Comau Robotics

Instruction Handbook

SMART5 NJ4 170 – 2.5 – I

SMART5 NJ4 175 – 2.2 – I

SMART5 NJ4 170 – 2.9 – I

SMART5 NJ4 220 – 2.7 – I

SMART5 NJ4 220 – 2.4 – I

SMART5 NJ4 220 – 3.0 – I
SMART5 NJ4 270 – 2.7 – I
Technical Specification

CR00757667-en_00/1110
The information contained in this manual is the property of COMAU S.p.A.

Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A.

COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation.

Copyright © 2010 by COMAU

 Summary

SUMMARY

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Symbols in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...17

Robot SMART5 NJ4 - I The family. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Robot mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Interchangeability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3. TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4. OPERATING AREAS AND ROBOT OVERALL DIMENSIONS . . . . . . . . . . . . . . . . ...27

SMART5 NJ4 170 – 2.5 - I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SMART5 NJ4 170 – 2.5 - I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SMART5 NJ4 175 – 2.2 - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SMART5 NJ4 175 – 2.2 - I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SMART5 NJ4 220 – 2.7 - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SMART5 NJ4 220 – 2.7 - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SMART5 NJ4 220 – 2.4 - I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SMART5 NJ4 220 – 2.4 - I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SMART5 NJ4 170 – 2.9 - I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SMART5 NJ4 170 – 2.9- I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SMART5 NJ4 270 – 2.7 - I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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Summary

SMART5 NJ4 270 – 2.7 - I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SMART5 NJ4 220 – 3.0 - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SMART5 NJ4 220 – 3.0 -I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5. ROBOT FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..42

Tool coupling flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6. LOADS AT WRIST AND ADDITIONAL LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..47

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Determination of max loads at wrist flange (QF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Additional loads (QS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7. PREPARATION FOR ROBOT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..61

Environment conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Environment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Operating space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Attachment to a Steel Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Steel Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Attachment to a plate with adjustable level (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Secure plate to the floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Stress on supporting structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

8. OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..72

APPLICABILITY OF OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Axis 1 work area partialization assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Axis 2 work area partialization assembly -
2 areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Axis 1 adjustable mechanical hard stop assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Axis 2 adjustable mechanical hard stop assembly (code CR82342500) . . . . . . . . . . . . . . . . . . 81
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Axis 2 adjustable mechanical hard stop assembly (code CR82344800) . . . . . . . . . . . . . . . . . . 83
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Screws and pins kit for robot mounting (code CR82342700) . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Leveling plate unit for robot mounting (code CR82342800) . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Non adjustable plate for robot mounting (code 82343100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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Fall-prevention brackets assembly for ceiling attachment (code CR82348800) . . . . . . . . . . . . 88

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
NJ ceiling mounting and fall-prevention assembly - BRIC (code CR82344700) . . . . . . . . . . . . 91
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Axis 1 adjustable mechanical hard stop assembly (code CR82273200) . . . . . . . . . . . . . . . . . . 94
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Axis 2 adjustable mechanical hard stop assembly (code CR82273300) . . . . . . . . . . . . . . . . . . 97
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Axis 1 mechanical hard stop on-off assembly (lock pin - code CR82344300 . . . . . . . . . . . . . . 98
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Axis 1 mechanical hard stop on-off assembly - lock pin (code CR82273600). . . . . . . . . . . . . 100
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Axis 1 work area partialization assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Axis 2 work area partialization assembly -
2 areas (code CR82273400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Screws and pins kit for robot mounting (code 82314700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Leveling plate unit for robot mounting
(code 82314800) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Calibration tool (code 82314100). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Gauged tool assembly L=200 mm
(code 82109501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Fork liftable option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Distribution connection guard assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Guard assembly for ventilated motor ax1
(code 82309259) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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Preface

PREFACE

Symbols in the manual

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

This symbol applies to operating procedures, technical information and

precautions that are to be complied with and/or properly performed to prevent
possible injuries.

This symbol applies to operating procedures, technical information and

precautions that are to be complied with and/or properly performed to prevent
possible equipment damages.

This symbol applies to operating procedures, technical information and

precautions that need necessarily to be highlighted.

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 Preface

Reference documents
This document refers tol robot SMART5 NJ4 - I with standard outfitting.
The composition of the complete set of manuals containing the robot system and control
documentation is indicated in the following table:

Comau Robot Set Manuali

– Technical Specifications
SMART5 NJ4 - I – Transport and Installation
– Electrical diagram
SMART5 NJ4 170 – 2.5 - I – Maintenance
SMART5 NJ4 170 – 2.9 - I
Comau
SMART5 NJ4 170 – 2.9 - I – Maintenance
SMART5 NJ4 220 – 2.4 - I
SMART5 NJ4 220 – 2.7 - I
SMART5 NJ4 220 – 3.0 - I – Maintenance
SMART5 NJ4 270 – 2.7 - I

These manuals are to be integrated with the following documents:

C5G Control Unit – Technical Specifications

– Transport and installation
– Guide to integration, safeties, I/O and
communications
– Maintenance
Comau – Use of Control Unit.
– Electrical diagram
Programming – EZ PDL2 Easy programming environment
– PDL2 Programming Language Manual
– Move programming
– VP2 Visual PDL2

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General Safety Precautions

1. GENERAL SAFETY PRECAUTIONS

It deals with a general specification that apply to the whole Robot System. Due to
ist significance, this document is referred to unreservedly in any system
instruction manual.

This specification deals with the following topics:

– Responsibilities
– Safety Precautions.

1.1 Responsibilities
– The system integrator is responsible for ensuring that the Robot System (Robot
and Control System) are 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 protection and safety devices necessary, the issuing of declarations
of conformity and any CE markings of the system are the responsibility of the
Integrator.
– COMAU Robotics & Service shall in no way be held liable for any accidents caused
by incorrect or improper use of the Robot System (Robot and Control System), by
tampering with circuits, components or software, or the use of spare parts that are
not included in the spare parts list.

– The application of these Safety Precautions is the responsibility of the persons

assigned to direct / supervise the activities indicated in the Applicability sectionally
are to make sure that the Authorised Personnel is aware of and scrupulously follow
the precautions contained in this document as well as the Safety Standards in
addition to the Safety Standards in force in the country in which it is installed.
– The non-observance of the Safety Standards could cause injuries to the operators
and damage the Robot System (Robot and Control System).

The installation shall be made by qualified installation Personnel and should

conform to all national and local codes.

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 General Safety Precautions

1.2 Safety Precautions

1.2.1 Purpose
These safety precautions are aimed to define the behaviour and rules to be observed
when performing the activities listed in the Applicability section.

1.2.2 Definitions
Robot System (Robot and Control System)
The Robot System is a functional unit consisting of Robot, Control Unit, Programming
terminal and possible options.

Protected Area
The protected area is the zone confined by the safety barriers and to be used for the
installation and operation of the robot

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

Assigned Personnel
The persons assigned to direct or supervise the activities of the workers referred to in
the paragraph above.

Installation and Putting into Service

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

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

Auto / Remote Automatic Mode

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

Maintenance and Repairs

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

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General Safety Precautions

Putting Out of Service and Dismantling

Putting out of service defines the activities involved in the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.

Integrator
The integrator is the professional expert responsible for the installation and putting into
service of the Robot and Control System.

Incorrect Use
Incorrect use is when the system is used in a manner other than that specified in the
Technical Documentation.

Range of Action
The robot range of action is the enveloping volume of the area occupied by the robot
and its fixtures during movement in space.

1.2.3 Applicability
These Specifications are to be applied when executing the following activities:
– Installation and Putting into Service;
– Programming Mode;
– Auto / Remote Automatic Mode;
– Robot axes release;
– Maintenance and Repairs;
– Putting Out of Service and Dismantling

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 General Safety Precautions

1.2.4 Operating Modes

Installation and Putting into Service
– Putting into service is only possible when the Robot and Control System has been
correctly and completely installed.
– The system installation and putting into service is exclusively the task of the
authorised personnel.
– The system installation and putting into service is only permitted inside a protected
area of an adequate size to house the robot and the fixtures it is outfitted with,
without passing beyond the safety barriers. It is also necessary to check that under
normal robot movement conditions there is no collision with parts inside the
protected area (structural columns, power supply lines, etc.) or with the barriers. If
necessary, limit the robot working areas with mechanical hard stop (see optional
assemblies).
– Any fixed robot control protections are to be located outside the protected area and
in a point where there is a full view of the robot movements.
– The robot installation area is to be as free as possible from materials that could
impede or limit visibility.
– During installation the robot and the Control Unit are to 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.
– Secure the robot to the support, with all the bolts and pins foreseen, tightened to
the torque indicated in the product Technical Documentation.
– If present, remove the fastening brackets from the axes and check that the fixing
of the robot fixture is secured correctly.
– Check that the robot guards are correctly secured and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– If applicable, connect the robot pneumatic system to the air distribution line paying
attention to set the system to the specified pressure value: a wrong setting of the
pressure system influences correct robot movement.
– Install filters on the pneumatic system to collect any condensation.
– Install the Control Unit outside the protected area: the Control Unit is not to be used
to form part of the fencing.
– Check that the voltage value of the mains is consistent with that indicated on the
plate of the Control Unit.
– Before electrically connecting the Control Unit, check that the circuit breaker on the
mains is locked in open position.

– Connection between the Control Unit and the three-phase supply mains at the
works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned
appropriately for the power installed on the Control Unit. See the product
Technical Documentation.
– The power supply cable is to enter the Control Unit through the specific fairlead and
be properly clamped.
– Connect the earth conductor (PE) then connect the power conductors to the main
switch.

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General Safety Precautions

– Connect the power supply cable, first connecting the earth conductor to the circuit
breaker on the mains line, after checking with a tester that the circuit breaker
terminals are not powered. 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.
– Check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors could cause permanent damage to the
Control Unit components.
– The C5G Control Unit manages internally the main safety interlocks (gates,
enabling pushbuttons, etc.). Connect the C5G 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
(emrgency stop, gates safey 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 the contacts must be included of the control
unit emergency stop buttons, which are on X30. The push buttons are not
interlocked in the emergency stop circuit of the Control Unit.

– The safety of the system cannot be guaranteed if these interlocks are wrongly
executed, incomplete or missing.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic states; in Programming the power is cut out (power
contactors open) immediately. The procedure for the selection of the controlled
stop time (that can be set on SDM board) is contained in the Installation manual .
– When preparing protection barriers, especially light barriers and access doors,
bear in mind that the robot stop times and distances are according to the stop
category (0 or 1) and the weight of the robot.

Check that the controlled stop time is consistent with the type of Robot connected
to the Control Unit. The stop time is selected using selector switches SW1 and
SW2 on the SDM board.

– Check that the environment and working conditions are within the range specified
in the specific product Technical Documentation.
– The calibration operations are to be carried out with great care, as indicated in the
Technical Documentation of the specific product, and are to be concluded
checking the correct position of the machine.
– To load or update the system software (for example after replacing boards), use
only the original software handed over by COMAU Robotics & Service.
Scrupulously follow the system software uploading procedure described in the
Technical Documentation supplied with the specific product. After uploading,
always make some tests moving the robot at slow speed and remaining outside the
protected area.
– Check that the barriers of the protected area are correctly positioned.

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 General Safety Precautions

Programming Mode
– The robot is only to be programmed by the authorised personnel.
– Before starting to program, the operator must check the Robot System (Robot and
Control System) to make sure that there are no potentially hazardous irregular
conditions, and that there is nobody inside the protected area.
– When possible the programming should be controlled from outside the protected
area.
– 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 hand-held programming unit functions
correctly (slow speed, emergency stop, enabling device, etc.).
– During the programming session, only the operator with the hand-held terminal 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) is always to be controlled from a position
outside the range of the robot, after checking that there is nobody in the area
involved. The Drive On operation is concluded when the relevant machine status
indication is shown.
– When programming, the operator is to keep at a distance from the robot to be able
to avoid any irregular machine movements, and in any case in a position to avoid
the risk of being trapped between the robot and structural parts (columns, barriers,
etc.), or between movable parts of the actual robot.
– When programming, the operator is to avoid remaining in a position where parts of
the robot, pulled by gravity, could execute downward movements, or move
upwards or sideways (when installed on a sloped 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 slow speed has been executed. The
test is to be controlled from a safe distance.
– Special attention is to be paid when programming using the hand-held terminal: 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.
– In both cases operate cautiously, always remaining out of the robot’s range of
action and test the cycle at slow speed.

