SMART S4

REL. 1.X/2.X/3.X

USER MANUAL

00755056 / GB 3MU-S4 05/0103

The information contained within this manual is the property of COMAU S.p.A.
Any reproduction, even partial is forbidden without previous written authorisation
from COMAU S.p.A.
COMAU reserves the right to modify without previous warning, the characteristics of the product
presented in this manual.

PRINTED IN ITALY - 01/2003

Copyright © 1998 by COMAU
 SCHEDA AGGIORNAMENTI

SCHEDA AGGIORNAMENTI

NOTA: La presente edizione del manuale, rispetto alla precedente, ha subito interventi di modi-
fica dei contenuti tecnici per aggiornamento del prodotto. Le parti aggiornate sono di se-
guito riportate.
Titolo: MANUALE UTENTE SMART S4 REL. 1.X/2.X/3.X

AGGIORN. CAPITOLO ARGOMENTO PAG. No OPERAZ.

05/0103 - Copertina - Sostituita
05/0103 - Retro - Sostituita
05/0103 - Divisori di Capitolo - Sostituite
05/0103 2 Trasporto SMART S4 7÷10 Sostituite
05/0103 5 Manutenzione Preventiva SMART S4 5 Sostituita

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05/0103
UPDATING LIST

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 SAFETY REGULATIONS

SAFETY REGULATIONS

RESPONSIBILITY

• The "integrator" shall be responsible for introducing the robot system into a manufacturing
or research environment, issuing the declaration of conformity and applying the EC label to
the system in accordance with the safety standards referred to in the "Machines Directive".
• COMAU S.p.A. disclaims all responsibility for injury or damage arising from the incorrect or
improper use of the robot system, from the use of any unspecified spare parts and from
tampering with circuits, components and system software.
• The foremen who manage / supervise the operations specified in point 3 are responsible for
ensuring that these safety rules are enforced. They must make sure that all authorized
personnel have been instructed as regards the rules contained in this document and the
general safety rules applicable to the robot system and that the aforesaid personnel comply
with all these rules.
• Failure to observe safety standards may cause personal injury and damage to control system
components.

SAFETY REGULATIONS

1. PURPOSE
1.1 The purpose of these safety regulations is to define a series of behaviour rules and duties to be observed
when performing the activities listed in point 3, to ensure the safety of personnel, equipment and the
surrounding environment.

2. DEFINITIONS
2.1 Robot System
The term Robot System refers to the functional assembly consisting of: control unit, robot, portable
programming and/or emergency terminal and any options.
2.2 Protected Area
Protected Area is the area that is enclosed by protective barriers, in which the robot is to be installed
and operated.
2.3 Authorised Personnel
Authorised Personnel is the group of persons that have been appropriately trained and delegated to
perform the activities listed in point 3.
2.4 Foremen
Foremen are personnel who direct or supervise the activities assigned to subordinate workers as defined
in the previous paragraph.
2.5 Installation and commissioning
The term installation refers to the integration of the robot system mechanics and electrics into a
manufacturing situation or research environment in accordance with the safety requirements laid down
in the Machines Directive.
The term commissioning refers to the operations involved in verifying system operation once the system
has been installed.
2.6 Operation during Programming
Operating mode under operator control. This mode excludes automatic operation and permits the
following activities: manual movement in the various different modes, programming of work cycles at
reduced speed, programmed cycle testing at reduced speed and when permitted, at working speed.

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SAFETY REGULATIONS

2.7 Automatic Operation

Operating mode in which the robot performs the programmed cycle autonomously at working speed
inside the protected area, with protective barriers closed and interlocked with the emergency stop circuit,
and with local (situated outside the protected area)or remote start/stop.
2.8 Emergency Manual Operation
Operating mode that permits movement of the robot with downgraded safety system in the case of a
fault, under operator control and with protective barriers closed.
2.9 Maintenance and Repairs
The maintenance and repairs procedure involves the periodic checking and/or replacement of parts
(mechanical, electrical, software) or robot system components, and the procedure of identifying the cause
of a fault, and consequently restoring the robot system to its original operating conditions.
2.10 Removal from Service and Dismantling
Removal from Service refers to the removal of the robot system (mechanical and electrical) from the
manufacturing situation or research environment.
Dismantling involves the demolition and disposal of the components that make up the robot system.
2.11 Integrator
The integrator is the qualified person responsible for the application of the robot system.
2.12 Incorrect Use
Incorrect Use is when the system is used outside the limits specified in the technical documentation.
2.13 Work Envelope
The robot’s work envelope is the area in which the robot, including fixtures, moves.

3. FIELD OF APPLICATION
3.1 These regulations must be complied with when performing the following activities:
• installation and commissioning;
• operation during programming;
• automatic operation;
• emergency manual operation;
• maintenance and repairs;
• removal from service and dismantling;

4. OPERATING MODES
4.1 Installation and Commissioning
4.1.1 Commissioning is allowed only when the robot system is incorporated in a manufacturing system or in
a research environment that guarantees the use of safety conditions.
4.1.2 Installation and commissioning of the system must be performed by authorized personnel only.
4.1.3 The system must only be installed and commissioned inside a protected area of a suitable size to house
the robot and its relative dressing, without any part of these being outside the safety guards. Also, make
sure that during normal robot movements this does not collide with other parts inside the protected area
(for instance, structural pillars, mains, etc.). If necessary, restrict the robot work area by means of
mechanical stops.
4.1.4 The robot installation area must be kept free, as far as possible, from any materials that may obstruct or
limit visibility.
4.1.5 During installation, handle the robot and control unit as specified in the Product User Manual; if they
must be lifted, check that the eyebolts are secured correctly and use only suitable slings and equipment.
4.1.6 Secure the robot to the support with all the bolts provided.
4.1.7 Remove any anchoring brackets from the axes and check that the robot fixtures are secured correctly.

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 SAFETY REGULATIONS

Installation and Commissioning (con.t)

4.1.8 Check that the robot guards are fixed correctly and that there are no loose or loosened parts, check also
that the control unit components are in good condition.
4.1.9 When required, connect the robot’s pneumatic system to the air distribution network and check carefully
to make sure that the pressure is set correctly. If the pressure of the balancing system is not correct it
will affect the robot’s movements.
Also install filters to collect any condensate in the system.
4.1.10 Install the control unit so that the control panel can only be operated from outside the protected area.
4.1.11 Check that the pre-engineered voltage on the power supply transformers indicated on the specific rating
plate corresponds to the power mains voltage.
4.1.12 Before making the electrical connections to the control unit, make sure that the power mains circuit
breaker is locked in the open position.
4.1.13 The connection between the control unit and the mains circuit breaker must be effected by means of a
shielded quadripole cable (3-phases + ground) of suitable dimensions for the control unit power installed
4.1.14 The supply cable must enter the control unit through the appropriate raceway and locked correctly
4.1.15 .After connecting the ground conductor (PE), connect the power conductors of the power cable to the
main circuit breaker or to the terminals on the controller Assemble the protectiive cover on the main
circuit breaker or on the input terminals.
4.1.16 Connect the supply cable to the circuit breaker on the power mains after checking, with the use of an
appropriate instrument, that the circuit breaker terminals are disconnected.
4.1.17 The controller can be provided with an internal lighting circuit and service socket connected downstream
of the main circuit breaker. Should it be necessary to power the circuits independently from the main
circuit breaker, it will be necessary to alter an internal connection by connecting a shielded three-core
cable (2 phases + ground) to the mains, scaled according to the protection rating of the mains, in the
same way and according to the same sequence of operations as specified for connection of the power
supply.
4.1.18 Connect the earth wire and the signals and power cables between the control unit and the robot.
4.1.19 Check that the control unit door(s) is/are locked with the special key.
4.1.20 The components of the control unit may be permanently damaged if the connectors are connected
incorrectly.
4.1.21 The C3G Plus internally makes the main safety interlocks (gates, enable button, etc.). Should it be
necessary to connect to the signals provided to make additional external circuits, make sure that these
signals are used according to safety regulations. The safety of interlock signals leading from the transfer
line (emergency stop, gates safety, etc.), i.e. providing correct and safe circuits is the task of the robot
system integrator.
System safety cannot be guaranteed if these interlocks are missing, incomplete or incorrectly
established.
4.1.22 Stopping due to tripping of the protective barrier safety devices causes uncontrolled stopping of the robot
with possible loss of the trajectory programmed. To stop the robot with controlled ramping down, it is
advisable to connect the interlock signals so as to activate a Drive Off command before the emergency
stop
Example: opening of the protective barrier safety locks causes Remote Drive Off; opening of the
protective barriers causes an emergency stop.
4.1.23 If the C3G-CSM (Controlled Stop Module) is installed on the controller, in AUTO LOCAL and AUTO
REMOTE states, an emergency stop and/or opening of the safety gates causes controlled stopping of
the robot (EN 60204-1), category 1 stop). In this way, power is cut off (opening of the power contactor)
after 1 second. In PROGR. programming status, the power is cut off immediately (EN 60204-1, category
0 stop). These times must be taken into account when installing the protective barriers in particular if
light curtains are used.

