Comau Robot Rebel s6 Technical Specifications Transport and Installation and Maintenance PDF

Robot Rebel-S6
Rel. 1.0
Technical Specifications,
Transport and Installation and
Maintenance
Description of the available versions and technical

features of the application
Integration principles of the application and
description of the available options
Information on the preparations and necessary
requirements for installation of the application
Maintenance procedures
CR00758126-en_00/2016.11
Instructions handbook
The contents of this handbook are the property of COMAU S.p.A.
Any reproduction, even partial, is prohibited without prior written authorization from COMAU S.p.A.
COMAU reserves the right to modify, without notice, the features of the product presented in this handbook.
Copyright © 2008-2016 by COMAU - Published on 11/2016

Comau Robotics Product Instruction
SUMMARY
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Documents storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Limits on the handbook contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Symbols used in the handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MODIFICATION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1. GENERAL SAFETY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Essential safety requirements applied and fulfilled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2. TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

Robot general description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Robot axes identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Declaration of incorporation of partly completed machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Name and address of the manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Available versions and technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Available versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operational areas and Robot overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Robot wrist features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Wrist loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Machining tool fixing on Robot wrist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149) . . . . . . . . . . . . . . . . . . . . . . . .39
Interfaces on Robot wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Description of the Robot mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Matching with the Control Unit and user customizations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Management and control through Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Connections overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Robot connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
X50 connector pinout on Robot base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
X70 connector pinout on Robot wrist body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
3
SUMMARY
AIR fittings features on Robot wrist base/body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Robot integration principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Available solutions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Screws and pins unit for Robot fixing (CR82417300). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Stresses on the supporting structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Integration of the Robot in production cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Axis 1 mechanical limit switch (CR82417400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Devices for calibration and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Robot axes integrated brake releasing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Calibrated Tool Unit - Tool Master L=117 mm (81783801) . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Calibration tool (CR82415200). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Tool for ball screw disassembly (CR82392144). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Plate for tensioning axis 4 belt (CR82392162). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3. TRANSPORT AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..74

Installation summarizing table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Preparation for Robot installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Staff in charge of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Working environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Installation environment requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Environment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Operating space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Operating environment prearrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Foundations preparations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Stresses on the supporting structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Robot transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Robot weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Robot overall dimensions and transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Robot lifting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Robot Rebel-S6-0.xx lifting and transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Robot Rebel-S6-0.xxc lifting and transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Robot Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Preliminary requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Possible installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Robot floor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Drilling diagram on backing plan for Robot floor fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Procedure of Robot fixing to the backing surface (floor installation) . . . . . . . . . . . . . . . . . .87
Robot wall installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Drilling diagram on backing plan for Robot wall fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Procedure of Robot fixing to the backing surface (wall installation) . . . . . . . . . . . . . . . . . . .91
Robot ceiling installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Drilling diagram on backing plan for Robot ceiling fixing . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Procedure of Robot fixing to the backing surface (ceiling installation) . . . . . . . . . . . . . . . . .94
Robot installation completion and/or customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Installation of the ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149) option on the
Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4
SUMMARY
Suggestions for the construction of a tool suitable for ISO tool coupling flange ISO 9409 - 1 -
A40 (CR82392149). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Suggestions for the construction of the flange, to be carried out by the Integrator . . . . . . . 100
Modifications in the Robot Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Robot connection with R1C-4 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Preliminary precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Connection with the R1C-4 Control Unit (main motors and encoder cables). . . . . . . . . . . . 104
Connection of I/O signals cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Operations related to the first startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Precautions before the first power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Control Unit power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Floor / ceiling / wall installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Load auto-determination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Safety functional verifications of the robotic system integrated in the production cell . . . . . 107
4. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...108
General requirements for the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Precautions during the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Precautions at the end of the maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Maintenance staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Assembly notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Parts disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Assistance for troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Problem analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Diagnostic messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Traceability for replacement purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Components replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Robot wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Comau service centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
How to disconnect the electrical power supply on R1C-4 Control Unit . . . . . . . . . . . . . . . . . . 116
Precautions and risks associated with the electrical power supply disconnection . . . . . . . . 116
Disconnection of the electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
How to move the Robot in case of emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Use of the brake releasing device integrated on Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Risks deriving from Robot axes releasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Usage procedure of the integrated brake release device. . . . . . . . . . . . . . . . . . . . . . . . . .120
Maintenance structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Summary diagram of the maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Preventive maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Robot cleaning and general inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Encoder batteries: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5
SUMMARY
Lubrication procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Precautions when using lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Remarks on lubrication operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Summary of lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Axes 3 and 4 recirculating ball screw lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Special maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Special maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
AXIS 1 MOTOR: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
AXIS 3 BELT: complete replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
AXIS 4 BELTS: complete replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
AXIS 3 RECIRCULATING BALL SCREW: complete replacement . . . . . . . . . . . . . . . . . . . 187
WIRING: complete replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Software procedures following the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Encoder recognition procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Robot calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Calibration - Basic concepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Calibration tool description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Reference notches description and position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
Calibration - Operating procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Axis 3 and 4 calibration tool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
Robot axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
Axis 2 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
Procedures following the calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Calibration position check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235
Calibration position check with Tool Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
Saving the calibration file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
6
PREFACE
PREFACE
This chapter contains:
– Reference documentation
– Documents storage
– Limits on the handbook contents
– Symbols used in the handbook
– Modification History.
Reference documentation
This document refers to the Robot in standard outfitting indicated below:
– Rebel-S6-0.45 - Rel. 1.0
– Rebel-S6-0.60 - Rel. 1.0
– Rebel-S6-0.75 - Rel. 1.0
– Rebel-S6-0.60c - Rel. 1.0
– Rebel-S6-0.75c - Rel. 1.0
The structure of the complete set of handbooks describing the Robot and Control Unit
is detailed in the following table:
Manufacturer Robot Set of Handbooks

– Technical Specifications,
Robot Rebel-S6-0.xx
Transport, Installation and
Comau Robot Rebel-S6-0.xxc
Maintenance
Rel. 1.0
– Electrical circuit diagram
These handbooks must be integrated with the following documents:
Manufacturer Description Set of Handbooks

R1C-4 Control Unit – Technical Specifications,
Transport, Installation and
Comau Maintenance
– Use of R1C-4 Control Unit
– Electrical circuit diagram
Programming – PDL2 Programming
Language Manual
Comau
– Motion programming
– VP2 Visual PDL2
7
PREFACE
Documents storage
All provided documentation must be placed in close proximity to the area where is
installed the robotic system, maintained available for all people that work on it and
preserved intact for the entire operational life of the robotic system.
Limits on the handbook contents

The images included in the instructions handbook have the purpose to represent the
product
and can differ from what is actually visible on the robotic system.
Symbols used in the handbook

Here are the symbols that represent: WARNING, CAUTION and NOTES and their
meaning.
This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed may cause injuries to the staff.
This symbol indicates operating procedures, technical information and precautions that
if are not observed and/or correctly performed may cause equipment damage.
The symbol indicates operating procedures, technical information and precautions that
must be underlined.
The symbol draws the attention to materials disposal that is regulated by the WEEE
Directive.
The symbol points out to avoid environmental contamination and to properly dismiss the
materials in the appropriate collection sites.
8
MODIFICATION HISTORY
MODIFICATION HISTORY
The following table shows the history of the Handbook release, with related changes /
improvements made.
Edition of the
Date Contents
Handbook
2016-09 00/2016.09 First release of the Handbook.
2016-11 00/2016.11 Added Chap.4. - Maintenance on page 108
9
GENERAL SAFETY REQUIREMENTS
1. GENERAL SAFETY REQUIREMENTS
This chapter deals with general specifications that apply to the whole Robot System.
Considering its significance, this chapter is referred unreservedly in each system
instructions handbook.
This chapter deals with the following topics:

– Responsibilities
– Safety requirements.
1.1 Responsibilities
– The system integrator is responsible for ensuring that the Robotic system (Robot
and Control Unit) is installed and handled in accordance with the Safety Standards
in force in the country where the installation takes place. The application and use
of the necessary protection and safety devices, the issuing of declaration of
conformity and any EC marking of the system are the responsibility of the
Integrator.
– COMAU refuses any responsibility for accidents caused by incorrect or improper

use of the Robotic system (Robot and Control Unit), by tampering with circuits,
components, software and with the use of spare parts that are not included in the
spare parts list.
– The application of these Safety Requirements is the responsibility of the persons
assigned to direct / supervise the activities indicated in the section Applicability,
which should make sure that the Authorised Personnel is aware of and
scrupulously follow the requirements contained in this document in addition to the
general Safety Standards applicable to Robotic system (Robot and Control Unit) in
force in the Country where the system is installed.
– The non-observance of the Safety Standards may cause to the operators
permanent injuries or death and can damage the Robotic system (Robot and
Control Unit).
The installation shall be carried out by qualified Personnel and must conform to all
National and Local standards.
10
1.1.1 Essential safety requirements applied and fulfilled

The robotic system consisting of Control Unit and Robot considers as applied and
fulfilled the following Essential Safety Requirements, Annex I of 2006/42/EC Machinery
Directive: 1.1.3 – 1.1.5 – 1.2.1 – 1.2.2 – 1.2.3 – 1.2.4.3 – 1.2.5 – 1.2.6 – 1.3.2 – 1.3.4 –
1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4 – 1.5.6 – 1.5.8 – 1.5.9 – 1.5.10 – 1.5.11 – 1.5.13 – 1.6.3
– 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2 – 1.7.4.
In case only the Robot is provided are to be considered as applied the following
requirements: 1.1.3 – 1.1.5 – 1.3.2 – 1.3.4 – 1.3.8.1 – 1.5.1 – 1.5.2 – 1.5.4 – 1.5.6 – 1.5.8
– 1.5.9 – 1.5.10 – 1.5.11 – 1.5.13 – 1.6.4 – 1.6.5 – 1.7.1 – 1.7.1.1 – 1.7.2 – 1.7.4.
1.2 Safety requirements
1.2.1 Purpose
These safety requirements are aimed to define the behaviour and obligations to be
observed when performing the activities listed in the Applicabilitysection.
1.2.2 Definitions
Robotic system (Robot and Control Unit)
Robotic system is the workable assembly composed of: Robot, Control Unit, Teach
Pendant and other possible options.
Protected Area
The protected area is the zone confined by the protection barriers and intended to be
used for the installation and operation of the Robot.
Authorised Personnel
Authorised personnel defines the group of persons who have been appropriately trained
and assigned to carry out the activities listed in the section Applicability.
Staff in Charge
The staff in charge defines the personnel who manage or supervise the activities of the
employed persons defined in the preceding point.
Installation and Startup

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

Operating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual movement of Robot axes and programming
of work cycles at low speed, programmed cycle testing at low speed and, when allowed,
at working speed.
11
Functioning in Auto / Remote Mode

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

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

Decommissioning is defined as the activity that involve the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.
Integrator
The integrator is the professional expert responsible for the Robot and Control System
installation and startup.
Misuse
Misuse is defined as the use of the system outside the limits specified in the Technical
Documentation.
Action Area
The Robot action area is the enveloping volume of the area occupied by the Robot and
its equipment during movement in the area.
1.2.3 Applicability
These requirements must be applied when carrying out the following activities:
– Installation and Startup
– Functioning in Programming Mode
– Functioning in Auto / Remote Mode
– Maintenance and Repair
– Decommissioning and Dismantling.
12
1.2.4 Operating modes