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General Safety Precautions

Auto / Remote Automatic Mode

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

Robot axes release

– In the absence of motive power, the robot axes movement is possible by means of
optional release devices and suitable lifting devices. Such devices only enable the
brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enable button) are cut out; also the robot
axes can move upwards or downwards because of the force generated by the
balancing system, or the force of gravity.

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

– Enabling the brake releasing device may cause the axes falling due to gravity as
well as possible impacts due to an incorrect restoration, after applying the brake
releasing module. The procedure for the correct usage of the brake releasing
device (both for the integrated one and module one) is to be found in the
maintenance manuals.
– When the motion is enabled again following the interruption of an unfinished
MOVE, the track recovery typical function may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next automatic cycle
restarting. Avoid moving the Robot to positions that are far away from the ones
provided for the motion restart; alternatively disable the outstanding MOVE
programmes and/or instructions.

Maintenance and Repairs

– When assembled in COMAU Robotics & Service, the robot is supplied with
lubricant that does not contain substances harmful to health, however, in some
cases, repeated and prolonged exposure to the product could cause skin irritation,
or if swallowed, indisposition.
First Aid. Contact with the eyes or the skin: wash the contaminated zones with
abundant water; if the irritation persists, consult a doctor.
If swallowed, do not provoke vomiting or take anything by mouth, see a doctor as
soon as possible.

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 General Safety Precautions

– Maintenance, trouble-shooting and repairs are only to be carried out by authorised

personnel.
– When carrying out maintenance and repairs, the specific warning sign is to be
placed on the control panel of the Control Unit, stating that maintenance is in
progress and it is only to be removed after the operation has been completely
finished - even if it should be temporarily suspended.
– Maintenance operations and replacement of components or the Control Unit are to
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 coming from connections to peripheral units or external
power sources (e.g. 24 Vdc inputs/outputs). Cut out external sources when
operating on parts of the system that are involved.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Faulty components are to be replaced with others having the same code, or
equivalent components defined by COMAU Robotics & Service.

After replacement of the SDM module, check on the new module that the setting
of the stop time on selector switches SW1 and SW2 is consistent with the type of
Robot connected to the Control Unit.

– Trouble-shooting and maintenance activities are to be executed, when possible,

outside the protected area.
– Trouble-shooting executed on the control is to be carried out, when 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 are to be observed
when operating with hazardous voltages present.
– Trouble-shooting on the robot is to be carried out with the power supply cut out
(Drive off).
– At the end of the maintenance and trouble-shooting operations, all deactivated
safety devices are to be reset (panels, protection shields, interlocks, etc.).
– Maintenance, repairs and trouble-shooting operations are to be concluded
checking the correct operation of the Robot System (Robot and Control System)
and all the safety devices, executed from outside the protected area.
– When loading the software (for example after replacing electronic boards) the
original software handed over by COMAU Robotics & Service is to be used.
Scrupulously follow the system software loading procedure described in the
specific product Technical Documentation; after loading always run a test cycle to
make sure, remaining outside the protected area
– Disassembly of robot components (motors, balancing cylinders, etc.) may cause
uncontrolled movements of the axes in any direction: before starting a disassembly
procedure, consult the warning plates applied to the robot and the Technical
Documentation supplied.
– It is strictly forbidden to remove the protective covering of the robot springs.

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General Safety Precautions

Putting Out of Service and Dismantling

– Putting out of service and dismantling the Robot and Control System is only to be
carried out by Authorised Personnel.
– Bring the robot to transport position and fit the axis clamping brackets (where
applicable) consulting the plate applied on the robot and the robot Technical
Documentation.
– Before stating to put out of service, the mains voltage to the Control Unit must be
cut out (switch off the circuit breaker on the mains distribution line 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 distribution line,
first disconnecting the power conductors, then the earth. 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 earth cable.
– If present, disconnect the robot pneumatic system from the air distribution line.
– Check that the robot is properly balanced and if necessary sling it correctly, then
remove the robot securing bolts from the support.
– Remove the robot and the Control Unit from the work area, applying the rules
indicated in the products Technical Documentation; if lifting is necessary, check the
correct fastening of the eye-bolts and use appropriate slings and equipment only.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU Robotics & Service,
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 safeguarding
the environment.
– 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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 General Safety Precautions

1.2.5 Performance
The performances below shall be considered before installing the robot system:
– Stop distances
– Mission time (typ. case).

Stop distances
– With Robot in programming modality (T1), if you press the sttop pushbutton (red
mushroom-shaped one on WiTP) in category 0 (secondo norma EN60204-1), you
will obtain:

Tab. 1.1 - Stop spaces in programming modality (T1)

Expected Stopping Stopping
Mode Case
speed time space
Nominal 120 ms 30 mm
T1 250 mm/s
Limit 500 ms 125 mm

Tab. 1.2 - Safety electronics reaction time in programming

modality (T1)
Expected Stopping
Mode Case
speed time
For the safety inputs of the SDM module (e.g.
stop pushbutton of TP in wired version)
For the stop stop and enabling device inputs 150 ms
from the TP in wireless version, when the
T1 250 mm/s
safety wire trasmission is active.
For the time-out of stop input and enabling
device from TP in wireless version, when the 350 ms
safety wire transmission is lost or interrupted.

– Considering the Robot in automatico modality, under full extension, full load and
maximmum speed conditions, if you press the stop pushbutton (red
mushroom-shaped one on WiTP) in category 1 (according to norm EN60204-1)
you will trigger the Robot complete stop with controlled deleration ramp.
Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 °
motion, that correspond to about 3000 mm movement measured on TCP flange.
Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5
seconds.

Mission time (typ. case)

– We remind you that the safety system efficiency covering is equal to 20 years
(mission time of safety-related parts of control systems (SRP/CS), according to
EN ISO 13849-1).

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General Safety Precautions

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 General Description

2. GENERAL DESCRIPTION

2.1 Robot SMART5 NJ4 - I The family

The family of SMART5 NJ4 robots consists of machines with high load capacity
dedicated to applications requiring the ability to program "point-to-point" or in "trajectory
control."
The design of SMART5 NJ4 - I Robots is derived from the NJ4 basic version; the
difference is in the tool flange, type ISO 160, where the outer drum is not present; the
flange is axially perforated, thus allowing the passage of pipes and cables for
interconnection to the welding gun (or any other equipment). This solution allows
maintaining the setting used in the robot application within the mechanical structure
without the interference of external wires or pipes.

Fig. 2.1 - SMART5 NJ4 - I Robot wrist

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General Description

Tab. 2.1 - Robot SMART5 NJ4 - I versions available

Payload Reach
Robot Type Installation Robot view
kg (lb) mm (in)

170 2501 Floor /

SMART5 NJ4 170 - 2.5 - I
(374.8) (98.5) Ceeling

175 2205 Floor /

SMART5 NJ4 170 - 2.2 - I
(385.8) (86.9) Ceeling

175 2205 Floor /

SMART5 NJ4 175 - 2.2 - I
(385.8) (86.9) Ceeling

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 General Description

Tab. 2.1 - Robot SMART5 NJ4 - I versions available (Continued)

Payload Reach
Robot Type Installation Robot view
kg (lb) mm (in)

170 2918 Floor /

SMART5 NJ4 170 - 2.9-I
(374.8) (114.9) Ceiling

220 2738 Floor /

SMART5 NJ4 220 - 2.7;
(485) (107.8) Ceiling

220 2417
SMART5 NJ4 220-2.4-I Floor/Ceiling
(485) (95.2)

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General Description

Tab. 2.1 - Robot SMART5 NJ4 - I versions available (Continued)

Payload Reach
Robot Installation Robot view
kg (lb) mm (in)

220 3002
SMART5 NJ4 220-3.0-I Floor
(485) (118.2)

270 2703
SMART5 NJ4 270-2.7 Floor
(595.2) (106.4)

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 General Description

2.2 Robot mechanical

Every robot is parallelogram type with 6 degrees of freedom.
The fixed base is secured to the floor by four M24 screws and precisely located in
relation to the mounting plate by means of two special Ø 30 mm pins.
On the fixed robot base a column rotates with vertical rotation axis (axis 1); the column
supports the motorisation of axes 2 and 3, consisting of a motor clamped directly on the
reduction unit.
The mechanical connection between column and forearm is obtained by the robot arm,
consisting of a body ending with forks. The lower fork interfaces:
– on one side with the reduction unit axis 2 driving shaft from which it receives
motion;
– on the opposite side, with the driving shaft of reduction unit axis 3 in idle mode,
without receiving motion.
The upper fork of the arm is fitted with two coaxial pins, on which the forearm is jointed.
The lever assembly uses a crank to transmit motion from the reduction unit of axis 3
(below) to the connecting rod with fulcrum on the forearm body located in the upper part
of the robot.
The "hollow"-shaped forearm allows the passage of wiring and piping used in the robot
application and supports the gear motor of axis 4 and interfaces with the upper arm fork
and upper pivot point of the connecting rod, from which it receives the motion.
At the front end of the forearm is the wrist integrating the gear motors for the axes 5 and
6. The wrist is "hollow" to allow the passage of the robot setting and is equipped with an
ISO 160 flange for tools (Fig. 2.1 - SMART5 NJ4 - I Robot wrist on page 17).
The flange is different from the standard version, as the external drum is not present and
as for the axial drilling, allowing the passage of pipes and cables for connection to the
welding gun (or any other equipment). This solution allows maintaining the robot setting
within the mechanical structure, by eliminating the cumbersome outer cables or pipes.
The axis 5 is defined as the rotation axis of the oscillating body, perpendicular to the
wrist body, while the axis 6 is defined as the rotation axis of the robot tool flange.
The robot axes are equipped with software limit switch (programmable) and/or shock
absorbing mechanisms supplied as standard or optional (Tab. 2.2 - Axes limit switches
and work area restrictors on page 21)
The motors are of the AC brushless type and incorporate the brake and encoder.

Tab. 2.2 - Axes limit switches and work area restrictors

Standard Optional
Robot Model Software limit Mechanical limit Mechanical mobile Work area restrictors
switch switch limit switch

Ax 1 ( da 1 a 3 aree)
SMART5 NJ4 Ax 1-2-3-4-5-6 Ax 1-2-3-5 Ax 1
Ax 2 ( da 1 a 2 aree)

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General Description

2.3 Interchangeability
The interchangeability of robots of the same version is a fundamental characteristic in
order to enable rapid substitution, or to transfer the same program to another robotic
station.
This characteristic is guaranteed by:
– adequate construction tolerances of all the parts that make up the structure
– precise robot location on the mounting plate by means of two pins (supplied with
the robot)
– possibility of bringing the axes to a known position (Calibration) using a specific tool
(the same for all axes and all models).
These features make it possible to transfer programs between robots of the same
version.
The above-mentioned characteristics are indispensable for effective “off-line
programming” executed in virtual environment.

2.4 Calibration
Calibration is the operation that makes it possible to bring the robot axes to a known
position to ensure the correct repetition of programmed cycles and interchangeability
between machines of the same version.
There are two calibration methods:
– Precise calibration: executed using a special tool that is the same for all axes and
all models. This operation must be executed after special maintenance operations
involving the separation of the kinematic chain between the motor and the robot
axis, or when particularly demanding cycles regarding precision have to be
executed.
– Calibration using location notches enables rapid but improper calibration with less
precision, and it may not restore robot movements with the precision that is
required by the specific application. Calibration by notches consists of bringing the
robot axes onto the calibration notches, aligning them with precision by sight,
without using specific tools, executing the calibration commands axis by axis.