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Installation and Commissioning (con.t)

4.1.24 Check that the environmental and operating conditions do not exceed the limits specified in the product
User Manual.
4.1.25 Calibration operations must be carried out with extreme care as specified in the User Manual, and must
be completed by checking the correct machine position.
4.1.26 Only the original disks, supplied by COMAU S.p.A. with the robot, must be used to load or update the
system software (e.g. after replacing cards). After loading the software, always run a safety test cycle
from outside the protected area. When loading the system software, follow the procedure described in
the Product User Manual to the letter.
4.1.27 Make sure that the safety barrier around the protected area has been cerrectly fitted
4.2 Operation during Programming
4.2.1 The robot can only be programmed by authorised personnel.
4.2.2 Before programming, the operator must check the robot system to ensure there are no potentially
dangerous anomalous conditions and (ensure) that there is nobody inside the protected area.
4.2.3 Whenever possible, programming must be done from outside the protected area.
4.2.4 Whenever work must be carried out inside the protected area, the operator outside the protected area
must make sure that all the necessary protections have been installed and are operational and in
particular that the portable programming unit functions correctly (reduced speed, enable pushbutton,
emergency stop, etc.).
4.2.5 The operator can enter the protected area during programming only if he has the programming terminal.
4.2.6 During programming, only the operator with the programming terminal may remain within the protected
area. If the presence of another operator is absolutely necessary, he must have a further three-position
safety device connected to the control system.
4.2.7 During programming, the operator must keep far enough away from the robot to be able to avoid any
unexpected movements from the robot, and in a position to avoid being caught between the robot and
parts of the surrounding structure( pillars, safety barrier, etc.), or between moving parts of the robot.
4.2.8 During programming, the operator must not approach any parts of the robot that may drop or lift due to
the gravity.
4.2.9 The motors must always be activated (Drive On) from outside the robot’s work envelope after checking
there is noone inside the area involved. The Drive On operation is concluded when the relevant machine
status message is displayed.
4.2.10 Programmed cycle testing at working speed (a function that is included only if specific request is made),
in situations which require close visual observation with the operator inside the protected area, must only
be carried out after a complete test cycle has been run at reduced speed. Testing must be controlled
from a safe distance.
4.2.11 Be extremely careful when programming from the portable programming terminal: the hardware and
software safety devices are in operation, but robot movement is under the operator’s control.
4.2.12 The first time a new program is run, the robot may move along an unexpected path.
The modification of steps in the program (e.g. shifting one step from one part of the program to another,
incorrect recording of a step, modification of the robot position outside the path that joins two steps in
the program), may give rise to movements that were not envisaged by the operator during program
testing.
In both cases, it is extremely important to proceed with caution, and remain outside the robot’s work
envelope.

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 SAFETY REGULATIONS

4.3 Automatic Operation

4.3.1 The robot system can only be activated for automatic operation by authorised personnel when the
protective barriers are closed and electrically interlocked as specified in the safety standards.
4.3.2 Prior to activating automatic operation, the operator must check the robot system and the protected area
to make sure there are no potentially dangerous anomalous conditions.
4.3.3 The operator can only activate automatic operation after checking that:
• the robot system is not being maintenanced or repaired;
• the protective barriers have been positioned correctly;
• there is noone inside the protected area;
• the control unit doors are locked by properly key.
• the safety devices (emergency stop, protective barrier safety devices) are working properly;
• the portable programming terminal has been placed in its housing (this condition is requested by
the controller in Auto-Remote status).
4.3.4 Special attention must be paid when selecting the automatic- remote status, in which the line PLC may
automatically switch on the motors and start the program.
4.4 Emergency Manual Operation
(In case the manual emergency operation state is provided for)
4.4.1 Emergency Manual Operation can only be activated by authorised personnel.
4.4.2 This operating mode must only be used when special robot system conditions will not allow the use of
manual movement during programming.
4.4.3 Emergency manual operation must be controlled from outside the protected area since the safety system
is downgraded.
4.4.4 If it is absolutely necessary to work inside the protected area, The robot system integrator must realize
an appropriate safety circuit that allows the operator to move the robot with the safety barriers
deactivated.
In that case, before performing manual emergency operations, the operator must check, while remaining
outside the protected area, the correct functioning of the safety devices that are active in this state and
the teach pendant utilized as a portable emergency pushbutton panel..
4.4.5 Take great care during emergency manual operation remaining outside the work envelope of the robot
and its fixtures and pay particular attention to the axes that may drop due to the force of gravity.
4.4.6 Braking release device of robot axes. With the driving force excluded, the robot can be moved by the
manual brake release device, directly connected to the robot or installed on it, which only permits the
deactivation of the brake of each axis individually .
In this situation all the system safety devices (including the emergency stop and enable buttons) are
excluded. Any axes to be handled (that could drop due to the force of gravity) should be put in slings.

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SAFETY REGULATIONS

4.5 Removal from Service and Dismantling

4.5.1 Only authorised personnel may remove the robot system from service.
4.5.2 Position the robot ready for transport and fit anchoring brackets when required.
4.5.3 Prior to starting the removal from service procedure it is obligatory to disable the power grid circuit breaker
and lock it in the open position.
4.5.4 After using a specific instrument to check that the terminals are disconnected, disconnect the supply
cable from the power mains circuit breaker by first disconnecting the power conductors and then the
ground connector. Disconnect the main circuit breaker supply cable on the control unit and remove this.
4.5.5 Disconnect the cable that powers the internal lighting and the service socket (if these circuits are powered
from outside) on the controller after locking the corresponding circuit breaker on the mains supply in the
open position, and (after) checking that the system is not live disconnecting first of all the phase
conductors and then the ground conductor.
4.5.6 Disconnect the cables connecting the robot and the control unit, then disconnect the earth
4.5.7 Disconnect the robot pneumatic system from the air distribution network (if applicable).
4.5.8 Make sure that the robot is correctly balanced and, if necessary, harness it correctly and then
disassemble the robot anchor bolts from the support structure
4.5.9 Remove the robot and the control unit from the work area in accordance with all the instructions given
in the Product User Manual; if the equipment is to be lifted, check that the eyebolts are secured properly
and use only suitable slings and equipment.
4.5.10 Before starting to dismantle the robot system components (disassembly, demolition and disposal),
contact COMAU , or one of its branches. Depending on the type of robot and control unit, they will
provide information regarding the operations to be carried out so as to comply with the current safety
regulations, and protect the environment.
4.5.11 Any waste must be disposed of in accordance with the current legislation of the country where the robot
system has been installed.

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 SAFETY REGULATIONS

4.6 Maintenance and Repairs

4.6.1 Only authorised personnel may perform operations relating to maintenance, troubleshooting and repairs.
4.6.2 An appropriate notice must be posted on the control panel of the control unit while maintenance and
repairs are being carried out; this notice must not be removed until the operations have been completed
even if they are temporarily suspended.
4.6.3 Maintenance operations and the replacement of components or the control unit must be carried out with
the main circuit breaker padlocked in the open position.
4.6.4 Even when the main circuit breaker is open and the control unit is therefore not supplied, interconnected
voltages may come from peripheral units (e.g. input/output 24 Vdc or 110 Vac) or from external power
supplies (e.g. internal lighting system 110 Vac or 220 Vac). The relevant external sources should
therefore be deactivated when work is to be carried out on the system.
4.6.5 The main circuit breaker must be padlocked open before removing panels, protective screens, grills, etc.
4.6.6 Faulty components must be replaced with others having the same code.
4.6.7 Checks for faults on the control unit must, whenever possible, be performed outside the protected area.
4.6.8 If the control unit needs to be powered in order to proceed with the troubleshooting, all the precautions
required by the safety standards regarding personnel working in the presence of dangerous voltages
must be taken.
4.6.9 All troubleshooting on the robot must be carried out with the power deactivated (Drives off ).
4.6.10 All deactivated safety devices (panels, protective screens, interlocks, etc.) must be restored upon
completion of maintenance and troubleshooting.
4.6.11 Upon completion of any maintenance, repairs and troubleshooting, the robot system and all its safety
devices must be checked for correct operation from outside the protected area.
4.6.12 Only the original disks, provided by COMAU S.p.A. with the robot, must be used to load software (e.g.
after replacing electronic cards). Always run a safety test cycle from outside the protected area, once
the software has been loaded. When loading the system software, follow the procedure described in the
Product User Manual to the letter.

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 INTRODUCTION

INTRODUCTION

HOW TO USE THIS MANUAL

The graphic devices which have been adopted in this manual are explained in this paragraph.

CAUTIONS, WARNINGS AND NOTES

The definitions which follow apply to all the CAUTIONS, WARNINGS and NOTES to be found in
this manual.

