminary precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connection with the R1C Control Unit (motors and encoder main cables) . . . . . . . . . . . . . . 76
Connection of I/O signals cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Operations related to the first startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Precautions before the first power up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Control Unit power up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Ceiling / wall installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Load auto-determination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Safety functional inspections of the robotic system integrated in the production cell. . . . . . . 80

4. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..81

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 Comau Robotics Product Instruction

SUMMARY

General requirements for the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Precautions during the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Precautions at the end of the maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Maintenance staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Assembly notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Parts disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Assistance for troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Problem analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Diagnostic messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Traceability for replacement purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Components replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Robot wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Comau service centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
How to disconnect the electrical power supply on the Control Unit . . . . . . . . . . . . . . . . . . . . . . 89
Precautions and risks associated with the electrical power supply disconnection . . . . . . . . . 89
Disconnection of the electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Maintenance structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Summary diagram of the maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Preventive maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Robot cleaning and general inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Special maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Special maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Calibration - Basic concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Calibration - Operating procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Calibration tool description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Reference notches description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Reference notches location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
From axis 1 to 5 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Axis 6 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
AXIS 1 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
AXIS 2 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
AXIS 3 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
AXIS 5 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
AXIS 6 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
AXIS 1 BELT: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
AXIS 3 BELT: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
AXIS 5 BELT: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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Comau Robotics Product Instruction

SUMMARY

AXIS 6 BELT: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

AXIS 6 GEARBOX: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
SOLENOID VALVES UNIT:
complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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 Comau Robotics Product Instruction

PREFACE

PREFACE
This chapter contains:
– Reference documentation
– Documents storage
– Limitations on the handbook contents
– Symbols used in the handbook
– Modification History.

Reference documentation
This document refers to the Robot in standard outfitting indicated below:
– Racer 5 - Rel. 1.0

The structure of the complete set of handbooks describing the Robot and Control Unit
is detailed in the following table:

Manufacturer Robot Set of Handbooks

– Technical Specifications,
Racer 5 Robot Transport, Installation
Comau
Rel. 1.0 and Maintenance
– Electrical circuit diagram

These handbooks must be integrated with the following documents:

Manufacturer Description Set of Handbooks

R1C Control Unit – Technical Specifications,
Transport, Installation
Comau and Maintenance
– Use of R1C Control Unit
– Electrical circuit diagram
Programming – PDL2 Programming
Language Manual
Comau
– Motion programming
– VP2 Visual PDL2

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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.

Limitations 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.

Symbols used in the handbook

Here are 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 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.

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 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
2016-08 00/2016.08 First release of the Handbook.
2016-11 00/2016.11 Has been included the new version Racer5-0.80

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Comau Robotics Product Instruction

GENERAL SAFETY REQUIREMENTS

1. GENERAL SAFETY REQUIREMENTS

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

This chapter deals with the following topics:

– Information on Robot supply
– Responsibilities
– Safety requirements.

1.1 Information on Robot supply

WARNING: The integrator who combines the Robot with one Control Unit different from
the Comau Control Unit is responsible for the partly completed machinery safety, in all
functional fields and for the proper integration, installation, motion and inspection in all
the allowed modalities, programming software, command devices in automatic mode
and programming.

In addition the integrator is also responsible for implementation of the instructions

handbooks on the dynamic performances, use and functioning, software and any other
useful information to integrate the functional aspects deriving from the Control Unit that
will be matched with the Robot.

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1.2 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.

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

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

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

1.2.1 Essential safety requirements applied and fulfilled

The robotic system consisting of Control Unit and Robot considers as applied and
fulfilled the following Essential Safety Requirements, Annex I of 2006/42/EC Machinery
Directive: 1.1.3 – 1.1.5 – 1.2.1 – 1.2.2 – 1.2.3 – [Link] – 1.2.5 – 1.2.6 – 1.3.2 – 1.3.4 –
[Link] – 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 – [Link] – 1.7.2 – 1.7.4.
In case only the Robot is provided are to be considered as applied the following
requirements: 1.1.3 – 1.1.5 – 1.3.2 – 1.3.4 – [Link] – 1.5.1 – 1.5.2 – 1.5.4 – 1.5.6 – 1.5.8
– 1.5.9 – 1.5.10 – 1.5.11 – 1.5.13 – 1.6.4 – 1.6.5 – 1.7.1 – [Link] – 1.7.2 – 1.7.4.

1.3 Safety requirements

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

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

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

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

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

Installation and Startup

Installation is defined as the mechanical, electrical and software integration of the Robot
and Control System in any environment that requires controlled movement of Robot
axes, in compliance with the safety requirements of the country where the System is
installed.

Functioning in Programming mode

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

Functioning in Auto / Remote mode

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

Maintenance and Repair

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

Decommissioning and Dismantling

Decommissioning is defined as the activity that involve the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.

Integrator
The integrator is the professional expert responsible for the Robot and Control System
installation and startup.

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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.

1.3.3 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.

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1.3.4 Operating modes

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

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– 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, gates
safety devices etc.) i.e. the realisation of correct and safe circuits, is the
responsibility of the Robot and Control System integrator.

In the cell/line emergency stop circuit it is necessary to include the contacts of the
Control Unit emergency stop push-buttons, available on X30. The push-buttons are not
interlocked inside the emergency stop circuit of the Control Unit.

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

incomplete or missing execution.
– The safety circuit executes a controlled stop (IEC 60204-1, category 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic mode; in Programming mode the power is disabled
immediately.
– When preparing protection barriers, especially light curtains and access doors,
take into consideration the Robot stopping times and distances according to the
stop category (0 or 1) and the weight of the Robot.
– Check that the environmental and operating conditions do not exceed the limits
specified in the Technical Documentation of the specific product.
– The calibration operations must be carried out with great care, as indicated in the
Technical Documentation of the specific product, and should be concluded by
checking the correct position of the machine.

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

Functioning in Programming mode

– The programming of the Robot is exclusively the task of the authorized personnel.
– Before starting to program, the operator must check the Robotic system (Robot
and Control Unit) to make sure that there are no potentially dangerous irregular
conditions, and that there is nobody inside the protected area.
– The programming should be controlled from outside the protected area whenever
possible.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the Teach Pendant is working properly (low
speed, emergency stop device, enabling device, etc.).
– During the programming phases, only the operator with the Teach Pendant is
allowed inside the Protected Area.
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (DRIVE ON) always must be controlled from a position
outside the operating range of the Robot, after checking that there is nobody in the
area involved. The Drive On operation is considered complete when the relevant
machine status indication is shown.
– When programming, the operator must remain at an appropriate distance from the
Robot to be able to avoid any irregular machine movements, and in any case in a
suitable position to avoid the risk of being trapped between the Robot and
structural parts (columns, barriers, etc.), or between movable parts of the Robot.
– When programming, the operator must avoid to remain in a position where parts of
the Robot, pulled by gravity, could move downwards, upwards or sideways (when
installed on an inclined plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at low speed has been carried out. The
test must be controlled from a safe distance.
– Special attention is to be paid when programming using the Teach Pendant: in this
situation, although all the hardware and software safety devices are active, the
Robot movement depends on the operator.
– During the first running of a new program, the Robot may move along a path that
is not the one expected.
– The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the Robot position
out of the path that links two steps of the program), could give rise to movements
not envisaged by the operator when testing the program.

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

Functioning in Auto / Remote Mode

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

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Maintenance and Repair

– When assembled in COMAU the Robot is supplied with lubricants that do not
contain any harmful to health substances, however, in some cases, repeated and
prolonged exposure to the product may cause skin irritation, or if swallowed,
sickness.
First Aid Measures. In case of contact with the eyes or skin: rinse the affected
areas with copious amounts of water; should irritation persist, seek medical advice.
If swallowed, do not induce vomiting or administer anything by mouth; consult a
doctor as soon as possible.
– Maintenance, trouble-shooting and repair are only to be carried out by authorised
personnel.
– When carrying out maintenance and repair operations, the specific warning sign
stating the maintenance status must be placed on the control panel of the Control
Unit, until the end of the operation, even if it should be temporarily suspended.
– Maintenance and components or Control Unit replacement operations must be
carried out with the main switch in open position and locked with a padlock.
– Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages deriving from connection to peripheral units or external
power sources (e.g. 24 Vdc input/output). Power off the external sources when
operating on involved system parts.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open.
– Faulty components are to be replaced with others having the same Part No., or
equivalent components defined by COMAU.
– Trouble-shooting and maintenance activities must be carried out, whenever
possible, outside the protected area.
– Trouble-shooting executed on the control is to be carried out, whenever possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards must be observed
when operating in presence of dangerous voltages.
– Trouble-shooting on the Robot must be carried out with the power supply turned
off (DRIVE OFF).
– At the end of the maintenance and trouble-shooting operations, all the deactivated
safeties must be reset (panels, protection shields, interlocks, etc.).
– Maintenance, repair and trouble-shooting operations must be concluded with the
check of the correct functioning of the Robotic system (Robot and Control Unit) and
all the safety devices, executed from outside the protected area.
– During the software loading phases (for example after replacement of electronic
boards) use only the original software handed over by COMAU. Scrupulously
follow the system software loading procedure described in the specific product
Technical Documentation; after loading, to be sure, always run a test cycle,
remaining outside the protected area
– 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, consult the warning plates applied on the Robot and the
Technical Documentation supplied.

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– It is strictly forbidden to remove the protective covering of the Robot springs.

Decommissioning and Dismantling

– The decommissioning and removal of the Robot and Control System is exclusively
the task of Authorised Personnel.
– Move the Robot in transport position and assemble the axes locking brackets
(when required) following the instructions on the plate on the Robot and its
Technical Documents.
– Before decommissioning the mains voltage of the Control Unit must be powered
off (switch off the circuit breaker on the power mains and lock it in open position).
– After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the power mains,
first disconnecting the power conductors, then the earth one. Disconnect the power
supply cable from the Control Unit and remove it.
– First disconnect the connection cables between the Robot and the Control Unit,
then the ground cable.
– If present, disconnect the Robot pneumatic system from the air distribution mains.
– Check that the Robot is properly balanced and if necessary sling it correctly, then
remove the Robot securing bolts from the mount holder.
– Remove the Robot and Control Unit from the work area, following all the
requirements indicated in the products Technical Documents; if lifting is necessary,
check the eyebolts proper fixing and use only suitable slinging devices and
equipment.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU, or one of its
branches, who will indicate, according to the type of Robot and Control Unit, the
operating methods in accordance with safety principles and environment
safeguarding.
– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.

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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 Control Unit and user customizations
– Robot integration principles
– Devices for calibration

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2.1 Robot general description

The Robot is a machine specifically designed and constructed to be used in industrial
environments.
To function properly, the Robot must be matched with the specific Control Unit. The
Control Unit features must be consistent with the connected Robot.
The Robot Racer 5 is particularly suitable for applications of
• Assemblies
• Handling
• Tools machine enslavement
• Pick & Place

2.2 Robot axes identification

Hereinafter are identified the Robot axes:

Ax Robot axis
Mtr Motor axis

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2.3 Declaration of incorporation of partly completed

machinery
The assembly composed of the Robot and the Control Unit is provided with a
declaration of incorporation of partly completed machinery, as stated in the Annex
II b. of the 2006/42/EC Machinery Directive.

It is forbidden to start up 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.

The Declaration of incorporation of partly completed machinery is provided in

original copy with the assembly composed of the Robot and Control Unit.
The identification plate (Fig. 2.1) is installed on the Robot body.

Fig. 2.1 - Robot identification plate (example)

A xxxx REL. xxx

B CRxxxxxxxx

D xx lb / xx kg

– A: Machine name and release

– B: Product Part No.
– C: The date of issue and the serial number
– D: Weight

2.4 Name and address of the manufacturer

As defined by the Machinery Directive, the manufacturer is:

COMAU S.p.A.
Via Rivalta, 30
10095 Grugliasco (TO) - ITALY

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2.5 Available versions and technical features

This chapter contains:
– Available versions
– Technical features.

2.5.1 Available versions

The versions of the available Robots are listed in the following Tab. 2.1 - Robot available
versions on page 23.