Installation and Startup
– The startup is only possible when the Robot and Control System has been correctly
and completely installed.
– The system installation and startup is exclusively the task of the authorised
personnel.
– The system installation and startup is only permitted exclusively inside a protected
area of an adequate size to house the Robot and the equipment it is outfitted with,
without passing beyond the protection barriers. It is also necessary to check that in
normal Robot movement conditions there is no collision with parts inside the
protected area ( e.g structural columns, power supply lines, etc.) or with the
barriers. If necessary, limit the Robot work area using mechanical hard stop (see
optional units).
– Any fixed Robot control stations must be located outside the protected area and in
a point such as to permit a full view of the Robot movements.
– The Robot installation area must be as free as possible from materials that could
impede or limit the visibility.
– During installation the Robot and the Control Unit must be handled as described in
the product Technical Documentation; if lifting is necessary, check that the
eye-bolts are fixed securely and use only adequate slings and equipment.
– Fix the Robot to mount holder, with all the provided bolts and pins, tightened to the
tightening torque indicated in the product Technical Documentation.
– If present, remove the fixing brackets of the axes and verify the proper fixing of the
equipment the Robot is outfitted with.
– Check that the Robot guards are correctly fixed and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– Install the Control Unit outside the protected area: the Control Unit should not be
used as part of the fencing.
– Check that the voltage value of the power mains is consistent with that indicated
on the nameplate of the Control Unit.
– Before electrically connect the Control Unit, check that the circuit breaker on the
power mains is locked in open position.
– The connection between the Control Unit and the three-phase supply mains of the
plant, must be made using the cable included in the supply or by means of a cable
(User charge) having the same characteristics and appropriate size for the power
installed on the Control Unit. See the product Technical Documentation.
– Connect the ground cable (PE) then connect the power conductors to the main
switch.
– Connect the power supply cable, first connecting the ground cable to the circuit
breaker on the power mains line, after checking with a tester that the circuit breaker
terminals are not powered. It is recommended to connect the cable armouring to
the earth.
– Connect the signals and power cables between the Control Unit and the Robot.
– Connect the Robot to earth or to the Control Unit or to a nearby earth socket.
13
– A wrong connection of the connectors may cause permanent damage to the

Control Unit components.
– The Control Unit manages internally the main safety interlocks (gates, enabling
push-buttons, etc.). Connect the Control Unit safety interlocks to the line safety
circuits, taking care to connect them as required by the Safety Standards. The
safety of the interlock signals coming from the transfer line (emergency stop, gates
safety devices etc.) i.e. the realisation of correct and safe circuits, is the
responsibility of the Robot and Control System integrator.
In the cell/line emergency stop circuit it is necessary to include the contacts of the
Control Unit emergency stop push-buttons, available on X30. The push-buttons are not
interlocked inside the emergency stop circuit of the Control Unit.
– The safety of the system cannot be guaranteed in case of interlocks erroneous,

incomplete or missing execution.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic mode; in Programming mode the power is disabled
immediately.
– When preparing protection barriers, especially light curtains and access doors,
take into consideration the Robot stopping times and distances according to the
stop category (0 or 1) and the weight of the Robot.
– Check that the environmental and operating conditions do not exceed the limits
specified in the Technical Documentation of the specific product.
– The calibration operations must be carried out with great care, as indicated in the
Technical Documentation of the specific product, and should be concluded by
checking the correct position of the machine.
14
– To load or update the system software (for example after boards replacing), use
only the original software handed over by COMAU. Scrupulously follow the system
software loading procedure described in the Technical Documentation supplied
with the specific product. After loading, always make some Robot moving tests at
low speed remaining outside the protected area.
– Check that the barriers of the protected area are correctly positioned.
Functioning in Programming Mode

– The programming of the Robot is exclusively the task of the authorized personnel.
– Before starting to program, the operator must check the Robotic system (Robot
and Control Unit) to make sure that there are no potentially dangerous irregular
conditions, and that there is nobody inside the protected area.
– The programming should be controlled from outside the protected area whenever
possible.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the Teach Pendant is working properly (low
speed, emergency stop device, enabling device, etc.).
– During the programming phases, only the operator with the Teach Pendant is
allowed inside the Protected Area.
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (DRIVE ON) always must be controlled from a position
outside the operating range of the Robot, after checking that there is nobody in the
area involved. The Drive On operation is considered complete when the relevant
machine status indication is shown.
– When programming, the operator must remain at an appropriate distance from the
Robot to be able to avoid any irregular machine movements, and in any case in a
suitable position to avoid the risk of being trapped between the Robot and
structural parts (columns, barriers, etc.), or between movable parts of the Robot.
– When programming, the operator must avoid to remain in a position where parts of
the Robot, pulled by gravity, could move downwards, upwards or sideways (when
installed on an inclined plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at low speed has been carried out. The
test must be controlled from a safe distance.
– Special attention is to be paid when programming using the Teach Pendant: in this
situation, although all the hardware and software safety devices are active, the
Robot movement depends on the operator.
– During the first running of a new program, the Robot may move along a path that
is not the one expected.
– The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the Robot position
out of the path that links two steps of the program), could give rise to movements
not envisaged by the operator when testing the program.
15
– In both cases operate cautiously, always remaining out of the Robot range of action
and test the cycle at low speed.
Functioning in Auto / Remote Mode

– The activation of the automatic operation (AUTO and REMOTE states) is permitted
only with the Robotic system (Robot and Control Unit) integrated inside an area
with protection barriers properly interlocked, as required by the Safety Standards
currently in force in the Country where the installation takes place.
– Before starting the automatic mode the operator must check the Robot and Control
System and the protected area to make sure there are no potentially dangerous
irregular conditions.
– The operator can activate automatic operation only after having checked:
• that the Robot and Control System is not in maintenance or repair status;
• that the protection barriers are correctly positioned;
• that there is nobody inside the protected area;
• that the Control Unit doors are closed and locked with the appropriate key;
• that the safety devices (emergency stop, protection barrier safety devices)
are functioning;
– Special attention is to be paid when selecting the remote mode, in which the line
PLC can perform automatic operations of motors power up and program starting.
16
Maintenance and Repair

– When assembled in COMAU the Robot is supplied with lubricants that do not
contain any harmful to health substances, however, in some cases, repeated and
prolonged exposure to the product may cause skin irritation, or if swallowed,
sickness.
First Aid Measures. In case of contact with the eyes or skin: rinse the affected
areas with copious amounts of water; should irritation persist, seek medical advice.
If swallowed, do not induce vomiting or administer anything by mouth; consult a
doctor as soon as possible.
– Maintenance, trouble-shooting and repair are only to be carried out by authorised
personnel.
– When carrying out maintenance and repair operations, the specific warning sign
stating the maintenance status must be placed on the control panel of the Control
Unit, until the end of the operation, even if it should be temporarily suspended.
– Maintenance and components or Control Unit replacement operations must be
carried out with the main switch in open position and locked with a padlock.
– Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages deriving from connection to peripheral units or external
power sources (e.g. 24 Vdc input/output). Power off the external sources when
operating on involved system parts.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open.
– Faulty components are to be replaced with others having the same Part No., or
equivalent components defined by COMAU.
– Trouble-shooting and maintenance activities must be carried out, whenever
possible, outside the protected area.
– Trouble-shooting executed on the control is to be carried out, whenever possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards must be observed
when operating in presence of dangerous voltages.
– Trouble-shooting on the Robot must be carried out with the power supply turned
off (DRIVE OFF).
– At the end of the maintenance and trouble-shooting operations, all the deactivated
safeties must be reset (panels, protection shields, interlocks, etc.).
– Maintenance, repair and trouble-shooting operations must be concluded with the
check of the correct functioning of the Robotic system (Robot and Control Unit) and
all the safety devices, executed from outside the protected area.
– During the software loading phases (for example after replacement of electronic
boards) use only the original software handed over by COMAU. Scrupulously
follow the system software loading procedure described in the specific product
Technical Documentation; after loading, to be sure, always run a test cycle,
remaining outside the protected area
– The disassembly of Robot components (e.g. motors, balancing cylinders, etc.) may
cause uncontrolled movements of the axes in different directions: before starting a
disassembly procedure, consult the warning plates applied on the Robot and the
Technical Documentation supplied.
17
– It is strictly forbidden to remove the protective covering of the Robot springs.
Decommissioning and Dismantling

– The decommissioning and removal of the Robot and Control System is exclusively
the task of Authorised Personnel.
– Move the Robot in transport position and assemble the axes locking brackets
(when required) following the instructions on the plate on the Robot and its
Technical Documents.
– Before decommissioning the mains voltage of the Control Unit must be powered
off (switch off the circuit breaker on the power mains and lock it in open position).
– After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the power mains,
first disconnecting the power conductors, then the earth one. Disconnect the power
supply cable from the Control Unit and remove it.
– First disconnect the connection cables between the Robot and the Control Unit,
then the ground cable.
– If present, disconnect the Robot pneumatic system from the air distribution mains.
– Check that the Robot is properly balanced and if necessary sling it correctly, then
remove the Robot securing bolts from the mount holder.
– Remove the Robot and Control Unit from the work area, following all the
requirements indicated in the products Technical Documents; if lifting is necessary,
check the eyebolts proper fixing and use only suitable slinging devices and
equipment.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU, or one of its
branches, who will indicate, according to the type of Robot and Control Unit, the
operating methods in accordance with safety principles and environment
safeguarding.
– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.
18
TECHNICAL SPECIFICATIONS
2. TECHNICAL SPECIFICATIONS
– Robot general description
– Robot axes identification
– Declaration of incorporation of partly completed machinery
– Name and address of the manufacturer.
– Available versions and technical features
– Robot wrist features
– Description of the Robot mechanics
– Matching with the Control Unit and user customizations
– Robot integration principles
– Devices for calibration and maintenance
– Options
19
2.1 Robot general description

The Robot is a machine specifically designed and constructed to be used in industrial
environments.
To function properly, the Robot must be matched with the specific R1C-4 Control Unit.
The Control Unit features must be consistent with the connected Robot.
The Robot Rebel-S6 is particularly suitable for applications of:
• Assemblies
• Handling
• Pick & Place.
20
2.2 Robot axes identification

Hereinafter are identified the Robot axes:
Robot Rebel-S6-0.xx
Ax Robot axis Mtr4 Ax2

Ax3
Mtr Motor axis
Mtr3
Ax1
Ax4
Mtr2
Mtr1
Robot Rebel-S6-0.45 representative image

Robot Rebel-S6-0.xxc
Ax2
Ax Robot axis
Mtr Motor axis
Ax3
Mtr4
Mtr3
Ax4
Mtr2 Mtr1
Ax1
Robot Rebel-S6-0.60c representative image
21
2.3 Declaration of incorporation of partly completed

machinery
The assembly composed of the Robot and the Control Unit is provided with a
declaration of incorporation of partly completed machinery, as stated in the Annex
II b. of the 2006/42/EC Machinery Directive.
It is forbidden to startup the assembly consisting of the Robot and Control Unit before
the machine in which it will be incorporated has been declared in compliance with the
regulations stated in the 2006/42/EC Machinery Directive.
The Declaration of incorporation of partly completed machinery is provided in

original copy with the assembly composed of the Robot and Control Unit.
The identification plate (Fig. 2.1) is installed on the Robot body.
Fig. 2.1 - Robot identification plate (example)
A xxxx
xxxxxxx
xxxxxxxxxx
B xxxx REL. xxx
C CRxxxxxxxx
E xx lb / xx kg
– A: Name and address of the manufacturer

– B: Machine name and release
– C: Product Part No.
– D: The date of issue and the serial number
– E: Weight
2.4 Name and address of the manufacturer