WARNING
☞ Operating procedures, technical information and precautions which, if not respected and/or
carried out correctly, may cause injury to personnel.

CAUTION
☞ Operating procedures, technical information and precautions which, if not respected and/or
carried out correctly, may cause damage to the equipment.

NOTE: Operating procedures, technical information and precautions which it is essential to

highlight.

OPERATIONAL PROCEDURES

This manual contains operational procedures described using lists and sub-lists.
These procedures are used when the information they contain is descriptive and concerns actions to
be performed, and the procedure requires complex explanatory diagrams.

NOTE: This manual concerns the SMART S4 robot. For information about the control system
with which operation is controlled, refer to the appropriate Operations and Maintenance
Manual.

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INTRODUCTION

TRAINING COURSES
COMAU Robotica organizes special training courses for the personnel responsible for the use,
programming and maintenance of the robot systems.
Further courses may be prepared to meet particular requirements and to supply technical and practical
information, depending on the knowledge of the participants.

REFERENCE DOCUMENTATION
For further information on the SMART S4 robot consult the following documentation:
☞ Caratteristiche Tecniche/Technical Features;
☞ SMART S4 Manuale di Manutenzione/Maintenance Manual;
☞ C3G-901 Operations and Maintenance Manual;
☞ C3G Plus Operations and Maintenance Manual;
☞ C3G Plus Specifiche Tecniche/Technical Specifications;
☞ C3G Operations Manual (C3G-901 Control System);
☞ C3G Programming Guide (C3G Plus Control System);
☞ EZ Programming Environment;
☞ PDL2 Programming Language Manual.
These manuals are supplied by COMAU Robotics at list price.
FIRST EDITION:
October 1996
UPDATING:
01 December 1997
02 Aprile 1998
03 Aprile 2000

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 SUMMARY

This manual contains:

CHAPTER 1 - SYSTEM OVERVIEW

SMART S4 ROBOT

CHAPTER 2 - TRANSPORT AND INSTALLATION

SMART S4 TRANSPORT AND INSTALLATION

SMART S4 TRANSPORT

SMART S4 INSTALLATION

ASSEMBLY USING ROBOT CENTERING PLATE

CONNECTING UP THE PNEUMATIC AND ELECTRICAL SUPPLIES

INSTALLING SAFETY DEVICES

OPERATOR’S POSITIONS

RPT MODULE BATTERY CONNECTION

(OPTION FOR REL 1.X AND 2.X)

INSTALLATION OF OPTIONAL DEVICES

LIMIT STOPS DESCRIPTION

STANDARD MECHANICAL LIMIT STOPS

OPTIONAL MECHANICAL LIMIT STOPS

OPTIONAL ELECTRICAL LIMIT SWITCHES

LIMIT STOPS ADJUSTMENT

ELECTRICAL LIMIT SWITCHES

MECHANICAL LIMIT STOPS

CHAPTER 3 - ROBOT I/O

SMART S4 INPUTS/OUTPUTS

JUMPERS ON SMART S4

EXCLUSION OF SAFTY DEVICES ON BOARD THE ROBOT

CHAPTER 4 - CALIBRATION
SMART S4 CALIBRATION

PRELIMINARY OPERATIONS

CALIBRATION PERFORMED BY MEANS OF INDICES

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SUMMARY

CALIBRATION PERFORMED BY MEANS OF TOOLS

CHAPTER 5 - PREVENTIVE MAINTENANCE

SMART S4 PREVENTIVE MAINTENANCE

LUBRICATION

LUBRICANT TOPPING-UP

RPT MODULE BACK-UP BATTERY REPLACEMENT

(OPTION FOR REL 1.X AND 2.X)

EXTRAORDINARY MAINTENANCE

DISPOSAL OF PARTS

APPENDIX A - WIRING DIAGRAMS

APPENDIX B - ERROR CODES

APPENDIX C - TECHNICAL FEATURES

TECHNICAL FEATURES OF THE ROBOT

APPENDIX D - SPARE PARTS LIST

SPARE PARTS LIST

GENERAL

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 CHAPTER 1
SYSTEM OVERVIEW

Introduction to the SMART S4 robot.

The following chapter is composed by:

BOOKLET REVISION TOTAL

PAGES

SMART S4 ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03/0400 4

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 SMART S4 ROBOT

SMART S4 ROBOT

The SMART S4 is a six-axis robot with an anthropomorphic structure which has been designed by
COMAU to handle medium loads. It can perform the execute applications such as:
☞ light handling;
☞ mounting.

Axis 1 stroke: ± 152,5°

Axis 2 stroke: + 105° -78°
Axis 3 stroke: +125° -155°
Axis 4 stroke: ± 210°
Axis 5 stroke: ± 125°
Axis 6 stroke: ± 2700°

SMART S4 Robot

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SMART S4 ROBOT

The high technology solutions adopted guarantee exceptional performance in all applications. This
performance is expressed in:
☞ one of the largest work envelopes in its category;
☞ a wrist with a extremely extended work envelope which allows more flexibility in the operating
area;
☞ maximum load capacity on wrist: 147.1 N (15 kg);
☞ maximum additional load capacity: 147.1 N (15 kg) and total load capacity: 245.2 (25 kg);

CAUTION
☞ The maximum load on wrist and the maximum additonal load MUST NOT BE applied
together.
For further information consult the Technical Features of the Robot.

☞ brakes on all axes;

☞ protection level (IP65 for the wrist body and IP54 for the rest of the robot);
☞ the provision for mounting numerous optional device;
☞ oil lubrication for all reduces;
☞ electrical and pneumatic services on the forearm;
☞ positioning accuracy and repeatability with limited tolerance.
The movement of the axes is controlled by brushless motors. These reduce the need for maintenance, and
have the advantage of lower inertia and greater heat dissipation which enables the robot to be used in
particularly rigorous cycles; while motion is only transmitted through gear reducers and belt (axes 5 and 6).
The provisions for the fitting of optional devices are as follows:
☞ the robot is fitted with an internal air line including an upper connection on the forearm for
controlling the pneumatic actuators;
☞ the wiring includes an independent service line connected to the distribution signals assy, equipped
with a connector on the upper plate of the forearm near the pneumatic connection;
☞ the upper part of the forearm has flat surfaces and threaded holes for the installation of tools;
☞ the robot is fitted with standard mechanical stops. Additional adjustable mechanical stops and
electrical travel limits may be installed as an optional extra. The electrical travel limits are adjusted
according to the presence and assembly position of the mechanical stops;
☞ special accessories are available for transporting the robot with a lift truck, and centering the
floor-mounted robot.

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 SMART S4 ROBOT

CAUTION
☞ The information relating to:
✎ CELL CONTROLLER
✎ OPERATIONS TO BE PERFORMED ON FIRST INSTALLATION
is to be found in the specific Cell Controller documentation.

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SMART S4 ROBOT

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 CAPITOLO 2
TRASPORTO E INSTALLAZIONE

Informazioni tecniche necessarie per una corretta in-

stallazione e procedure da eseguire sul robot a seguito
dell’installazione.

Il presente capitolo è così composto:

FASCICOLO REVISIONE PAGINE

TOTALI

TRASPORTO E INSTALLAZIONE SMART S4. . . . . . . . . . . . . . 05/0103 12

COLLEGAMENTO BATTERIA MODULO RPT

(OPZIONE PER REL.2.X/3.X) . . . . . . . . . . . . . . . . . . . . . . . 03/0400 2

INSTALLAZIONE DISPOSITIVI OPZIONALI . . . . . . . . . . . . . . 00/1096 4

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SMART S4 TRANSPORT AND INSTALLATION

SMART S4 TRANSPORT AND INSTALLATION

SAFETY STANDARDS
F The insertion of the cell controller into a production unit must be carried out in compliance
with the Machines Directive with particular attention paid to the safety interlocks which
the control system is designed to handle. The failure to use or the incomplete use of these
interlocks means that the control system does not meet these standards.

F Installation operations on both the robot and the cell controller must be performed while
the system is off: the main circuit breaker MUST be in the OFF position.

F Operate with care during installation. On power up of the drives, an error in the robot’s wi-
ring may provoke uncontrolled movements. If this occurs, immediately press the
EMERGENCY STOP push-button on the operator panel or on the programming termi-
nal, then check the connections which have been made and the corresponding wires.

F Before performing any transport and/or installation operations carefully read the Safety
Regulations listed at the beginning of this manual.

SMART S4 TRANSPORT
The robot is shipped to the customer in a wooden pallet or in a wooden box.
Dimensions and weights are indicated in the table below:

Box for
Robot Robot + Pallet Wooden box
robot and controller
49.21 x 31.5 x 81.89 in 51.18 x 31.5 x 84.64 in 92.52 x 45.27 x 86.61 in
SMART S4: 936.95 lb (L x D x H) (L x D x H) (L x D x H)
1041.82 lb

The packaging must be raised using a lift truck or by means of a hoist and cables which pass transver-
sally under the wooden base and which are long enough not to demage the upper stringers of the case.