Tab. 2.1 - Robot available versions

Reach (to
Wrist Nominal
the wrist Assemblin Part No.
Robot type load wrist load Application type
centre) g position Robot
(kg) (lb) (kg) (lb)
(mm) (ft)
Racer 5-0.63 630 - Handling
Floor / CR82412800
Rel. 1.0 (2.07) - Machine
Ceiling /
5 1 enslavement
Wall /
Racer 5-0.80 (11.0) (2.2) 809 - Sealing
Inclined CR82412900
Rel. 1.0 (2.65) - Assemblies
plane*
- Pick & Place

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2.5.2 Technical features

Tab. 2.2 - Robot Technical Features

VERSION Racer5-0.63 Racer5-0.80

Structure / n° axes Anthropomorphic / 6 axes
Maximum wrist load 5 kg (11.0 lb)
Nominal wrist load 1 kg (2.2 lb)
Axis 4 torque 8.83 Nm
Axis 5 torque 8.83 Nm
Axis 6 torque 4.91 Nm
Admissible inertia on axis 4 0.42 kg x m²
Admissible inertia on axis 5 0.42 kg x m²
Admissible inertia on axis 6 0.18 kg x m²
Axis 1 +/- 170° (400°/s)
Axis 2 -95° / +135 ° (360 °/s) -85° / +135 ° (360 °/s)
Axis 3 -155° / +90° (400 °/s)
Stroke /(Speed)
Axis 4 +/- 200° (500 °/s)
Axis 5 +/- 125° (500 °/s)
Axis 6 +/- 2700° (800 °/s)
Max horizontal reach 630 mm (2.07 ft) 809 mm (2.65 ft)
Repeatability +/- 0.03 mm
Robot weight 30 kg (66 lb) 32 kg (70 lb)
Features of the tool coupling Robot wrist ISO 9409 - 1 - A 25
Motors AC Brushless
Position measurement system Encoder
Protection degree IP54 (IP 65 **)
Assembly position Floor / Ceiling / Wall *
Operating environment temperature 0°C to +45°C
Storage temperature -10°C to + 55°C
Relative humidity 5% to 95% without condensate
Maximum temperature gradient 1.5 °C/min
* not allowed with maximum load
** Optional

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2.5.3 Operational areas and Robot overall dimensions

This paragraph contains the operational areas drawings of the available versions:
– Racer5-0.63
– Racer5-0.80

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Fig. 2.2 - Racer5-0.63

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Fig. 2.3 - Racer5-0.80

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2.6 Robot wrist features

This Paragraph contains:
– Robot wrist flange diagrams
– Wrist loads

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2.6.1 Robot wrist flange diagrams

This paragraph contains the technical drawings of the Robot wrist flange, with
dimensions and distances between holes centres used for tool coupling.

Fig. 2.4 - Tool coupling flange ISO 9409 - 1 - A 25 (front view)

Ø0,04
90°
45°
Ø0,25

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2.6.2 Wrist loads

This paragraph describes the procedures for determining the maximum load applicable
to the Robot flange (P) which is defined using the wrist load graphs, where the curves
of maximum load (P) are plotted according to coordinates LZ and LY of the load
barycentre.

Lz
Ly
Robot Z Y
Racer 5
Lx Lxy

X
P

The area defined by the loading curves defines the barycentre distances admissible for
load application specified on the area.
In the following Fig. 2.5 is shown the diagram of Maximum load capacity on the Robot
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.

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Fig. 2.5 - Maximum load capacity on the Robot flange

Robot Racer 5

– M: mass
– O: reference point for wrist load calculation

The curves in the graph are to be considered valid by using a control system suitably
dimensioned according to technical characteristics of the machine motors.

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2.7 Description of the Robot mechanics

Degrees of freedom
The Robot is an anthropomorphic type with 6 degrees of freedom.

Robot configuration

A- Base
B- Column
C- Arm
D- Forearm
E- Wrist body
F- Flange

The fixed Robot base is anchored to a structure (fixing plate).

On the fixed Robot base, a column rotates with vertical rotating axis (axis 1); the column
supports the axis 2 motorizations.
One arm connects the axis 2 to the forearm and includes the gear motors of the axis 2
and 3.
At the front end of the forearm is situated the wrist that integrates the gear motors for
axes 5 and 6.

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Robot axes motors

The Robot has got 6 axes, each one is controlled by a motor gear (detail on par. 2.2
Robot axes identification on page 21).
The motors are of AC brushless type and integrate inside them the brake and the
encoder.
The gearboxes are of the type with reduced clearance specific for robotic applications.

Robot axes stroke limitation (Areas limitation)

Robot axes are provided with software limit switches (programmable).
In addition (optional) the Robot can be provided with a mechanical hard stop that can be
installed on the axis 1 as shown in figure for the safety areas partialization, see
par. [Link] Mechanical hard stop (CR82392900) on page 52.

Fig. 2.6 - Mechanical hard stop (optional)

For all details on options needed for safety areas partialization see the par. 2.9.3
Integration of the Robot in production cells on page 51.

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2.8 Matching with Control Unit and user

customizations
This chapter contains:
– Management and control through Control Unit
– Connections overview
– Robot connections

2.8.1 Management and control through Control Unit

The Robot is managed and controlled by the COMAU Control Unit and is not allowed
another matching.
The Robot is matched with a specific size of the Control Unit (see purchase Part No. on
the Control Unit handbook ).
The electrical connection between Robot and Control Unit is made possible by specific
Kits of connection cables.
In addition apposite options on Control Unit can solve integration requirements.
For this Robot version, it is possible the matching with the following Control Units:
– R1C Control Unit

Robot Racer 5 in configuration with R1C Control Unit

A Robot
B R1C Control Unit
C Connection cables kit

R1C Control Unit (B) and the connection cables (C) are described in the Technical
specifications, Transport and Installation and Maintenance handbook of R1C Control
Unit.

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2.8.2 Connections overview

The Integrator must connect the Robot to the Control Unit through specific cables (see
par. 2.8.1).
In addition, he provides on the Robot several prearrangements to optimize the Robot
integration in the production process (air connection, electrical connections).

A Base plate (A)

B Body wrist applications connection
(B)

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[Link] Robot connections

The following figure shows all available connections on the base plate of the Robot
(distribution panel, A) and all the optional connections available on the Robot wrist body
(B).
Robot base plate

Base plate (A)

Code
Function Description
Base plate Wrist body
The Encoder signals connector X1 is directly
connected on the Control Unit through a specific
cable.
X1 --- Encoder signals connector For further information on Encoder / Signals:
Control Unit: see “Technical Specifications,
Transport and Installation and Maintenance”
handbook of the Control Unit.
The motors signals connector X2 is directly
connected on the Control Unit through a specific
cable.
Motor and Brake signals
X2 --- For further information on motor/brakes signals:
connector
Control Unit: see “Technical Specifications,
Transport and Installation and Maintenance”
handbook of the Control Unit.
Quick coupling fitting for air pipe Ø 6 mm. The
AIR1 AIR AIR1 fitting for air delivery inner pipe ends on the Robot wrist body without
interruption.
Quick coupling fitting for air pipe Ø 6 mm. The
AIR2 SMC group AIR2 fitting for air delivery inner pipe reaches up the solenoid valves unit
(SMC), where fitted.

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Base plate (A)

Code
Function Description
Base plate Wrist body
The X50 connector is connected to the X70
Connector for I/O signals
X50 X70 connector in the wrist body area, by means of a
cable.
cable inside the Robot that connects all the pins.
The M12 connector tagged ETH on Robot base is
Ethernet connector for data connected to the ETH connector in the wrist body
ETH ETH
cable area, by means of a inner cable that connects all
the pins.

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Robot wrist body (B, where fitted)

Body wrist applications connection (B)

Code
Function Description
Wrist body Wrist
The X70 connector is connected to X50
X70 --- I/O signals connector connector on Robot base by means of a specific
cable.
Quick coupling fitting for air pipe Ø 6 mm. The
AIR --- AIR fitting for air passage pipe starts at the Robot base (AIR1) and reaches
up to the Robot wrist body without interruptions.
Ethernet connector for data The cable starts at the Robot base and ends up
ETH ETH
cable the Robot wrist body without interruptions.
Solenoid valves unit (EV1A, The solenoid valves unit (SMC) where fitted, is
SMC group ---
EV1B, EV2A, EV2B) powered by AIR 2 and X50/DS.

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[Link] X50 Connector pinout on Robot base

– Connector for:
• I/O signals
• 24 Vdc
– male 19 pins crimp (on Robot base)

Front view - Male connector

Tab. 2.3 - X50 connector pinout detail

Pin Description Pin Description

1 Robot alarm 11 Output 4
2 HSI 12 0V(24Vdc)
3 Input 1 13 Output 5
4 Input 2 14 Output 6
5 Input 3 15 ---
6 +24Vdc I/O 16 ---
7 Input 4 17 ---
8 Output 1 18 ---
9 Output 2 19 0V(24Vdc)
10 Output 3

Tab. 2.4 - Example of mating connector suitable for X50

– Connector for:
• I/O signals
• 24 Vdc
– female 19 pins crimp mating
HUMMEL Part No.: 7,106,500,000

Front view - Female connector

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[Link] Ethernet Connector pinout on Robot wrist base / body

– Connector for TX / RX signals
– female M12, 4 pins crimp (on Robot base / wrist body)

Mating connectors in par. [Link] Mating

connectors kit for I/O (optional) on page 45.

Front view - Female connector

Tab. 2.5 - ETH Connector pinout detail

Pin Description
1 TX+
2 RX+
3 TX-
4 RX-

Tab. 2.6 - Example of mating connector suitable for Ethernet

– M12 connector for TX / RX signals
– male 4 pins crimp mating

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[Link] X70 Connector pinout on Robot wrist body

– Connector for:
• I/O signals
• 24 Vdc
– female 10 pins crimp (on Robot wrist body)

Mating connectors in par. [Link] Mating

connectors kit for I/O (optional) on page 45.

Front view - Female connector

Tab. 2.7 - X70 Connector pinout detail

Pin Description Pin Description

1 Robot alarm / Air input 6 Input 4
2 HSI 7 Output 5
3 Input 1 8 Output 6
4 Input 2 9 +24V I/O
5 Input 3 10 0V (24Vdc)

Tab. 2.8 - Example of mating connector suitable for X70

– X70 Connector for:
• I/O signals
• 24 Vdc
– male 10 pins crimp mating

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[Link] AIR fitting features on Robot wrist base/body

– Quick coupling fitting for air supply to the devices
installed on Robot
– external Ø pipe 6 mm
– max supported pressure 1 MPa (10 Bar)

[Link] Features of the solenoid valves unit on Robot wrist body

– Solenoid valve 4/2 bistable double solenoid
– Max. Pressure 0.7 MPa
– Power supply voltage: 24Vdc
– Current: 25 mA
– Quick brass fitting for pipe connection with external Ø
4 mm (Part No.: KQ2S04-M5A) - [Link]: 4
– Silencer (Part No.: AN05-M5) - [Link]: 1

Tab. 2.9 - Solenoid valves unit pneumatic diagram

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Tab. 2.10 - Motor and encoder cables between Control Unit and Robot

Comau Part No. Description

Kit consisting of encoder signals cable and motors cable.
CR18947280
Cables length 5 m (16 ft)

[Link] Mating connectors kit for I/O (optional)

The I/O kits (optional) are divided in 90° and straight connectors; allow to have available
directly the male mating connector to connect on the relevant female connector (X70
and ETH).

The connectors pinout corresponds to the panel connectors installed on Robot wrist
body.

90° Connectors kit (X70 / ETH)

COMAU Part No.: CR18707660
– X70 Connector for:
• I/O signals
• 24 Vdc
– male 10 pins crimp mating

– M12 connector for TX / RX signals

– male 4 pins crimp mating

Straight Connectors kit (X70 / ETH)

COMAU Part No.: CR18707760
– X70 Connector for:
• I/O signals
• 24 Vdc
– male 10 pins crimp mating

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90° Connectors kit (X70 / ETH)

COMAU Part No.: CR18707660
– M12 connector for TX / RX signals
– male 4 pins crimp mating

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2.9 Robot integration principles

This chapter contains:
– Available solutions for installation
– Stresses on the supporting structure
– Integration of the Robot in production cells

2.9.1 Available solutions for installation

Depending on the applications and operating requirements, the Robot can be installed
on the floor, to the wall, on inclined plane or on ceiling.
For all possible solutions, the Robot must always be installed on a supporting structure
interposed between the Robot base and the installation surface.

Available OPTIONS for installation

Robot type Installation Type
Optional solutions Matched Robot fixing
(available alternatives) components
Floor / Inclined
Racer5-0.63 Plate / Support provided by the Screws and pins unit for Robot
plane / Wall /
Racer5-0.80 integrator fixing
Ceiling

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[Link] Screws and pins unit for Robot fixing

B
C

Purpose
The option fixing screws and pins allows to properly fix the Robot on the floor, on ceiling,
to the wall and on inclined plane.

Technical features and structure

The unit consists of screws and pins needed to fix the Robot to a steel plate provided
with relevant holes.

Limitations
– Use 1 unit to fix 1 Robot.

Fixing components

a. Socket hex head screw - ISO 4762 - M8x35 - 8.8 - A3K ([Link]: 4)

b. Washer - UNI 1751 - B8 ([Link]: 4)

c. Plane washer - ISO 7089 - 8 - 200 HV ([Link]: 4)

d. Pin - ISO 8735 - 6X32 - B - ST ([Link]: 2)

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Fig. 2.7 - Use method of the option diagram

Dimensions in millimetres

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2.9.2 Stresses on the supporting structure

The possible vibrations transmitted by machines nearby the Robot installation area, can
reduce the precision and repeatability of the Robot movements.
It is recommended to prepare a suitable foundation in order to reduce at minimum level
the transmitted vibrations.
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. 2.8 - Stresses on the supporting structure on page 50.