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 Technical Characteristics

3. TECHNICAL CHARACTERISTICS

3.1 Overview
The technical characteristics of the family robot SMART5 NJ4 - I are indicated in
following tables:
– Tab. 3.1 - SMART5 NJ4 170 – 2.5 - I; SMART5 NJ4 175 – 2.2 - I; Characteristics
and performance on page 24
– Tab. 3.2 - SMART5 NJ4 220 – 2.4 - I; SMART5 NJ4 220 – 2.7 - I; SMART5 NJ4
170 – 2.9 - I; Characteristics and performance on page 25
– Tab. 3.3 - SMART5 NJ4 220 – 3.0 - I; SMART5 NJ4 270 – 2.7 - I; Characteristics
and performance on page 26

The operating area and overall dimensions of the robot versions are contained in
Chap.4. - Operating Areas and Robot Overall Dimensions on page 27.

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Technical Characteristics

Tab. 3.1 - SMART5 NJ4 170 – 2.5 - I;

SMART5 NJ4 175 – 2.2 - I;
Characteristics and performance
VERSION NJ4 170 – 2.5 - I NJ4 175-2.2 - I
Parallelogram Parallelogram
Structure / n° axes
6 axes 6 axes
170 kg (1) 175 kg (1)
Load at wrist
(375 lb) (386 lb)
50 kg (2) 50 kg (2)
Additional load on forearm
(110 lb) (110 lb)
Torque axis 4 1010 Nm 1010 Nm
Torque axis 5 804Nm 804Nm
Torque axis 6 412 Nm 412 Nm
Axis 1 +/- 180° (110°/s) +/- 180° (110°/s)
Axis 2 +95° -75° (110°/s) +95° -75° (110°/s)
Axis 3 -10°/ -230° (110°/s) -10°/ -230° (110°/s)
Stroke / (Speed)
Axis 4 +/- 200° (180°/s) +/- 200° (180°/s)
Axis 5 +/- 200°(140°/s) +/- 200°(140°/s)
Axis 6 +/- 200° (190°/s) +/- 200° (190°/s)
2500 mm 2204 mm
Maximum horizontal reach
(98.5 in) (87in)
+/- 0,1 mm +/- 0,1 mm
Repeatability
(0.003937 in) (0.003937 in)
1100 kg 1080 kg
Robot weight
(2425 lb) (2381 lb)
ISO 9409 - 1 - A 125 ISO 9409 - 1 - A 125
Tool coupling flange
ISO 9409 - 1 - A 160 ISO 9409 - 1 - A 160
Motors AC brushless AC brushless
Position measurement system con encoder con encoder
Total power installed 8 kVA 8 kVA
Protection class IP65 IP65
Working temperature 0 ÷ + 45 °C 0 ÷ + 45 °C
Storage temperature - 40 °C ÷ + 60 °C - 40 °C ÷ + 60 °C
Colour of robot (standard) Red RAL 3020 Red RAL 3020
On the floor On the floor
Assembly position
From the ceiling From the ceiling

(1) See par. 6.2 Determination of max loads at wrist flange (QF) on page 48

(2) See Chap.6.2 - Determination of max loads at wrist flange (QF) on page 48 il par. 6.3 Additional loads (QS)
on page 56

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 Technical Characteristics

Tab. 3.2 - SMART5 NJ4 220 – 2.4 - I;

SMART5 NJ4 220 – 2.7 - I;
SMART5 NJ4 170 – 2.9 - I;
Characteristics and performance

VERSION NJ4 220-2.4 - I NJ4 220-2.7 - I NJ4 170 – 2.9 - I

Parallelogram Parallelogram Parallelogram
Structure / n° axes
6 axes 6 axes 6 axes
220 kg (1) 220 kg (1) 170 kg (1)
Load at wrist
(485 lb) (485 lb) (375 lb)
25 kg (2) 25 kg (2) (3) 25 kg (2)
Additional load on forearm
(55.1155 lb) (55.1155 lb) (55.1155 lb)
Torque axis 4 1320 Nm 1320 Nm 1010 Nm
Torque axis 5 950 Nm 950 Nm 804Nm
Torque axis 6 690 Nm 690 Nm 412 Nm
Axis 1 +/- 180° (100°/s) +/- 180° (100°/s) +/- 180° (110°/s)
Axis 2 -75° / +95° (90°/s) -75° / +95° (90°/s) +95° -75° (90°/s)
Axis 3 -10°/ -256° (110°/s) -10°/ -256° (110°/s) -10°/ -230° (110°/s)
Stroke / (Speed)
Axis 4 +/- 200° (130°/s) +/- 200° (130°/s) +/- 200° (130°/s)
Axis 5 +/- 200° (125°/s) +/- 200° (125°/s) +/- 200°(140°/s)
Axis 6 +/- 200° (170°/s) +/- 200° (170°/s) +/- 200° (190°/s)
2417 mm 2738 mm 2918 mm
Maximum horizontal reach
(95.15719 in) (107.795 in) (114.8815 in)
+/- 0,15mm +/- 0,15mm +/- 0,1mm
Repeatability
(0.0059 in) (0.0059 in) (0.003937 in)
1260 kg 1290 kg 1240 kg
Robot weight
(2778 lb) (2844 lb) (2734 lb)
ISO 9409 - 1 - A 125 ISO 9409 - 1 - A 125 ISO 9409 - 1 - A 125
Tool coupling flange
ISO 9409 - 1 - A 160 ISO 9409 - 1 - A 160 ISO 9409 - 1 - A 160
Motors AC brushless AC brushless AC brushless
Position measurement system con encoder con encoder con encoder
Total power installed 8 kVA 8 kVA 8 kVA
Protection class IP65 IP65 IP65
Working temperature 0 ÷ + 45 °C 0 ÷ + 45 °C 0 ÷ + 45 °C
Storage temperature - 40 °C ÷ + 60 °C - 40 °C ÷ + 60 °C - 40 °C ÷ + 60 °C
Colour of robot (standard) Red RAL 3020 Red RAL 3020 Red RAL 3020
On the floor On the floor On the floor
Assembly position
From the ceiling From the ceiling From the ceiling

(1) See par. 6.2 Determination of max loads at wrist flange (QF) on page 48

(2) See Chap.6.2 - Determination of max loads at wrist flange (QF) on page 48 il par. 6.3 Additional loads (QS)
on page 56

(3) By loading a QF = 220 kg on the robot wrist, no extra QS load on the forearm can be applied.

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Technical Characteristics

Tab. 3.3 - SMART5 NJ4 220 – 3.0 - I;

SMART5 NJ4 270 – 2.7 - I;
Characteristics and performance

VERSION NJ4 220-3.0 - I NJ4 270 – 2.7 - I

Parallelogram Parallelogram
Structure / n° axes
6 axes 6 axes
220 kg (1) 270 kg (1)
Load at wrist
( 485 lb) (595 lb)
25 kg (2) 25 kg (2
Additional load on forearm
(55 lb) (55 lb)
1320 Nm 1960 Nm
Torque axis 4
(2910 lb) (4321 lb)
Torque axis 5 950 Nm 1457 Nm
Torque axis 6 690 Nm 834 Nm
Axis 1 +/- 180° (90°/s) +/- 180° (90°/s)
Axis 2 +75° / -75° (90°/s) +75° / -75° (90°/s)
Axis 3 -231°/ 0° (90°/s) -231°/ 0° (90°/s)
Stroke / (Speed)
Axis 4 +/- 200° (115°/s) +/- 200° (115°/s)
Axis 5 +/- 200° (125°/s) +/- 200° (125°/s)
Axis 6 +/- 200° (170°/s) +/- 200° (170°/s)
3002 mm 2703 mm
Maximum horizontal reach
(118 in) (106 in)
+/- 0,15mm +/- 0,15mm
Repeatability
(0.0059 in) (0.0059 in)
2005 kg 1975 kg
Robot weight
(4420 lb) (4354 lb)
ISO 9409 - 1 - A 125 ISO 9409 - 1 - A 125
Tool coupling flange
ISO 9409 - 1 - A 160 ISO 9409 - 1 - A 160
Motors AC brushless AC brushless
Position measurement system con encoder con encoder
Total power installed 8 kVA 8 kVA
Protection class IP65 IP65
Working temperature 0 ÷ + 45 °C 0 ÷ + 45 °C
Storage temperature - 40 °C ÷ + 60 °C - 40 °C ÷ + 60 °C
Colour of robot (standard) Red RAL 3020 Red RAL 3020
Assembly position On the floor On the floor

(1) See par. 6.2 Determination of max loads at wrist flange (QF) on page 48

(2) See Chap.6. - Loads at Wrist and Additional Loads on page 47 il par. 6.3 Additional loads (QS) on page 56

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 Operating Areas and Robot Overall Dimensions

4. OPERATING AREAS AND ROBOT

OVERALL DIMENSIONS
This chapter describes the operating area and overall dimensions of the
robot versions listed below:

– SMART5 NJ4 170 – 2.5 - I

– SMART5 NJ4 175 – 2.2 - I

– SMART5 NJ4 220 – 2.7 - I

– SMART5 NJ4 220 – 2.4 - I

– SMART5 NJ4 170 – 2.9 - I

– SMART5 NJ4 270 – 2.7 - I

– SMART5 NJ4 220 – 3.0 - I

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Operating Areas and Robot Overall Dimensions

SMART5 NJ4 170 – 2.5 - I

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 Operating Areas and Robot Overall Dimensions

SMART5 NJ4 170 – 2.5 - I

Pos X Z Ax.2 Ax.3

[mm] [mm] [deg] [deg]
1 412,67 1427,67 -75° -86°
2 -719,93 2225,51 -75° -10°
3 -64,83 2940,42 -20° -10°
4 2438,01 314,06 95° -125°
5 650 -103,76 95° -234,37°
6 650 309,29 69,07° -230,07°
7 1447 2130 0° -90°

Joints in Calibration Position (pos.7)

Ax 1 Ax 2 Ax 3 Ax 4 Ax 5 Ax 6
0° 0° -90° 0° 0° 0°

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Operating Areas and Robot Overall Dimensions

SMART5 NJ4 175 – 2.2 - I

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 Operating Areas and Robot Overall Dimensions

SMART5 NJ4 175 – 2.2 - I

Pos X Z Ax.2 Ax.3

[mm] [mm] [deg] [deg]
1 702,44 1350,03 -75° -86°
2 -430,15 2147,86 -75° -10°
3 37,78 2658,52 -20° -10°
4 2139,15 340,21 95° -125°
5 650 -267,82 95° -216,26°
6 650 278,05 42,35° -203,35°
7 1447 1830 0° -90°

Joints in Calibration Position (pos.7)

Ax 1 Ax 2 Ax 3 Ax 4 Ax 5 Ax 6
0° 0° -90° 0° 0° 0°

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Operating Areas and Robot Overall Dimensions

SMART5 NJ4 220 – 2.7 - I

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 Operating Areas and Robot Overall Dimensions

SMART5 NJ4 220 – 2.7 - I

Pos X Z Ax.2 Ax.3

[mm] [mm] [deg] [deg]
1 409,76 1464,77 -75° -86°
2 -778,86 2324,83 -75° -10°
3 -45,78 3124,85 -20° -10°
4 2668,24 264,16 95° -125°
5 700 -85,98 95° -239,05°
6 700 270,51 75,92° -236,92°
7 1565 2255 0° -90°

Joints in Calibration Position (pos.7)

Ax 1 Ax 2 Ax 3 Ax 4 Ax 5 Ax 6
0° 0° -90° 0° 0° 0°

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Operating Areas and Robot Overall Dimensions

SMART5 NJ4 220 – 2.4 - I

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 Operating Areas and Robot Overall Dimensions

SMART5 NJ4 220 – 2.4 - I

Pos X Z Ax.2 Ax.3

[mm] [mm] [deg] [deg]
1 723,69 1380,65 -75 -86
2 -464,94 2240,71 -75 -10
3 65,38 2819,45 -20 -10
4 2344,47 292,49 95 -125
5 650 -275,39 95 -222,17
6 650 242,21 51,51 -212,51
7 1565 1930 0° -90°

Joints in Calibration Position (pos.7)

Ax 1 Ax 2 Ax 3 Ax 4 Ax 5 Ax 6
0° 0° -90° 0° 0° 0°

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Operating Areas and Robot Overall Dimensions

SMART5 NJ4 170 – 2.9 - I

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 Operating Areas and Robot Overall Dimensions

SMART5 NJ4 170 – 2.9- I

Joints in Calibration Position (pos.7)

Ax 1 Ax 2 Ax 3 Ax 4 Ax 5 Ax 6
0° 0° -90° 0° 0° 0°

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Operating Areas and Robot Overall Dimensions

SMART5 NJ4 270 – 2.7 - I

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 Operating Areas and Robot Overall Dimensions

SMART5 NJ4 270 – 2.7 - I

Pos X Z Ax.2 Ax.3

[mm] [mm] [deg] [deg]
1 596,83 1847,19 -75° -81°
2 -804,22 2616,76 -75° 0°
3 -315 3254,33 -30° 0°
4 2702,87 1341,36 75° -105°
5 850 351,16 75° -222,20°
6 850 534,41 61,27° -217,27°
7 1665 2440 0° -90°

Joints in Calibration Position (pos.7)

Ax 1 Ax 2 Ax 3 Ax 4 Ax 5 Ax 6
0° 0° -90° 0° 0° 0°

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Operating Areas and Robot Overall Dimensions

SMART5 NJ4 220 – 3.0 - I

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 Operating Areas and Robot Overall Dimensions

SMART5 NJ4 220 – 3.0 -I

Joints in Calibration Position (pos.7)

Ax 1 Ax 2 Ax 3 Ax 4 Ax 5 Ax 6
0° 0° -90° 0° 0° 0°

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Robot Flange

5. ROBOT FLANGE

5.1 Tool coupling flange

Following chapter show the drawings of the tool attachment flange with drilling
dimension and spacing for fixtures attachment.
On the flange the Calibrated Fixture is attached that is used to precisely calculate the
location of the flange centre when fixtures are installed.