The manufacturer, as defined in the Machinery Directive, is indicated on the nameplate
of the Robot (see Fig. 2.1, “A” field).
22
2.5 Available versions and technical features

This paragraph contains:
– Available versions
– Technical features.
– Operational areas and Robot overall dimensions
2.5.1 Available versions

The versions of the available Robots are listed in the following Tab. 2.1 - Robot
Rebel-S6 available versions on page 23.
Tab. 2.1 - Robot Rebel-S6 available versions
Reach (to
Maximum Nominal
the wrist Assemblin Part No.
Robot type wrist load wrist load Application type
centre) g position Robot
(kg) (lb) (kg) (lb)
(mm) (ft)
Rebel-S6-0.45 450
CR82412300
Rel. 1.0 (17.71)
Rebel-S6-0.60 600
Floor / Wall CR82412400
Rel. 1.0 (23.62)
Handling,
Rebel-S6-0.75 6 1 750
CR82412500 Assemblies, Pick
Rel. 1.0 (13.22) (2.2) (29.52)
& Place
Rebel-S6-0.60c 600
CR82415700
Rel. 1.0 (23.62)
Ceiling
Rebel-S6-0.75c 750
CR82415800
Rel. 1.0 (29.52)
Rebel-S6-0.45 Rebel-S6-0.60c
Robot Rebel-S6-0.45 and Rebel-S6-0.60c representative image
23
2.5.2 Technical features

Tab. 2.2 - Robot Rebel-S6 technical features
VERSION Rebel-S6-0.45 Rebel-S6-0.60 Rebel-S6-0.60c Rebel-S6-0.75 Rebel-S6-0.75c

Structure / n° axes SCARA / 4 axes
Maximum wrist load 6 kg (13.22 lb)
Nominal wrist load 1 kg (2.20 lb)
Admissible inertia on
0.12 kg x m²
axis 4
Admissible inertia on
0.12 kg x m²
axis 5
Axis 1 +/- 132° (450°/s)
Stroke Axis 2 +/- 150° (720 °/s)
/(Speed) Axis 3 -50 mm / +150 mm (1300 mm/s)
Axis 4 +/- 2700° (2400 °/s)
Max horizontal reach 450 mm (1.48
600 mm (1.97 ft) 750 mm (2.46 ft)
ft)
Repeatability +/- 0.02 mm
Robot weight 19 kg (41.88
20 kg (44.09 lb) 21 kg (46.29 lb)
lb)
Motors AC Brushless
Position measurement
Encoder
system
IP protection degree IP10 (IP54*)
ISO protection degree Bellows (Axis Z stroke reduction - 30 mm)
Assembly position Floor / Wall Ceiling Floor / Wall Ceiling
Matchable Control Unit R1C-4
Operating environment
+5°C to +45°C
temperature
Storage temperature -10°C to + 55°C
Relative humidity 5% to 95% without condensate
Maximum temperature
1.5 °C/min
gradient
* Optional
24
2.5.3 Operational areas and Robot overall dimensions

This paragraph contains the drawings of the operational areas of the available versions:
– Rebel-S6-0.45
– Rebel-S6-0.60
– Rebel-S6-0.60c
– Rebel-S6-0.75
– Rebel-S6-0.75c
25
Fig. 2.2 - Rebel-S6-0.45
(450)
275 175 162
STROKE +150
560 MAX
0
57
STROKE -50
669 Base mounting face
506,95
450
Maximum space
175
290
°
° -132
-150
115
0
0
115
506,95
+15
Center of joint #3
R33
450
0°
R2 1,95
+132 75
°
R15
50
R4
1,31
449,05
392,1
5
,9
450
06
R5
506,95
Dimensions in millimetres
26
27
Fig. 2.3 - Rebel-S6-0.60
(600)
275 325 162
stroke +150
560 max
0
57
stroke -50
656,95
Maximum space
600
-150° -132°
240
115
0
115
Center of joint #3
+150 +13
° 2°
656,95
R331,95
600
R162
R2
75
,628
00
R6
549,42
492,47
5
,9
56
600
R6
656,95
28
29
Fig. 2.4 - Rebel-S6-0.60c
(600)
275 325 162
Base mounting face

145 MAX
STROKE -265
STROKE -465
239
57
819
Maximum space
656,95
600
275
°
-150° -132 4 3
150
0
2
7
+15 +13 5 6 150
Center of joint #3
0°
600
2°
656,95
R331,95
R162,6
R2
75
3
00
R6
492,47
549,42
95
,
56
600
R6
656,95
30
31
Fig. 2.5 - Rebel-S6-0.75
(750)
275 475 162
stroke +150
560 max
0
stroke -50

969
0
806,95
750
Maximum space
317,84
-150° °
-132
0 77,994
0
77,994
+150 +132
° °
Center of joint #3
1,95
806,95
R33
R273
R275
,9
750
50
R7
592,84
649,79
5
,9
06
R8
750
806,95
32
33
Fig. 2.6 - Rebel-S6-0.75c
(750)
275 475 162
-265 145 MAX
Base mounting face

STROKE
239
57
STROKE+465
969
0
806,95
750
Maximum space
1
273,86
317,84
°
-150 -132°
2
0
+150 +132 3
° °
Center of joint #3
1,95
806,95
R33
R273
R275
,9
750
50
R7 4
649,79
592,84
, 95
06
750
R8
806,95
34
35
2.6 Robot wrist features

This Paragraph contains:
– Wrist loads
– Machining tool fixing on Robot wrist
– Interfaces on Robot wrist
36
2.6.1 Wrist loads

The max load (P) that can be applied to the Robot flange is defined using the wrist load
graphs where the maximum load (P) curves are plotted according to the coordinates LZ
and LY of the load barycentre.
Robot
Rebel-S6
The area defined by the loading curves defines the barycentre distances admissible for
load application specified on the area.
In the following Fig. 2.7 is shown the diagram of Max load capacity on the Robot
Rebel-S6 flange.
The inertia specified in the graph curves refers to the centre of gravity of the load applied
on the flange.
When applying loads different from the values specified in the graphs, check the Robot
use limitations by means of the SMART Payload software function.
Fig. 2.7 - Max load capacity on the Robot Rebel-S6 flange
0 0,05 0,1 0,15 0,2 0,25 0,3 0,35 0,4

Lxy [m]
6 5 4 3 2 1 [kg]
The illustrated graph is to be considered valid by using a control system appropriately

dimensioned according to technical characteristics of the machine motors.
37
2.6.2 Machining tool fixing on Robot wrist

The Robot wrist is designed for the fixing of the user's machining tool.
To ensure a proper installation, the machining tool must be fixed to the shaft end by
means of an adapter flange.
It is possible to install:
– the ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149) option, can be
supplied by Comau upon request;
– a flange properly realized by the user; in this regard in the following Fig. 2.8 are
indicated the dimensions of the fixing point on the shaft.
Fig. 2.8 - Flange fixing point for tool on Robot wrist.
Detail a
View from A
B B
40
+90°
10
15
10
ø3
ø 14
ø 20 h7
A
a
8,5
87,2
17
174,4 B-B
38
2.6.2.1 ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149)
Purpose
The ISO flange allows the proper fixing of the machining tool on the Robot wrist.
Technical features and structure

The option consists of a metal coupling flange, 2 fixing screws and a grub screw.
Fixing components
– Socket hex head screws M5x16 (q.ty 2)
– Cone point grub screw M4x10 (q.ty 1).
Limitations
– Do not install tool weighing more than the Robot capacity.
For details, see the Robot par. 2.5.2 Technical features on page 24 .
39
Fig. 2.9 - Option method of use diagram
1. Socket hex head screw M5x16 - 12.9 - ISO 4762

2. Cone point grub screw M4x10 - 45H - ISO 4027
40
2.6.3 Interfaces on Robot wrist

On the upper part of the Robot wrist is present the plate (A) on which there are the
following interfaces:
– Signal lamp (B) that indicates the Drive On status of the Robot;
– Robot axes integrated brake releasing device (C);
– Fittings and connectors to perform the necessary Robot connections.
On Robot Rebel-S6-0.60c and Rebel-S6-0.75c the plate (A) is rotated 180°.
Fig. 2.10 - Interfaces detail on Robot wrist
A B
41
2.7 Description of the Robot mechanics
Degrees of freedom
The Robot is of SCARA type with 4 degrees of freedom.
Robot Rebel-S6 configuration

The Robot Rebel-S6-0.45 model consists mainly of a base unit and a wrist unit.
The base unit of aluminum alloy integrates the gearmotor for axis 1 and is anchored to
the floor or wall according to the type of installation.
On the base unit, rotates the wrist unit that integrates the gearmotors for axes 2, 3 and
4. In the wrist body is present also the axis 3 sliding screw.
The socket head screw allows to insert within it cables and pipes to bring on the tool
installed on the wrist, possible customer's installations.
In the models Rebel-S6-0.60 and Rebel-S6-0.75c it is present, in single or double
configuration, a spacer that extends the arm and increases the working area of the
Robot.
Rebel-S6-0.45
A- Base unit
B- Wrist unit
A
B
42
Rebel-S6-0.60
A- Base unit
B- Spacer
C- Wrist unit
Rebel-S6-0.60c
A- Base unit
B- Spacer
C- Wrist unit
C
B
A
43
Rebel-S6-0.75
A- Base unit
B- Spacer
C- Wrist unit
C
B
Rebel-S6-0.75c
A- Base unit
B- Spacer
C- Wrist unit C
44
Spacer
The spacer is made of aluminum alloy and has a standard length of 150 mm. The spacer
is provided with centering dowel pins and screws for precise fixing on the base unit and
on the wrist unit or on any additional spacer. Depending on the needs, the User may
require Comau to provide for the additional installation* of spacers (up to two
consecutive, as shown in Fig. 2.11) obtaining an increase of up to 300 mm of the length
of the reach.
For further details see par. 3.5.3 Modifications in the Robot Reach on page 101.
*Not possible on Rebel-S6-0.75 and Rebel-S6-0.75c
Fig. 2.11 - Spacer
Robot axes motors

The Robot has four axes (details in par. 2.2 Robot axes identification on page 21):
– axes 1 and 2 controlled by gearmotors
– axes 3 and 4 controlled by motor, belt drive system and ball screw.
The motors are of AC brushless type and integrate inside them the encoder. The axis 3
and 4 motors are also provided with integrated brake.
The gearboxes are of the type with reduced clearance specific for robotic applications.
45
Robot axes stroke limitation (Areas limitation)

Robot axes are provided with software limit switches (programmable).
In addition, the Robot axis 1 stroke limitation can be reached by installing the Axis 1
mechanical limit switch (CR82417400) option, thus obtaining the partialization of the
safety areas (details in par. 2.9.4).
Ball screw
The Robot wrist is equipped with ball screw with spline shaft to ensure a high positioning
accuracy.
The vertical motion (Ax 3) and rotation (Ax 4) of the ball screw are controlled by two
specific motors through belt drive.
At the end of the screw, two mechanical limit switches are fixed.
Inside the ball screw it is possible to insert cables and pipes to bring on the tool installed
on the wrist, possible customer's installations (see Fig. 2.8).
Fig. 2.12 - Ball screw
46
Encoder supply batteries