Fig. 2.8 - Stresses on the supporting structure

Mk

Fv

Mr

Fo

Robot Movement Type Fv (N) Fo (N) Mr (Nm) Mk (Nm)

Accelerating 590 630 220 490
Racer5-0.63
Emergency braking 990 1290 440 1030
Accelerating 530 510 220 480
Racer5-0.80
Emergency braking 760 1010 440 940

The figure represents the Robot installed on the floor but it is valid for the Robot installed
in the other positions.

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2.9.3 Integration of the Robot in production cells

To guarantee the safety minimum requirements of the Robot inserted in production
cells, it is possible to limit Axis 1 stroke, depending on the cell configuration and the
specific production needs.
The axis stroke limitation allows to avoid interferences with other machine parts and
assure a safe area, usually the one where the operator works, during the motion
trajectories of the Robot working cycle.
It is possible to install on the Robot a series of options to partialize its axes in safety
areas, as shown in the following table.

Type of
Available solutions for areas limitation Supply Application
intervention
Axis 1
Axis 2
Axis 3
Software limit switch Standard Software *1
Axis 4
Axis 5
Axis 6

Type of
Available solutions for safety areas partialization Supply Application
intervention
Mechanical hard stop (CR82392900) Optional Axis 1 Mechanical *2

Software *1: Detection of the work areas

Mechanical *2: Mechanical hard stop by means of screw

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[Link] Mechanical hard stop (CR82392900)

Purpose
The option mechanical stop block (mechanical hard stop) axis 1 allows to reduce the
stroke of axis 1 in both work directions in steps of 45°.

Technical features and structure

The mechanical hard stop consists of a stop screw.
The screw must be fixed on one of the six threaded holes present on the Robot base to
limit the axis 1 stroke.
The axis 1 mechanical hard stop meets “man safety” requirements being able to absorb
all the axis kinetic energy.

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:
– the base in the fixing area of the stop screw
– 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.

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Limitations
– Use max 2 mechanical hard stop for each Robot (to limit the axis 1 stroke in both
rotation directions).

Fig. 2.9 - Option method of use diagram

Ax.1 stroke in the negative Ax.1 stroke in a positive

Pos. way way

FROM [°] TO [°] FROM [°] TO [°]

1 0 -135 0 170
2 0 -90 0 170
3 0 -45 0 170
0 -170 0 170
4 0 -170 0 45
5 0 -170 0 90
6 0 -170 0 135

1. Socket hex head screw M12x30 - 12.9 - ISO 4762 - (CR82392112)

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2.10 Devices for calibration

The robot is provided with a series of necessaries options to carry out the calibration
operations of the robot axes, as described in the following table.

Tab. 2.11 - Available options

Robot type Option description Ref.

Calibration tool (CR82392800) par. 2.10.1

Racer 5
Calibrated tool unit - Tool Master L=117 mm (CR82392146) par. 2.10.2

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2.10.1 Calibration tool (CR82392800)

Fig. 2.10 - Calibration from axis 1 to 5

Fig. 2.11 - Axis 6 calibration

Purpose
The calibration tool unit with mechanical wrench allows to carry out a correct manual
calibration of each Robot axis.

Technical features and structure

The tool for calibration consists of a wrench to be inserted into the specific seats on each
axis of the Robot to obtain a mechanical calibration of the notches (calibration from axis
1 to 5 Fig. 2.10).
The calibration of the axis 6, instead, must be carried out assembling the calibration tool
on the wrist flange using appropriate screws and rotating it so as to align the tool and
the seat on the wrist, obtaining in such way a visual calibration (Fig. 2.11).

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Limitations
– None

Fig. 2.12 - Calibration tool diagram

4
5
1

1. Gauge
2. Centering
3. Fixing pin ISO 8734 - 4X8 - B - ST
4. Socket hex head screws - ISO 4762 - M4X8 - 8.8 - A3K ([Link]: 4)
5. Cross-slotted screw - ISO 7046/2 M3X6 INOX

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2.10.2 Calibrated tool unit - Tool Master L=117 mm (CR82392146)

Purpose
The calibrated tool unit is used to calculate the TCP (Tool Centre Point) in relation to the
Robot flange.

Technical features and structure

The unit consists of a support flange and a cylindrical tip of length defined so that the
end is positioned in a given point in relation to the wrist centre.
The unit is directly assembled on the axis 6 flange. Any possible equipment must be
disassembled to assemble the unit.
When it is not used to calculate the TCP, the calibrated tool must be removed from the
Robot wrist.
The Fig. 2.13 - Racer 5 on page 58 shows the dimensioning referred to the center of the
Robot flange.

Limitations
– It is necessary to disassemble any equipment mounted on the Robot wrist.

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Fig. 2.13 - Racer 5

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3. TRANSPORT AND INSTALLATION

3.1 Installation summarizing table

The table below summarises the Robot installation sequence.
The table can be used as a check list for the installation activities progress. In this case
it is recommended to copy the table below and fill in the appropriate box “Done” at the
end of each operation.

Tab. 3.1 - Installation summarizing table

Step Operation Done

Preparation for Robot installation
1 Working environmental conditions
2 Operating environment prearrangements
3 Foundations preparation
4 Stresses on the supporting structure
Robot transport
5 Robot overall dimensions and transport position
6 – Robot Racer5-0.63 lifting by means of crane or
overhead traveling crane
7 – Robot Racer5-0.80 lifting by means of crane or
overhead traveling crane
Robot Installation
8 Robot fixing on the backing plan
Robot connection with Control Unit R1C
9 Connection with the R1C Control Unit (motors and
encoder main cables)
10 Connection of I/O signals cables

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3.2 Preparation for Robot installation

This chapter contains:
– Staff in charge of installation
– Working environmental conditions
– Operating environment prearrangements
– Foundations preparation
– Stresses on the supporting structure.

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.

In this chapter are described the prearrangements to carry out properly the Robot
installation.
The installation operating procedure is described in the chapter Robot Installation.

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3.2.1 Staff in charge of installation

Staff in charge of installation must be trained to operate correctly with lifting devices.
Furthermore, the personnel must be trained in mechanics and therefore aware of the
dangers associated with the installation operations.

3.2.2 Working environmental conditions

This paragraph contains:
– Installation environment requirements
– Environment data
– Operating space.

[Link] Installation environment requirements

The environment for Robots use is the usual workshop environment and therefore
premises protected from atmospheric agents such as rain, hail, snow, fog or airborne
dust, etc.
Of course it should not present corrosive vapours or excessive heat sources.
The machine shall be placed in an equipped environment with all the safety
arrangements deriving from the laws in force in the user country.
The work environment where the Robot will be installed shall comply with the following
aspects:
– The environmental conditions (clime, vibrations, etc.) shall comply with the
indications given in the Technical specifications chapter. Moreover it is forbidden
to install the Control Unit and the Robot in environments:
• with deflagration risk
• with temperature higher than the maximum admissible
• subjected to nuclear radiations.
– The backing plane on which the Robot will be installed must be able to support its
weight and ensure a stable support.

[Link] Environment data

– Operating environment temperature: 0°C ÷ 45°C
– Relative humidity: 5% ÷ 95% without condensate.
– Storage environment temperature: -10 °C ÷ 55 °C.
Store only in closed, dry and protected from weather conditions environments
– Maximum temperature gradient: 1.5 °C/min.

For further information see the par. 2.5.2 Technical features on page 24 of the Robot.

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[Link] Operating space

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.

3.2.3 Operating environment prearrangements

The area chosen for the Robot installation must be equipped with connections required
for:
– Robot and Control Unit functioning (electrical system)
– application functioning foreseen for the Robot (pneumatic system, Gas supply,
etc.).

3.2.4 Foundations preparation

In case of Robot installation on the floor, the User Customer must appropriately
prepare the foundations on which the Robot shall be installed.
The foundations must be realized in such a way as to support adequately the weight and
stresses generated by the Robot.
Find below recommendations for the foundations preparation:
– Type of concrete: non-slatted cement
– Concrete thickness: block dimension + 50 mm (minimum)
– Concrete resistance: Fck,cube = 25 N/mm²

The floor shall be regular, levelled and perfectly flat.

The possible vibrations transmitted by machines nearby the Robot installation area, can
reduce the precision and repeatability of the Robot movements.
It is recommended to prepare a suitable foundation in order to reduce at minimum level
the transmitted vibrations.

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 .

3.2.5 Stresses on the supporting structure

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 50) in the
chapter “Technical Specifications” of the Robot.

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3.3 Robot transport

This paragraph contains:
– Robot weight
– Robot overall dimensions and transport position.
– Robot motion methods.

3.3.1 Robot weight

In the following table are listed the Robot weights depending on the type of packaging
used for transport.

Packaging type Weight

30 kg
Robot Racer5-0.63 without packaging
(66 lb)
32 kg
Robot Racer5-0.80 without packaging
(70 lb)

3.3.2 Robot overall dimensions and transport position

The correct transport position of the Robot differs depending on the Robot type and is
illustrated in the following figures:
– Robot Racer5-0.63 transport position and overall dimensions diagram
– Robot Racer5-0.80 transport position and overall dimensions diagram
In addition are listed the maximum dimensions of the Robot on the pallet and the value
of the angles position of the single Robot axes.

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.

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Fig. 3.1 - Robot Racer5-0.63 transport position and overall dimensions

diagram

1,2m
0,8m

Dimensions in millimetres

Racer5-0.63 AXIS 1 AXIS 2 AXIS 3 AXIS 4 AXIS 5 AXIS 6

Joint position (± 0.5°) 0° -58° -90° 0° +90° 0°

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Fig. 3.2 - Robot Racer5-0.80 transport position and overall dimensions diagram

Dimensions in millimetres

Racer5-0.80 AXIS 1 AXIS 2 AXIS 3 AXIS 4 AXIS 5 AXIS 6

Joint position (± 0.5°) -90° -85° 90° 90° -125° 0°

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3.3.3 Robot motion methods

In the following section are described the possible Robot lifting methods:
– Robot Racer5-0.63 lifting by means of crane or overhead traveling crane
– Robot Racer5-0.80 lifting by means of crane or overhead traveling crane

If necessary to lift the Robot after installation (lifting from fixing plate), the lifting shall
always be carried out by means of an upward translation, perpendicular to the fixing
plate until obtaining the extraction of the pins from the seats on the Robot base, in order
to avoid damages to centering pins.

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[Link] Robot Racer5-0.63 lifting by means of crane or overhead traveling

crane

Lifting means: – Crane or overhead crane with adequate load to be lifted

capacity, taking into consideration the safety limits
Equipment: – Qty 1 lifting belt A L = 800 mm (31.50 in)
– Qty 1 lifting belt B L = 1200 mm (47.24 in)
Lifting diagram:

Operative notes: – Tie the rope A by sliding it under the Robot base as shown
in the figure.
– Tie the rope B by sliding it under the axis 3 arm.
– Slightly lift the Robot by checking the equilibrium and
balance.
– Lift the Robot flat keeping it in balanced position.
– Move carefully the Robot.

At the end of the procedure, remove the eyebolts A used for the Robot lifting.

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[Link] Robot Racer5-0.80 lifting by means of crane or overhead traveling

crane

Lifting means: – Crane or overhead crane with adequate load to be lifted

capacity, taking into consideration the safety limits
Equipment: – Qty 1 lifting belt A L = 1200 mm (47.24 in)
– Qty 1 lifting belt B L = 1200 mm (47.24 in)
Lifting diagram:
A

Operative notes: – Tie the rope A by making a loop on the axis 1 column.
– Tie the rope B by sliding it under the axis 3 arm.
– Slightly lift the Robot by checking the equilibrium and
balance.
– Lift the Robot flat keeping it in balanced position.
– Move carefully the Robot.

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3.4 Robot Installation

This chapter contains:
– Preliminary Requirements
– Diagram of drilling on plate for fixing the Robot
– Robot fixing on the backing plan.

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3.4.1 Preliminary Requirements

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 the 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 one plate with drillings, see Fig. 3.3, for screws and pins
(for the main dimensions of the fixing points see Screws and pins unit for Robot fixing in
the chapter Technical Specifications).
The plate must be realised by the integrator and be made of S235JR steel.

The integrator must verify the stress produced by the Robot and the conditions of
resistance on the plate.

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3.4.2 Diagram of drilling on plate for fixing the Robot

The following Fig. 3.3 shows the diagram of the drilling to carry out on the plate for fixing
the Robot.

Fig. 3.3 - Diagram of drilling on plate for fixing the Robot

B B

B B

Dimensions in millimetres
A: centring holes (details on Screws and pins unit for Robot fixing)
B: Threaded holes for Robot fixing (details on Screws and pins unit for Robot fixing)

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3.4.3 Robot fixing on the backing plan

Status: – Power turned off

Material: – Components of the Screws and pins
unit for Robot fixing
Equipment: – Torque wrench with 6 mm bit
Fixing – Socket hex head screw - ISO 4762 -
components: M8x35 - 8.8 ([Link]: 4)
– Washer - UNI 1751 - B8 ([Link]: 4)
– Plain washer - ISO 7089 ([Link]: 4)
– Pin - ISO 8735 - 6X32 - B ([Link]: 2)

Preliminary procedures / notes

None

Operating procedure

C C

C C

B
A = Diagram of the backing plane drilling position (Plate / Structure)
B = Through hole for pin Ø=6 mm H7
C = Threaded through hole M8
a. Clean the plate on which the Robot must be placed.