– Fig. 5.1 - SMART5 NJ4 170 – 2.9 - I; SMART5 NJ4 170 – 2.5 - I; SMART5 NJ4 175
– 2.2 - I; ( ISO 9409-1- A160)- front view on page 43
– Fig. 5.2 - SMART5 NJ4 170 – 2.9 - I; SMART5 NJ4 170 – 2.5 - I; SMART5 NJ4 175
– 2.2 - I ( ISO 9409-1- A160)-- lateral view on page 44

– Fig. 5.3 - SMART5 NJ4 220 – 2.4 - I; SMART5 NJ4 220 – 2.7 - I; SMART5 NJ4 220
– 3.0 - I; SMART5 NJ4 270 – 2.7 - I (ISO 9409-1- A125; ISO 9409-1- A200)- front
view on page 45
– Fig. 5.4 - SMART5 NJ4 220 – 2.4 - I; SMART5 NJ4 220 – 2.7 - I; SMART5 NJ4 220
– 3.0 - I; SMART5 NJ4 270 – 2.7 - I (ISO 9409-1- A125; ISO 9409-1- A200)-lateral
view on page 46

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 Robot Flange

Fig. 5.1 - SMART5 NJ4 170 – 2.9 - I;

SMART5 NJ4 170 – 2.5 - I;
SMART5 NJ4 175 – 2.2 - I;
( ISO 9409-1- A160)- front view

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Robot Flange

Fig. 5.2 - SMART5 NJ4 170 – 2.9 - I;

SMART5 NJ4 170 – 2.5 - I;
SMART5 NJ4 175 – 2.2 - I
(ISO 9409-1- A160)- lateral view

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 Robot Flange

Fig. 5.3 - SMART5 NJ4 220 – 2.4 - I;

SMART5 NJ4 220 – 2.7 - I;
SMART5 NJ4 220 – 3.0 - I;
SMART5 NJ4 270 – 2.7 - I
(ISO 9409-1- A200)- front view

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Robot Flange

Fig. 5.4 - SMART5 NJ4 220 – 2.4 - I;

SMART5 NJ4 220 – 2.7 - I;
SMART5 NJ4 220 – 3.0 - I;
SMART5 NJ4 270 – 2.7 - I
(ISO 9409-1- A200)-lateral view

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 Loads at Wrist and Additional Loads

6. LOADS AT WRIST AND ADDITIONAL

LOADS

6.1 Overview
This chapter describes the procedures to determine the maximum load that can be
applied to the robot flange and any additional load applied on the forearm.
Load capacity on the flange according to the distance from the centre of gravity
– Fig. 6.2 - SMART5 NJ4 170 – 2.5 -I; Maximum load capacity of the flange on
page 49
– Fig. 6.3 - SMART5 NJ4 175 – 2.2 - I Maximum load capacity of the flange on
page 50

– Fig. 6.4 - SMART5 NJ4 220 – 2.7 - I Maximum load capacity of the flange on
page 51
– Fig. 6.5 - SMART5 NJ4 220 – 2.4 - I Maximum load capacity of the flange on
page 52

– Fig. 6.6 - SMART5 NJ4 170 – 2.9 - I; Maximum load capacity of the flange on
page 53

– Fig. 6.7 - SMART5 NJ4 270 – 2.7 - I Maximum load capacity of the flange on
page 54
– Fig. 6.8 - SMART5 NJ4 220 – 3.0 - I Maximum load capacity of the flange on
page 55

Areas in which the centre of gravity position related to additional load is allowed
– Fig. 6.9 - (Additional loads centre of gravity position on page 57

Centre distances and dimensions of holes to fasten any fixtures applied on the robot
forearm
– Fig. 6.10 - SMART5 NJ4 170 – 2.5 -I; SMART5 NJ4 175-2.2 - I Drilling for
fixtures attachment on page 58
– Fig. 6.11 - SMART5 NJ4 220-2.4 - I; SMART5 NJ4 220-2.7 - I; SMART5 NJ4
170 – 2.9 - I Drilling for fixtures attachment on page 59
– Fig. 6.12 - SMART5 NJ4 220 – 3.0 - I; SMART5 NJ4 270 – 2.7 - I Drilling for
fixtures attachment on page 60
Abbreviations
In this chapter the following abbreviations have been used:
– QF =Max. load applied to the flange;
– QS = Additional load applied to the forearm;
– QT =Max total load applied on the robot;
– LZ = Distance of load P centre of gravity from the flange axis;
– Lxy = Distance of load P centre of gravity from axis 6.

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Loads at Wrist and Additional Loads

Fig. 6.1 - Centre of gravity co-ordinates of the applied load

Z
Lx Ly

Y
Lx
X
y
P Lz

6.2 Determination of max loads at wrist flange

(QF)
The maximum load that can be applied to the flange is defined using the wrist load
graphs, where the curves of maximum load QF are plotted according to co-ordinates LZ
and LY of the load centre of gravity.
The area below the load curve defines centre of gravity distances allowed for the
application of the load indicated on it.

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 Loads at Wrist and Additional Loads

Fig. 6.2 - SMART5 NJ4 170 – 2.5 -I;

Lz [mm] Maximum load capacity of the flange

600

550

M = 140 kg
500
2
J 0 = 30 kgm
450

400 M = 150 kg
2
J 0 = 35 kgm
350

300
M = 160 kg
2
250 J 0 = 38 kgm

200
M = 170 kg
150 2
J 0 = 40 kgm

100

50

0
0 50 100 150 200 250 300 350
Lxy [mm]

– M: Weight
– J0: Inertia

The inertia specified in the graph curves refers to the centre of gravity of the load
applied on the flange.
With application of different loads on the values specified in the graphs, test the
limits of the robot's used by the SMART Payload software.

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Loads at Wrist and Additional Loads

Fig. 6.3 - SMART5 NJ4 175 – 2.2 - I

Maximum load capacity of the flange
Lz [mm]

550
M = 145 kg
2
500 J 0 = 30 kgm

450
M = 155 kg
2
400 J 0 = 35 kgm

350

M = 165 kg
300 2
J 0 = 38 kgm

250

200
M = 175 kg
150 J 0 = 40 kgm
2

100

50

0
0 50 100 150 200 250 300 350
Lxy [mm]

– M: Weight
– J0: Inertia

The inertia specified in the graph curves refers to the centre of gravity of the load
applied on the flange.
With application of different loads on the values specified in the graphs, test the
limits of the robot's used by the SMART Payload software.

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 Loads at Wrist and Additional Loads

Fig. 6.4 - SMART5 NJ4 220 – 2.7 - I

Maximum load capacity of the flange
Lz [mm]

650

600
M = 150 kg
550 J 0 = 68 kgm
2

500
M = 160 kg
2
450 J 0 = 73 kgm

400
M = 175 kg
2
J 0 = 80 kgm
350

300 M = 190 kg
2
J 0 = 86 kgm
250

M = 205 kg
200 2
J 0 = 93 kgm

150
M = 220 kg
2
100 J 0 = 100 kgm

50

0
0 50 100 150 200 250 300 350 400 450
Lxy [mm]

– M: Weight
– J0: Inertia

The inertia specified in the graph curves refers to the centre of gravity of the load
applied on the flange.
With application of different loads on the values specified in the graphs, test the
limits of the robot's used by the SMART Payload software.

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Loads at Wrist and Additional Loads

Fig. 6.5 - SMART5 NJ4 220 – 2.4 - I

Maximum load capacity of the flange
Lz [mm]

650

600
M = 150 kg
550 J 0 = 68 kgm
2

500
M = 160 kg
2
450 J 0 = 73 kgm

400
M = 175 kg
2
J 0 = 80 kgm
350

300 M = 190 kg
2
J 0 = 86 kgm
250

M = 205 kg
200 2
J 0 = 93 kgm

150
M = 220 kg
2
100 J 0 = 100 kgm

50

0
0 50 100 150 200 250 300 350 400 450
Lxy [mm]

– M: Weight
– J0: Inertia

The inertia specified in the graph curves refers to the centre of gravity of the load
applied on the flange.
With application of different loads on the values specified in the graphs, test the
limits of the robot's used by the SMART Payload software.

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 Loads at Wrist and Additional Loads

Fig. 6.6 - SMART5 NJ4 170 – 2.9 - I;

Maximum load capacity of the flange
Lz [mm]

600

550

M = 140 kg
500
2
J 0 = 30 kgm
450

400 M = 150 kg
2
J 0 = 35 kgm
350

300
M = 160 kg
2
250 J 0 = 38 kgm

200
M = 170 kg
150 2
J 0 = 40 kgm

100

50

0
0 50 100 150 200 250 300 350
Lxy [mm]

– M: Weight
– J0: Inertia

The inertia specified in the graph curves refers to the centre of gravity of the load
applied on the flange.
With application of different loads on the values specified in the graphs, test the
limits of the robot's used by the SMART Payload software.

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Loads at Wrist and Additional Loads

Fig. 6.7 - SMART5 NJ4 270 – 2.7 - I

Maximum load capacity of the flange
Lz [mm]

700

650

600

550

500
M = 210 kg
2
450 J 0 = 130 kgm

400
M = 230 kg
350 2
J 0 = 140 kgm

300 M = 250 kg
2
J 0 = 150 kgm
250

200 M = 270 kg
2
150 J 0 = 170 kgm

100

50

0
0 50 100 150 200 250 300 350
Lxy [mm]

– M: Weight
– J0: Inertia

The inertia specified in the graph curves refers to the centre of gravity of the load
applied on the flange.
With application of different loads on the values specified in the graphs, test the
limits of the robot's used by the SMART Payload software.

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 Loads at Wrist and Additional Loads

Fig. 6.8 - SMART5 NJ4 220 – 3.0 - I

Maximum load capacity of the flange
Lz [mm]

650

600
M = 150 kg
550 J 0 = 68 kgm
2

500
M = 160 kg
2
450 J 0 = 73 kgm

400
M = 175 kg
2
J 0 = 80 kgm
350

300 M = 190 kg
2
J 0 = 86 kgm
250

M = 205 kg
200 2
J 0 = 93 kgm

150
M = 220 kg
2
100 J 0 = 100 kgm

50

0
0 50 100 150 200 250 300 350 400 450
Lxy [mm]

– M: Weight
– J0: Inertia

The inertia specified in the graph curves refers to the centre of gravity of the load
applied on the flange.
With application of different loads on the values specified in the graphs, test the
limits of the robot's used by the SMART Payload software.