Inside the wrist there are two batteries of 1.5 Ah, 3.6 V to power the motors encoders
even with the Control Unit turned off.
Fig. 2.13 - Encoder supply batteries
The batteries have a duration of five years; any anomalies or malfunctions are signalled
to the operator by alarm on the Teach Pendant page (optional) or on PC (via WinR1C
software).
The verification and replacement procedures are indicated in the Maintenance chapter
of this handbook.
47
2.8 Matching with the Control Unit and user

customizations
– Management and control through Control Unit
– Connections overview
– Robot connections
– X50 connector pinout on Robot base
– X70 connector pinout on Robot wrist body
– AIR fittings features on Robot wrist base/body
2.8.1 Management and control through Control Unit

The Robot is managed and controlled by the COMAU Control Unit and is not allowed
another matching.
The Robot is matched with a specific size of the Control Unit (see purchase Part No. on
the Control Unit handbook).
The electrical connection between Robot and Control Unit is made possible by specific
Kits of connection cables.
In addition apposite options on Control Unit can solve integration requirements.
For this Robot version, it is possible the matching with the following Control Units:
– R1C-4 Control Unit
Robot Rebel-S6 in configuration with R1C-4 Control Unit
A Robot
B R1C-4 Control Unit
B
C Connection cables kit
R1C-4 Control Unit (B) and the connection cables (C) are described in the Technical
specifications, Transport and Installation and Maintenance handbook of R1C-4 Control
Unit.
48
2.8.2 Connections overview

The integrator must connect the Robot to the Control Unit through specific cables (see
par. 2.8.1).
In addition, he provides on the Robot several prearrangements to optimize the Robot
integration in the production process (air connection, electrical connections).
Robot Rebel-S6-0.xx
A Base plate (A) B

B Wrist applications connection (B)
Robot Rebel-S6-0.xxc
A Base plate (A) B

B Wrist applications connection (B)
On Robot Rebel-S6-0.60c and Rebel-S6-0.75c the Base plate (A) the plate Wrist
applications connection (B) are rotated 180°.
49
2.8.2.1 Robot connections

The following figure shows all available connections on the base plate of the Robot
(distribution panel, A) and all optional connections available on the Robot wrist (B).
Robot base plate
AIR1 AIR2
AIR3
X50
A
A
X1 X2
Base plate (A)
Code
Function Description
Base plate Wrist body
X1 --- Encoder signals cable gland ---
Motor and Brakes signals
X2 --- ---
cable gland
Quick coupling fitting for air pipe Ø 6 mm. The
AIR1 AIR1 AIR1 fitting for air delivery internal pipe reaches up to the AIR1 fitting on
Robot wrist body.
AIR2
AIR2 AIR2 fitting for air delivery internal pipe reaches up to the AIR2 fitting on
Robot wrist body.
AIR3 AIR3 AIR3 fitting for air delivery internal pipe reaches up to the AIR3 fitting on
Robot wrist body.
The X50 connector is connected to the X70
Connector for I/O signals connector in the wrist body area, by means of a
X50 X70
cable. cable inside the Robot that connects all the pins.
For further details see par. 2.8.2.2.
50
Robot wrist body (B)
AIR3 X70 AIR1 AIR2
Wrist applications connection (B)
Code
Function Description
Wrist body
The X70 connector is connected to X50
X70 I/O signals connector connector on Robot base with specific cable. For
further details see par. 2.8.2.2.
AIR1 AIR fitting for air passage pipe starts at the Robot base (AIR1) and reaches
up to the Robot wrist body without interruptions.
Quick coupling fitting for air pipe Ø 4mm. The
51
2.8.2.2 X50 connector pinout on Robot base

– Connector for:
• I/O signals
• 24 Vdc
– male 15 pins (on Robot base)
Front view - Male connector

Tab. 2.3 - X50 connector pinout detail

Pin Description* Pin Description*
1 INPUT5 9 OUTPUT2
2 INPUT6 10 OUTPUT3
3 INPUT1 11 OUTPUT4
4 INPUT2 12 0 Vdc OUT
5 INPUT3 13 OUTPUT5
6 +24 Vdc I/O 14 OUTPUT6
7 INPUT4 15 0 Vdc
8 OUTPUT1
*Pinout valid only when using the optional connection cable between Control Unit and Robot (Services cable).
In the absence of such a cable, the X50 connector is available to the User and can be used according to the
specific needs. The X50 connector is connected pin-to-pin to X70 connector on Robot wrist body, through
internal cable.
52
2.8.2.3 X70 connector pinout on Robot wrist body

– Connector for:
• I/O signals
• 24 Vdc
– female 15 pins crimp (on Robot wrist body)
Front view - Female connector

Tab. 2.4 - X70 Connector pinout detail

Pin Description* Pin Description*
1 INPUT5 9 OUTPUT2
2 INPUT6 10 OUTPUT3
3 INPUT1 11 OUTPUT4
4 INPUT2 12 0 Vdc OUT
5 INPUT3 13 OUTPUT5
6 +24 Vdc I/O 14 OUTPUT6
7 INPUT4 15 0 Vdc
8 OUTPUT1
*Pinout valid only when using the optional connection cable between Control Unit and Robot (Services cable).
In the absence of such a cable, the X50 connector is available to the User and can be used according to the
specific needs. The X50 connector is connected pin-to-pin to X70 connector on Robot wrist body, through
internal cable.
2.8.2.4 AIR fittings features on Robot wrist base/body

– Quick coupling fittings for air supply to the devices
installed on Robot
– pipe external Ø 6 mm (AIR1 and AIR2)
– pipe external Ø 4 mm (AIR3)
– max supported pressure 1 MPa (10 Bar)
53
2.9 Robot integration principles

– Available solutions for installation
– Stresses on the supporting structure
– Integration of the Robot in production cells
2.9.1 Available solutions for installation

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

Robot type Installation Type
Optional Robot fixing
Available solutions
components
Rebel-S6-0.45
Rebel-S6-0.60 Floor / Wall
Backing surface / supporting Screws and pins unit for Robot
Rebel-S6-0.75
structure (made by the integrator) fixing (CR82417300)
Rebel-S6-0.60c
Ceiling
Rebel-S6-0.75c
54
2.9.1.1 Screws and pins unit for Robot fixing (CR82417300)
Purpose
The fixing screws and pins unit allows to properly fix the Robot on the floor, to the wall
and on ceiling.

The unit consists of screws and pins needed to fix the Robot to a steel backing surface
provided with appropriate holes.
Limitations
– Use 1 unit to fix 1 Robot.
Fixing components
– Socket hex head screw M8x25 8.8 ISO 4762-A3K (q.ty 4) (A)
– Plain washer, internal Ø 8 mm (q.ty 4) (B)
– Split spring washer 8x14,8x2 DIN127B (q.ty 4) (C)
– Dowel pin with extraction hole Ø 6x20 (q.ty 2) (D)
55
Fig. 2.14 - Robot floor and ceiling fixing option method of use diagram
Tolerance applies only to pins
1 1
3 4 Detail A 3
2 2
1. Socket hex head screw M8x25 8.8 ISO 4762-A3K
2. Plain washer, internal Ø 8 mm
3. Split spring washer 8x14,8x2 DIN127B
4. Dowel pin with extraction hole Ø 6x20
56
Fig. 2.15 - Robot wall fixing option method of use diagram
1 Detail A
3
1
3 4
1. Socket hex head screw M8x25 8.8 ISO 4762-A3K
2. Plain washer, internal Ø 8 mm
3. Split spring washer 8x14,8x2 DIN127B
4. Dowel pin with extraction hole Ø 6x20
57
2.9.2 Stresses on the supporting structure

The possible vibrations transmitted by machines nearby the Robot installation area, can
reduce the precision and repeatability of the Robot movements.
It is recommended to prepare a suitable foundation in order to reduce at minimum level
the transmitted vibrations.
Because of the considerable stress discharged on the ground by the Robot and the need
to have appropriate backing plans, direct fixing on the floor is not foreseen.
The values of stresses created by the Robot on the supporting structure are indicated in
he following Fig. 2.16 - Stresses on the supporting structure on page 59.
58
Fig. 2.16 - Stresses on the supporting structure
Diagram valid for Robot Rebel-S6-0.45, Rebel-S6-0.60 and Rebel-S6-0.75
Mk
Fv
Mr
Fo
Diagram valid for Robot Rebel-S6-0.60c and Rebel-S6-0.75c
Mk
Fv
Mr
Fo
Robot Rebel-S6-0.60c representative image
59
Robot model Movement Type Fv (N) Fo (N) Mr (Nm) Mk (Nm)

Accelerating 310 300 140 130
Rebel-S6-0.45
Emergency braking 460 600 280 250
Rebel-S6-0.60
Rebel-S6-0.60c
Rebel-S6-0.75
Rebel-S6-0.75c
The figures represent the Robot installed on the floor / ceiling but are valid also for Robot
installed in other positions (e.g. to wall).
60
2.9.3 Integration of the Robot in production cells

To guarantee the minimum safety requirements of the Robot integrated in production
cells, it is possible to limit the axes stroke, depending on the cell configuration and
specific production needs.
The axis stroke limitation allows to avoid interferences with other machine parts and
assure a safe area, usually the one where the operator works, during the motion
trajectories of the Robot working cycle.
It is possible to install on the Robot a series of options to partialize its axes in safety
areas, as shown in the following table.
Type of
Available solutions for areas limitation Supply Application
intervention
Axis 1
Axis 2
Software limit switch Standard Software*¹
Axis 3
Axis 4
Type of
Available solutions for safety areas partialization Supply Application
intervention
Axis 1 mechanical limit switch (CR82417400) Optional Axis 1 Mechanical*²
Software *¹: Detection of the work areas

Mechanical *²: Mechanical stop by means of screw
61
2.9.4 Axis 1 mechanical limit switch (CR82417400)
Purpose
The mechanical stop block option (mechanical limit switch) axis 1 allows to limit the
stroke of the Robot axis 1.

The mechanical limit switch consists of two stop screws (A).
The screws must be fixed, according to the specific requirements, in two of the four
holes on the Robot arm, close to the base.
On Robot Rebel-S6-0.45, Rebel-S6-0.60 and Rebel-S6-0.75 the screws of the Axis 1

mechanical limit switch (CR82417400) must be mounted on the lower side of the Robot
arm. On Robot Rebel-S6-0.60c and Rebel-S6-0.75c the screws must be mounted on the
upper side of the Robot arm.
It is possible to mount, in all configurations, one or both of the stop screws (A) thus
obtaining the following stroke limitations:
– negative limit switch ÷ 0° / 0° ÷ + 100°
– negative limit switch ÷ 0° / 0° ÷ + 115°
– -100° ÷ 0 / 0 ÷ positive limit switch
– -115° ÷ 0 / 0 ÷ positive limit switch
– -100° ÷ 0 / 0 ÷ +100°
– -100° ÷ 0 / 0 ÷ +115°
– -115° ÷ 0 / 0 ÷ +100°
– -115° ÷ 0 / 0 ÷ + 115°
The axis 1 mechanical limit switch it is able to absorb all the axis kinetic energy.
62
After the impact of the axis 1 on the set screws, the stop screws must be replaced.
Also the integrity of the parts involved in the impact is to be checked, such as:
– Robot arm in the fixing area of the stop screw
– Robot base in the vicinity of the impact area
– equipment moved by Robot
The failed replacement in case of impact will undermine the correct functioning (and
therefore the Robot stopping) in case of later interventions.
Limitations
– Use max 2 mechanical limit switches for each Robot (to limit the axis 1 stroke in
both rotation directions).
63
Fig. 2.17 - Option method of use diagram
Configuration with stroke limitation ± 100°
1 1
1. Axis 1 mechanical limit switch (q.ty 2 socket hex head screws - ISO 4762 - M10X25 - 12.9 - A3K)
64
Configuration with stroke limitation ± 115°
1 1
1. Axis 1 mechanical limit switch (q.ty 2 socket hex head screws - ISO 4762 - M10X25 - 12.9 - A3K)
65
2.10 Devices for calibration and maintenance

The Robot is provided with a series of devices necessary to carry out the calibration and
maintenance operations, as described in the following table.
Tab. 2.5 - Available devices

Robot type Description Ref.
Robot axes integrated brake releasing device par. 2.10.1

Calibrated Tool Unit - Tool Master L=117 mm (81783801) par. 2.10.2
Rebel-S6-0.xx /
Calibration tool (CR82415200) par. 2.10.3
Rebel-S6-0.xxc
Tool for ball screw disassembly (CR82392144) par. 2.10.4
Plate for tensioning axis 4 belt (CR82392162) par. 2.10.5
66
2.10.1 Robot axes integrated brake releasing device
Purpose
In absence of motive power, the Robot axes 3 and 4 movement is possible by means of
brake releasing devices.
The integrated brake releasing device allows the brake deactivation of the axis 3 and 4
by pressing the button A (provided with identification logo as shown in figure) on the
Robot wrist plate.
During the axes brake release activity, all the system safety devices (including the
emergency stop and the enabling push-button) are cut-off.