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Operating procedure (Continued)

b. Lift the Robot

c. Correctly position the Robot D H

on the plate in the vicinity of the
through holes for the 2 pins, E, G E
as indicated in figure.
F

d. Insert in the seat the 2 pins E.

D
e. Position the 4 washers F and
the 4 washers G as shown in
figure and screw the four fixing
screws H of the Robot,
tightening them to the 25 Nm.
torque.

Follow-up procedures
None

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3.5 Robot connection with Control Unit R1C

This chapter deals with the following topics:
– Preliminary precautions
– Connection with the R1C Control Unit (motors and encoder main cables).
– Connection of I/O signals cables

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3.5.1 Preliminary precautions

Preliminary procedures / notes
The Control Unit features must be consistent with the connected Robot.
For this reason, both the Robot and the Control Unit are provided with
approval documents on which is highlighted the serial number of the
related Robot / Control Unit which it must be matched with.

Always respect this matching to allow to the Robot configuration file to

control the torques and the functions of the motors.

At the end of the installation procedure it will be possible to check the

proper matching between the Robot and Control Unit displaying the main
screen of the Teach Pendant.

Cable ducts arrangement:

– Install the cable ducts respecting the minimum bending radiuses (Minimum is 10
times the cable diameter).
– Do not carry out bends with angles of 90°.
– For Robots installed on the floor, do not place the cable duct near the Robot
distribution panel, but leave enough space to carry out properly both the
connection and the disconnection of the connectors.
– When installing the cables avoid contact of the cable sheaths with sharp edges
in order to avoid damaging the sheaths; protect the edges of the terminal section
of the cable ducts to avoid abrasion on the sheaths.
For Robots installed on raised supports, do not place any cable support near the
connectors, but at a minimum distance of approx. 600 mm from the connectors cable
gland.
Connections on Robot:
– When connecting, avoid tight bending radii on the cables. A bending radius of
approx. 10 times the cable diameter is recommended.
– The cable must not be too stretched.
– Do not roll the power cables in excess (motors, weld cables, etc.) in case of
hanks with many overlaying coils (maximum 2 coils) to avoid the risk of
overheating and damage due to lack of dissipation in air.
– The connection between Harting connectors (male and female) must be made
without forcing, to avoid the re-entry or the bending of the pins.
– During the connection, keep the mating connector parallel to the panel connector
it must be connected to.
– The connection between connectors is to be made avoiding axial and/or lateral
movements in order to avoid damaging the coding pins and contacts.
– The coding pins on both connections are to be used to guide the connector
coupling.
– The two levers on the panel connector are only to be used to secure the
mechanical clamping of the connection and not to facilitate the connection.
– In case of Robots installed on supporting stand, it is advisable to support the
cables so that the weight does not force the connectors on Robot base.

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3.5.2 Connection with the R1C Control Unit (motors and

encoder main cables)

Status: – Power turned off

Material: – Not required
Equipment: – Standard maintenance equipment
Fixing – ---
components:

Preliminary procedures / notes

Before connecting the Robot it is necessary to verify the correct matching
with the Control Unit. Further details in par. 3.5.1 Preliminary
precautions on page 75.

Operating procedure
a. Connect the ground wire (Robot side) on the distribution panel on Robot base.

b. Connect the cables by means of X1, X2 connectors on the distribution panel on

Robot base.

c. Clamp each connector with its clamping levers.

R1C Connector Panel Motor Break cable Robot base

X1 X2

Encoder cable

Follow-up procedure
– Pull softly the cables and the ground wire to check the proper connection.

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3.5.3 Connection of I/O signals cables

Status: – Power turned off

Material: – Facility cable (optional)
Equipment: – Standard maintenance equipment
Fixing – ---
components:

Preliminary procedures / notes

Before connecting the Robot it is necessary to verify the correct matching
with the Control Unit. Further details in par. 3.5.1 Preliminary
precautions on page 75.

In the following procedure some examples are shown.

For further information refer to the specific application handbook.

Operating procedure
a. Connect one end of the facility cable to the X55 connector on Control Unit base.

b. Connect the other end of the facility cable to the X50 connector on Robot base.
Version with R1C Control Unit

R1C Connector Panel

Robot base

X55 X50
Service cable

Follow-up procedure
– Pull softly the cables to check the correct connection.

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3.6 Operations related to the first startup

This chapter deals with the following topics:
• Precautions before the first power up
• Control Unit power up
• Safety functional inspections of the robotic system integrated in the production cell

3.6.1 Precautions before the first power up

– The robotic system (consisting of Robot and Control Unit) must be integrated in a
complex system and properly interfaced. If the safety signals interfacing circuits
are not connected, the Control Unit can be powered up but it will not be possible to
activate the Robot motors.

For the proper interfacing refer to the principle diagrams given in the "Transport and
Installation" chapter of the Control Unit.

– The battery in the UPS module of the Control Unit must be recharged in advance
to guarantee controlled shutdowns. The first complete loading is obtained in about
3 hours. During this period, the Control Unit could not guarantee controlled
shutdowns in case of electrical power supply lacking.

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3.6.2 Control Unit power up

– To start the Control Unit, close the main switch (position “I”).
– During the first seconds after the power up, the system carries out the required
self-tests to check the functionality of the modules. This activity is signalled by the
lighting on of the LED present on the modules.
– After performing the tests and the following system loading, the Teach Pendant will
be the interface for any kind of activity required on the Robotic system (moving,
programming, diagnostics, etc.).

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 the requirements, the following documents are recommended:
– for power-up, Use of the Robotic system: Use of the Control Unit
– for special applications: (several handbooks of the applications).

[Link] Ceiling / wall installation

In case of installation on ceiling / inclined plane of the Robot, be sure about the proper
configuration of the Robot installation position on ceiling:
1. On the Teach Pendant enter the screen page "Assembly" accessible by selecting
“Setup” and “Arm”.
2. Select the option “ceiling” / “inclined plane”
3. Save the configuration using the key Save (F5) and exit from the screen page
"Assembly" using the key Close (F6).

[Link] Load auto-determination

To carry out the auto-determination of the load (software option) it is necessary to have
available some cubic metres of free space to allow the Robot axes to move during
performing the function.

For further information, see the "Motion Programming" handbook.

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3.6.3 Safety functional inspections of the robotic system

integrated in the production cell
Before putting into production, check carefully the safety aspects of the robotic system
related to the integration in the production cell.
Particularly, but not limited only to the items below, check:
– the safety shutdowns commands functionality
– the movable guards safety circuits functionality, checking that after the guards
opening (access door) the Robot motion is allowed only in Programming mode
– the operational areas deriving from possible installation of the options related to
partialization
– the safety signals of interchange with the cell
– that the operational spaces of the Robot are consistent with the perimeter fences.

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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 the Control Unit
– Maintenance structure
– Preventive maintenance
– Special maintenance
– Calibration - Basic concepts
– Spare parts list

The maintenance activities that are not expressly mentioned in this handbook are not
authorized. If necessary, require the manufacturer intervention.

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4.1 General requirements for the maintenance

4.1.1 Precautions before starting

– Most maintenance activities on the Robot are to be performed with electrical and
pneumatic power supplies turned off. In these cases the maintenance sheet bears
the inscription “Main switch open (OFF)”.
For the electric power provided by the R1C Control Unit disconnection procedure,
see par. 4.4 How to disconnect the electrical power supply on the Control Unit on
page 89.
For the disconnection procedures of power sources (electrical and pneumatic),
refer to the handbook of the cell which integrates the Robot.
– Use only original spare parts. The spare parts are provided by Comau. The spare
parts list is given in Chap.4.21 - Spare parts list on page 165.

4.1.2 Precautions during the maintenance

– If the type of defect allows the Robot repositioning, it is recommended to set it in
home position before starting the maintenance operations.

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.

4.1.3 Precautions at the end of the maintenance activities

– After maintenance operations check the Robot proper functioning. Check the
correct execution of some Robot working cycles and the correct functioning of
safety devices before leaving the station.

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. Moreover,
the Teach Pendant must be placed in close proximity to the operator.

4.1.4 Maintenance staff

The staff in charge of maintenance activities must be instructed to properly use the lifting
means (in case of complete Robotic system replacement).
Moreover, the staff must be warned or trained in mechanical, fluidic and electrical fields
and therefore be aware of the dangers deriving from energies and precautions to be
taken for safe accessing the Robot installation area.

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4.1.5 Required equipment

The systems fixing the components (screws, nuts) have been standardised, using as
few variations as possible.
The minimum required equipment for maintenance intervention of the Robot is divided
depending on the type of maintenance operation:
– for preventive maintenance see par. 4.6.2 Required equipment on page 94.
– for special maintenance see par. 4.7.2 Required equipment on page 96.

4.1.6 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 to the screw threads, see Tab. 4.2
- Threadlock products on page 84.
• Use recommended products on sealing surfaces and to fix the components,
see Tab. 4.3 - Products for sealing and fixing on page 84.
• 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. 4.1 - Tightening torque for
Hex head screws and Socket hex head screws (Nm) on page 84.

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.

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Tab. 4.1 - Tightening torque for Hex head screws and Socket hex head
screws (Nm)

Class 12.9 screws

Class Class 10.9*¹ Class 12.9*¹
dxp (only per NABTESCO
8.8*¹ screws screws screws
gearbox)
3 x 0.5 1.5 1.9 2.3 -
4 x 0.7 3.1 4.3 5.2 -
5 x 0.8 6 8.5 10.1 9.01 ± 0.49
6x1 10.4 14.6 17.5 15.6 ± 0.78
8 x 1.25 24.6 34.7 41.6 37.2 ± 1.86
10 x 1.5 50.1 70.5 84.6 73.5 ± 3.43
12 x 1.75 84.8 119 143 129 ± 6.37
14 x 2 135 190 228 205 ± 10.2
16 x 2 205 288 346 319 ± 15.9
18 x 2.5 283 398 478 441 ± 22
20 x 2.5 400 562 674 539 ± 27
24 x 3 691 971 1170 -

*¹ admissible tolerance 0/-10%

A tolerance of ± 10% is allowed on tightening torques of screws and lock nuts for
preloading of bearings.

Tab. 4.2 - Threadlock products

AREXONS product

Material for screws For

for screws
M8 and plugs and
M5 or M6
onwards fittings
Aluminium 52A22
Steel 35A72
52A22
Cast iron 52A43
Aluminium with Heli-coil -

For screws up to M4 do not use threadlocker.

Tab. 4.3 - Products for sealing and fixing

Application AREXONS product

Flat sealant 35A73
Polyurethane sealant BOSTIK MK2639
Bearing fasteners 56A41
High strength fasteners 56A48

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4.1.7 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 is installed.

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4.2 Assistance for troubleshooting

4.2.1 Problem analysis

The R1C Control Unit provides information on the System status using:
– LEDs, positioned on modules and boards
– diagnostic messages, displayed on the Teach Pendant.
For troubleshooting operation it could be useful to use one or both modes (LEDs,
messages), depending on the system status:
– during the boot phase, the Teach Pendant is not operative and it is necessary to
consult the signalling issued by LEDs present on the modules
– when the Teach Pendant is enabled, the Diagnostic messages provided are more
efficient
– in each case, especially for auxiliaries circuits power supply, LEDs represent the
most immediate diagnostic
– pin outs described in the “Technical specification” handbook of the Control Unit,
allow to check the presence of the related foreseen signal
– for connection between the modules and further information on circuits, see the
electrical circuit diagram of the Control Unit.

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4.2.2 Diagnostic messages

Diagnostic messages are codified by means of numerical codes with a brief description
and can be seen on the Teach Pendant.
To facilitate the understanding of the message, find the cause that generated it and the
corresponding remedy to be taken, it is possible to use the WinR1C software.
In the main window of the software (Fig. 4.1) the above information can be viewed. To
recall the information indicate in the field (A) the error code and then press the "Find"
button (B).

Fig. 4.1 - WinR1C main window regarding error codes

A B

For further information on Win R1C software, error messages and recovery mode
consult the "Use of Control Unit" handbook.

4.2.3 Traceability for replacement purposes

Each cable / component is codified with a label containing serial number (S/N) and the
purchase Part No. (P/N).
Codes are so defined:
– S/N followed by 4 digits (production year and month) and two alphabetical letters
– P/N followed by 8 digits (purchase part no.), one separation point and two digits for
review.