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Loads at Wrist and Additional Loads

6.3 Additional loads (QS)

Besides the load on the flange QF, an additional load QS can be applied on the robot
forearm; maximum loads applicable on the robot are those indicated in Tab. 6.1
- Maximum applicable loads on page 56.
The following indications are to be observed in every application,
– the centre of gravity of the load applied on flange QF is to be within the area
subtended by the curves of following graphs in Fig. 6.2 - SMART5 NJ4 170 – 2.5
-I; Maximum load capacity of the flange on page 49
– the centre of gravity of additional load QS has to be within the area of the graph
shown in Fig. 6.9 - (Additional loads centre of gravity position on page 57.
To install special fixtures on the robot, the holes provided on the robot forearm can be
used seet following drawings:
– Fig. 6.10 - SMART5 NJ4 170 – 2.5 -I; SMART5 NJ4 175-2.2 - I Drilling for fixtures
attachment on page 58
– Fig. 6.11 - SMART5 NJ4 220-2.4 - I; SMART5 NJ4 220-2.7 - I; SMART5 NJ4 170
– 2.9 - I Drilling for fixtures attachment on page 59
– Fig. 6.12 - SMART5 NJ4 220 – 3.0 - I; SMART5 NJ4 270 – 2.7 - I Drilling for fixtures
attachment on page 60.

Tab. 6.1 - Maximum applicable loads

QF QT
QS
Max overall load that Max overall load that
SMART5 Max load additional on
can be applied on can be applied on
forearm
flange robot

NJ4 170 – 2.5 - I 170 kg (375 lb) 50 kg (110.23 lb) 220 kg (485.02 lb)

NJ4 175 – 2.2 - I 175 kg (386 lb) 50 kg (110.23 lb) 225 kg (496.04 lb)

NJ4 170 – 2.9 - I 170 kg (375 lb) 25 kg (55 lb) 195 kg (430 lb)

220 kg (485.02 lb) 5 kg (11.23 lb)

NJ4 220 – 2.7 - I 225 kg (496.04 lb)
195 kg (430 lb) 25 kg (55 lb)

NJ4 220 – 2.4 - I 220 kg (485.02 lb) 25 kg (55 lb) 245 kg (540 lb)

NJ4 270 – 2.7 - I 220 kg (485.02 lb) 25 kg (55 lb) 295 kg (650 lb)

NJ4 220 – 3.0 - I 220 kg (485.02 lb) 25 kg (55 lb) 245 kg (540 lb)

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 Loads at Wrist and Additional Loads

Fig. 6.9 - (Additional loads centre of gravity position

The diagram shown in the Figure can also be applied to ceiling installation.

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Loads at Wrist and Additional Loads

Fig. 6.10 - SMART5 NJ4 170 – 2.5 -I; SMART5 NJ4 175-2.2 - I
Drilling for fixtures attachment

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 Loads at Wrist and Additional Loads

Fig. 6.11 - SMART5 NJ4 220-2.4 - I; SMART5 NJ4 220-2.7 - I;

SMART5 NJ4 170 – 2.9 - I Drilling for fixtures attachment

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Loads at Wrist and Additional Loads

Fig. 6.12 - SMART5 NJ4 220 – 3.0 - I; SMART5 NJ4 270 – 2.7 - I
Drilling for fixtures attachment

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 Preparation for Robot Installation

7. PREPARATION FOR ROBOT

INSTALLATION

Before carrying out any type of installation operation carefully read Chap.1. -
General Safety Precautions on page 6.
The robot has to be coupled to the C5G Control Unit. No other use is permitted.
Any exceptions are to be explicitly authorised by COMAU Robotics & Service.

This chapter contains specifications and technical information required for the
robot installation. The installation operation procedure is described in the
specific TRANSPORT AND INSTALLATION manual.

7.1 Environment conditions

The environment for robot use is the usual workshop environment.

7.1.1 Environment data

– Operating environment temperature: 0°C ÷ 45°C
– Relative humidity: 5% ÷ 95% without condensation.
– Storage environment temperature: -40 °C ÷ 60 °C.
– Maximum temperature gradient: 1,5 °C/min.

7.1.2 Operating space

The maximum overall dimensions of the robot operating area is indicated in the Chap.4.
- Operating Areas and Robot Overall Dimensions on page 27 .

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Preparation for Robot Installation

7.2 Attachment to a Steel Plate

7.2.1 Steel Plate
The robot can be attached to a steel plate already drilled for the screws and pins. The
steel plate can be prepared by the robot integrator or otherwise it can be supplied as an
optional, see:
– Fig. 7.1 - SMART5 NJ4 170-2.5 - I; SMART5 NJ4 170-2.9 - I; SMART5 NJ4
175-2.2 - I; SMART5 NJ4 220-2.4 - I; SMART5 NJ4 220-2.7 - I Fastening Plate (not
adjustable leveling) (code CR82343100) on page 64.
To anchor the robot to the plate an optional kit is available that contains the mechanical
components needed for the anchorage, see:
– Fig. 7.2 - SMART5 NJ4 170-2.5 - I; SMART5 NJ4 170-2.9 - I; SMART5 NJ4
175-2.2 - I; SMART5 NJ4 220-2.4 - I; SMART5 NJ4 220-2.7 - I Screws and pins to
mount the robot (code CR82342700) on page 65
– Fig. 7.3 - SMART5 NJ4 220-3.0 - I; SMART5 NJ4 270-2.7 - I Screws and pins to
mount the robot (code CR 82314700) ; on page 67

The robot is to be anchored on a flat horizontal surface with the following

planarity tolerance:

7.2.2 Attachment to a plate with adjustable level (optional)

The robot can be assembled using an optional assembly consisting of 4 floor attachment
plates and a steel plate fastened to the robot that can be adjusted in level through the
specific screws, see:
– Fig. 7.4 - SMART5 NJ4 170-2.5 - I; SMART5 NJ4 170-2.9 - I; SMART5 NJ4
175-2.2 - I; SMART5 NJ4 220-2.4 - I; SMART5 NJ4 220-2.7 - I Adjustable level
plate for robot mounting (code CR82342800) on page 68.
– Fig. 7.5 - SMART5 NJ4 220-3.0 - I; SMART5 NJ4 270-2.7 - I Adjustable level plate
for robot mounting (code 82314800) on page 69

Tab. 7.1 - Fastening Plate Robot Applicability

SMART5 NJ4 170 – 2.5 - I
SMART5 NJ4 170 – 2.9 - I
SMART5 NJ4 220 – 3.0 - I
Robot SMART5 NJ4 175 – 2.2 - I
SMART5 NJ4 270 – 2.7 - I
SMART5 NJ4 220 – 2.4 - I
SMART5 NJ4 220 – 2.7 - I
Assembly Code Reference Code Reference
Fastening Plate
CR82343100 Fig. 7.1 - -
( not adjustable level)

Level adjustment plate assy CR82342800 Fig. 7.4 82314800 Fig. 7.5

Screws and pins CR82342700 Fig. 7.2 CR82314700 Fig. 7.3

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 Preparation for Robot Installation

7.2.3 Secure plate to the floor

Use chemical anchorage blocks to secure the plate to the floor.

Tab. 7.2 - Recommended components for securing the leveling

plate to the floor (not supplied

Hole depth
Component Reference Code Q.ty
diameter
Chemical
HILTI HVU M20x170 See
capsule Ø 24x 170 mm
Fig. 7.2
HAS-E (Ø 0.94 x 6.70 in)
Fig. 7.3
Pin HILTI
M20x170/48

Please read the instructions before using the recommended fastening

components

To avoid any micro movements of the plate caused by repeated alternated stress
generated by the robot during normal work cycles, lay the plates on a layer of aligning
mortar specifically for metal on concrete applications.

The mounting of the plate to the floor is to ensure the possibility to level the robot
with a tolerance of ± 0.5/1000 mm and is to be able to support the stresses
indicated in the Fig. 7.6 - Stress on the robot supporting structure on page 70

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Preparation for Robot Installation

Fig. 7.1 - SMART5 NJ4 170-2.5 - I; SMART5 NJ4 170-2.9 - I;

SMART5 NJ4 175-2.2 - I; SMART5 NJ4 220-2.4 - I;
SMART5 NJ4 220-2.7 - I Fastening Plate (not adjustable
leveling) (code CR82343100)

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Fig. 7.2 - SMART5 NJ4 170-2.5 - I; SMART5 NJ4 170-2.9 - I;

SMART5 NJ4 175-2.2 - I; SMART5 NJ4 220-2.4 - I;
SMART5 NJ4 220-2.7 - I
Screws and pins to mount the robot (code CR82342700)

1. Centring Ø = 30 mm ( 1.18 in) L = 80 mm (q.ty = 1)

2. Centring Ø = 30 mm ( 1.18 in) L = 60 mm (q.ty = 1)
3. Socket head cap screw M 10 x 90 (8.8) (q.ty = 1)
4. Socket head cap screw M 10 x 70 (8.8) (q.ty = 1)
5. Partially threaded hex head screw M 24 x 100 (8.8.) (q.ty = 6)
6. Split washer Ø = 24mm ( 0.94 in ) (q.ty = 6)
7. Flat washer Ø = 24 mm ( 0.94 in ) (q.ty = 6)
8. Fastening Plate

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Preparation for Robot Installation

Key: Fig. 7.3 - SMART5 NJ4 220-3.0 - I; SMART5 NJ4 270-2.7 - I Screws and pins to
mount the robot (code CR 82314700) ; on page 67
1. Centring Ø = 30 mm ( 1.18 in) L = 80 mm ( 3.15in) (q.tà = 1)
2. Centring Ø = 30 mm ( 1.18 in) L = 60 mm ( 2.36 in) (q.tà = 1)
3. Socket head cap screw M 10 x 90 (8.8) (q.tà = 1)
4. Socket head cap screw M 10 x 70 (8.8) (q.tà = 1)
5. Partially threaded hex head screwM 24 x 100 (8.8.) (q.tà = 6)
6. Flat washer Ø = 24mm ( 0.94 in ) (q.tà = 6)
7. Flat washer Ø = 24 mm (0.94 in )( (q.tà = 6)

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Fig. 7.3 - SMART5 NJ4 220-3.0 - I; SMART5 NJ4 270-2.7 - I

Screws and pins to mount the robot
(code CR 82314700) ;

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Preparation for Robot Installation

Fig. 7.4 - SMART5 NJ4 170-2.5 - I; SMART5 NJ4 170-2.9 - I;

SMART5 NJ4 175-2.2 - I; SMART5 NJ4 220-2.4 - I;
SMART5 NJ4 220-2.7 - I Adjustable level plate for robot
mounting (code CR82342800)

1
1

1. Piastra livellabile (q.tà =1)

2. Piastra (q.tà = 4)
3. Regolo (q.tà = 8)
4. Vite TE INTERAMENTE FILETTATA M20x100-8.8 (q.tà = 4)
5. Dado esagonale M20 -8 FE/ZN 12 (q.tà = 4)

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Fig. 7.5 - SMART5 NJ4 220-3.0 - I; SMART5 NJ4 270-2.7 - I

Adjustable level plate for robot mounting (code
82314800)

1. Leveling plate (q.ty =1)

2. Plate (q.ty = 4)
3. Straight edge (q.ty = 8)
4. Fully threaded hex head screw M20x100-8.8 (q.ty = 4

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Preparation for Robot Installation

7.3 Stress on supporting structure

The foundations where the robot is installed are not to suffer vibrations coming from
other machines (such as sledge hammers, presses, etc.). The values of the stress
generated by the robot on the supporting structure differ according to whether it is
installed on the floor or on the ceiling, as shown in the figures Fig. 7.6 .

Because of the considerable stress discharged to the ground by the robot, and
the need to have an appropriate supporting surface, direct fixing to the floor is not
foreseen. The robot mounting surface must be horizontal

Fig. 7.6 - Stress on the robot supporting structure

Robot on floor installation Robot on ceiling installation

Fo
Mk

Fv

Fv Mk

Fo

Mr
Mr

Robot shown on figure is indicative.