The integrated brake releasing device consists of the button to release the brake of the
axes 3 and 4.
It is electrically connected to the dedicated pins on XMTR3 and XMTR4 connectors of
the Robot motors.
In order to be able to operate the integrated brake releasing device requires:
• The electric power is delivered to the Control Unit.
• The Control Unit is ON with 24Vdc section available and working properly.
• Robot connected to the Control Unit.
• Motors off (Drive OFF). With Drive ON motors, the push-button pressure is
not influential.
Limitations
– Motion freedom of axes is conflicted and slowed down by dynamic braking.
Refer also to the R1C-4 Control Unit “Technical Specifications, Transport and
Installation, Maintenance” handbook.
For details, see the Robot Maintenance Chapter.
67
2.10.2 Calibrated Tool Unit - Tool Master L=117 mm (81783801)
Purpose
The calibrated tool unit (A) is used to calculate the TCP (Tool Centre Point) in relation
to the Robot flange.

The unit consists of a cylindrical push rod of defined length so that the end is positioned
at a precise point in relation to the Robot flange centre.
This push rod is screwed directly on the ISO tool coupling flange ISO 9409 - 1 - A40
(CR82392149) in radial position to it and does not require the disassembly of the
equipment possibly mounted on the flange itself.
When it is not used to calculate the TCP, the calibrated tool must be removed from the
Robot flange.
Limitations
– It requires the presence of the ISO tool coupling flange ISO 9409 - 1 - A40
(CR82392149) option.
68
2.10.3 Calibration tool (CR82415200)
AX 3 and 4 AX 1 and 2
Purpose
The calibration tool option consists of a mechanical key, a flange and a bracket.
The option allows to manually carry out a proper calibration of each Robot axis.

The calibration of the axes 1 and 2 is carried out using the mechanical key (Fig. 2.18) to
be inserted into the specific seats on axis 1 and 2 of the Robot.
The calibration of the axis 3 and 4 will be carried out by fixing the bracket and the flange
to the wrist using the appropriate screws. Then align the bracket and the flange so as to
obtain a seat where to insert the mechanical key(Fig. 2.19).
Limitations
– None
Fig. 2.18 - Axis 1 - 2 calibration tool use diagram
1. Mechanical key
69
On Robot Rebel-S6-0.60c and Rebel-S6-0.75c the axis 1 calibration notch is situated on

the opposite side to what shown in figure.
Fig. 2.19 - Axis 3 - 4 calibration tool use diagram
1. Bracket
2. Flange
3. Mechanical key
70
2.10.4 Tool for ball screw disassembly (CR82392144)
Purpose
The tool allows the assembly of the axis 3 and 4 pulleys on the ball screw, in case of
replacement of the screw itself.

The option consists of a metal shaft (A) having different diameters, which, inserted
inside the ball screw, allows the disassembly of the two bearing units on which the axes
3 and 4 pulleys will have to be assembled.
71
2.10.5 Plate for tensioning axis 4 belt (CR82392162)
Purpose
The plate allows to perform the tensioning of the axis 4 first belt after the replacement
of the axis 4 motor.

The option consists of a drilled metal plate (A) to be inserted on the axis 4 bearing unit
in order to allow the tensioning of the axis 4 belt (using a compression dynamometer).
72
2.11 Options
The Robot can be integrated with additional options to better adapt to the installation
requirement. These options, if not differently specified, can be chosen among the
available ones, combining them. All possible limitations to the mutual incompatibility or
maximum quantity that can be installed are clearly defined.
For a better finding, the options are listed below organised according to the topic and
application field, while the details are directly described in the related chapter.
Tab. 2.6 - Available options
Available options for installation

– Screws and pins unit for Robot fixing (CR82417300)
– ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149)
Available options for integration in production cells
– Axis 1 mechanical limit switch (CR82417400)
Available options for calibration
– Calibrated Tool Unit - Tool Master L=117 mm (81783801)
– Calibration tool (CR82415200)
Available options for maintenance
– Robot axes integrated brake releasing device
– Tool for ball screw disassembly (CR82392144)
– Plate for tensioning axis 4 belt (CR82392162)
73
TRANSPORT AND INSTALLATION
3. TRANSPORT AND INSTALLATION
3.1 Installation summarizing table

The table below summarises the Robot installation sequence.
The table can be used as a check list for the installation activities progress. In this case
it is recommended to copy the table below and fill in the appropriate box “Done” at the
end of each operation.
Tab. 3.1 - Installation summarizing table
Step Operation Done

Preparation for Robot installation
1 Working environmental conditions
2 Operating environment prearrangements
3 Foundations preparations
4 Stresses on the supporting structure
Robot transport
5 Robot overall dimensions and transport position
6 Robot lifting and transport
Robot Installation
7 Robot floor installation:
– Drilling diagram on backing plan for Robot floor
fixing
– Procedure of Robot fixing to the backing surface
(floor installation)
8 Robot wall installation
– Drilling diagram on backing plan for Robot wall
fixing
(wall installation)
9 Robot ceiling installation
– Drilling diagram on backing plan for Robot
ceiling fixing
(ceiling installation)
Robot installation completion and/or customization
10 Installation of the ISO tool coupling flange ISO 9409
- 1 - A40 (CR82392149) option on the Robot
11 Suggestions for the construction of the flange, to be
carried out by the Integrator
12 Modifications in the Robot Reach
Robot connection with R1C-4 Control Unit
13 Connection with the R1C-4 Control Unit (main
motors and encoder cables)
74
Tab. 3.1 - Installation summarizing table (Continued)
Step Operation Done

14 Connection of I/O signals cables
75
3.2 Preparation for Robot installation

– Staff in charge of installation
– Working environmental conditions
– Operating environment prearrangements
– Foundations preparations
– Stresses on the supporting structure.
Before carrying out any type of installation operation carefully read the Chap.1. -
General Safety Requirements on page 10.
The Robot has to be matched with Comau Control Unit. Any other use is prohibited.
Possible exceptions must be expressly authorised by COMAU.
76
3.2.1 Staff in charge of installation

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

– Installation environment requirements
– Environment data
– Operating space.
3.2.2.1 Installation environment requirements

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

– Operating environment temperature: +5°C ÷ +45°C.
– Relative humidity: 5% ÷ 95% without condensate.
– Storage environment temperature: -10 °C ÷ 55 °C.
Store only in closed, dry and protected from weather conditions environments.
– Maximum temperature gradient: 1.5 °C/min.
For further information see the par. 2.5.2 Technical features on page 24 of the Robot.
77
3.2.2.3 Operating space
The maximum overall dimension of the Robot operating area is indicated in the graphs
Operational areas and Robot overall dimensions (see par. 2.5.3 on page 25) in the
chapter “Technical Specifications” of the Robot.
3.2.3 Operating environment prearrangements

The area chosen for the Robot installation must be equipped with connections required
for:
– Robot and Control Unit functioning (electrical system)
– application functioning foreseen for the Robot (pneumatic system).
3.2.4 Foundations preparations

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

The possible vibrations transmitted by machines nearby the Robot installation area, can
reduce the precision and repeatability of the Robot movements.
It is recommended to prepare a suitable foundation in order to reduce at minimum level
the transmitted vibrations.
to have appropriate backing plans, direct fixing on the floor is not foreseen.
The Robot must be fixed on a horizontal flat surface with flatness tolerance of:
0,2 .
When choosing the place of installation, make sure that there is an adequate space
(approximately 50 cm) next to the Robot base, in order to allow easy access to the Robot
distribution panel (e.g. for maintenance operations).
3.2.5 Stresses on the supporting structure
The graphs and the values of the stress generated by the Robot are listed in the
paragraph Stresses on the supporting structure (see par. 2.9.2 on page 58) in the
chapter “Technical Specifications” of the Robot.
78
3.3 Robot transport

– Robot weight
– Robot overall dimensions and transport position.
– Robot lifting and transport.
79
3.3.1 Robot weight

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

Robot Rebel-S6-0.45 without packaging 19 kg (41.88 lb)
Robot Rebel-S6-0.60 without packaging
20 kg (44.09 lb)
Robot Rebel-S6-0.60c without packaging
Robot Rebel-S6-0.75 without packaging
21 kg (46.29 lb)
Robot Rebel-S6-0.75c without packaging
3.3.2 Robot overall dimensions and transport position

The values of the angles position of the Robot individual axes (transport position) differ
depending on the Robot Rebel-S6-0.xx model, and are listed in the following Tab. 3.2.
Tab. 3.2 - Robot transport positions (individual axes values)
Data valid for Robot Rebel-S6-0.45
Axis 1 Axis 2 Axis 3 Axis 4

Joint position (± 0.5°)
+132° -150° +50 mm 0°
Data valid for Robot Rebel-S6-0.60 and Rebel-S6-0.60c

+132° +150° + 50 mm 0°
Data valid for Robot Rebel-S6-0.75 and Rebel-S6-0.75c

+132° +150° +50 mm 0°
The Robot is stable only in transport position and without the installed equipment.
Any movement of the Robot axes made when the Robot is not fixed to the floor can
cause overturning.
For details on lifting and transport procedures of various Robot models, see the next
par. 3.3.3 Robot lifting and transport on page 81.
80
3.3.3 Robot lifting and transport

The following are the main operations required for a correct lifting and transport of the
Robot:
– Robot Rebel-S6-0.xx lifting and transport
– Robot Rebel-S6-0.xxc lifting and transport
If it would be necessary to lift the Robot after the installation (lifting from fixing surface),
the lifting shall always be carried out by means of a translation perpendicular to the fixing
surface until obtaining the extraction of the pins from the seats on Robot base, in order
to avoid damages to the centering pins.
3.3.3.1 Robot Rebel-S6-0.xx lifting and transport
Equipment: – Truck for Robot transport (minimum carrying capacity 25

Kg)
– If necessary, ropes for Robot anchoring
Lifting diagram:
Operative notes: Move the Robot in transport position (see Tab. 3.2).
–Working in two, manually lift the Robot by holding

it from the parts (A) indicated in figure.
– Pose the Robot on the transport truck, ensuring its
stability.
– If necessary, suitably anchor the Robot to the truck, for
example using appropriate ropes.
– Move the Robot near the installation position.
81
3.3.3.2 Robot Rebel-S6-0.xxc lifting and transport
Equipment: – Truck for Robot transport (minimum carrying capacity 25