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4.2.4 Components replacement

To replace the components, it is recommended to detect the damaged component
trough the identification and codification of the connectors, cables and modules in order
to replace it with an identical one.
The par. 4.21 Spare parts list on page 165 provides part numbers and descriptions of
components available as spare parts.
Spare parts can be acquired directly by Comau at the addressed listed on par. 4.3.1
Comau service centre on page 88 where it is also possible to ask for repair of the
damaged component.

Do not carry out autonomous or not authorized repairs on the damaged modules.
Repairs can be carried out only by Comau.

4.3 Robot wiring diagram

For further details see the Robot electrical diagram and connection details.

4.3.1 Comau service centre

In case of need it is possible to contact the Comau Service Centre at the following
addresses:

Sector Address Service provided

Assistance in troubleshooting and software
[Link]@[Link]
options request
Service
[Link]@[Link] To require spare parts
[Link]@[Link] To require repair activities

As an alternative refer to the manufacturer according to what is indicated in par. 2.4

Name and address of the manufacturer on page 22.

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4.4 How to disconnect the electrical power supply on

the Control Unit

4.4.1 Precautions and risks associated with the electrical power

supply disconnection
– After the Control Unit shutdown wait for at least 30 seconds before power it up
again.
– Before removing a connector wait for at least 30 seconds.
The non-compliance with these warnings may result in:
• 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.

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4.4.2 Disconnection of the electrical power supply

Status: – Before disconnecting the electrical

power supply, it is recommended to
deactivate the Robotic system by
means of the shutdown software
procedure.
Material: – Not necessary
Equipment: – Not required

Preliminary procedures / notes

– Most maintenance activities on the Control Unit are to be carried out with
electrical power supply turned off. In those cases the maintenance sheet bears
the inscription “Main switch 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 switch 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 in
which the Robotic System is integrated.

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Operating procedure
Main switch 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 switch in 0

(OFF) position.

With main switch open, the X120 connector and the upstream cables of the
main switch are under voltage.

Electrical power supply turned off

The X120 connector must not be removed with the Q100 main switch
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 front of the
Control Unit.

c. Remove the X120 mating

connector

Follow-up procedure
– Not necessary.

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4.5 Maintenance structure

4.5.1 Overview
The Robot maintenance is divided in:
– Summary diagram of the maintenance operations
– Preventive maintenance
– Special maintenance

It is recommended to carry out accurate and precise preventive maintenance operations

in order to retain
over the long term the Robot functional features.
Poor or missing preventive maintenance activities during the warranty period, will be
regarded as prejudicial
to the warranty itself.
The final user must carry out only the maintenance activities given in this
maintenance handbook: for further necessary operations contact the Comau
service centre.

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4.5.2 Summary diagram of the maintenance operations

The Fig. 4.2 presents the complete maintenance plan diagram in which are identified the
positions and frequency of the maintenance interventions to be carried out on Robot.
In the figure are shown the intervention points which can be identified with the
references given in the summarising tables of Tab. 4.5 and Tab. 4.7.

Fig. 4.2 - Summary diagram of the maintenance operations

Pn = Preventive Maintenance
Sn = Special Maintenance

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4.6 Preventive maintenance

This chapter contains:
– Precautions before starting (see par. 4.6.1 on page 94)
– Required equipment (see par. 4.6.2 on page 94)
– Preventive maintenance plan (see par. 4.6.3 on page 94)

It is recommended to carry out accurate and precise preventive maintenance operations

in order to retain over the long term the Robot functional features.

4.6.1 Precautions before starting

– Read carefully the instructions described in par. 1. General Safety Requirements
on page 10
– To guarantee the Control Unit proper functioning, it is necessary to carry out
periodically preventive maintenance operations, to reduce the amount of faults
caused by the ordinary deterioration over time and maintain longer its functional
features.

Poor or missing preventive maintenance activities during the warranty period, will be
regarded as prejudicial to the warranty itself.

4.6.2 Required equipment

The minimum equipment required for Robot preventive maintenance is:

Tab. 4.4 - Required equipment

Material and detergents for cleaning

4.6.3 Preventive maintenance plan

Find in Tab. 4.4 the preventive maintenance plan based on periodicity.
Tab. 4.5 - Preventive maintenance plan

Intervention / Sheet Paragrap

Frequency Ref. ¹
h
90 days Robot cleaning and general inspection par. 4.6.4 P1
¹ The reference is given in Fig. 4.2 - Summary diagram of the maintenance operations
on page 93.

Pn = Preventive Maintenance

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4.6.4 Robot cleaning and general inspection

Status: – Power supplies (electrical and
pneumatic) cut off
Material: – Material and detergents for cleaning
Equipment: – 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
Fixing – ---
components:

Preliminary procedures / notes

– The frequency of intervention indicated in Tab. 4.5 - Preventive maintenance
plan on page 94 can 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 integrity and good conservation state of all the Robot parts.

Check of Robot fixing

c. 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.

d. 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

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4.7 Special maintenance

– par. 4.7.1 Precautions before starting on page 96
– par. 4.7.2 Required equipment on page 96
– par. 4.7.3 Special maintenance plan on page 97

4.7.1 Precautions before starting

– Read carefully what described in par. 4.1 General requirements for the
maintenance on page 82.

4.7.2 Required equipment

The minimum equipment required for Racer5 preventive maintenance is:

Tab. 4.6 - Required equipment

2.5 - 3 mm Allen wrench

Torque wrench with appropriate bits
Open-end wrench for hex nut Ø6
1 mm thickness gauge
Frequency meter
A pair of scissors

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4.7.3 Special maintenance plan

Find in Tab. 4.7 the special maintenance plan.

Tab. 4.7 - Special maintenance plan

Intervention / Sheet Ref. *¹

AXIS 1 MOTOR: complete replacement S1
AXIS 2 MOTOR: complete replacement S2
AXIS 3 MOTOR: complete replacement S3
AXIS 5 MOTOR: complete replacement S4
AXIS 6 MOTOR: complete replacement S5
AXIS 1 BELT: complete replacement S6
AXIS 3 BELT: complete replacement S7
AXIS 5 BELT: complete replacement S8
AXIS 6 BELT: complete replacement S9
AXIS 6 GEARBOX: complete replacement S10
SOLENOID VALVES UNIT: complete replacement S11
¹ The reference is given in Fig. 4.2 - Summary diagram of the maintenance operations
on page 93.

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4.8 Calibration - Basic concepts

– par. 4.9.1 Calibration tool description
– par. 4.9.2 Reference notches description

4.9 Calibration - Operating procedures

– par. 4.9.3 Reference notches location
– par. 4.9.4 From axis 1 to 5 calibration
– par. 4.9.5 Axis 6 calibration

The calibration must be carried out on Robot free of loads applied to the axes. (verify)

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4.9.1 Calibration tool description

The calibration of the axes must be carried out using two tools (reference gauge) which
must be positioned in the notches (Fig. 4.4) present on each axis of the Robot.

Fig. 4.3 - Calibration tool

– T1: Reference gauge for axes from 1 to 5

– T2: Reference gauge for axis 6 (together with T1 reference gauge)

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4.9.2 Reference notches description

The Robot is equipped with seats on each axis where to insert the reference gauge, the
coincidence of the two seats identifies the axis reference notch (Fig. 4.4).
The reference notch of the axis taken into consideration, is composed of a fixed part (A)
and a mobile part (B) and their alignment makes possible the Robot calibration.

Fig. 4.4 - Aligned reference notch

By means of the Teach Pendant, move at low speed the Robot axes up to coincide the
movable notch with the fixed notch.
Insert the reference gauge in the seat of the aligned reference notch. The insertion must
occur easily, without forcing. In case of even a minimum jam, remove the reference
gauge, move the axis that is to be calibrated and try to insert again.

Fig. 4.5 - Example of gauge inserted on notch

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4.9.3 Reference notches location

The following are the points where it is necessary to insert the reference gauge to
perform the calibration.
– Axis 1 calibration notch location
– Axis 2 calibration notch location
– Axis 3 calibration notch location
– Axis 4 calibration notch location
– Axis 5 calibration notch location
– Axis 6 calibration notch location

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Notches location details for inserting the reference gauge.

Axis 1 calibration notch location

Axis 2 calibration notch location

Axis 3 calibration notch location

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Notches location details for inserting the reference gauge.

Axis 4 calibration notch location

Axis 5 calibration notch location

Axis 6 calibration notch location

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4.9.4 From axis 1 to 5 calibration

To obtain an accurate calibration, is advisable to proceed as follows:

Preliminary procedures / notes

The calibration must be carried out on Robot free of loads applied to the axes.
To carry out the calibration it is necessary to have the "SERVICE" access privileges

a. Select the axis to be calibrated.

b. Move at low speed the Robot axis until

reaching the axis reference notch.

c. Slightly move the axis in negative direction

with respect to the reference notch.

d. Access the “Login” page.

e. Access with user name GA (General

Access).

f. Access the “Home” page.

g. Access the “Motion” page.

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h. Access the “Advanced” page.

i. Enable the “Jog” feed mode.

j. Enable the “Angular” mode.

k. Move the Robot axis in negative direction a

little out from the calibration notch.

l. Set a 0.05° increment.

m. Move of 0.05° in positive direction the Robot

axis.

n. Insert the T1 reference gauge (Fig. 4.3).

In the event of detecting a minimum forcing
when inserting the reference gauge repeat
the procedure from step l.

o. Remove the T1 reference gauge.

Do not move the Robot with the inserted reference gauge.

Follow-up procedures
– Check the correct functioning of the Robot running a slow speed work program.

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4.9.5 Axis 6 calibration

To obtain the calibration of axis 6 is necessary to proceed as follows:

Preliminary procedures / notes

The calibration must be carried out on Robot free of loads applied to the axes.

a. Fix to the Robot wrist the T1 reference

gauge (B) using the 4 screws (A) .
B A
b. Move the Robot axis 5 to the dimension of
-118°.

c. Move at low speed the Robot axis until

reaching the reference notch.
A C
d. Insert the T2 reference gauge (C) in the seat
formed by the T1 reference gauge (A) and
by the notch on the axis as shown in figure.
In the event of detecting a minimum forcing
when inserting the reference gauge repeat
the procedure from step c.

e. Remove the T2 reference gauge (C).

f. Remove the 4 fixing screws (B) and remove

the T1 reference gauge (A).

Do not move the Robot with the inserted reference gauge.

Follow-up procedures
– Check the correct functioning of the Robot running a slow speed work program.

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4.10 AXIS 1 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 (turned off).
Material: – Axis 1 motor [See Chap.4.21 - Spare
parts list on page 165]
Equipment: – 2.5 - 3 mm Allen wrench
– Torque wrench with appropriate bits
– 1 mm thickness gauge
– A pair of scissors
– Frequency meter for belt tensioning
– Mechanical puller for pins Ø7
Fixing – Socket hex head screws M3x25 (12.9)
components: – Socket hex head screws M4x10 (8.8)
– Socket hex head screws M4x16 (8.8)
– Washers Ø4
– Nylon wiring cable ties

Preliminary procedures / notes

HIGH TEMPERATURES DANGER
Danger because of possible high temperature of the motor.
Before working on the motor check the motor temperature. Wait till the
temperature is not dangerous and if it is necessary use appropriate gloves
for high temperatures.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or beat against the motor during
disassembly and reassembly.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.

– If the Robot functions allow it, connect the Control Unit to the power supply and
position the Robot in transport position.
Disconnect the electrical power and the pneumatic power (if present), details in
par. 4.4 How to disconnect the electrical power supply on the Control Unit on
page 89.
– Remove all connectors of the cables connecting with R1C on Robot base.
– Remove the two centering pins from the Robot base using a puller.
– Remove the 4 fixing screws M8x35.
– After unscrewing the Robot fixing screws, position it with the axis 1 motor
accessible. For more information on Robot fixing points, refer to par. 3.4.3 Robot
fixing on the backing plan on page 72.

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Operating procedure
a. Unscrew and remove all the
socket hex head screws M4x10
(A) that fix the guard (B) as
shown in figure.

b. Disconnect the motor connector

and the encoder connector of
the axis 1 motor (C).

c. Cut the nylon cable ties using

the scissors and pull out the
insulating covering (D) of the
motor.

Do not throw the

insulating covering of the
motor.

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Operating procedure (Continued)

d. Unscrew the 2 socket hex head screws M4x10 (E) without removing the bracket
(F).

e. Unscrew the 4 socket hex head screws M4x16 and the related washers Ø4 (G)
of the Axis 1 motor.

f. Pull out the motor and remove the belt (H).

g. Bring the motor on the

workbench.

h. Loosen the 4 fixing screws (L)

(socket hex head M3x16).

i. Remove completely the 2 fixing

screws (socket hex head
M3x16) (L) and insert them in
the two threaded holes (M).

j. Screw the 2 just inserted

screws to extract the pulley.

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Operating procedure (Continued)

k. Remove the pulley (N) from the motor.

l. Insert the pulley (N) on the new motor.

m. Remove the 2 socket hex head screws M3x16 from the two extraction holes.

n. Reposition the 2 fixing screws (socket hex head M3x16) in the original seat.
o. Insert the thickness gauge of 1 mm (P) between the motor flange and the pulley.