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TRANSPORT AND INSTALLATION SMART S4

CAUTION
F When raising the robot, check that the belts do not become entangled with components in-
stalled on the robot (motors, flexible sheaths, etc.) and that they are strong enough to sup-
port the weight of the robot.

After unpacking, the robot may be moved by means of ropes, as shown in the following picture, or by
means of a fork lift truck, provided the robot is equipped with the suitable optional unit on its base.

This is a schematic drawing

The overall dimensions of the robot when in transport position are: L = 46.06 in
D = 25.6 in
H = 73.62 in

Moving the Robot

SMART S4 INSTALLATION
The operating environment of the system which incorporates the SMART S4 robot is the normal
workshop environment. Obviously places containing corrosive vapours or sources of excess heat sho-
uld be avoided.
The temperature of the environment should be between 0°C and 45°C.

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SMART S4 TRANSPORT AND INSTALLATION

CAUTION
F The information relating to:
. robot work envelope and overall dimension,
. robot base and centering plate,
. stress transmitted to the floor,
. definition of max load on the flange,
. defining the maximum additional load,
. tool mounting flange,
is to be found in the Technical Features of the Robot.

The robot can be installed in two different ways:

- to the floor;
- to the ceiling.
The foundations on which the robot is placed must not be subject to vibrations caused by other machi-
nes (for example hammers, presses etc.).
When installed on the floor, the robot is secured to a centering plate (optional) by three screws and is
centred using two pins: this solution allows the robot to be positioned accurately and easily replaced.
If the robot is installed on the floor, the centering plate (optional) must be secured in a trench using sui-
table braces sunk into the cement foundation. The plate must be levelled using a centesimal level ( 0.05
mm for a length of 1 m) before the cement sets.
The preparation of the foundation and the support structure of the robot is the responsibility of the cu-
stomer.
Proceed with the installation of the robot as follows:
a. Clean the base of the robot.
b. Transport the robot to its installation site, then carefully position it on the centering plate so that it is
level. When lowering it, precentre and centre the bushings on the fixed base of the robot with the
pins of the robot attachment base.
c. Tighten the robot securing screws on the fixed base.
d. Remove the two blocking brackets (A) secured with two TCEI M10x20 screws and two split wa-
shers 10x20x2, with as shown in the following figure.

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TRANSPORT AND INSTALLATION SMART S4

The “joint position” with the robot in trasport position is the following:

. axis 1: 0°;

. axis 2: -30°;

. axis 3: -150°;

. axis 4: -90°;

. axis 5: -90°;

. axis 6: 0°.

ASSEMBLY USING ROBOT CENTERING PLATE

An optional steel plate is available on which the 3 threaded holes and the 2 holes per pin for correct robot
fastening are machined. To fasten the plate to the floor, use 4 Rawlplugs or chemical bolts. The condi-
tions which guarantee interchangeability are provided.
The recommended components are indicated in the table below:

Static safety load (kN) in con- Hole

Rawlplug Reference Code crete 30 N/mm2 diameter
COMAU
Code
Tension Shear (mm)

Mechanical M12 25L 44-160 9.7 12.4 20 00312605

Chimical R-CAS 00312692
capsule and 12/M12 13.4 7.5 14 (1)
stud M12 x 160 60-460 00312687

(1) When using chemical bolts the concrete floor can be drilled directly through the existing 14 mm diam. holes.

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SMART S4 TRANSPORT AND INSTALLATION

A. Blocking Bracket

Position of the Blocking Brackets

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TRANSPORT AND INSTALLATION SMART S4

CONNECTING UP THE PNEUMATIC AND ELECTRICAL SUPPLIES

To connect up the robot’s internal line to the compressed air distribution network, attach the external
compressed air supply tube to the 3/8" gas union located on the robot distribution signal assembly (loca-
ted wiht X1 and X2 connectors). The outlet of the robot’s internal air tube is located on the top of the fo-
rearm where there is 3/8" gas union.

NOTE: the unions terminate with a cap which should only be removed if the pneumatic line is
used.
Two electrical connectors are provided on the forearm upper part, near the pneumatic connection: X91
for optional services and X92 for safety flange connection. All signals available on their pins are sent to
the X1 connector in the distribution signals unit from where they are input to the control system through
the service/resolver cable.

1. X91 connector
2. X92 connector
3. Compressed air outlet
4. X1 connector
5. Compressed air inlet
6. Earth point
7. X2 connector

Connections for the Pneumatic and Electrical Supplies

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SMART S4 TRANSPORT AND INSTALLATION

INSTRUCTIONS FOR INSTALLING ROBOT/CONTROL

CONNECTION CABLES

LAYING CABLES IN RACEWAYS

- Install cable raceways bearing in mind minimum curvature radii (minimum 10 times cable diame-
ter).

- Avoid curves with angles of 90°.

- Before installing check the layout of connector polarization and do not rotate cables by 180° to
adapt these to their counterparts.

- In robots mounted on raised supports, cable supports must never be installed in the vicinity of con-
nectors. These must be placed at a minimum distance of approximately 600 mm from connector
glands.

- In floor-mounted robots, raceways must never be placed in the vicinity of the robot distribution box
and there must be sufficient space to allow connectors to be connected and disconnected correctly.

- When installing cables take care not to allow cable sheathing to come into contact with sharp edges,
as this could damage the sheath; protect the sharp edges of the end of raceways to prevent damage to
sheathing.

CONNECTIONS TO THE ROBOT

- Make sure that the polarizations on the cable connector and relative counterpart correspond.
- When making connections, keep the mobile connector on the cable parallel to the fixed connector to
which this is to be connected.

- Avoid axial and/or lateral movements when making the connections between connectors in order to
avoid damage to polarizations and contacts.

- The polarizations on both connections must be used to guide connector coupling

- The two levers on the fixed connector must only be used to check the mechanical tightness of the
connection and not to make connection easier.

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TRANSPORT AND INSTALLATION SMART S4

INSTALLING SAFETY DEVICES

In order to ensure the safety of the operator during the work cycle of the robot system, it is necessary to
install the robot inside an enclosure which is connected to the cell controller safety circuits by means of
electrical devices (microswitches and safety catches on the gates and additional emergency push-but-
tons).

NOTE: An example of these connections is supplied in the cell controller Circuit Diagrams.
Before installing the enclosure it is necessary to know the robot’s work envelope, including the tools
mounted on the flange, and to take into account the following spaces:

- maximum space: this is the space which can be crossed by the robot’s moving parts, as defined by
COMAU, plus the space which can be crossed by the end device and the work piece.

- restricted space: this is the portion of the maximum space which has been reduced by means of li-
mitation devices (for example software limit switch) which determine the limits which cannot be
exceeded during the normal work cycle or in the event of a break down in the robot system;

- protected space: this is the space delineated by the protection devices.

NOTE: The minimum distance advisable for the installation of the safety enclosure is about 1 m
from the maximum space.

Example of Restricted Space, Maximum Space and Protected Space

WARNING
F The cell controller must be installed outside the safety enclosure.

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SMART S4 TRANSPORT AND INSTALLATION

OPERATOR’S POSITIONS

WARNING
F When the control system is powered, safety devices MUST be connected and working pro-
perly.

The area in which the operator MUST be depends on the operations to be performed and on the cell con-
trol status:

- When the control system is in the HOLD state, DO NOT approach the robot operating area since
HOLD

any pressure of the key and then the key will start the cycle with the consequent
movement of the robot.

- During calibration and programming operations, the operator can enter the protected area ONLY
IF he has the programming terminal.

- During robot maintenance operations the operator can enter the protected area ONLY IF the cell
controller is powered off.

- Control system maintenance operations MUST BE performed with the power grid cable di-
sconnected.

RPT MODULE BATTERY CONNECTION (OPTION FOR REL .1. X

AND 2.X)

The RPT module (option for release 1.X and 2.X and not installed in release 3.X) contains a back-up
battery, which is used to supply the module when there is a failure in the grid power supply so that the
absolute position of the robot is retained.

WARNING
F The battery must be connected while the cell controller and the robot are power supplied:
proceed with the greatest care in order to avoid short-circuit caused by not insulated equip-
ment or human contact.

- The robot may move if the keys on the programming terminal are pressed accidentally.

- The back-up battery must be connected in the way described below:

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TRANSPORT AND INSTALLATION SMART S4

- check that all the wiring has been carried out correctly;
- switch on the cell controller by moving the main circuit breaker into the ON position;
- find the switch (S1 BATTERY) located on the front of the distribution assy, under a protection;
- switch on the battery by moving the switch to ON;
- switch off the cell controller s by moving the main circuit breaker into the OFF position.

RPT Battery Switch Location

CAUTION
F The RPT module (option for release 1.X and 2.X and not installed in release 3.X) back-up
battery can retain data for 600 consecutive hours when there is no power supply. If the con-
trol system has to be switched off for more than 25 days, save the data which is safeguarded
by the back-up battery (as described in the following paragraphs), then disconnect the bat-
tery, to prevent it going flat. Batteries MUST be replaced after 3 years of operation.