Kg)
– If necessary, ropes for Robot anchoring
Lifting diagram:
A A
Operative notes: Move the Robot in transport position (see Tab. 3.2).
–Working in two, manually lift the Robot by holding

it from the parts (A) indicated in figure.
– Pose the Robot on the transport truck, ensuring its
stability.
– If necessary, suitably anchor the Robot to the truck, for
example using appropriate ropes.
– Move the Robot near the installation position.
82
3.4 Robot Installation

– Preliminary requirements
– Possible installations
– Robot floor installation
– Robot wall installation
83
3.4.1 Preliminary requirements
to have appropriate backing plans:
– direct fixing on the floor is not foreseen.
– the Robot must be fixed on a horizontal flat surface with flatness tolerance of:
0,2 .
It should be noted that in order to use the load auto-determination option it is necessary
to have some cubic meters of free space to allow the Robot axes to move while
performing the function.
The Robot must be fixed: to a metal backing surface (plate / structure) fitted with
drillings, see Fig. 3.1, for screws and pins (for the main dimensions of the fixing points
see Screws and pins unit for Robot fixing (CR82417300) in the Technical Specifications
chapter).
The backing surface must be realised by the integrator and made of S235JR steel.
In case of Robot Rebel-S6-0.60c and Rebel-S6-0.75c (ceiling installation), the backing

surface must be realized in such a way as to allow freedom of movement of the
corrugated pipe of the wiring (outgoing from the upper side of the Robot base).
The integrator must check the stresses discharged by the Robot and the resistance
conditions on the backing surface / structure (see par. 2.9.2 Stresses on the supporting
structure on page 58) and fix properly the backing surface / structure of the Robot to the
floor or on any specific equipment / supporting stand.
84
3.4.2 Possible installations

The Robot Rebel-S6, depending on the model, can be installed on the floor, wall or
ceiling.
Depending on the type of chosen installation, it is necessary to perform the following
specific procedures:
– Robot floor installation
– Robot wall installation
– Robot ceiling installation
3.4.3 Robot floor installation

The Robots Rebel-S6-0.xx can be installed on the floor, on flat metal surface fitted with
appropriate holes, to be realized by the Integrator.
Below are given:
– Drilling diagram on backing plan for Robot floor fixing
– Procedure of Robot fixing to the backing surface (floor installation)
to be executed for the Robot floor installation.
85
3.4.3.1 Drilling diagram on backing plan for Robot floor fixing

The following figure Fig. 3.1 represents the drilling diagram to be carried out on the
backing plan for Robot floor fixing.
Fig. 3.1 - Drilling diagram on backing plan for Robot floor fixing
B A A
CL
A
A
B
A A
Tolerance only
on pins
Section A - A
N° 2 holes N° 4 holes
ø6H7 - thru M8 - thru
A: threaded holes for Robot fixing (details on Screws and pins unit for Robot fixing (CR82417300))
B: centring holes (details on Screws and pins unit for Robot fixing (CR82417300))
86
3.4.3.2 Procedure of Robot fixing to the backing surface (floor installation)
Status: – Power turned off

Material: – Components of the Screws and pins
unit for Robot fixing (CR82417300)
Equipment: – Torque wrench with 6 mm bit
Fixing – Socket hex head screw M8x25 8.8
components: ISO 4762-A3K (q.ty 4)
– Plain washer, internal Ø 8 mm
– Split spring washer 8x14,8x2; DIN127
B
– Dowel pin with extraction hole Ø 6x20
Preliminary procedures / notes

None
Operating procedure
C C
B A
B C
A = Diagram of the backing plane drilling position (Plate / Structure)

B = Through hole for pin Ø=6 mm H7
C = Threaded through hole M8
87
Operating procedure (Continued)

a. Clean the backing surface E and the Robot base D.
b. Lift the Robot as indicated in
par. 3.3.3 Robot lifting and
transport on page 81.
J
H
F
c. Position properly the Robot D G
on the backing plan E .
E D
d. Insert in the seat the 2 pins F.
e. Insert the 4 fixing screws J, the

4 washers G and the 4 split
spring washers H.
f. Tighten the 4 fixing screws J to

a 25 Nm. torque.
Follow-up procedures
None
88
3.4.4 Robot wall installation

The Robots Rebel-S6-0.xx can be installed on the wall, on flat metal surface fitted with
Below are given:
– Drilling diagram on backing plan for Robot wall fixing
– Procedure of Robot fixing to the backing surface (wall installation)
to be executed for the Robot floor installation.
89
3.4.4.1 Drilling diagram on backing plan for Robot wall fixing

The following figure Fig. 3.2 represents the drilling diagram to be carried out on the
backing plan for Robot wall fixing.
Fig. 3.2 - Drilling diagram on backing plan for Robot wall fixing
A A
B B
A
CL
A A
Section A - A
N° 4 holes N° 2 holes
M8 - thru ø6H7 - thru
A: threaded holes for Robot fixing (details on Screws and pins unit for Robot fixing (CR82417300))
B: centring holes (details on Screws and pins unit for Robot fixing (CR82417300))
90
3.4.4.2 Procedure of Robot fixing to the backing surface (wall installation)

B

None
Operating procedure
C C
B B
C CL C
A = Diagram of the backing surface drilling position (Plate / Structure)

91

Carry out the operations by working in two.
a. Clean the backing surface E and the Robot base D.

For the lifting, refer to par. 3.3.3 Robot lifting and transport on page 81.
b. Position the Robot on the

backing plane E.
c. Insert the 2 pins F.

F
d. Insert the 4 fixing screws J, the
4 washers G and the 4 split
spring washers H.
e. Tighten the 4 fixing screws J to

a 25 Nm. torque.
J HG D
None
92
3.4.5 Robot ceiling installation

The Robots Rebel-S6-0.xxc can be installed on ceiling, on flat metal surface fitted with
Such backing surface / supporting structure must be realized in such a way as to allow
freedom of movement of the corrugated pipe of the wiring, outgoing from the upper side
of the Robot base (for details, refer to par. par. 3.4.1)
Below are given:
– Drilling diagram on backing plan for Robot ceiling fixing
– Procedure of Robot fixing to the backing surface (ceiling installation)
to be executed for the Robot ceiling installation.
3.4.5.1 Drilling diagram on backing plan for Robot ceiling fixing
The drilling diagram for Robot ceiling fixing is identical to the drilling diagram for Robot
floor fixing. Please refer to par. 3.4.3.1.
93
3.4.5.2 Procedure of Robot fixing to the backing surface (ceiling

installation)

B

None
Operating procedure
C C
B A
B D
C
C
A = Diagram of the backing plane drilling position (Plate / Structure)

D = Compartment for Robot wiring corrugated pipe coming out (see Fig. 3.4)
94

Carry out the operations by working in two.
a. Clean the backing surface F and the Robot base E.

For the lifting, refer to par. 3.3.3 Robot lifting and transport on page 81.
b. Lift the Robot from the transport

truck. E F
c. Position the Robot on the
backing surface F, making sure
that the corrugated pipe of the
wiring can move freely.
d. Insert the 2 pins G. H

J
e. Insert the 4 fixing screws K, the K
4 washers H and the 4 split G
spring washers J.
f. Tighten the 4 fixing screws K to

a 25 Nm. torque.
None
95
3.5 Robot installation completion and/or

customization
This paragraph provides the following information:
– Installation of the ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149) option
on the Robot
– Suggestions for the construction of the flange, to be carried out by the Integrator
– Modifications in the Robot Reach
96
3.5.1 Installation of the ISO tool coupling flange ISO 9409 - 1 -

A40 (CR82392149) option on the Robot

Material: – ISO tool coupling flange ISO 9409 - 1
- A40 (CR82392149)
Equipment: – Torque wrench with 3 and 4 mm insert
Fixing – Socket hex head screw M5x16 (q.ty 2)
components: – Grub screw M4x10

– The following procedure represents the Robot Rebel-S6-0.45. However, the
procedure is valid for all Robot Rebel-S6 models.
Operating procedure
a. Clean the seat of the axis 3 shaft A on which will be installed the flange.
b. Position the flange B on the
shaft.
c. Align the hole C present on the

shaft, with the hole D present on
the flange. A
d. After having reached the
correct positioning, insert and C
tighten the fixing grub screw B
M4x10 inside the hole D. D
e. Tighten the two socket hex
head screws M5x16 E to the 6
Nm. torque.
97
None
98
3.5.1.1 Suggestions for the construction of a tool suitable for ISO tool
coupling flange ISO 9409 - 1 - A40 (CR82392149)
When using the option ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149), the
Integrator must provide for the construction of a machining tool suitable for the flange
itself. In the following Fig. 3.3 and Fig. 3.4 are given the drilling diagrams and
mechanical drawings of the flange, useful for the construction of the machining tool.
Fig. 3.3 - Drilling diagram on flange (1 of 2)

10
5 - THRU
R25
M6 - 6H
4x
A
A
8
+0,012
10
20
6 H7 0
25 ±0,025 25
D
5,50
13
8
0.04 B
SECTION A-A
1.6
1.6
6 H7
63 h8 -0,046
0
99
Fig. 3.4 - Drilling diagram on flange (2 of 2)
R
2
A 1.6 1 X 45°
1.6
SECTION D-D
B
+0,025
31,50 H7 0
0.03 A
3.5.2 Suggestions for the construction of the flange, to be

carried out by the Integrator
If the ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149) option is not used, the
Integrator may realize a customized flange.
In order to allow the correct assembly on the axis 3 shaft of the Robot, this flange must
be realized according to the dimensions specified in par. 2.6.2 Machining tool fixing on
Robot wrist on page 38.
100
3.5.3 Modifications in the Robot Reach

The Reach of the Robot can be changed, with steps of 150 mm, from a minimum value
of 450 mm to a maximum of 750 mm.
To accomplish this, you must carry out:
– the installation (or removal) of the Spacer (details in par. 2.7 Description of the
Robot mechanics on page 42)
– the installation of appropriate Kit Update, as shown in the following:
Tab. 3.3 - Kit Update ordering part numbers
Part No. Description

Kit update to Rebel-S6-0.45
CR82419000 (can be used on Rebel-S6-0.60, Rebel-S6-0.60c
Rebel-S6-0.75 and Rebel-S6-0.75c)
CR82419100 (can be used on Rebel-S6-0.45, Rebel-S6-0.75 and
Rebel-S6-0.75c)
CR82419200 (can be used on Rebel-S6-0.45, Rebel-S6-0.60 and
Rebel-S6-0.60c)
The modifications of the Robot Reach must be carried out exclusively by Comau staff.
101
3.6 Robot connection with R1C-4 Control Unit

– Preliminary precautions
– Connection with the R1C-4 Control Unit (main motors and encoder cables).
– Connection of I/O signals cables
102
3.6.1 Preliminary precautions

The Control Unit features must be consistent with the connected Robot.
For this reason, both the Robot and the Control Unit are provided with
approval documents on which is highlighted the serial number of the
related Robot / Control Unit which it must be matched with.
Always respect this matching to allow to the Robot configuration file to

control the torques and the functions of the motors.
At the end of the installation procedure it will be possible to check the

proper matching between the Robot and Control Unit displaying the main
screen of the Teach Pendant.
Cable ducts arrangement:

– Install the cable ducts respecting the minimum bending radiuses (Minimum is 10
times the cable diameter).
– Do not carry out bends with angles of 90°.
– For Robots installed on the floor, do not place the cable duct near the Robot
distribution panel, but leave enough space to carry out properly both the
connection and the disconnection of the connectors.
– When installing the cables avoid contact of the cable sheaths with sharp edges
in order to avoid damaging the sheaths; protect the edges of the terminal section
of the cable ducts to avoid abrasion on the sheaths.
For Robots installed on raised supports, do not place any cable support near the
connectors, but at a minimum distance of approx. 600 mm from the connectors cable
gland.
Connections on Robot:
– When connecting, avoid tight bending radii on the cables. A bending radius of
approx. 10 times the cable diameter is recommended.
– The cable must not be too stretched.
– Do not roll the power cables in excess (motors, weld cables, etc.) in case of
hanks with many overlaying coils (maximum 2 coils) to avoid the risk of
overheating and damage due to lack of dissipation in air.
– The connection between (male and female) connectors must be done without
forcing, to avoid the re-entry or the bending of the pins.
– During the connection, keep the mating connector parallel to the panel connector
it must be connected to.
– The connection between connectors is to be made avoiding axial and/or lateral
movements in order to avoid damaging the coding pins and contacts.
– The coding pins on both connections are to be used to guide the connector
coupling.
– The two levers on the panel connector are only to be used to secure the
mechanical clamping of the connection and not to facilitate the connection.
– In case of Robots installed on supporting stand, it is advisable to support the
cables so that the weight does not force the connectors on Robot base.
103
3.6.2 Connection with the R1C-4 Control Unit (main motors and
encoder cables)

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

Before connecting the Robot it is necessary to verify the correct matching
with the Control Unit. Further details in par. 3.6.1 Preliminary
precautions on page 103.
The following procedure represents the Robot Rebel-S6-0.45. In case of
Robot Rebel-S6-0.60c and Rebel-S6-0.75c the base plate is rotated 180°.
Operating procedure
a. Carry out the cables connection through X10, X60 connectors on the connectors
panel of the R1C-4 Control Unit.
R1C-4 Connector Panel Robot base
Encoder cable
Motor & Brake cable
Follow-up procedure
– Not necessary
104
3.6.3 Connection of I/O signals cables

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

Before connecting the Robot it is necessary to verify the correct matching
with the Control Unit. Further details in par. 3.6.1 Preliminary
precautions on page 103.
The following procedure represents the Robot Rebel-S6-0.45. In case of
Robot Rebel-S6-0.60c and Rebel-S6-0.75c the base plate is rotated 180°.
The following procedure describes only the I/O signals cable connection.
For other users connection, see the specific application handbook.
Operating procedure
a. Carry out the cable connection through X55 connector on the connectors panel
of the R1C-4 Control Unit.
b. Carry out the cable connection through X50 connector on Robot base.
R1C-4 Connector Panel Robot base
X55 X50
Service cable
Follow-up procedure
– Not necessary
105
3.7 Operations related to the first startup

• Precautions before the first power up
• Control Unit power up
• Safety functional verifications of the robotic system integrated in the production cell
3.7.1 Precautions before the first power up

– The robotic system (consisting of Robot and Control Unit) must be integrated in a
complex system and properly interfaced. If the safety signals interfacing circuits
are not connected, the Control Unit can be powered up but it will not be possible to
activate the Robot motors.
For the proper interfacing refer to the principle diagrams given in the "Transport and
Installation" chapter of the Control Unit.
3.7.2 Control Unit power up

– To start the Control Unit, close the main switch (position “I”).
– During the first seconds after the power up, the system carries out the required
self-tests to check the functionality of the modules. This activity is signalled by the
lighting on of the LED present on the modules.
– After performing the tests and the following system loading, the WinR1C software
(or the Teach Pendant, if present) will be the interface for any kind of activity
required on the Robotic system (moving, programming, diagnostics, etc.).
The vastness of the topics related to the Control Unit power up, motion and
programming and other necessary topics, requires the consultation of additional
handbooks.
Depending on requirements, the following documents are recommended:
– for Robotic system power up, use: Use of the Control Unit
– for specific applications: various handbooks of the applications.
106
3.7.2.1 Floor / ceiling / wall installation
The following procedure indicates the necessary operations in case of Robot ceiling or
wall installation, with reference to the pages of the Teach Pendant (optional).
In the absence of the Teach Pendant, the same operations can be performed through
Virtual TP interface on WinR1C software.
In case of Robot ceiling / wall installation, ensure the proper configuration of the Robot
ceiling installation position:
1. Go to the “Mounting” page accessed by selecting “Setup” and “Motion”.
2. According to need select:
• “On ceiling” option in case of ceiling installation
• “On floor” option in case of floor or wall installation.
3. Save the configuration by touching the “Apply” key (remaining on the Mounting
page) or the OK key (exiting). In both cases the user is asked whether he wants to
save the system configuration.
3.7.2.2 Load auto-determination

To carry out the auto-determination of the load (software option) it is necessary to have
available some cubic metres of free space to allow the Robot axes to move during
performing the function.
For further information, see the "Motion Programming" handbook.
3.7.3 Safety functional verifications of the robotic system

integrated in the production cell
Before putting into production, check carefully the safety aspects of the robotic system
related to the integration in the production cell.
Particularly, but not limited only to the items below, check:
– the safety shutdowns commands functionality
– the movable guards safety circuits functionality, checking that after the guards
opening (access door) the Robot motion is allowed only in Programming mode
– the operational areas deriving from possible installation of the options related to
sectoring
– the safety signals of interchange with the cell
– that the operational spaces of the Robot are consistent with the perimeter fences.
107
MAINTENANCE
4. MAINTENANCE
– General requirements for the maintenance
– Assistance for troubleshooting
– How to disconnect the electrical power supply on R1C-4 Control Unit
– How to move the Robot in case of emergency
– Maintenance structure
– Preventive maintenance
– Special maintenance
– Robot calibration
– Spare parts list
The maintenance activities that are not expressly mentioned in this handbook are not
authorized. If necessary, require the manufacturer intervention.
108
MAINTENANCE
4.1 General requirements for the maintenance
4.1.1 Precautions before starting

– Most maintenance activities on the Robot are to be performed with electrical and
pneumatic power supplies turned off. In these cases the maintenance sheet bears
the inscription “Main switch open (OFF)”.
For the electrical power supply provided by the R1C-4 Control Unit disconnection
procedure, see par. 4.4 How to disconnect the electrical power supply on R1C-4
Control Unit on page 116.
For the disconnection procedures of power sources (electrical and pneumatic),
refer to the handbook of the cell which integrates the Robot.
– Use only original spare parts. The spare parts are provided by Comau. The spare
parts list is given in Chap.4.11 - Spare parts list on page 242.
4.1.2 Precautions during the maintenance

– If the type of defect allows the Robot repositioning, it is recommended to set it in
home position before starting the maintenance operations.
If maintenance and/or troubleshooting activities are carried out on the safety circuits, do
not stand near the Robot and move in jog at a suitable distance.
4.1.3 Precautions at the end of the maintenance activities

– After maintenance operations check the Robot proper functioning. Check the
correct execution of some Robot working cycles and the correct functioning of
safety devices before leaving the station.
At the end of each maintenance operation, the first machine power up shall be regarded
as a test for the whole system. During this phase the operator must stand outside the
Robot range of action but in a position that allows to observe its movements. It must also
have a Teach Pendant (optional, if any) or other safety shutdown device in the
immediate vicinity.
4.1.4 Maintenance staff

The staff in charge of maintenance activities must be instructed to properly use the lifting
means (in case of complete Robotic system replacement).
Moreover, the staff must be warned or trained in mechanical, fluidic and electrical fields
and therefore be aware of the dangers deriving from energies and precautions to be
taken for safe accessing the Robot installation area.
109
MAINTENANCE
4.1.5 Required equipment

The systems fixing the components (screws, nuts) have been standardised, using as
few variations as possible.
The minimum required equipment for maintenance intervention of the Robot is divided
depending on the type of maintenance operation:
– for preventive maintenance see par. 4.7.2 Required equipment on page 124.
– for special maintenance see par. 4.8.2 Required equipment on page 137.
4.1.6 Assembly notes

Special maintenance operations must be carried out by technicians using appropriate
tools, applying standard operating procedures even if not expressly mentioned,
including the following:
• Check the O-rings, oil retaining rings and bearings wear condition and replace
them if necessary;
• When reassembling, consider the following guidelines:
• Apply the recommended threadlockers to the screw threads, see Tab. 4.2
- Threadlock products on page 111.
• Use recommended products on sealing surfaces and to fix the components,
see Tab. 4.3 - Products for sealing and fixing on page 112.
• While disassembling and reassembling the components, comply with the
screw tightening torques. Unless otherwise specified, tighten to the tightening
torques required for the type of screws used and tighten the screws and/or
nuts to the required tightening torque, see Tab. 4.1 - Tightening torque for
Hex head screws and Socket hex head screws (Nm) on page 111.
An excessive tightening may impair the thread and consequently the maintaining in
position of the item.
An insufficient tightening can cause the item falling and/or overheating (and consequent
breaking) due to an incorrect adherence to the dissipating structure.
• Apply AREXONS 52A22 or LOCTITE 222 to the outside diameter of the

gaskets for rotary shafts and rubber sealing plugs.
• Use FUCHS ANTICORIT DFW to protect any exposed machined surfaces.
• When assembling double-lipped rotary seals or in case of a double seal, fill
the gap between the two lips with "NLGI NR.2” grade grease.
110
MAINTENANCE
Tab. 4.1 - Tightening torque for Hex head screws and Socket hex head
screws (Nm)
Class 12.9 screws

Class Class 10.9*¹ Class 12.9*¹
dxp (only per NABTESCO
8.8*¹ screws screws screws
gearbox)
3 x 0.5 1.5 1.9 2.3 -
4 x 0.7 3.1 4.3 5.2 -
5 x 0.8 6 8.5 10.1 9.01 ± 0.49
6x1 10.4 14.6 17.5 15.6 ± 0.78
8 x 1.25 24.6 34.7 41.6 37.2 ± 1.86
10 x 1.5 50.1 70.5 84.6 73.5 ± 3.43
12 x 1.75 84.8 119 143 129 ± 6.37
14 x 2 135 190 228 205 ± 10.2
16 x 2 205 288 346 319 ± 15.9
18 x 2.5 283 398 478 441 ± 22
20 x 2.5 400 562 674 539 ± 27
24 x 3 691 971 1170 -
*¹ admissible tolerance 0/-10%
A tolerance of ± 10% is allowed on tightening torques of screws and lock nuts for
preloading of bearings.
Tab. 4.2 - Threadlock products
Product
Material for screws For

for screws
M8 and plugs and
M5 or M6
onwards fittings
Aluminium Loctite 222
Steel Loctite 572
Loctite 222
Cast iron Loctite 243
Aluminium with Heli-coil -
For screws up to M4 do not use threadlocker.
As an alternative to the products indicated in the table Tab. 4.2 it's possible to use:
– Arexons 52A22 (alternative for Loctite 222)
111
MAINTENANCE
Tab. 4.3 - Products for sealing and fixing
Application Product
Flat sealant Arexons 35A73
Polyurethane sealant BOSTIK MK2639
Bearing fasteners Arexons 56A41
High strength fasteners Arexons 56A48
As an alternative to the products indicated in the table Tab. 4.3 it's possible to use:
– Loctite 518 (alternative for Arexons 35A73)
4.1.7 Parts disposal
The disposal of used oils and greases must be carried out in accordance with the
legislation in force in the country where the Robot is installed.
Should it become necessary the Robot partial or total disposal, it must be carried out
a separate collection of the parts to be disposed (e.g. iron with iron and plastic with
plastic).
The disposal of these parts also must be carried out in accordance with the legislation
in force in the country where the Robot is installed.
112
MAINTENANCE
4.2 Assistance for troubleshooting
4.2.1 Problem analysis