Tighten the 4 screws starting with a screw and continuing clockwise or

counterclockwise, perform an initial fixing round and then tighten to torque.

p. Tighten the 4 screws (Q) (socket hex head M3x25) to the 2.2 Nm. torque.

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Operating procedure (Continued)

q. Insert the motor in the lower compartment of the Robot.

Check if there are no signs of wear or damage on the driving belt, if not
found, use the same driving belt.
Otherwise, replace the driving belt with a new one.

r. Position the driving belt (H) on the pulley.

s. Place the motor in assembling position, verifying the correct belt alignment and
checking the position of the motor connector and encoder connector (see figure).

t. Screw the 4 socket hex head screws M4x16 and the related washers Ø4 (G) and
tighten to the 3.1 Nm. torque.

u. Screw the two socket hex head screws M4x10 (E) of the bracket (F), tightening
them to the 3.1 Nm. torque.

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Operating procedure (Continued)

v. Tension the belt creating a distance between the pulleys, this distance is
obtained applying a gentle pressure outwards on the motor, as shown in figure.

w. By using the frequency meter, check the correct tensioning of the axis 1 belt (H).
Here are the reference values:
New belt: 476 Hz with a tolerance of ±4 Hz
Belt in use: 345 Hz with a tolerance of ±4 Hz

Trigger the vibration of the belt with a light blow near the centre of the free
section, by means of a rigid object (e.g. screwdriver) with the microphone
already positioned as shown in figure.

In case the instrument does not detect a frequency value, orientate better
the microphone bringing it closer to the belt, then repeat the reading.
However avoid any contact between the belt and microphone.

x. Repeat the operation from step v. until reaching the specified frequency.

y. Screw the two socket hex head screws M4x10 (E), tightening them to the 1 Nm.
torque.

z. Connect the motor connector

and the encoder connector (C)
to the axis 1 motor.

aa. Wind the previously removed

insulating covering (D) on axis 1
motor using 2 nylon cable ties.

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Operating procedure (Continued)

ab. Insert the lower guard (B) and
tighten the fixing screws (A)
(socket hex head M4x10) to the
tightening torque of 3.1 Nm.

Follow-up procedures
– For fixing the Robot to the backing plan refer to par. 3.4.3 Robot fixing on the
backing plan on page 72
– Carry out the calibration procedure, as described in par. 4.8 Calibration - Basic
concepts on page 98
– Check the correct functioning of the Robot running a slow speed work program.

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AXIS 2 MOTOR: COMPLETE REPLACEMENT

4.11 AXIS 2 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 (turned off).
Material: – Axis 2 motor [See Chap.4.21 - Spare
parts list on page 165]
Equipment: – 2.5 - 3 mm Allen wrench
– Torque wrench with appropriate bits
– 1 mm thickness gauge
– A pair of scissors
Fixing – Socket hex head screws M3x25 (12.9)
components: – Socket hex head screws M4x10 (8.8)
– Socket hex head screws M4x16 (8.8)
– Washers Ø4
– Nylon cable ties

Preliminary procedures / notes

HIGH TEMPERATURES DANGER
Danger because of possible high temperature of the motor.
Before working on the motor check the motor temperature. Wait till the
temperature is not dangerous and if it is necessary use appropriate gloves
for high temperatures.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or beat against the motor during
disassembly and reassembly.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.

– If the Robot functions allow it, connect the Control Unit to the power supply and
position the Robot in transport position.
Disconnect the electrical power and the pneumatic power (if present), details in
par. 4.4 How to disconnect the electrical power supply on the Control Unit on
page 89.

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Operating procedure
a. Unscrew and remove all the
socket hex head screws M4x10
(A) that fix the guard (B) as
shown in figure.

b. Disconnect the motor connector and the encoder connector of the axis 2 motor.

c. Cut the cable ties (B) that keep the cables fixed to the axis 2 motor protective
bracket (C).

d. Unscrew the 2 screws M4x10 (D) that fix the bracket (C).

e. Remove the bracket (C).

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Operating procedure (Continued)

f. Remove the nylon cable ties
using the scissors and pull out
the insulating covering (E) of
the motor.

Do not throw the

insulating covering of the
motor.

g. Unscrew the 4 socket hex head

screws M5x12 (F) of the motor
supporting flange.

h. Remove the motor from its seat

and pull it out axially.
i. Loosen the 4 fixing screws (G)
(socket hex head M3x16).

j. Remove completely 2 fixing

screws (socket hex head
M3x16) (G) and insert them in
the two free holes (H).

k. Screw the 2 just inserted

screws to extract the pulley.

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Operating procedure (Continued)

l. Remove the pulley (L) from the motor.

m. Insert the pulley (L) on the new motor.

n. Remove the 2 socket hex head screws M3x16 (J) from the two extraction holes
(K).

o. Reposition the 2 fixing screws (J) (socket hex head M3x16) in the original seat.

p. Insert the thickness gauge of 2.8 mm (N) between the motor flange and the
pulley.

Tighten the 4 screws starting with a screw and continuing clockwise or

counterclockwise, to perform an initial fixing round and then tighten to
torque.

q. Tighten the 4 screws (P) (socket hex head M3x25) to a 2.2 Nm. torque.

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Operating procedure (Continued)

r. Insert the motor in its seat.

s. Screw the 4 socket hex head

screws M5x12 (F) of the motor
supporting flange and tighten to
the 6 Nm. torque.

t. Wind the previously removed

insulating covering (E) on axis 2
motor using 2 nylon cable ties.

u. Insert the bracket (C) on Robot and screw the 2 socket hex head screws M4x10
(D) tightening them to the 3.1 Nm. torque.

v. Fix the cables to the bracket (C) using 2 cable ties (B).

w. Connect the connector of the motor cable and the connector of the axis 2 motor
encoder cable.

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Operating procedure (Continued)

x. Insert the guard (B).

y. Screw all the socket hex head

screws M4x10 (A) and tighten
to the 3.1 Nm. torque.

Follow-up procedures
– Carry out the calibration procedure, as described in par. 4.8 Calibration - Basic
concepts on page 98
– Check the correct functioning of the Robot running a slow speed work program.

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AXIS 3 MOTOR: COMPLETE REPLACEMENT

4.12 AXIS 3 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 (turned off).
Material: – Axis 3 motor [See Chap.4.21 - Spare
parts list on page 165]
Equipment: – 2.5 - 3 mm Allen wrench
– Torque wrench with appropriate bits
– 1 mm thickness gauge
– A pair of scissors
– Frequency meter
Fixing – Socket hex head screws M3x25
components: – Socket hex head screws M4x10
– Socket hex head screws M4x16
– Socket hex head screws M4x25
– Washers Ø4
– Nylon cable ties

Preliminary procedures / notes

HIGH TEMPERATURES DANGER
Danger because of possible high temperature of the motor.
Before working on the motor check the motor temperature. Wait till the
temperature is not dangerous and if it is necessary use appropriate gloves
for high temperatures.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or beat against the motor during
disassembly and reassembly.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.

– If the Robot functions allow it, connect the Control Unit to the power supply and
position the Robot in transport position.
Disconnect the electrical power and the pneumatic power (if present), details in
par. 4.4 How to disconnect the electrical power supply on the Control Unit on
page 89.

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Operating procedure
a. Unscrew and remove all the
socket hex head screws M4x10
(A) that fix the left guard (B) as
shown in figure.

b. Disconnect the motor connector and the axis 3 motor encoder connector.

c. Cut the cable ties (B) that keep the cables fixed on the protective bracket (C) of
the axis 3 motor.

d. Unscrew the 2 screws M4x25 and the 2 spacers (D) of the bracket (C).

e. Remove the bracket (C).

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Operating procedure (Continued)

f. Unscrew all the socket hex
head screws M4x10 (E) and
remove the right guard (F).

g. Remove the driving belt (G)

from the pulley of the axis 3
motor.

h. Unscrew the 4 socket hex head

screws M4x16 and the related
washers Ø4 (H).

i. Remove the motor from its seat

pulling it out axially.

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Operating procedure (Continued)

j. Bring the motor on the
workbench.

k. Loosen the 4 fixing screws (J)

(socket hex head M3x16).

l. Remove completely the 2 fixing

screws (socket hex head
M3x16) (J) and insert them in
the two free holes (K).

m. Screw the 2 just inserted

screws to extract the pulley.

n. Remove the pulley (L) from the motor.

o. Insert the pulley (L) on the new motor.

p. Remove the 2 socket hex head screws M3x16 (J) from the two extraction holes
(K).

q. Reposition the 2 fixing screws (J) (socket hex head M3x16) in the original seat.

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Operating procedure (Continued)

r. Insert the thickness gauge of 1 mm (M) between the motor flange and the pulley.

Tighten the 4 screws starting with a screw and continuing clockwise or

counterclockwise, to perform an initial fixing round and then tighten to
torque.

s. Tighten the 4 screws (N) (socket hex head M3x25) to the 2.2 Nm. torque.

t. Insert the motor in its seat.

u. Screw the 4 socket hex head

screws M4x16 and the related
washers Ø4 (H) and tighten to
the 6 Nm. torque.

Check if there are no signs of wear or damage on the driving belt, if not
found, use the same driving belt.
Otherwise, replace the driving belt with a new one.
v. Position the driving belt (G) on
the pulley.

w. Check the correct alignment of

the belt (G).

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Operating procedure (Continued)

x. Tension the belt creating a distance between the pulleys, this distance is
obtained applying a gentle pressure outwards on the motor, as shown in figure.

y. By using the frequency meter, check the correct tensioning of the axis 3 belt (H).
Here are the reference values:
New belt: 197 Hz with a tolerance of ±4 Hz
Belt in use: 143 Hz with a tolerance of ±4 Hz

Trigger the vibration of the belt with a light blow near the centre of the free
section, by means of a rigid object (e.g. screwdriver) with the microphone
already positioned as shown in figure.

In case the instrument does not detect a frequency value, orientate better
the microphone bringing it closer to the belt, then repeat the reading.
However avoid any contact between the belt and microphone.

z. Repeat the operation from step x. until reaching the specified frequency.

aa. Insert the right guard (F).

ab. Screw all the socket hex head

screws M4x10 (E) and tighten
to the 3.1 Nm. torque.

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Operating procedure (Continued)

ac. Insert the bracket (C) and screw the 2 socket hex head screws M4x25 and the 2
spacers (D) tightening to the 3.1 Nm. torque.

ad. Fix the cables to the outermost part of the bracket (C) using 2 cable ties (B).

ae. Connect the motor connector and the axis 3 motor encoder connector.

af. Insert the left guard (B).

ag. Screw all the socket hex head

screws M4x10 (A) and tighten
to the 3.1 Nm. torque.

Follow-up procedures
– Carry out the calibration procedure, as described in par. 4.8 Calibration - Basic
concepts on page 98
– Check the correct functioning of the Robot running a slow speed work program.

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AXIS 5 MOTOR: COMPLETE REPLACEMENT

4.13 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 (turned off).
Material: – Axis 5 motor [See Chap.4.21 - Spare
parts list on page 165]
Equipment: – 2.5 - 3 mm Allen wrench
– Torque wrench with appropriate bits
– 1 mm thickness gauge
– A pair of scissors
– Frequency meter
Fixing – Socket hex head screws M3x25 (12.9)
components: – Socket hex head screws M4x10 (8.8)
– Socket hex head screws M4x16 (8.8)
– Washers Ø4
– Nylon cable ties

Preliminary procedures / notes

HIGH TEMPERATURES DANGER
Danger because of possible high temperature of the motor.
Before working on the motor check the motor temperature. Wait till the
temperature is not dangerous and if it is necessary use appropriate gloves
for high temperatures.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or beat against the motor during
disassembly and reassembly.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.

– If the Robot functions allow it, connect the Control Unit to the power supply and
position the Robot in transport position.
Disconnect the electrical power and the pneumatic power (if present), details in
par. 4.4 How to disconnect the electrical power supply on the Control Unit on
page 89.

Operating procedure
a. Unscrew and remove all the
socket hex head screws M4x10
(A) of the right and left
protective casing.

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Operating procedure (Continued)

b. Remove the driving belt (B)
from the axis 5 motor pulley.

c. Remove the cable fixing tie.

d. Remove the connector of the

motor and the axis 6 motor
encoder connector, to improve
the accessibility.

e. Remove the connector of the

motor and of the axis 5 motor
encoder.

f. Disconnect the connectors of the solenoid valves (if necessary remove the unit,
refer to par. 4.20 SOLENOID VALVES UNIT: complete replacement on
page 161).
g. Unscrew the 4 socket hex head
screws M4x16 and the related
washers Ø4 (C) of the Axis 5
motor.

h. Remove the motor from its seat

pulling it out axially.

i. Bring the motor on the

workbench.

j. Loosen the 4 fixing screws (D)

(socket hex head M3x16).

k. Remove completely the 2 fixing

screws (socket hex head
M3x16) (D) and insert them in
the two free holes (E).