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 INSTALLATION OF OPTIONAL DEVICES

INSTALLATION OF OPTIONAL DEVICES

LIMIT STOPS DESCRIPTION

This booklet described the standard and optional mechanical limit stops and the electrical limit switches
shown in the following figure.

STANDARD MECHANICAL LIMIT STOPS

The standard configuration robot is equipped with fixed, mechanical limit stops on all axes except for
axis 6, which has no limit stop.
The limit stop is a pad made of energy-absorbing material against which specially finished surfaces
on the robot’s moving parts strike.
The limit stops on axes 1, 3 and 5 are fixed, while the stop on axis 2 is adjustable. The stop for axis 4
is fixed and is located inside the forearm.

OPTIONAL MECHANICAL LIMIT STOPS

Optional adjustable mechanical stops are available for axes 1 and 3 to limit the run of these axes.

OPTIONAL ELECTRICAL LIMIT SWITCHES

These are available for axes 1, 2 and 3.

These limit switches consist of a pair of microswitches mounted on the fixed part of the relevant axis.
They are activated by strikers on the rotary part, which constitute the mechanical stops (fixed or
adjustable, if present).
If axis 1 (8) has no adjustable mechanical stops, the cam consists of a pin (9) to be inserted in the seat
made in the axis 1 reducer.

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INSTALLATION OF OPTIONAL DEVICES

1. Axis 5 - stationary mechanical

2. Axis 4 - mechanical (internal)
3. Axis 3 - adjustable mechanical
4. Axis 3 - stationary mechanical
5. Axis 3 - electrical
6. Axis 2 - adjustable mechanical
7. Axis 2 - electrical
8. Axis 1 - electrical
9. Axis 1 - electrical pin
10. Axis 1 - stationary mechanical
11. Axis 1 - adjustable mechanical

Limit Stops Location

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 INSTALLATION OF OPTIONAL DEVICES

LIMIT STOPS ADJUSTMENT

ELECTRICAL LIMIT SWITCHES

AXIS 1 (see figure Adjustment of Axis 1 Limit Switch): if electrical limit switches as well as
mechanical limit stops (3) are present, adjust the screws (2) so that during rotation of axis 1 the
microswitch button is operated without being damaged.
If electrical limit switches are present, they are operated by a pin (see figure Limit Stops Location, item
9).
reference dimension A = 163 mm

1. Microswitch
2. Adjustment screw
3. Axis 1 mechanical limit stop

Adjustment of Axis 1 Limit Switch

MECHANICAL LIMIT STOPS

AXIS 1 (see figure Adjustment of Axis 1 Limit Switch): mount strikers (3) in their seats at intervals
of 22°30’ for both right and left rotation.

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INSTALLATION OF OPTIONAL DEVICES

AXIS 2 (see figure Adjustment of Axis 2 Mechanical Stop): the movement of the axis can be stopped
by moving pad (1) to the alternative seat provided (2).

1. Pad
2. Seat

Adjustment of Axis 2 Mechanical Stop

AXIS 3 (see figure Adjustment of Axis 3 Mechanical Stop): the movement of the axis can be stopped
by inserting an optional pad (1) in seat (2) on the arm.

1. Optional pad
2. Seat

Adjustment of Axis 3 Mechanical Stop

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 CHAPTER 3
ROBOT I/O

Installation of the system without the machine line and

a description of all the I/O signals of the robot.

The following chapter is composed by:

BOOKLET REVISION TOTAL

PAGES

SMART S4 INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . 00/1096 1

JUMPERS ON SMART S4 . . . . . . . . . . . . . . . . . . . . . . . . . 00/1096 1

This page has been left intentionally blank
 SMART S4 INPUTS/OUTPUTS

SMART S4 INPUTS/OUTPUTS

Each robot is fitted with connectors to which the user can connect equipment. The SMART S4 robot
has the connectors X92 and X91. Their pin-outs are shown below.
Connector X92 Signal Assignment
PIN
SIGNAL
X92
1 Safety flange Output
2 0 V (+24 Vdc)
3 Safety flange Input

☞ to connect the safety flange to the microswitch, use pins 1 and 3;

☞ to connect the magnetic safety flange use pins 1, 2 and 3;
☞ if safety flange is not used, pins 1 and 3 must be connected with a jumper.
Connector X91 Signal Assignment
PIN
SIGNAL
X91
A +24 VDC
B 0 VDC
C User available wire 15
D User available wire 16
E User available wire 17
F User available wire 18
G User available wire 1
H User available wire 2
J HIGH SPEED INPUT+
K HIGH SPEED INPUT-
L User available wire 6
M User available wire 24
N User available wire 7
P User available wire 20
R User available wire 3
S User available wire 4

The pins T, U and V of the connector X91 are not used.

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SMART S4 INPUTS/OUTPUTS

CAUTION
☞ The information relating to:
✎ CONTROL SYSTEM INPUTS/OUTPUTS
is to be found in the Control System User Manual.

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 CHAPTER 4
CALIBRATION

Calibration procedures which can be carried out using

the control system.

The following chapter is composed by:

BOOKLET REVISION TOTAL

PAGES

SMART S4 CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . 03/0400 8

This page has been left intentionally blank
 SMART S4 CALIBRATION

SMART S4 CALIBRATION

The SMART S4 robots are calibrated at the COMAU factory after assembly. Reference indices are
installed on the six axes.

CAUTION
☞ For most applications, these indices bring the robot to its zero position with a sufficient
degree of accuracy; if, however, the robot has to be calibrated or reset after disassembly
that alters the robot’s geometry, use the special tools.

NOTES: For both global calibration and for calibration of individual axes, the axes must be
calibrated in increasing numeric order (Axis 1, Axis 2, Axis 3, ...) without varying the
position reached axis after axis.
The procedure that follows is only to be performed if the controller system software
version is a release prior to 5.0X. For software versions from 5.0X onwards only the
CAC command is necessary and the saving of the ASCII calibration file for the user
backup.
In the case of new calibration, it is necessary to save the new calibration data in the RPT
module (option for release 1.X and 2.X and not installed in release 3.X) and in file
C3G.SYS and then update the file containing the calibration data on system disk
1/3, using programme CAL_TP. Follow the "CREA-TION OF FILE CONTAINING
CALIBRATION DATA" procedure given in the Cell Controller Operations and
Maintenance Manual.

PRELIMINARY OPERATIONS

CAUTION
☞ The calibration of all the robot axes, with the exception of the axis 1, has to be executed
without the application of loads

a. Activate the PROGRAMMING operating mode on the control system by means of the state
selector.
b. Extract the programming terminal from its seat, press continously the Enabling push-button in
intermediate position and then press the DRIVE ON key for the insertion of the driving units

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SMART S4 CALIBRATION

CALIBRATION PERFORMED BY MEANS OF INDICES

CAUTION
☞ It allows the check of the calibration position with a limited precision. But such a precision
is sufficient for the normal applications and for the TURN-SET operations.

NOTE: All the commands given from the keyboard must be confirmed by pressing the
ENTER

key. Some of them require further confirmation from the operator, on being
asked ARE YOU SURE?; in these cases Y (Yes) must be entered and confirmed with
ENTER

the key.
a. Move the robot axes in sequence until the calibration indices correspond.
b. By means of the DAR (Display Arm Resolver) command, display, on the terminal, the axis
position and only when the value is quite stable (usually it is necessary to wait for some seconds),
execute the following procedure:
✎ Select the command CAC (Configure Arm Calibrate) on the programming terminal key-
board.
ENTER

✎ Select the arm to be calibrated and confirm with .

ENTER

✎ Select the axis in question and confirm with . (By entering * all the axes are selected).

CAUTION
☞ At the end of the calibration operations, the user can, by means of the CAV (Configure
Arm View Call), detect the value of the resolver axis dimension and update the machine
board
☞ Steps c. and d. of the procedure are only to be performed when the controller system
software version is prior to 5.0X.

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 SMART S4 CALIBRATION

c. Store the calibration data in the RPT ( optional for release 1.X and 2.X and not installed in release
3.x) 1.module by proceeding as follows:
✎ Select the command CARS on the programming terminal keyboard.
ENTER

✎ Select the Servo module in question and confirm with (an operation which only needs
to be performed if more that one robot is handled by a single control system).
d. Store the calibration data in the C3G.SYS file, proceeding as follows:

✎ Deactivate the drives by pressing the DRIVE

OFF
key.
✎ Select the command CS on the programming terminal keyboard.