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Tab. 7.3 - Stress values on the robot supporting structure

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

Accelerating 16300 6000 8000 22000
SMART5 NJ4 170-2.5 - I
Emergency braking 17000 11200 16000 30000
Accelerating 17000 6000 8000 23000
SMART5 NJ4 170-2.9 - I
Emergency braking 22000 9000 16000 40000
Accelerating 15000 4200 8000 17200
SMART5 NJ4 175-2.2 - I
Emergency braking 16500 7500 16000 24000
Accelerating 18000 6000 8000 25000
SMART5 NJ4 220-2.4 - I
Emergency braking 24000 12000 16000 43000
Accelerating 18000 7000 8000 26000
SMART5 NJ4 220-2.7 - I
Emergency braking 24000 13000 16000 41000
Accelerating 25000 7000 12000 33000
SMART5 NJ4 220-3.0 - I
Emergency braking 32000 21000 24000 59000
Accelerating 26000 7000 12000 35000
SMART5 NJ4 270-2.7 - I
Emergency braking 37000 22000 23000 72000

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Optional Equipment

8. OPTIONAL EQUIPMENT

8.1 APPLICABILITY OF OPTIONS

For the Robot SMART5 NJ4- I Family, multiple options are possible, depending on the
type of robot.
The list of available options for the types of robots breaks down in the following tables:
– Tab. 8.1 - SMART5 NJ4 170-2.5 - I; SMART5 NJ4 175-2.2 - I; SMART5 NJ4
170-2.9 - I; SMART5 NJ4 220-2.4 - I; SMART5 NJ4 220-2.7 - I Options available
on page 73

– Tab. 8.2 - SMART5 NJ4 220–3.0 - I; SMART5 NJ4 270–2.7 - I Options available
on page 74

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Tab. 8.1 - SMART5 NJ4 170-2.5 - I; SMART5 NJ4 175-2.2 - I;

SMART5 NJ4 170-2.9 - I;

SMART5 NJ4 220-2.4 - I; SMART5 NJ4 220-2.7 - I

Options available

Code COMAU

SMART5
Description Applicability
NJ4 170-2.9;
NJ4 170-2.5;
NJ4 220-2.4;
NJ4 175-2.2
NJ4 220-2.7

CR82343300 Axis 1 work area partialization assembly - 1 area 1

CR82343200 Axis 1 work area partialization assembly - 2 areas 1
CR82342200 Axis 1 work area partialization assembly - 3 areas 1
CR82342300 CR82344900 Axis 2 work area partialization assembly - 2 areas 1
CR82342400 Axis 1 adjustable mechanical hard stop assembly 1
Axis 2 adjustable mechanical hard stop assembly (code
CR82342500 - 1
CR82342500)
Axis 2 adjustable mechanical hard stop assembly (code
- CR82344800 1
CR82344800)
CR82342700 Screws and pins kit for robot mounting (code CR82342700) 1
CR82342800 Leveling plate unit for robot mounting (code CR82342800) 1
CR82343100 Non adjustable plate for robot mounting (code 82343100) 1
Axis 1 mechanical hard stop on-off assembly (lock pin - code
CR82344300 1
CR82344300
Fall-prevention brackets assembly for ceiling attachment (code
CR82348800 1
CR82348800)
NJ ceiling mounting and fall-prevention assembly - BRIC (code
CR82344700 1
CR82344700)
CR82352200
Distribution connection guard assembly 1
82352200
82314100 Calibration tool (code 82314100) 1
82109501 Gauged tool assembly L=200 mm (code 82109501) 1
CR82351700 -
Fork liftable option 1
- CR82274800

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Optional Equipment

Tab. 8.2 - SMART5 NJ4 220–3.0 - I;

SMART5 NJ4 270–2.7 - I Options available
Codice
COMAU

SMART5 Description Applicability

NJ4 220 – 3.0
NJ4 270 – 2.7
CR82273200 Axis 1 adjustable mechanical hard stop assembly (code CR82273200) 1
CR82273300 Axis 2 adjustable mechanical hard stop assembly (code CR82273300) 1
CR82273600 Axis 1 mechanical hard stop on-off assembly - lock pin (code CR82273600) 1
CR82325600 Axis 1 work area partialization assembly - 3 areas (code CR82325600) 1
CR82325700 Axis 1 work area partialization assembly - 2 areas (code CR82325700) 1
CR82325800 Axis 1 work area partialization assembly - 1 areas (code CR82325800) 1
CR82273400 Axis 2 work area partialization assembly - 2 areas (code CR82273400) 1
CR82274800
Fork liftable option 1
CR82351700
82109501 Gauged tool assembly L=200 mm (code 82109501) 1
82314800 Leveling plate unit for robot mounting (code CR82342800) 1
82314700 Screws and pins kit for robot mounting (code 82314700) 1
CR82352200
Distribution connection guard assembly 1
CR82276800
82309259 Guard assembly for ventilated motor ax1 (code 82309259) 1
CR82273500 Springs guard assembly 1
CR82341605 Centering dia 100 / 125 1

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 Optional Equipment

8.2 Axis 1 work area partialization assembly

(1 area, code CR82343300 - 2 areas, code CR82343200 - 3 areas, code
CR82342200)

1. Microswitch support
2. Microswitch with six pushbuttons
3. LH cam holder
4. RH cam holder
5. Micro switch
6. Cam
7. Stubbed socket head cap screw M6x10
8. Socket head cap screw M6x45
9. Socket grub screw
10. Low hex nut M6-0,5
11. Parallel pin Ø4x40
12. Socket head cap screw M6x60

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Optional Equipment

8.2.1 Description
Restrictor assy for one or two area Restrictor assy for three areas

The axis 1 work area shut-off assembly makes it possible to electrically sector the robot
work area using pushbutton micro switches of different types according to the number
of areas to be sectored, in detail :
– for up to 3 work areas a six-pushbutton micro is used
– for up to 2 work areas a 4-pushbutton micro is used
– for a single work area a two-pushbutton micro switch is used.
The work areas are each controlled by two safety micro switches in conformity with the
most severe safety standards.
The assembly consists of:
• a pushbutton multiple microswitch with Harting connector;
• set of plastic cams.
The cams are to be cut to the required length for the application, then they are to be
inserted, positioned and locked on two cam holders fastened to the robot column instead
of the protection guard.
For the microswitch electrical connection the following is foreseen:
• for a three areas restrictor - a 32 pin Harting connector
• for a one or two areas restrictor - a 90° female 19-pin connector..

For the microswitch assembly internal electrical layout see the robot Circuit
Diagram.

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 Optional Equipment

8.3 Axis 2 work area partialization assembly -

2 areas

1. LH cam holder
2. RH cam holder
3. Mechanical limit switch with six pushbuttons
4. Support
5. Transfer box
6. Cam holder support

8.3.1 Description
The axis 2 work area partialization assembly enables electrical partialization of up to 2
work areas, each of which is controlled by two safety micro-switches built to the strictest
safety standards.
The assembly consists of:
• a 4-pushbutton multiple micro-switch with output to cable gland,
• a set of plastic cams to be cut to the length required for the specific application.
The cams must be inserted and blocked on the cam holders fastened to the robot by
means of the specific supports.
The free connector is supplied for the external connection.
The kit includes:
• Nr. 1 connector (supplied by FCI) 19 pins, type UTG1619SN;

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Optional Equipment

• Nr. 19 female contacts to be crimped, type SC20ML-1S6 for wires from AWG 20;
• Nr. 1 cable clamp with PG16 (for cables from Ø 8 mm2 to Ø 16 mm2).
To crimp the female pins onto the wires from AWG 20 it is recommended to use the FCI
"crimping tool" type Y14MTV or Y16SCM2.

For the circuitry diagram inside the microswitch assy, see the robot Circuit
Diagram.

Tab. 8.3 - Electrical characteristics of axis 1, axis 2 and axis 3

mechanical limit switch assembl
ELECTRICAL DATA
Type of switch BSE 85 per DIN EN 60204-1
Insulation Gruppo C (VDE 0110)
Maximum voltage 50 Vac
Maximum current 2A
Minimum load ≥ 20 mA
Contact resistance < 40 mΩ
Interruption current 2 A, cos ϕ=0,8

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 Optional Equipment

8.4 Axis 1 adjustable mechanical hard stop

assembly

1. Stopper axis 1 (q.ty 2)

2. Socket head cap screw M20 x 90-12.9

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Optional Equipment

Tab. 8.4 - Stroke limitations can be obtained with the adjustable

mechanical limit switch assy of axis 1
Corsa ax1 negativa Corsa ax1 positiva
Ax.1 negative strok e Ax.1 positive strok e
Pos.
from [°] to [°] from [°] to [°]

1 -130 -180 -125 + 180

2 -115 -180 -110 + 180
3 -100 -180 -95 + 180
4 -85 -180 -80 + 180
5 -70 -180 -65 + 180
6 -55 -180 -50 + 180
7 -40 -180 -35 + 180
8 -25 -180 -20 + 180
9 -10 -180 -5 + 180
10 5 -180 +10 + 180
11 20 -180 +25 + 180
12 35 -180 +40 + 180
13 50 -180 +55 + 180
14 65 -180 +70 + 180
15 80 -180 +85 + 180
16 95 -180 +100 + 180
17 110 -180 +115 + 180
18 125 -180 +130 + 180

8.4.1 Description
The axis 1 adjustable mechanical limit switch unit limits the stroke of axis 1 in both work
directions in steps of 15°. The group consists of two stop buffers to be attached with the
screws supplied, in the specific seats on the robot base to limit the stroke of axis 1 in
both directions; if the stroke is to be limited in only one direction, only one of the two
stops will be used
The axis 1 adjustable mechanical limit switch assembly meets "man safety"
requirements since it is able to absorb all the axis kinetic energy.

Once the stop has been used (impact), the following parts must be replaced:
- mechanical hard stop, fastening screws and dowel pin;
-rubber stop blocks and fastening screws.
Also the integrity of the robot parts involved is to be checked, for example:
- the part of the base housing the assembly;
- the part of the column housing the stop;
- the equipment being used by the robot.
Failure to replace any damaged parts will undermine correct operation (and thus
stopping) in future.

After an impact, check the clearance on axis and correct any slackening of the
axis.

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 Optional Equipment

8.5 Axis 2 adjustable mechanical hard stop

assembly (code CR82342500)

Aplicable to robot SMART5 NJ4 170-2.5 - I; SMART5 NJ4 175-2.2 - I

1. Front stopper axis 2 (code CR82000542) - GS500

2. Rear stopper axis 2 (code CR82000543) - GS500
3. Socket head cap screw M12 x 35 -12.9 [screw HSHC-ISO 4762]

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Optional Equipment

Tab. 8.5 - Stroke limitations can be obtained with the adjustable

mechanical limit switch assy of axis 2
Axis 2 negative stroke Axis 2 positive stroke
Pos.
from [°] to [°] from [°] to [°]
1 -65 -75 -55 +95
2 -50 -75 -40 +95
3 -35 -75 -25 +95
4 -20 -75 -10 +95
5 -5 -75 5 +95
6 10 -75 20 +95
7 25 -75 35 +95
8 40 -75 50 +95
9 55 -75 65 +95
10 70 -75 80 +95

8.5.1 Description
The axis 2 adjustable mechanical hard stop assembly can be used to limit the stroke of
axis 2 in both directions of work with steps of 15°.
The group consists of two sets of 2 blocks to be interposed between the column
structure and the rubber stop already installed on the robot.
The axis 2 adjustable mechanical hard stop assembly satisfies “operator safety”
requirements as it can absorb all of the kinetic energy of the axis.

Once the stop has been used (impact), the following parts must be replaced:
- mechanical hard stop, fastening screws and dowel pin;
-rubber stop blocks and fastening screws.
Also the integrity of the robot parts involved is to be checked, for example:
- the part of the base housing the assembly;
- the part of the column housing the stop;
- the equipment being used by the robot.
Failure to replace any damaged parts will undermine correct operation (and thus
stopping) in future.