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Operating procedure (Continued)

l. Remove the pulley (H) from the motor.

m. Insert the pulley (H) on the new motor.

n. Remove the 2 socket hex head screws M3x16 (F) from the two extraction holes
(G).

o. Reposition the 2 fixing screws (F) (socket hex head M3x16) in the original seat.

p. Insert the thickness gauge of 1 mm (J) between the motor flange and the pulley.

Tighten the 4 screws starting with a screw and continuing clockwise or

counterclockwise, to perform an initial fixing round and then tighten to
torque.

q. Tighten the 4 screws (K) (socket hex head M3x25) to the 2.2 Nm. torque.

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Operating procedure (Continued)

r. Insert the motor in its seat.

s. Screw the 4 socket hex head

screws M4x16 and the related
washers Ø4 (C) of the axis 5
motor diagonally and finally
tighten them to the 3.1 Nm.
torque.

Screw the unit diagonally

to fix properly the motor.

Check if there are no signs of wear or damage on the driving belt, if not
found, use the same driving belt.
Otherwise, replace the driving belt with a new one.

t. Fit the driving belt (B) on the

pulley of the just replaced axis 5
motor, as shown in figure.

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Operating procedure (Continued)

u. Tension the belt creating a distance between the pulleys, this distance is
obtained applying a gentle pressure outwards on the motor, as shown in figure.

v. By using the frequency meter, check the correct tensioning of the axis 5 belt (B).
Here are the reference values:
New belt: 119 Hz with a tolerance of ±4 Hz
Belt in use: 86 Hz with a tolerance of ±4 Hz.
Trigger the vibration of the belt with a light blow near the centre of the free
section, by means of a rigid object (e.g. screwdriver) with the microphone
already positioned as shown in figure.

In case the instrument does not detect a frequency value, orientate better
the microphone bringing it closer to the belt, then repeat the reading.
However avoid any contact between the belt and microphone.

w. Repeat the operation from step u. until reaching the specified frequency.

x. Connect the motor connector

and the axis 5 motor encoder
connector.

y. Connect the connectors of the

solenoid valves.

z. Insert the previously removed

cable tie.

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Operating procedure (Continued)

aa. Insert the left and right
protective casings on Robot.

ab. Screw the previously removed

screws M4x10 (A) and tighten
them to the 3.1 Nm. torque.

Follow-up procedures
– Carry out the calibration procedure, as described in par. 4.8 Calibration - Basic
concepts on page 98
– Check the correct functioning of the Robot running a slow speed work program.

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AXIS 6 MOTOR: COMPLETE REPLACEMENT

4.14 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 (turned off).
Material: – Axis 6 motor [See Chap.4.21 - Spare
parts list on page 165]
Equipment: – 2.5 - 3 mm Allen wrench
– Torque wrench with appropriate bits
Fixing – Socket hex head screws M3x25 (12.9)
components: – Socket hex head screws M4x10 (8.8)
– Socket hex head screws M4x16 (8.8)
– Washers Ø4
– Nylon cable ties

Preliminary procedures / notes

HIGH TEMPERATURES DANGER
Danger because of possible high temperature of the motor.
Before working on the motor check the motor temperature. Wait till the
temperature is not dangerous and if it is necessary use appropriate gloves
for high temperatures.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or beat against the motor during
disassembly and reassembly.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.

– If the Robot functions allow it, connect the Control Unit to the power supply and
position the Robot in transport position.
Disconnect the electrical power and the pneumatic power (if present), details in
par. 4.4 How to disconnect the electrical power supply on the Control Unit on
page 89.

Operating procedure
a. Unscrew and remove all the
socket hex head screws M4x10
(A) of the right and left
protective casing.

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Operating procedure (Continued)

b. Remove the driving belt (B)
from the axis 6 motor pulley.

c. To facilitate the extraction of the

axis 6 motor, remove also the
driving belt from the pulley of
the axis 5 motor.

d. Remove the cable fixing tie.

e. Remove the connector of the

motor and of the axis 6 motor
encoder.

f. Disconnect the connectors of the solenoid valves (if necessary remove the unit,
refer to par. 4.20 SOLENOID VALVES UNIT: complete replacement on
page 161).
g. Unscrew the 4 socket hex head
screws M4x16 and the 4
washers Ø4 (C) of the axis 6
motor.

h. Remove the motor from its seat

pulling it out axially.

i. Bring the motor on the

workbench.

j. Loosen the 4 fixing screws (D)

(socket hex head M3x16).

k. Remove completely the 2 fixing

screws (socket hex head
M3x16) (D) and insert them in
the two free holes (E).

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Operating procedure (Continued)

l. Remove the pulley (H) from the motor.

m. Insert the pulley (H) on the new motor.

n. Remove the 2 socket hex head screws M3x16 (F) from the two extraction holes
(G).

o. Reposition the 2 fixing screws (F) (socket hex head M3x16) in the original seat.

p. Insert the thickness gauge of 1 mm (J) between the motor flange and the pulley.

Tighten the 4 screws starting with a screw and continuing clockwise or

counterclockwise, to perform an initial fixing round and then tighten to
torque.

q. Tighten the 4 screws (K) (socket hex head M3x25) to the 2.2 Nm. torque.

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Operating procedure (Continued)

Check if there are no signs of wear or damage on the driving belt, if not
found, use the same driving belt.
Otherwise, replace the driving belt with a new one.

r. Insert the motor in its seat.

s. Screw the 4 socket hex head

screws M4x16 and the related
washers Ø4 (C) of the axis 6
motor diagonally and finally
tighten them to the 3.1 Nm.
torque.

Screw the unit diagonally to fix properly the motor.

t. Fit the driving belt (B) on the

pulley of the axis 5 motor.

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Operating procedure (Continued)

u. Fit the driving belt (B) on the
pulley of the just replaced axis 6
motor.

v. Tension the belt creating a distance between the pulleys, this distance is
obtained applying a gentle pressure outwards on the motor, as shown in figure.

w. By using the frequency meter, check the correct tensioning of the axis 5 and axis
6 belt (B).
Here are the reference values:
New belt: 212 Hz with a tolerance of ±4 Hz
Belt in use: 154 Hz with a tolerance of ±4 Hz.

Trigger the vibration of the belt with a light blow near the centre of the free
section, by means of a rigid object (e.g. screwdriver) with the microphone
already positioned as shown in figure.

In case the instrument does not detect a frequency value, orientate better
the microphone bringing it closer to the belt, then repeat the reading.
However avoid any contact between the belt and microphone.

x. Repeat the operation from step v. until reaching the specified frequency.

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Operating procedure (Continued)

y. Connect the motor connector
and the axis 6 motor encoder
connector.

z. Connect the connectors of the

solenoid valves.

aa. Insert the previously removed

cable tie.

ab. Insert the left and right

protective casings on Robot.

ac. Screw all the previously

removed socket hex head
screws M4x10 (A) and tighten
to the 3.1 Nm. torque.

Follow-up procedures
– Carry out the calibration procedure, as described in par. 4.8 Calibration - Basic
concepts on page 98
– Check the correct functioning of the Robot running a slow speed work program.

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AXIS 1 BELT: COMPLETE REPLACEMENT

4.15 AXIS 1 BELT: 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 (turned off).
Material: – Axis 1 driving belt [See Chap.4.21 - Spare
parts list on page 165]
Equipment: – 3 mm Allen wrench
– Torque wrench with appropriate bits
– 20 mm open-end wrench
– Frequency meter
– 20 mm box wrench
Fixing – Socket hex head screws M4x10 (8.8)
components: – Socket hex head screws M4x16 (8.8)

Preliminary procedures / notes

HIGH TEMPERATURES DANGER
Danger because of possible high temperature of the motor.
Before working on the motor check the motor temperature. Wait till the
temperature is not dangerous and if it is necessary use appropriate gloves
for high temperatures.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or beat against the motor during
disassembly and reassembly.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.

– If the Robot functions allow it, connect the Control Unit to the power supply and
position the Robot in transport position.
Disconnect the electrical power and the pneumatic power (if present), details in
par. 4.4 How to disconnect the electrical power supply on the Control Unit on
page 89.
– Remove all connectors of the cables connecting with R1C on Robot base.
– Remove the two centering pins from the Robot base using a puller.
– Remove the 4 fixing screws M8x35.
– After unscrewing the Robot fixing screws, position it with the axis 1 motor
accessible. For more information on Robot fixing points, refer to par. 3.4.3 Robot
fixing on the backing plan on page 72.

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Operating procedure
a. Unscrew and remove all the
socket hex head screws M4x10
(A) that fix the guard (B) as
shown in figure.

b. Disconnect the motor connector

and the encoder connector of
the axis 1 motor (C).

c. Remove the nylon cable ties

using the scissors and pull out
the insulating covering (D) of
the motor.

Do not throw the

insulating covering of the
motor.

d. Remove the 4 fixing screws

M8x35 (E).

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Operating procedure (Continued)

e. Using a hex wrench Ø 20
remove the Ethernet connector
(F).

f. Disconnect the air pipes from

the fittings (G).

g. Remove the frontal fixing

screws of the X50 connector (H)
and remove the cables from the
connector.

h. Remove the fixing cable ties (J).

i. Remove the fixing screws of the

ground cables (K).

j. Remove the inserts (L) of the

power connectors and of the
motors encoder, passing them
by the Robot base plate.

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AXIS 1 BELT: COMPLETE REPLACEMENT

Operating procedure (Continued)

k. Unscrew the 2 socket hex head screws M4x10 (M) without removing the bracket
(N).

l. Unscrew the 4 socket hex head screws M4x16 and the related washers Ø4 (P)
of the Axis 1 motor.

m. Pull out the motor and remove the belt (Q).

n. Group the wiring to facilitate the

removal of the belt (Q).

o. Insert through the X50

connector hole the new belt (Q).

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Operating procedure (Continued)

p. Position the driving belt (Q) on the pulley.

q. Place the motor in assembling position, verifying the correct belt alignment and
checking the position of the motor connector and encoder connector (see figure).

r. Screw the 4 socket hex head screws M4x16 and the related washers Ø4 (P) to
the 3.1 Nm. tightening torque.

s. Screw the two socket hex head screws M4x10 (M) of the bracket (N), tightening
them to a torque of 3.1 Nm.

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AXIS 1 BELT: COMPLETE REPLACEMENT

Operating procedure (Continued)

t. Tension the belt creating a slight distance between the pulleys, this distance is
obtained applying a gentle pressure outwards on the motor, as shown in figure.

u. By using the frequency meter, check the correct tensioning of the axis 1 belt (H).
The instrument must measure 476 Hz with a tolerance of ± 4 Hz.

Trigger the vibration of the belt with a light blow near the centre of the free
section, by means of a rigid object (e.g. screwdriver) with the microphone
already positioned as shown in figure.

In case the instrument does not detect a frequency value, orientate better
the microphone bringing it closer to the belt, then repeat the reading.
However avoid any contact between the belt and microphone.

v. Repeat the operation from step t. until reaching the specified frequency.

w. Screw the two socket hex head screws M4x10 (M), tightening them to a torque
of 1 Nm.

x. Screw the Ethernet connector

(F).

y. Connect the air pipes to the

fittings (G).

z. Screw the fixing screws of the

X50 connector (H).

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AXIS 1 BELT: COMPLETE REPLACEMENT

Operating procedure (Continued)

a. Insert the fixing cable ties (J).

b. Screw the fixing screws of the

ground cables (K).

c. Insert the inserts (L) of the

power connectors and of the
motors encoder, passing them
by the Robot base plate.

d. Screw the 4 fixing screws

M5x12 (E).

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AXIS 1 BELT: COMPLETE REPLACEMENT

Operating procedure (Continued)

e. Connect the motor connector
and the encoder connector (C)
to the axis 1 motor.

f. Wind the previously removed

insulating covering (D) on axis 1
motor using 2 nylon cable ties.

g. Insert the lower guard (B) and

tighten the fixing screws (A)
(socket hex head M4x10) to the
tightening torque of 3.1 Nm.

Follow-up procedures
– For fixing the Robot to the backing plan refer to par. 3.4.3 Robot fixing on the
backing plan on page 72
– Carry out the calibration procedure, as described in par. 4.8 Calibration - Basic
concepts on page 98
– Check the correct functioning of the Robot running a slow speed work program.

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AXIS 3 BELT: COMPLETE REPLACEMENT

4.16 AXIS 3 BELT: 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 (turned off).
Material: – Axis 3 driving belt [See Chap.4.21 - Spare
parts list on page 165]
Equipment: – 3 mm Allen wrench
– Torque wrench with appropriate bits
– Frequency meter
Fixing – Socket hex head screws M4x10
components:

Preliminary procedures / notes

HIGH TEMPERATURES DANGER
Danger because of possible high temperature of the motor.
Before working on the motor check the motor temperature. Wait till the
temperature is not dangerous and if it is necessary use appropriate gloves
for high temperatures.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or beat against the motor during
disassembly and reassembly.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.