1. Axis 1 calibration indice

2. Axis 2 calibration indice
3. Axis 3 calibration indice
4. Axis 4 calibration indice
5. Axis 5 calibration indice
6. Axis 6 calibration indice

Calibration indice

Position of Calibration Indices

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SMART S4 CALIBRATION

CALIBRATION PERFORMED BY MEANS OF TOOLS

NOTE: The calibration using tools is executed in the case of mechanical dismounting actions
that change the robot geometry or if it is necessary to execute a specific check of the
calibration position.
All the axes of the robot are provided by precision mechanical machining to allow calibration level
bubble (No. 81.7267.00) tool and dial gauge support tool (81.9091.00).
Accurately clean the housing calibration axes (A, B, C, D, E and F) shown in the Axes Calibration
Robot .
Axes positioning
The releasing of the enabling push-button placed on the programming terminal (DRIVE OFF) can
cause light movements of the axes caused by the gravity of the applied masses. Such movements are
highly pointed out if the DRIVE ON / OFF functions are quickly executed.
The system automatically recovers such movements moving the axes on their correct calibration
position if they have already been calibrated.

CAUTION
☞ During the calibration procedure, limit at the minimum value the number of the driving
unit activation /deactivation actions (DRIVE ON / DRIVE OFF) in such a way to prevent
some possible light movements of the axes.

The new positioning of the axes can be checked on the programming terminal detecting the joint
dimensions by means of the Dispay - Arm - Joint ( F2; F1; F4) commands.

CAUTION
☞ After each DRIVE ON of the system, check on the programming terminal that the axes
return on their calibration position.
It the axes do not return on the correct positions it is necessary to re-start the calibration
procedure from the beginning.

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 SMART S4 CALIBRATION

Calibration of all the axes

CAUTION
☞ Proceed with calibration using tools following the axis 1, 2, 3, 4, 5, and 6 sequence without
changing the position of the single axes after calibration.

✎ Move the robot axes on the calibration notches with the maximum allowable visual precision.
1 6

✎ By means of the manual movement keys - + to - +

move the robot on to the
indices;
✎ Execute the calibration by means of the CAC command (refer to the paragraph Calibration
using Indexes).
Single axis calibration
a. Move on the exact calibration position the axes that affect the final position of the axis that is being
calibrated. Such axes are pointed out with the character X into the following table.

AXES AXES REQUESTED ON CALIBRATION POSITION

1 2 3 4 5 6
Axis 1 - - - - - -
Axis 2 - - - - - -
Axis 3 - X - - - -
Axis 4 - - - - - -
Axis 5 - X X - - -
Axis 6 - - - X - -

b. Execute the calibration of the single axis by means of the CAC command (refer to the paragraph
Calibration using Indexes)

NOTA Example: If it has to be calibrated the axis 5, move the axes 2 and 3 on their exact
calibration positions.
All commands entered on the keyboard must be confirmed with the ENTER key. Some of these
commands request further confirmation by the operator displaying the Are you sure? prompt. In these
cases, enter Y (yes) and confirm with ENTER.

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SMART S4 CALIBRATION

AXIS 1
a. Using the teach pendant, position the column of the robot so that the axis 1 mobile reference index
coincides with the fixed index.
b. Fasten the dial gauge holder in the housing provided on the column
c. Preload the rod of the dial gauge by few millimeters and rotate axis 1, at slow speed, from the
negative to the positive direction, until the minimum point on the index of the dial gauge is
reached
45 0 45 0

40 5 40 5

35 10 35 10

30

25 20
15
MINIMUM POINT 30

25 20
15

45 0

40 5

35 10

- + 30

25 20
15
- +

AXIS ROTOTION DIRECTION

CAUTION
☞ If the minimum point has been exceeded, it is necessary to return on the beginning position
and to repeat the detection moving the robot axis from the negative direction to the positive
one in such a way to recover the possible mechanic backlash of the axis

c. Calibrate axis 1 according to the procedures described in the Calibration using indexes paragraph
from step b.
d. If the fixed and mobile index do not coincide, correct the position of the mobile index until it
matches. Tighten the lock screws and seal them.
AXIS 2
a. Position the level holder tool on the machined surface on the base in the lengthwise direction (L);
then adjust it until the level bubble is centred to compensate for any inclination in the robot’s base.
b. Move the level holder tool, for axis 2 calibration on the machined surface on the arm (B), and fix
it with M6x15 fixing screws.

NOTE: When performing these operations, do not alter the position of the calibration tool
assumed in step a, and do not turn it 180°.
c. Use the programming teminal to move the axis being calibrated until the level bubble is centred.
d. Calibrate the axis in accordance with the procedures described in the paragraph entitled: "Calibra-
tion Performed by means of Indices", steps b.

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 SMART S4 CALIBRATION

AXIS 3
a. Move the level holder tool on the machined surface of the wrist body (C) and fix it with M6x15
fixing screws.

NOTE: When performing these operations, do not alter the position of the calibration tool
assumed in step a, and do not turn it 180°.
b. Use the programming teminal to move the axis being calibrated until the level bubble is centred.
c. Calibrate the axis in accordance with the procedures described in the paragraph entitled: "Calibra-
tion Performed by means of Indices", steps b.

AXIS 4
^C
a. Activate the character menu by pressing the CHAR key on the programming terminal keyboard
and then write MOVE ARM TO [1] {0, 0, -90, 90, 0, 0} and confirm the command by pressing the
ENTER

key;
b. Position the level holder tool on the machined surface in the robot’s base in the crosswise direction
(T); then adjust it until the bubble is centred to compensate for any inclination in the robot’s base.
c. Move the level holder tool on the machined surface on the forearm front part (D) and fix it with
the M6x15 fixing screws.

NOTE: When performing these operations, do not alter the position of the calibration tool
assumed in step a, and do not turn it 180°.
d. Use the programming teminal to move the axis being calibrated until the level bubble is centred.
e. Calibrate the axis in accordance with the procedures described in the paragraph entitled: "Calibra-
tion Performed by means of Indices", steps b.

AXIS 5
a. Position the level holder tool on the machined surface on the base in the lengthwise direction (L)
and rotate it by 180° with respect to its previous longitudinal position; adjust it until the level bubble
is centred to compensate for any inclination in the robot’s base.
TOP
b. Press the key to return to the main menu.
F3
c. Press the key to activate the EXEC (Execute) command.
d. Bring axis 4 to 0° position as described below:
^C
✎ activate the character menu by pressing the key on the programming terminal keyboard
CHAR

and then write MOVE ARM TO [1] {0, 0, -90, 0, 0, 0} and confirm the command by pressing
ENTER

the key;
START

✎ keep the key and the HOLD TO RUN CONTROL DEVICE button pressed to move
the robot to the required position.

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SMART S4 CALIBRATION

6
e. Press the - +
key for manual movement and keep the HOLD TO RUN CONTROL
DEVICE button pressed: rotate axis 6 until the two holes for the calibration level pins on the tool
mounting flange are vertically aligned.
f. Move the level holder tool on the tool mounting flange (E) and fix it with the M6x15 fixing screws.
g. Use the programming teminal to move the axis 5 until the level bubble is centred.
h. Calibrate axis 5 in accordance with the procedures described i the paragraph entitled: "Calibration
Performed by means of Indices", steps b.
AXIS 6
a. Position the level holder tool on the machined surface in the robot’s base in the crosswise direction
(T); then adjust it until the bubble is centred to compensate for any inclination in the robot’s base.
b. Insert the two pins into the calibration level holes on the tool mounting flange;
c. Move level holder tool on to the two pins (F).

NOTE: When performing these operations, do not alter the position of the calibration tool
assumed in step a, and do not turn it 180°.
d. Use the programming teminal to move the axis being calibrated until the level bubble is centred.
e. Calibrate the axis in accordance with the procedures described in the paragraph entitled: "Calibra-
tion Performed by means of Indices", steps b.

NOTE: Mount the calibration indices if they have been involved in robot disassembly.

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03/0400
 SMART S4 CALIBRATION

AXIS 3

AXIS 4

AXIS 1

AXIS 5

AXIS 2 AXIS 6

Axes Calibration Robot

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SMART S4 CALIBRATION

This has been intentionally blank

10
03/0400
 CHAPTER 5
PREVENTIVE MAINTENANCE

Periodic operations to be performed in order to keep

the robot in working order.

The following chapter is composed by:

BOOKLET REVISION TOTAL

PAGES

SMART S4 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . 05/0103 6

This page has been left intentionally blank
 SMART S4 PREVENTIVE MAINTENANCE

SMART S4 PREVENTIVE MAINTENANCE

WARNING
☞ Before carrying out any operation, carefully read the Safety Regulations listed at the
beginning of this manual.
☞ Maintenance operations on the robot and on the system must be carried when the system
is off: the main circuit breaker MUST be in the OFF position.

LUBRICATION
This paragraph describes the preventive maintenance operations necessary to keep the robot in perfect
working order.
A general lubrication and mechanical check must be carried out after the first 150 hours of robot
operation. This check must be carried out on the Manufacturer’s premises after the initial running-in.
Subsequent interventions must be carried out by the Customer at the prescribed intervals.
The following figures show the lubrication points, marked with appropriate symbols, and the position
of the lubricant top-up/drainage plugs; the quantity of lubricant needed and the prescribed intervals are
listed in table form.