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 Optional Equipment

8.6 Axis 2 adjustable mechanical hard stop

assembly (code CR82344800)
Aplicable to robot SMART5 NJ4 170-2.9 - I; SMART5 NJ4 220-2.4 - I;
SMART5 NJ4 220-2.7 - I

1. Stopper blocks ax.2 (Q.ty 2)

2. Socket head cap screw M12 x 45 -12.9 [Q.ty 12]

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Optional Equipment

8.6.1 Description
The axis 2 adjustable mechanical hard stop assembly can be used to limit the stroke of
axis 2 in both directions of work with steps of 12°.
The group consists of two sets of 2 blocks to be interposed between the column
structure and the rubber stop already installed on the robot.
The axis 2 adjustable mechanical hard stop assembly satisfies “operator safety”
requirements as it can absorb all of the kinetic energy of the axis.

Once the stop has been used (impact), the following parts must be replaced:
- mechanical hard stop, fastening screws and dowel pin;
-rubber stop blocks and fastening screws.
Also the integrity of the robot parts involved is to be checked, for example:
- the part of the base housing the assembly;
- the part of the column housing the stop;
- the equipment being used by the robot.
Failure to replace any damaged parts will undermine correct operation (and thus
stopping) in future.

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 Optional Equipment

8.7 Screws and pins kit for robot mounting (code

CR82342700)

1. Location Ø = 30 mm L = 80 mm (q.ty = 1)
2. Location Ø = 30 mm L = 60 mm (q.ty = 1)
3. Socket head cap screw M 10 x 90 (8.8) (q.ty = 1)
4. Socket head cap screw M 10 x 70 (8.8) (q.ty = 1)
5. Partially threaded hex head screw M 24 x 100 (8.8.) (q.ty = 6)
6. Split spring washer Ø = 24 mm (q.ty = 6)
7. Flat washer Ø = 24 mm (q.ty = 6)

8.7.0.1 Description
The kit consists of the screws and pins needed to secure the robot to a steel plate
provided with the relevant holes.
The steel plate and its arrangement to secure the robot is to be performed by the
installer.

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Optional Equipment

8.8 Leveling plate unit for robot mounting (code

CR82342800)

1
1

1. Leveling plate (q.ty =1)

2. Plate (q.ty 4)
3. Straight edge (q.ty = 8)
4. M20x100 fully threaded hex head cap screw -8.8 (q.ty = 4)
5. M20 -8 FE/ZN 12 hex nut (q.ty = 4)

8.8.1 Description
The robot leveling plate assembly is used to ensure that the robot is anchored correctly
to the floor. This assembly satisfies the following requirements:
– it ensures good mounting plate levelness, to avoid any incorrect stresses on the
structure of the robot base
– a perfectly aligned robot assembly that facilitate "off-line programming"
applications.
The assembly consists of:
– four steel plates that are anchored to the floor by means of chemical bolts (for a
total of 16 anchor bolts, which are not supplied)
– a leveling plate that is welded to the plates described above after using the specific
adjustment screws to obtain optimal robot leveling

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 Optional Equipment

8.9 Non adjustable plate for robot mounting

(code 82343100)

1. Robot mounting plate

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Optional Equipment

8.10 Fall-prevention brackets assembly for ceiling

attachment (code CR82348800)

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 Optional Equipment

1. Bracket
2. Bracket
3. Hex head screw M16x40
4. Hex head screw M20x40
5. Hex head screw M6x16
6. Flat washer for screw M16
7. Flat washer for screw M20

Brackets on base front Bracket on robot lower distribution

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Optional Equipment

8.10.1 Description
The fall-prevention brackets assembly for ceiling installation can be used when the robot
is attached to the ceiling, to sustain it in safety should the standard fastening screws
become loose.
The assembly consists of three strong steel brackets, two attached to the front of the
base and one on the rear above the lower distribution.
The brackets are clamped to the mounting base with 6 M16 screws. Fig. 8.1 - Plate
drilling diagram to fasten the fall-prevention brackets (codice CR82348800) on page 90
shows the centre distances and dimensions of the holes for the attachment of the
brackets to the robot support plate.

When assembling, lock all the screws to the torque indicated in the SMART
Maintenance Manual.

The procedure for robot ceiling assembly is contained in the Transport and
Installation Manual .

Fig. 8.1 - Plate drilling diagram to fasten the fall-prevention

brackets (codice CR82348800)

1. Robot fastening screws

2. Robot location pins
3. Plate fastening screws

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 Optional Equipment

8.11 NJ ceiling mounting and fall-prevention

assembly - BRIC (code CR82344700)

8.11.1 Description
The fastening and fall-prevention assembly for NJ robot attachment to the ceiling (with
BRIC structure) is a variant of the assembly described in par. 8.10 Fall-prevention
brackets assembly for ceiling attachment (code CR82348800) on page 88. The
fall-prevention brackets and the robot base are fastened by six screws (4) passing
through the robot support plate and driven-in from the upper side of this.
The assembly consists of three strong steel brackets, two (1) of which are fastened to
the front of the robot and one (2) above the lower distribution on the rear of the robot.
Also four angle brackets (3) are provided, with welded nut (5) to lock the 4 through
screws that fasten the robot base to the support plate.
The support plate that sustains the robot has to be prepared with the specified holes for
the screws as indicated in Fig. 8.3 - Plate drilling diagram to fasten the fall-prevention
brackets - BRIC on page 93.

When assembling, lock all the screws to the torque indicated in the SMART NJ4
Maintenance Manual.

The procedure for robot ceiling assembly is contained in the SMART NJ4
Transport and Installation Manual.

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Optional Equipment

Fig. 8.2 - NJ ceiling mounting and fall-prevention assembly -

BRIC (code CR82344700)

1 Staffa 10 Hex head screw M24x140

2 Bracket 11 Flat washer for screw M6
3 Bracket 12 Flat washer for screw M16
4 Bracket 13 Flat washer for screw M20
5 Bracket 14 Flat washer for screw M24
6 Centring 15 Spring washer for screw M24
7 Centring 16 Socket head cap screw M6x16
8 Hex head screw M16x80 17 Socket head cap screw M10x70
9 Hex head screw M20x40 18 Socket head cap screw M10x90

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 Optional Equipment

Fig. 8.3 - Plate drilling diagram to fasten the fall-prevention

brackets - BRIC

1. Robot fastening screws

2. Robot location pins
3. Plate fastening screws

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Optional equipment

8.12 Axis 1 adjustable mechanical hard stop

assembly (code CR82273200)

1. Mechanical hard stop (q.ty 2)

2. M20 x70 socket head cap screw (8.8) (q.ty 4)
3. M24 x80 socket head cap screw (8.8) (q.ty 4)
4. Block (q.ty 2)

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 Optional equipment

Tab. 8.6 - Possible axis 1 stroke limitations

Corsa asse 1 in senso negativo Corsa asse 1 in senso positivo

Pos.
Negative strok e axis 1 Positive strok e axis 1
da from [°] a to [°] da from [°] a to [°]
1 - - +150 -180
2 +135 +180 +135 -180
3 +105 (2x15°) +180 +105 (2x15°) -180
4 +90 +180 +90 -180
5 +75 +180 +75 -180
6 +60 +180 +60 -180
7 +45 +180 +45 -180
8 +30 +180 +30 -180
9 +15 +180 +15 -180
10 0 +180 0 -180
11 -15 +180 -15 -180
12 -30 +180 -30 -180
13 -45 +180 -45 -180
14 -60 +180 -60 -180
15 -75 +180 -75 -180
16 -90 +180 -90 -180
17 -105 +180 -105 -180
18 -120 +180 -120 -180
19 -135 +180 -135 -180
20 -150 +180 - -

After an impact, check the clearance on axis 1 and correct any slackening of the
axis.
-

Once the stop has been used (impact), the following parts must be replaced:
- mechanical hard stop and fastening screws;
-rubber stop blocks and fastening screws.
Also the integrity of the robot parts involved is to be checked, for example:
- the part of the base housing the assembly;
- the part of the column housing the stop;
- the equipment being used by the robot.
Failure to replace any damaged parts will undermine correct operation (and thus
stopping) in future.

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Optional equipment

8.12.0.1 Description

The axis 1 adjustable mechanical limit switch unit limits the stroke of axis 1 in both work
directions in steps of 15° (except the base zone above the axis 1 reduction gear, where
the centre distance is 30°).
The assembly consists of two limit switch pads (1) to be attached in the seats provided
on the robot base using the screws supplied, and two blocks (4) for the attachment of
the pads (1) in the zone of the base provided to attach the microswitch units; if the stroke
is to be limited in one direction only, use only one of the two stops.
The axis 1 adjustable mechanical limit switch assembly meets "man safety"
requirements since it is able to absorb all the axis kinetic energy.

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8.13 Axis 2 adjustable mechanical hard stop

assembly (code CR82273300)

1. Rear block (q.ty 1)

2. Rear block (q.ty 1)
3. Front block (q.ty 1)
4. Front block (q.ty 1)
5. Socket head cap screw M16x35

8.13.1 Description
The axis 2 adjustable mechanical hard stop assembly can be used to limit the stroke of
axis 2 in both directions of work with steps of 15°.
The unit consists of two sets of blocks to insert between the column structure and the
stop pad already installed on the robot.
The stroke can be limited:
• in plus direction: to +60° or +45° using two front blocks (instead of the
+75°standard stroke)
• in minus direction: to -60° or -45° using two rear blocks (instead of the -60°standard
stroke).
The axis 2 adjustable mechanical hard stop assembly satisfies “operator safety”
requirements as it can absorb all of the kinetic energy of the axis.

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Optional equipment

8.14 Axis 1 mechanical hard stop on-off assembly

(lock pin - code CR82344300

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Tab. 8.7 - Possible axis 1 stroke limitations

Corsa asse 1 in senso negativo Corsa asse 1 in senso positivo

Pos.
Negative strok e axis 1 Positive strok e axis 1
da from [°] a to [°] da from [°] a to [°]
1 - - +150 -180
2 +135 +180 +135 -180
3 +105 (2x15°) +180 +105 (2x15°) -180
4 +90 +180 +90 -180
5 +75 +180 +75 -180
6 +60 +180 +60 -180
7 +45 +180 +45 -180
8 +30 +180 +30 -180
9 +15 +180 +15 -180
10 0 +180 0 -180
11 -15 +180 -15 -180
12 -30 +180 -30 -180
13 -45 +180 -45 -180
14 -60 +180 -60 -180
15 -75 +180 -75 -180
16 -90 +180 -90 -180
17 -105 +180 -105 -180
18 -120 +180 -120 -180
19 -135 +180 -135 -180
20 -150 +180 - -

8.14.1 Description
The axis 1 mechanical hard stopmechanical hard stop on-off assembly can be used to
enable the temporary sectoring of the robot work area and can be positioned on the
whole of the axis 1 stroke with steps of 15°.
The assembly consists of a mechanical plug and a block to be attached in the coupling
surfaces provided on the robot base. With the block, the plug can be mounted also in
the base sector where the microswitch included in the group is mounted to divide the
area, maintaining the step constant.
The lock pin is operated by a rotating pneumatic actuator and is complete with safety
micro-switches and electrically-controlled solenoid valves.
Inserted in the context of appropriate cell safety devices (safety PLC, accessory safety
barriers, etc.), with the mechanical on-off limit switch assembly a situation of complete
"man safety" can be reached; the management of the plug has to be assigned to a safety
system for the control of the robot position (e.g. area shut-off assembly in work area can
be supplied by COMAU Robotics ).
A maximum of 2 groups can be used on the robot to divide 3 work areas.