– If the Robot functions allow it, connect the Control Unit to the power supply and
position the Robot in transport position.
Disconnect the electrical power and the pneumatic power (if present), details in
par. 4.4 How to disconnect the electrical power supply on the Control Unit on
page 89.

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AXIS 3 BELT: COMPLETE REPLACEMENT

Operating procedure
a. Unscrew and remove all the
socket hex head screws M4x10
(A) that fix the right guard (B) as
shown in figure.

b. Remove the driving belt (C)

from the axis 3 motor pulley.

c. Insert the new belt (C) on the

axis 3 motor, as shown in figure.

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AXIS 3 BELT: COMPLETE REPLACEMENT

Operating procedure (Continued)

d. Tension the belt creating a slight distance between the pulleys, this distance is
obtained applying a gentle pressure outwards on the motor, as shown in figure.

e. By using the frequency meter, check the correct tensioning of the axis 3 belt.
The instrument must measure 197 Hz with a tolerance of ± 4 Hz.
Trigger the vibration of the belt with a light blow near the centre of the free
section, by means of a rigid object (e.g. screwdriver) with the microphone
already positioned as shown in figure.

In case the instrument does not detect a frequency value, orientate better
the microphone bringing it closer to the belt, then repeat the reading.
However avoid any contact between the belt and microphone.

f. Repeat the operation from step d. until reaching the specified frequency.

g. Insert the right guard (B).

h. Screw all the socket hex head

screws M4x10 (A) and tighten
to the 3.1 Nm. torque.

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AXIS 3 BELT: COMPLETE REPLACEMENT

Follow-up procedures
– Carry out the calibration procedure, as described in par. 4.8 Calibration - Basic
concepts on page 98
– Check the correct functioning of the Robot running a slow speed work program.

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AXIS 5 BELT: COMPLETE REPLACEMENT

4.17 AXIS 5 BELT: 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 (turned off).
Material: – Axis 5 driving belt [See Chap.4.21 - Spare
parts list on page 165]
Equipment: – 3 mm Allen wrench
– Torque wrench with appropriate bits
– Frequency meter
Fixing – Socket hex head screws M4x10 (8.8)
components:

Preliminary procedures / notes

HIGH TEMPERATURES DANGER
Danger because of possible high temperature of the motor.
Before working on the motor check the motor temperature. Wait till the
temperature is not dangerous and if it is necessary use appropriate gloves
for high temperatures.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or beat against the motor during
disassembly and reassembly.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.

– If the Robot functions allow it, connect the Control Unit to the power supply and
position the Robot in transport position.
Disconnect the electrical power and the pneumatic power (if present), details in
par. 4.4 How to disconnect the electrical power supply on the Control Unit on
page 89.

Operating procedure
a. Unscrew and remove all the
socket hex head screws M4x10
(A) of the right protective
casing.

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Operating procedure (Continued)

b. Remove the driving belt (B)
from the axis 5 motor pulley.

c. Insert the new belt (B) on the

axis 5 motor, as shown in figure.

d. Tension the belt creating a slight distance between the pulleys, this distance is
obtained applying a gentle pressure outwards on the motor, as shown in figure.

e. By using the frequency meter, check the correct tensioning of the axis 5 belt.
The instrument must measure 119 Hz with a tolerance of ± 3 Hz.
Trigger the vibration of the belt with a light blow near the centre of the free
section, by means of a rigid object (e.g. screwdriver) with the microphone
already positioned as shown in figure.

In case the instrument does not detect a frequency value, orientate better
the microphone bringing it closer to the belt, then repeat the reading.
However avoid any contact between the belt and microphone.

f. Repeat the operation from step d. until reaching the specified frequency.

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AXIS 5 BELT: COMPLETE REPLACEMENT

Operating procedure (Continued)

g. Insert the right protective casing
on the Robot.

h. Screw all the previously

removed socket hex head
screws M4x10 (A) and tighten
to the 3.1 Nm. torque.

Follow-up procedures
– Carry out the calibration procedure, as described in par. 4.8 Calibration - Basic
concepts on page 98
– Check the correct functioning of the Robot running a slow speed work program.

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AXIS 6 BELT: COMPLETE REPLACEMENT

4.18 AXIS 6 BELT: 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 (turned off).
Material: – Axis 6 driving belt [See Chap.4.21 - Spare
parts list on page 165]
Equipment: – 3 mm Allen wrench
– Torque wrench with appropriate bits
– Frequency meter
Fixing – Socket hex head screws M4x10 (8.8)
components:

Preliminary procedures / notes

HIGH TEMPERATURES DANGER
Danger because of possible high temperature of the motor.
Before working on the motor check the motor temperature. Wait till the
temperature is not dangerous and if it is necessary use appropriate gloves
for high temperatures.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or beat against the motor during
disassembly and reassembly.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.

– If the Robot functions allow it, connect the Control Unit to the power supply and
position the Robot in transport position.
Disconnect the electrical power and the pneumatic power (if present), details in
par. 4.4 How to disconnect the electrical power supply on the Control Unit on
page 89.

Operating procedure
a. Unscrew and remove all the
socket hex head screws M4x10
(A) of the left protective casing.

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AXIS 6 BELT: COMPLETE REPLACEMENT

Operating procedure (Continued)

b. Remove the driving belt (B)
from the axis 6 motor pulley.

c. Insert the new driving belt (B)

on the axis 6 motor, as shown in
figure.

d. Tension the belt creating a slight distance between the pulleys, this distance is
obtained applying a gentle pressure outwards on the motor, as shown in figure.

e. By using the frequency meter, check the correct tensioning of the axis 6 belt.
The instrument must measure 212 Hz with a tolerance of ± 4 Hz.
Trigger the vibration of the belt with a light blow near the centre of the free
section, by means of a rigid object (e.g. screwdriver) with the microphone
already positioned as shown in figure.

In case the instrument does not detect a frequency value, orientate better
the microphone bringing it closer to the belt, then repeat the reading.
However avoid any contact between the belt and microphone.

f. Repeat the operation from step d. until reaching the specified frequency.

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AXIS 6 BELT: COMPLETE REPLACEMENT

Operating procedure (Continued)

g. Insert the left protective casing
on the Robot.

h. Screw all the previously

removed socket hex head
screws M4x10 (A) and tighten
to the 3.1 Nm. torque.

Follow-up procedures
– Carry out the calibration procedure, as described in par. 4.8 Calibration - Basic
concepts on page 98
– Check the correct functioning of the Robot running a slow speed work program.

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 Comau Robotics Product Instruction

AXIS 6 GEARBOX: COMPLETE REPLACEMENT

4.19 AXIS 6 GEARBOX: 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 (turned off).
Material: – Axis 6 gearbox [See Chap.4.21 - Spare
parts list on page 165]
Equipment: – 3 mm Allen wrench
– Torque wrench with appropriate bits
– Open-end wrench for hex nut Ø6
– Spanner
Fixing – Socket hex head screws M4x6
components: – Socket hex head screws M4x10
– Socket hex head screws M4x16

Preliminary procedures / notes

HIGH TEMPERATURES DANGER
Danger because of possible high temperature of the motor.
Before working on the motor check the motor temperature. Wait till the
temperature is not dangerous and if it is necessary use appropriate gloves
for high temperatures.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or beat against the motor during
disassembly and reassembly.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.

Operating procedure
a. Unscrew and remove the 4
socket hex head screws M4x6
(A)

b. Remove the Harmonic Drive

unit.

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AXIS 6 GEARBOX: COMPLETE REPLACEMENT

Operating procedure (Continued)

c. Unscrew and remove the
socket hex head screws M4x10
(B) of the left sump.

d. Remove the belt (C) of the axis

6 motor.

For further information,

refer to par. 4.18 AXIS 6
BELT: complete
replacement on page 154

e. Block using the spanner the

rotation of the transmission unit.

f. Remove the fixing hex nut Ø6

and the washer (D).

g. Pull out and remove the unit, as

shown in figure.

During the unit removal

and insertion procedure,
do not inspect and/or
touch the fixing ring nuts.

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AXIS 6 GEARBOX: COMPLETE REPLACEMENT

Operating procedure (Continued)

h. Insert the new unit.

i. Block the rotation of the

transmission unit using the
spanner.

j. Fix the previously removed hex

nut Ø6 and the washer to the 6
Nm. tightening torque.

k. Insert the belt (C) of the axis 6

motor.

Remember to check the correct tensioning of the driving belt after the
removal.
For the complete procedure, refer to AXIS 6 BELT: complete replacement
(see par. 4.18 on page 154)

l. Insert the left sump.

m. Screw all the socket hex head

screws M4x10 (B) and tighten
to the 3.1 Nm. torque.

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AXIS 6 GEARBOX: COMPLETE REPLACEMENT

Operating procedure (Continued)

n. Insert the new Harmonic Drive
verifying the correct position of
the reference hole.

o. Fix the 4 socket hex head

screws M4x6 (A).

Follow-up procedures
– Carry out the calibration procedure, as described in par. 4.8 Calibration - Basic
concepts on page 98
– Check the correct functioning of the Robot running a slow speed work program.

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SOLENOID VALVES UNIT: COMPLETE REPLACEMENT

4.20 SOLENOID VALVES UNIT:

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 (turned off).
Material: – Solenoid valves unit [See Chap.4.21 -
Spare parts list on page 165]
Equipment: – 3 mm Allen wrench
– Torque wrench with appropriate bits
– Open-end wrench for hex nut Ø6
– Pliers
Fixing – Socket hex head screws M4x6
components: – Socket hex head screws M4x10
– Socket hex head screws M4x16

Preliminary procedures / notes

For greater freedom of movement it is advisable to remove the axis 6
motor. For the complete procedure, refer to AXIS 6 MOTOR: complete
replacement (see par. 4.14 on page 133)

Operating procedure
a. Remove all the socket hex head
screws M4x10 (A) of the right
and left protective casing.

Remove the axis 5 and 6 driving belts. For the complete procedure, refer
to AXIS 5 BELT: complete replacement (see par. 4.17 on page 151) and
AXIS 6 BELT: complete replacement (see par. 4.18 on page 154)

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SOLENOID VALVES UNIT: COMPLETE REPLACEMENT

Operating procedure (Continued)

b. Remove all the connectors of
the solenoid valves unit (B).

c. Remove the silencer M5 Ø6

(C).

d. Remove all the plugs Ø6 (D)

assembled on the fittings (E).

e. Remove the fittings (E) using the pliers.

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SOLENOID VALVES UNIT: COMPLETE REPLACEMENT

Operating procedure (Continued)

f. Unscrew the 3 socket hex head
screws (F).

g. Push the plate downwards and

remove the solenoid valves
unit.

h. Insert the new solenoid valves unit, as shown in figure.

i. Insert the plate and fix the socket hex head screws M4x10 (F) and tighten to the
3.1 Nm. torque.

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SOLENOID VALVES UNIT: COMPLETE REPLACEMENT

Operating procedure (Continued)

j. Insert all the fittings (E) plugs
(D) and the silencer (C) using, if
necessary the pliers.

k. Connect all the connectors of

the solenoid valves unit (B).

Reinsert the axis 5 and 6 driving belts.

Remember to check the correct tensioning of the driving belts after their
removal.
For the complete procedure, refer to AXIS 5 BELT: complete replacement
(see par. 4.17 on page 151) and AXIS 6 BELT: complete replacement (see
par. 4.18 on page 154)

l. Insert the left and right

protective casings on Robot.

m. Fix the socket hex head screws

M4x10 (A) and tighten to the 3.1
Nm. torque.

Follow-up procedures
– Carry out the calibration procedure, as described in par. 4.8 Calibration - Basic
concepts on page 98
– Check the correct functioning of the Robot running a slow speed work program.

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SPARE PARTS LIST

4.21 Spare parts list

This paragraph lists all available spare parts for the Racer5 Robot

Tab. 4.8 - Racer5 Robot spare parts

Axis
Pos. Comau Part No. Description [Link] Weight
Robot
0.003 Kg
A TEXXX-0000011756 Belt 255 - 3MGT - 15 Ax 1 1
(0.007 lb)
1.8 Kg
B CR82370003 Motor 1.27 NM - 230V - C5G - SAFE Ax 1-2 2
(3.97 lb)
0.002 Kg
C TMC000000015954 Belt 426 - 3MGT - 6 Ax 3 1
(0.004 lb)
1.4 Kg
D CR82370002 Motor 0.64 NM - 230V - C5G - SAFE Ax 3 1
(3.09 lb)
0.002 Kg
E TMC000000015955 Belt 510 - 3MGT - 6 Ax 5 1
(0.004 lb)
0.002 Kg
F TMC000000015953 Belt 324 - 3MGT - 6 Ax 6 1
(0.004 lb)
0.9 Kg
G CR82370001 Motor 0.32 NM - 230V - C5G - SAFE Ax 5-6 2
(1.98 lb)
H CR82392000 Valve block -- 1 --)
Gearbox HARMONIC DRIVE CSF 0.47 Kg
K CR82391906 Ax 6 1
14-50-2UH-SP (1.04 lb)

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SPARE PARTS LIST

166
 Original instructions

Made in Comau