NOTE: If the robot is used for light work cycles, maintenance can be carried out at greater
intervals than those specified in this chapter.

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SMART S4 PREVENTIVE MAINTENANCE

Lubrication
Ref.
Lubrication points Interval (h) Quantity Symbol
•
1 Axis 1 reducer 10000 3.5 kg
2 Axis 2 reducer 10000 3.5 kg
3 Axis 3 reducer 10000 1.75 kg
4 Axis 4 reducer 10000 0.6 kg
5 Axes 5 and 6 reducer 10000 0.6 kg

• Refer to the figure illustrating the Lubrication Points

Lubrication Points

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 SMART S4 PREVENTIVE MAINTENANCE

Recommended Lubricants
Symbol Class ISO FUCHS SHELL KLUBER ELF
Oil Renep Omala Lamora Reductelf
Compound 108 320 320 320

CAUTION
☞ These lubricants cannot be mixed together.

1. Axis 1 top-up
2. Axis 1 drainage
3. Axis 2 top-up
4. Axis 2 drainage
5. Axis 3 top-up
6. Axis 3 drainage
7. Axis 4 top-up
8. Axis 4 drainage
9. Axis 5 and 6 top-up/drainage

Position of the Lubricant Top-up/Drainage Plugs

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SMART S4 PREVENTIVE MAINTENANCE

LUBRICANT TOPPING-UP

Lubrication of mechanical components is necessary every 10000 hours of operation or after a partial
drainage of the lubricant following mechanical interventions. The Lubrication table gives the prescri-
bed quantities of lubricant.
Refer to the "Position of the Lubricant Top-up/Drainage Plugs" figure for the necessary lubricating
procedures.

NOTE: Apply a layer of LOCTITE 572 to the threads before screwing the lubricant fill/drain
plugs back in.
To top up the lubricants proceed as follows:

AXIS 1
a. Position axis 2 so as to insert the funnel on the robot’s base.
b. Undo the plug on top-up hole (1).
c. Undo the plug on drainage hole (2) and drain the oil.
d. Then screw the plug back into the drainage hole and pour the prescribed quantity of oil into the
top-up hole using a funnel provided with an air breather hole.
e. Screw the plug back into the top-up hole.

AXES 2, 3 AND 4
a. Position the axes so as to bring the drainage hole to a lower position with respect to the robot’s
base and drain the lubricant.
b. Separately lubricate axes 2, 3 and 4.
c. Undo the plug on top-up hole (3) for axis 2, (5) for axis 3 or (7) for axis 4.
d. Undo the plug on drainage hole (4) for axis 2, (6) for axis 3 or (8) for axis 4 and drain the oil.
e. Screw the plugs back into the drainage holes.
f. Position the axes so as to bring the top-up hole to a higher position with respect to the robot’s base
and pour the prescribed quantity of oil into the top-up hole for axis 2, axis 3 or axis 4; use a pipe
with an air breather hole.
g. Screw the plug back into top-up hole for axis 2, axis 3 or axis 4.

AXES 5 AND 6
a. Position axis 5 so as to bring top-up/drainage hole (9) to a higher or a lower position with respect
to the robot’s base, according to the operation to be performed.
b. Bring the top-up/drainage hole to the lowest position, undo the plug on the hole and drain the oil.
Rotate axis 5 so as to bring the hole to the highest position and top up with the prescribed quantity
of oil.
c. Screw the plug back into the top-up/drainage hole.

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SMART S4 PREVENTIVE MAINTENANCE

RPT MODULE BACK-UP BATTERY REPLACEMENT (OPTION FOR

REL 1.X / 2.X)
The RPT module (option for release 1.X and 2.X and not installed in release 3.X) back-up battery
MUST be replaced after three years.

EXTRAORDINARY MAINTENANCE
All extraordinary maintenance operations that can be carried out on the SMART S4 robot are described
in the SMART S4 Manuale di Manutenzione/Maintenance Manual.

GENERAL REQUIREMENTS FOR CLEANING ROBOTS

The robot is designed to operate in heavy-duty cycles without requiring any special maintenance opera-
tions: inspect robot parts regularly to make sure that they have not been damaged and clean parts that are
most exposed to wear and tear in connection with the specific robot application.
In case of welding applications, the robot flange, the electrical connectors installed on the flange and
any other parts that are exposed to weld sparks must be cleaned regularly: do not allow dirt and scale to
build up, as this could undermine removal and disassembly.
Depending on the specific operating requirements, the outer surface of the robot can be cleaned, provi-
ded special care is taken when cleaning machined surfaces and data plates: avoid the use of particularly
aggressive solvents that could damage seals, wiring, paintwork and data plates.
If compressed air or pressurized water are used, do not direct the jet onto fulcrums, bearings and seals,
as this could undermine correct lubrication.
Remember that the robot’s protection index is only guaranteed with the robot fully assembled and all
guards installed correctly.

DISPOSAL OF PARTS
All used grease/oils and dead batteries MUST be disposed of in accordance with the current legislation
of the country in which the robot and the control unit have been installed.
If the robot or the control unit is partially or completely disposed of, the various parts MUST be grou-
ped together according to their nature (e.g. all iron together and all plastic together), and disposed of ac-
cordingly. These parts MUST also be disposed of in accordance with the current legislation of the
country in which the robot and control unit have been installed.

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PREVENTIVE MAINTENANCE SMART S4

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 APPENDIX A
WIRING DIAGRAMS
The wiring diagrams for the standard configuration of SMART S4 robot are an enclosure of this manual,
for any other configurations/options installed refer to the specific documentation and wiring diagrams.

APPENDIX B
ERROR CODES
For CAUSES and REMEDIES of error codes, refer to the control unit Use and Maintenance manual.
This page has been left intentionally blank
 APPENDIX C
TECHNICAL FEATURES

Technical features of the robot.

The following chapter is composed by:

BOOKLET REVISION TOTAL

PAGES

TECHNICAL FEATURES OF THE ROBOT . . . . . . . . . . . . . . . 02/0498 10

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 SMART S4

SMART S4

CARATTERISTICHE TECNICHE
TECHNICAL FEATURES

02/0400
SMART S4

CARATTERISTICHE GENERALI GENERAL FEATURES

Numero assi 6 Number of axes

Asse 1 ± 152,5° (160°/s) Axis 1
Asse 2 + 105° - 78° (115°/s) Axis 2
Corsa Stroke
(Velocità) Asse 3 + 125° - 155° (180°/s) Axis 3 (Speed)
Asse 4 ± 210° (280°/s) Axis 4
Asse 5 ± 125° (280°/s) Axis 5
Asse 6 ± 2700° (290°/s) Axis 6
Velocità in controllo di traiettoria 1,5 m/s Speed in trajectory control
1455 mm Orizzontale / Horizontal
Sbraccio max. Max. reach
2205 mm Verticale / Vertical
Ripetibilità ± 0,10 mm Repeatability
Carico max. al polso (1) 147,1 N (15 kg) Max. load on wrist (1)
Carico max. complessivo (2) 245,2 N (25 kg) Max. total load (2)
Asse 4 29,4 Nm (3 kgm) Axis 4
Coppia statica max. Asse 5 29,4 Nm (3 kgm) Axis 5 Max. static torque

Asse 6 19,6 Nm (2 kgm) Axis 6

Sistema di misura della posizione
Potenza totale installata
Alimentazione aria compressa
Condizioni ambientali
Peso
Finecorsa software
Finecorsa elettrici opzionali
Finecorsa meccanici standard
Finecorsa meccanici opzionali
Grado di protezione
Rumorosità nel ciclo campione
Posizione di montaggio
Assoluto con resolver / Absolute with resolver Position measurement system
C3G-901 3,8 kVA C3G-901
On board total power supply
C3G Plus 7 kVA C3G Plus
Solo per servizi opzionali / Only for optional services Compressed air supply
0° ÷ 45° C Op. temp. range
4169 N (425 kg) Robot weight
Standard e programmabili su tutti gli assi
Software limits
Standard and programmable on all the axes
Assi 1, 2 e 3 regolabili in funzione dei limiti definiti dai
finecorsa meccanici
Optional limit switches
Axes 1, 2 and 3 adjustable according to the limits established by the
mechanical stops
Assi 1, 3, 4 e 5 fissi / Axes 1, 3, 4 and 5 stationary
Asse 2 regolabile, riduzione corsa a -30° (corsa risultante +105° -30°) Standard mechanical stops
Axis 2 adjustable, stroke limitation at -30° (resulting stroke +105° -30°)
Asse 1 regolabile ogni 22,5° / Axis 1 adjustable every 22.5°
Asse 3 regolabile, riduzione corsa a + 22° (corsa risultante +22° -155°) Optional mechanical stops
Axis 3 adjustable, stroke limitation at +22° (resulting stroke +22° -155°)
IP 65 corpo polso / Wrist body
Protection degree
IP 54 robot
Livello equivalente medio inferiore a 70 dB (A)
Noise during test cycle
Equivalent average level lower than 70 dB (A)
A pavimento oppure a soffitto / Floor or overhead Assembly position

(1) Vedere figura Capacità di Carico sul Polso (Assi 5 e 6) / See figure Loading Capacity on Wrist (Axes 5 and 6).
(2) Vedere i limiti di applicazione del carico nella figura Distribuzione Carichi / See load application limits in figure Load Distribution.