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Optional equipment

8.15 Axis 1 mechanical hard stop on-off assembly

- lock pin (code CR82273600)

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Tab. 8.8 - Possible axis 1 stroke limitations

Corsa asse 1 in senso negativo Corsa asse 1 in senso positivo
Pos.
Negative strok e axis 1 Positive strok e axis 1
da from [°] a to [°] da from [°] a to [°]
1 - - +150 -180
2 +135 +180 +135 -180
3 +105 (2x15°) +180 +105 (2x15°) -180
4 +90 +180 +90 -180
5 +75 +180 +75 -180
6 +60 +180 +60 -180
7 +45 +180 +45 -180
8 +30 +180 +30 -180
9 +15 +180 +15 -180
10 0 +180 0 -180
11 -15 +180 -15 -180
12 -30 +180 -30 -180
13 -45 +180 -45 -180
14 -60 +180 -60 -180
15 -75 +180 -75 -180
16 -90 +180 -90 -180
17 -105 +180 -105 -180
18 -120 +180 -120 -180
19 -135 +180 -135 -180
20 -150 +180 - -

8.15.1 Description
The axis 1 mechanical hard stopmechanical hard stop on-off assembly can be used to
enable the temporary sectoring of the robot work area and can be positioned on the
whole of the axis 1 stroke with steps of 15°.
The assembly consists of a mechanical plug and a block to be attached in the coupling
surfaces provided on the robot base. With the block, the plug can be mounted also in
the base sector where the microswitch included in the group is mounted to divide the
area, maintaining the step constant.
The lock pin is operated by a rotating pneumatic actuator and is complete with safety
micro-switches and electrically-controlled solenoid valves.
Inserted in the context of appropriate cell safety devices (safety PLC, accessory safety
barriers, etc.), with the mechanical on-off limit switch assembly a situation of complete
"man safety" can be reached; the management of the plug has to be assigned to a safety
system for the control of the robot position (e.g. area shut-off assembly in work area can
be supplied by COMAU Robotics ).
A maximum of 2 groups can be used on the robot to divide 3 work areas.Sul robot
possono essere utilizzati fino ad un massimo di 2 gruppi per la parzializzazione di 3 aree
di lavoro.

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Tab. 8.9 - Electrical characteristics of axis 1 mechanical limit

switch assembly
ELECTRICAL DATA SG1-SG2
Description Solid state switch
Type of connection With 3 WIRES
Output PNP
Applicable load IC circuits, RELAY, PLC
Power supply voltage from 4.5 Vdc to 28 Vdc
Current draw ≤ 10 mA
Load voltage ≤ 10 Vdc
Load current ≤ 80 mA

ELECTRICAL DATA SG3

Description Microswitch with forced opening
contacts
Position of contacts 1 n.c. / 1 n.o.
Insulation Group C (VDE 0110)
Maximum nominal voltage 250 Vac
Maximum direct current 6A
Minimum load at 24 Vdc ≥ 20 mA
Contact resistance < 40 mΩ
Interruption power 2A

ELECTRICAL DATA VD1-VD2

Description Solenoid for solenoid valve
Power supply voltage 24 Vdc
Maximum voltage fluctuation ± 10% of power supply voltage
Maximum power 0,5-0,55 W

ELECTRICAL DATA X80-X81

Description Loose female connector
(HARTING 09330102701)
Type of connection Screwed (2,5 mm2/AWG 14
maximum)
Cable inlet Cable clamp PG21,
Ø outside cable from 13 mm2 to
18 mm2

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8.16 Axis 1 work area partialization assembly

( area 3 cod.CR82325600 - area 2 CR82325700 - area 1 CR82325800))

1. Micro limit switch

2. RH cam holder
3. LH cam holder
4. Cam
5. Stubbed socket head cap screw M6x10
6. Socket head cap screw M6x25
7. Socket grub screw to secure cams M6x8
8. Low hex nut M6
9. Internal thread parallel pin with dia 6x20 type B

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8.16.0.1 Description
Axis 1 work area partialization assembly Axis 1 work area partialization assembly
1-2 areas 3 areas

The axis 1 work area shut-off assembly makes it possible to electrically sector the robot
work area using pushbutton micro switches of different types according to the number
of areas to be sectored, in detail :
– for up to 3 work areas a six-pushbutton micro is used
– for up to 2 work areas a 4-pushbutton micro is used
– for a single work area a two-pushbutton micro switch is used
The work areas are each controlled by two safety micro switches in conformity with the
most severe safety standards
The assembly consists of:
• a multiple micro switch with Harting connector
• a set of plastic cams to be cut to the length required by the application and installed
on cam holder
The cams are to be inserted, positioned and clamped on the cam holders attached to
the robot column to substitute the protection guard

For the electrical connection of the microswitch the following is foreseen:

• with restrictor for three areas, a 32-pole HARTING connector
• with restrictor for one or two areas, a 90° 19-pole female connector.

For the microswitch assembly internal electrical layout see the robot Circuit
Diagram.

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8.17 Axis 2 work area partialization assembly -

2 areas (code CR82273400)

1. Support
2. Micro Switch
3. Left cam holder
4. Right cam holder
5. Stubbed socket head cap screw M6x10
6. Cam holder support
7. Cams
8. Parallel pin 4x20
9. Socket head cap screw M6x30
10. Socket head cap screw M6x12
11. Internal thread parallel pin 6x20
12. Socket head cap screw M6x25
13. Socket grub screw M6x8
14. Low hex nut M6
15. Internal thread parallel pin 6x30

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8.17.0.1 Description

The axis 2 work area partialization assembly enables electrical partialization of up to 2

work areas, each of which is controlled by two safety micro-switches built to the strictest
safety standards.
The assembly consists of:
• a 4-pushbutton multiple micro-switch with output to cable gland,
• a set of plastic cams to be cut to the length required for the specific application.
The cams must be inserted and blocked on the cam holders fastened to the robot by
means of the specific supports.

The free connector is supplied for the external connection.

The kit includes:
• Nr. 1 connector (supplied by FCI) 19 pins, type UTG1619SN;
• Nr. 19 female contacts to be crimped, type SC20ML-1S6 for wires from AWG 20;
• Nr. 1 cable clamp with PG16 (for cables from Ø 8 mm2 to Ø 16 mm2).

To crimp the female pins onto the wires from AWG 20 it is recommended to use the FCI
"crimping tool" type Y14MTV or Y16SCM2.

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Tab. 8.10 - Electrical characteristics of axis 1, axis 2 and axis 3

mechanical limit switch assembly
ELECTRICAL DATA
Type of switch BSE 85 per DIN EN 60204-1
Insulation Gruppo C (VDE 0110)
Maximum voltage 50 Vac
Maximum current 2A
Minimum load ≥ 20 mA
Contact resistance < 40 mΩ
Interruption current 2 A, cos ϕ=0,8

8.18 Screws and pins kit for robot mounting (code

82314700)
8.18.1 Description
The kit consists of the screws and pins needed to secure the robot to a steel plate
provided with the relevant holes.
The steel plate and its arrangement to secure the robot is to be performed by the
installer, with reference to following Fig. 8.4 - Screws and pins kit for robot mounting on
page 108

Key: Fig. 8.4 - Screws and pins kit for robot mounting on page 108
1. Location Ø = 30 mm L = 80 mm (q.ty = 1)
2. Location Ø = 30 mm L = 60 mm (q.ty = 1)
3. M 10 x 90 socket head cap screw (8.8) (q.ty = 1)
4. M 10 x 70 socket head cap screw (8.8) (q.ty = 1)
5. Partially threaded hex head screw M 24 x 100 (8.8.) (q.ty = 6)
6. Split spring washer Ø = 24mm (q.ty = 6)
7. Flat washer Ø = 24 mm (q.ty = 6)

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Fig. 8.4 - Screws and pins kit for robot mounting

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8.19 Leveling plate unit for robot mounting

(code 82314800)

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Key Leveling plate unit for robot mounting (code 82314800)

1. Leveling plate (q.ty =1)
2. Plate (q.ty 4)
3. Straight edge (q.ty = 8)
4. M20x100 fully threaded hex head cap screw -8.8 (q.ty = 4)
5. M20 -8 FE/ZN 12 hex nut (q.ty = 4)

8.19.1 Description
The robot leveling plate assembly is used to ensure that the robot is anchored correctly
to the floor. This assembly satisfies the following requirements:
– it ensures good mounting plate levelness, to avoid any incorrect stresses on the
structure of the robot base.
– a perfectly aligned robot assembly that facilitate "off-line programming"
applications.
The assembly consists of:
– four steel plates that are anchored to the floor by means of chemical bolts (for a
total of 16 anchor bolts, which are not supplied).
– a leveling plate that is welded to the plates described above after using the specific
adjustment screws to obtain optimal robot leveling.

8.20 Calibration tool (code 82314100)

1. Dial gauge holder

2. Tapered ring nut
3. Probe
4. Dial gauge

8.20.1 Description
The calibration kit with dial gauge is used to enable the correct manual calibration of
each robot axis.
The kit consists of a dial gauge holder that is screwed into the specific seats on each of
the robot axes and a centesimal dial gauge to find the correct calibration position.

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Tab. 8.11 - Example of use of the calibration kit

SMART5 NJ4 220 – 2.4 - I;
SMART5 NJ4 170 – 2.9 - I ;
SMART5 NJ4 220 – 2.7 - I;
ROBOT SMART5 NJ4 170 – 2.5 - I ;
SMART5 NJ4 220 – 3.0 - I;
SMART5 NJ4 175 – 2.2 - I
SMART5 NJ4 270 – 2.7 - I
a. Remove guards
from calibration
reference surfaces
and from seat for
dial gauge holder
fixture.

b. Align calibration
reference surfaces
by sight.

c. Assembly of dial
gauge holder
fixture.

d. Search for axis

calibration point.

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Optional equipment

8.21 Gauged tool assembly L=200 mm

(code 82109501)
8.21.1 Description
The gauged tool assembly is used to calculate the TCP (Tool Center Point) in relation
to the robot flange.
The assembly consists of a cylindrical test rod of a length that is defined so that the end
is at an exact position in relation to the center of the wrist.
The prod is screwed directly onto the axis 6 output flange in a radial position in relation
to the latter and there is no need to disassemble any tools that are installed on the
flange.

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Fig. 8.5 - SMART5 NJ4 170 – 2.9 - I;

SMART5 NJ4 170 – 2.5 - I;
SMART5 NJ4 175 – 2.2 - I;
(ISO 9409-1- A160)- front view

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Optional equipment

Fig. 8.6 - SMART5 NJ4 170 – 2.9 - I;

SMART5 NJ4 170 – 2.5 - I;
SMART5 NJ4 175 – 2.2 - I
(ISO 9409-1- A160)- lateral view

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Fig. 8.7 - SMART5 NJ4 220 – 2.4 - I;

SMART5 NJ4 220 – 2.7 - I;
SMART5 NJ4 220 – 3.0 - I;
SMART5 NJ4 270 – 2.7 - I
(ISO 9409-1- A160)- front view

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Optional equipment

Fig. 8.8 - SMART5 NJ4 220 – 2.4 - I;

SMART5 NJ4 220 – 2.7 - I;
SMART5 NJ4 220 – 3.0 - I;
SMART5 NJ4 270 – 2.7 - I
(ISO 9409-1- A160)- lateral view

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8.22 Fork liftable option

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8.22.1 Description
The forks assembly is an option necessary to lift and handle the robot by means of a lift
truck.
The assembly consists of two electro-welded steel boxed section supports, fastened in
a pre-set position of the robot column by means of screws. The forks of the lift truck are
inserted into the boxed sections to handle the robot safely in a balanced position

Before using he forks assembly read the use information in the manual supply
with the assembly

8.23 Distribution connection guard assembly

SMART5 NJ4 220 3.0 - I; SMART5 NJ4 270 2.7 - I
Code CR82276800

SMART5 NJ4 170-2.5 - I; SMART5 NJ4 175-2.2 - I; SMART5 NJ4 170 2.9 - I; SMART5 NJ4 220 2.4 - I;
SMART5 NJ4 220 2.7 - I;
Code CR82352200

8.23.1 Description
The assembly consists of a robust guard made out of sheet metal that is fastened to the
base of the robot to protect all the connectors connected to the robot distribution unit.

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8.24 Guard assembly for ventilated motor ax1

(code 82309259)

8.24.1 Description
The assembly consists of a strong sheet metal guard that is secured to the robot axis 1
reduction unit to protect the electric connectors of axis 1 motor.

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COMAU Robotics services
Repair: [email protected]
Training: [email protected]
Spare parts: [email protected]

Original instructions
Technical service: [email protected]
comau.com/robotics