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 VOLUME DI LAVORO ED INGOMBRO ROBOT / ROBOT WORK ENVELOPE AND OVERALL DIMENSION

02/0400
SMART S4

Unità di misura / Unit : mm

3
SMART S4
DETERMINAZIONE DEL CARICO MAX. ALLA
FLANGIA DI ATTACCO ATTREZZI (QF)
Il seguente diagramma riporta le curve di carico max QF
applicabile alla flangia di attacco attrezzi in funzione di
Ly e Lz definite nelle figure seguenti. Tutti i punti compresi
nell’area sottesa alle curve rappresentano le distanze Ly
e Lz baricentriche ammesse per il carico corrispondente
a ciascuna curva.
Esempio: con baricentro del carico P posto a
Lz = 100 mm
Ly = 150 mm
risulta un carico max. alla flangia QF = 88,27 N (9 kg).
DETERMINAZIONE DI Ly E Lz CON BARICENTRO
DEL CARICO P SUL PIANO ASSE 6
• Ly = Distanza baricentro carico P dall’asse flangia
• Lz = Distanza baricentro carico P dall’asse 6
DETERMINAZIONE DI Ly E Lz CON BARICENTRO
DEL CARICO P FUORI DAL PIANO ASSI 5 E 6
• Ly = L1 - L2 in cui:
L1 = Distanza baricentro carico P dall’asse 5
L2 = Distanza tra asse 5 e asse flangia
• Lz = Distanza baricentro carico P dall’asse 6
4 02/0400
DEFINITION OF MAX LOAD ON THE TOOL
MOUNTING FLANGE (QF)
The following diagram shows the curves of the max. load
QF that can be applied to the tool mounting flange. This
load depends on Ly and Lz defined in the figures. All
points within two curves represent the Ly and Lz dis-
tances of the centre of gravity allowed for the load
corresponding to each curve.
Example: with centre of gravity of load P at
Lz = 100 mm
Ly = 150 mm
max. load QF allowed on flange = 88.27 N (9 kg).
DEFINITION OF Ly AND Lz WITH CENTRE OF GRAV-
ITY OF LOAD P ON AXIS 5 PLANE
• Ly = Distance of centre of gravity of load P from flange axis
• Lz = Distance of centre of gravity of load P from axis 6
DEFINITION OF Ly AND Lz WITH CENTRE OF GRAVITY
OF LOAD P OUTSIDE THE AXIS 5 AND AXIS 6 PLANE
• Ly = L1 - L2 where:
L1 = Distance of centre of gravity of load P from axis 5
L1 = Distance between axis 5 and flange axis
• Lz = Distance of centre of gravity of load P from axis 6
 SMART S4

CAPACITÀ DI CARICO SUL POLSO (ASSI 5 E 6)

LOADING CAPACITY ON WRIST (AXES 5 AND 6)

Coppie statiche massime: Max. static torques:

Asse 5 = 3 kg * m Axis 5 = 3 kg * m
Asse 6 = 2 kg * m Axis 6 = 2 kg * m

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SMART S4

DISTRIBUZIONE CARICHI / LOAD DISTRIBUTION

Carico al Polso N (kg) ≤ 147 (15) ≤ 98 (10)

Load on Wrist N (kg)
Carico Supplementare N (kg) ≤ 98 (10) ≤ 147 (15)
Additional Load N (kg)
Area Posizione Baricentro
Carico Supplementare
Additional Load Centre of
Gravity Position Area

ATTENZIONE WARNING
Il massimo carico al polso 147 N (15 kg) ed il massimo The maximum load on wrist 147 N (15 kg) and the
carico supplementare 147 N (15 kg) NON DEVONO maximum additional load 147 N (15 kg) MUST NOT BE
coesistere. applied together.

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 SMART S4

FLANGIA ATTACCO ATTREZZI (ISO 9409-1-A63) / TOOL MOUNTING FLANGE (ISO 9409-1-A63)

Unità di misura / Unit : mm

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SMART S4

BASE E PIASTRA CENTRAGGIO ROBOT / ROBOT BASE AND CENTERING PLATE

n°3 M 12X 35 n°2 Ø 12x40 (H7/m6)

Frontale Robot / Robot Front Side

Unità di misura / Unit : mm

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 SMART S4

SOLLECITAZIONI TRASMESSE AL PAVIMENTO

STRESS TRANSMITTED TO THE FLOOR

Fv ≡ 5300 N
Fo ≡ 2000 N
Mr ≡ 1500 Nm
Mk ≡ 3800 Nm

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SMART S4

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 APPENDIX D
SPARE PARTS LIST

SMART S4 robot spare parts list.

The following chapter is composed by:

BOOKLET REVISION TOTAL

PAGES

SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04/0302 2

This page has been left intentionally blank
 SPARE PARTS LIST

SPARE PARTS LIST

GENERAL
The following table lists the spare parts, in alphanumeric order, relating to the SMART S4 robot; the
following information are given:
☞ The CODE column contains the identity code of the components.
☞ The DESCRIPTION column contains the names of the units and components.
☞ The Q.TY column indicates the number of units or of components.

SMART S4 REL 3.X SPARE PARTS LIST

CODE DESCRIPTION Q.TY

00460710 POSITION MICROSWITCH - (HONEYWELL) 2
18815480 ROBOT ON-BOARD DISTRIBUTION SIGNAL ASSY ( old version) 1
18815481 ROBOT ON-BOARD DISTRIBUTION SIGNAL ASSY ( new version) 1
18937881 WIRING UNIT 1
81658700 AXES 4, 5 AND 6 MOTOR, NOMINAL TORQUE 0.4 Nm 3
81658800 AXES 1, 2 AND 3 MOTOR, NOMINAL TORQUE 2.9 Nm 3
81726700 SPIRIT LEVEL CALIBRATION TOOL ASSY 1
81781400 GEAR-BUSH ASSY AXES 1, 2 AND 3 3
81784700 COMPLETE AXIS 1 REDUCER MODULE 1
81788300 COMPLETE AXES 2 AND 3 TWIN REDUCER MODULE 1
81790218 AXIS 4 GEAR 1
81790270 AXES 5-6 DRIVE BELT type GT-8MR-1600-20 - (POWER GRIP) 2
81790272 AXES 5-6 MOTION TRANSMISSION BELT type GT-3MR-360-15 - 2
(POWER GRIP)
81794300 COMPLETE FOREARM UNIT 1
81794400 COMPLETE WRIST UNIT 1
81909100 AXIS 1 CALIBRATION TOOL UNIT 1

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SPARE PARTS LIST

SMART S4 REL 1.X/2.X SPARE PARTS LIST

CODE DESCRIPTION Q.TY

00460710 POSITION MICROSWITCH - (HONEYWELL) 2
00703603 RPT MODULE BATTERY (standard for C3G, optional for C3G Plus) 1
10120160 RESOLVER POSITION TRACKER (standard for C3G, optional for C3G 1
Plus)
10129860 C3G-RPC (RESOLVER PLUG TO CONTROL, for C3G Plus) 1
18811180 ROBOT ON-BOARD DISTRIBUTION SIGNAL ASSY (whit RPT, for 1
C3G)
18811181 ROBOT ON-BOARD DISTRIBUTION SIGNAL ASSY (whit RPC, for 1
C3G Plus)
18932481 WIRING UNIT 1
81658700 AXES 4, 5 AND 6 MOTOR, NOMINAL TORQUE 0.4 Nm 3
81658800 AXES 1, 2 AND 3 MOTOR, NOMINAL TORQUE 2.9 Nm 3
81726700 SPIRIT LEVEL CALIBRATION TOOL ASSY 1
81781400 GEAR-BUSH ASSY AXES 1, 2 AND 3 3
81784700 COMPLETE AXIS 1 REDUCER MODULE 1
81788300 COMPLETE AXES 2 AND 3 TWIN REDUCER MODULE 1
81790218 AXIS 4 GEAR 1
81790270 AXES 5-6 DRIVE BELT type GT-8MR-1600-20 - (POWER GRIP) 2
81790272 AXES 5-6 MOTION TRANSMISSION BELT type GT-3MR-360-15 - 2
(POWER GRIP)
81794300 COMPLETE FOREARM UNIT 1
81794400 COMPLETE WRIST UNIT 1
81909100 AXIS 1 CALIBRATION TOOL UNIT 1

NOTE: For location of spare parts and any replacement procedures, refer to the Maintenance
Manual

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