The R1C-4 Control Unit provides information on the system status through:
– LEDs, positioned on modules and boards
– diagnostic messages, displayed on the Teach Pendant (when present) or on
Virtual TP interface of the WinR1C software.
For troubleshooting operation it could be useful to use one or both modes (LEDs,
messages), depending on the system status:
– during the boot phase, the Teach Pendant is not operative and it is necessary to
consult the signalling issued by LEDs present on the modules
– when the Teach Pendant is enabled, the Diagnostic messages provided are more
efficient
– when the Teach Pendant is connected but not operating (e.g. damaged display),
the diagnostic messages will be provided on Virtual TP interface of the WinR1C
software
– in each case, especially for auxiliaries circuits power supply, LEDs represent the
most immediate diagnostic
– the pinouts given in the “Technical specification” handbook of the Control Unit,
allow to check the presence of the related signal foreseen
– for connection between the modules and further information on circuits, see the
electrical circuit diagram of the Control Unit.
113
MAINTENANCE
4.2.2 Diagnostic messages

Diagnostic messages are coded with numerical codes in combination with a brief
description and can be seen on the Teach Pendant (when present) or on Virtual TP
interface on WinR1C software.
To facilitate the understanding of the message, find the cause that generated it and the
corresponding remedy to be taken, it is possible to use the WinR1C software.
In the main window of the software (Fig. 4.1) the above information can be viewed. To
recall the information indicate in the field (A) the error code and then press the "Find"
button (B).
Fig. 4.1 - WinR1C main window regarding error codes
A B
For further information on Win R1C software, error messages and recovery mode
consult the "Use of Control Unit" handbook.
4.2.3 Traceability for replacement purposes

Each cable / component is codified with a label containing serial number (S/N) and the
purchase Part No. (P/N).
Codes are so defined:
– S/N followed by 4 digits (production year and month) and two alphabetical letters
– P/N followed by 8 digits (purchase part no.), one separation point and two digits for
review.
114
MAINTENANCE
4.2.4 Components replacement

To replace the components, it is recommended to detect the damaged component
trough the identification and codification of the connectors, cables and modules in order
to replace it with an identical one.
The par. 4.11 Spare parts list on page 242 provides part numbers and descriptions of
components available as spare parts.
Spare parts can be acquired directly by Comau at the addressed listed on par. 4.3.1
Comau service centre on page 115 where it is also possible to ask for repair of the
damaged component.
Do not carry out autonomous or not authorized repairs on the damaged modules.
Repairs can be carried out only by Comau.
4.3 Robot wiring diagram
For further details see the Robot electrical diagram and connection details.
4.3.1 Comau service centre

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

Assistance in troubleshooting and software
service.robotics@comau.com
options request
Service
spares.robotics@comau.com To require spare parts
repairs.robotics@comau.com To require repair activities
As an alternative refer to the manufacturer according to what is indicated in par. 2.4

Name and address of the manufacturer on page 22.
115
MAINTENANCE
4.4 How to disconnect the electrical power supply on

R1C-4 Control Unit
4.4.1 Precautions and risks associated with the electrical power

supply disconnection
– After the Control Unit shutdown wait for at least 30 seconds before power it up
again.
– Before removing a connector wait for at least 30 seconds.
The non-compliance with these warnings may result in:
• blocking of one or more internal modules of the Control Unit
• impairing the functioning of one or more internal modules of the Control Unit
– In case of occurring blocking of one or more modules, shut down the system, wait
for at least 30 seconds and reconnect the power supply.
Shutting down the Control Unit when the Robot is moving, forces the system and
consequently the Robot to immediately stop without deceleration ramps, with resulting
kinematic chain stress, trajectory direction deviation (unpredictable due to the force of
gravity) with consequent risks of impact. The constant repetition of this modality of
stopping can damage the Robotic System and/or the equipment connected to the
Robot.
116
MAINTENANCE
4.4.2 Disconnection of the electrical power supply
Status: – Before disconnecting the electrical

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

– Most maintenance activities foreseen on the Control Unit are to be carried out
with the electrical power supply turned off. In those cases the maintenance sheet
bears the inscription “Main switch open (OFF)”.
– Some activities, especially those related to cabinet main power supply
disconnecting, must be carried out only after having completely disconnected the
power supply of the electric mains. In these cases the maintenance sheet bears
the inscription “Electrical power supply turned off”.
The main switch located on the Control Unit disconnects the power supply
only of the Robot connected to it and occasionally of the application.
– To verify the area or devices powered by a specific Control Unit it may be

necessary to refer also to the Instructions Handbook of the machine in which the
Robotic System is integrated.
117
MAINTENANCE
Operating procedure
Main switch open (OFF)
a. Carry out the software
shutdown. Use the specific
command on the Teach
Pendant (when present) or on
Virtual TP interface on WinR1C
interface.
b. Wait for the ending of the

shutdown procedure.
c. Position the main switch in 0

(OFF) position.
With main switch open, the X120 connector and the upstream cables of the
main switch are under voltage.
Electrical power supply turned off

The X120 connector must not be pulled out with the Q100 main switch
closed.
a. Disconnect the electrical power

supply as indicated in the
previous steps.
b. This activity requires the

removal of X120 connector,
located in the front of the
Control Unit.
c. Remove the X120 connector

(IEC C19 female).
Follow-up procedure
– Not necessary.
118
MAINTENANCE
4.5 How to move the Robot in case of emergency

In this chapter are described the following topics:
– Precautions before starting
– Use of the brake releasing device integrated on Robot

– Read carefully the instructions described in par. 4.1 General requirements for the
maintenance on page 109
– The operating principle of the integrated brake releasing device consists in feeding
the axis 3 and axis 4 motors brakes with 24 Vdc coming from the Control Unit. The
command can thus generate the falling of axes subject to gravity (axis 3). Please
refer to par. 4.5.2.1 Risks deriving from Robot axes releasing on page 119.
4.5.2 Use of the brake releasing device integrated on Robot
4.5.2.1 Risks deriving from Robot axes releasing
The functionality of the integrated brake releasing device is always available with the
Control Unit powered on and the motor cables connected.
– The axes brake release generates the risk of falling of the axes subject to gravity.
– During the brake releasing operation, the operator must avoid being alongside the
Robot parts that can move downwards due to gravity. During the operations, any
operator can stand in the working area and in particular under the Robot.
– The dynamic brake release function could be compromised by failures occurred on
the Control Unit drive section having the same name or by the absence of motor
electrical connection: in this case the brake release provokes the axis free fall. In
case of proper function of the dynamic brake, there exists the fall risk, but with
slower fall.
119
MAINTENANCE
4.5.2.2 Usage procedure of the integrated brake release device

In absence of motive power, the Robot axes 3 and 4 movement is possible by means of
the integrated brake releasing device. This device allows only the deactivation of the
brake of both axes simultaneously. In that case, all system safety devices (including the
emergency stop and enabling push-button) are cut-off.
Status: – Power turned on, Control Unit

powered up
– Motors cable connected to Robot and
Control Unit
Material: – ---
Equipment: – ---
Fixing – ---
components:

The axes brake release generates the risk of falling of the axes subject to
gravity. Refer to par. 4.5.2.1 Risks deriving from Robot axes releasing on
page 119.
– The brake releasing operations must be performed by skilled and trained
personnel.
– The personnel must stand at a suitable distance from the Robot to be brake
released.
– To function properly, the integrated brake releasing device requires:
• that electric power is delivered to the Control Unit.
• that the Control Unit is on with 24Vdc section available and working
properly.
• Robot connected to the Control Unit by means of X2 motors cables.
• Motors off (Drive OFF). With Drive ON motors, the push-button pressure is
not influential.
– Motion freedom of axes is conflicted and slowed down by dynamic brake (if it is
not damaged).
– The released axis must always be supported so as to accompany the downward
movement
– Control the brake release by quick pressing the push-button
120
MAINTENANCE
Operating procedure
a. Manually support the axes of the Robot subject to gravity.
b. Press the push-button (A) to
obtain the axis 3 and 4 brake
release.
A
c. Manually move the required
axis (or axes).
121
MAINTENANCE
4.6 Maintenance structure
4.6.1 Overview
The Robot maintenance is divided in:
– Summary diagram of the maintenance operations
– Preventive maintenance
– Special maintenance
It is recommended to carry out accurate and precise preventive maintenance operations

in order to retain
over the long term the Robot functional features.
Poor or missing preventive maintenance activities during the warranty period, will be
regarded as prejudicial
to the warranty itself.
The final user must carry out only the maintenance activities exclusively listed in this
chapter: for further necessary operations contact Comau customer service.
122
MAINTENANCE
4.6.2 Summary diagram of the maintenance operations

The Fig. 4.2 presents the complete maintenance plan diagram in which are identified the
positions and frequency of the maintenance interventions to be carried out on Robot.
In the figure are shown the intervention points which can be identified with the
references given in the summarising tables of Tab. 4.5 and Tab. 4.8.
Fig. 4.2 - Summary diagram of the maintenance operations
Frequency
---** L2 L1 ---**
SW D.* P1 SW D.*
180 d L3 180 d
h = hours 90 d P2 90 d
d = days
Frequency
Failure
S6 S5 S3 S4 S2 S1 S7 Failure
h = hours
d = days
Representative image illustrating Robot Rebel-S6-0.45 (floor installation)
* Software Diagnostics (upon system Software signalling)

** Lubrication carried out by Comau, exclusively when installing the Robot.
Pn = Preventive Maintenance
Ln = Lubrication
Sn = Special Maintenance
123
PREVENTIVE MAINTENANCE
4.7 Preventive maintenance

– Precautions before starting (see par. 4.7.1 on page 124)
– Required equipment (see par. 4.7.2 on page 124)
– Preventive maintenance plan (see par. 4.7.3 on page 125)
– Lubrication procedures (see par. 4.7.6 on page 132)
It is recommended to carry out accurate and precise preventive maintenance operations

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

– Read carefully the instructions described in par. 1. General Safety Requirements
on page 10
– To guarantee the Robot proper functioning, it is necessary to carry out periodically
preventive maintenance operations, to reduce the amount of faults caused by the
ordinary deterioration over time and maintain longer its functional features.
Poor or missing preventive maintenance activities during the warranty period, will be
regarded as prejudicial to the warranty itself.

The minimum equipment required for Robot preventive maintenance is:
Tab. 4.4 - Required equipment

– Material and detergents for cleaning
– Torque ratchet wrench
– Set of bits and sockets for torque wrench
– 3 mm Allen wrench
– 8 mm open-end wrench
– Plastic cable ties
– Brush
If necessary:
– material and equipment for removing and fixing the warning signs
124
PREVENTIVE MAINTENANCE
4.7.3 Preventive maintenance plan

Find in Tab. 4.4 the preventive maintenance plan based on periodicity.
Tab. 4.5 - Preventive maintenance plan
Frequency Intervention / Sheet Paragraph Ref. ¹

90 days Robot cleaning and general inspection par. 4.7.4 P2
180 days Axes 3 and 4 recirculating ball screw lubrication par. 4.7.6.4 L3
Upon Software
Encoder batteries: replacement par. 4.7.5 P1
signaling
Axis 1 gearbox lubrication --- L1
----²
Axis 2 gearbox lubrication --- L2
¹ The reference is given in Fig. 4.2 - Summary diagram of the maintenance operations
on page 123.
² Lubrication carried out by Comau, exclusively when installing the Robot. Check the
presence of grease in case of motor replacement
Pn = Preventive Maintenance
Ln = Lubrication
125
PREVENTIVE MAINTENANCE - ROBOT CLEANING AND GENERAL INSPECTION
4.7.4 Robot cleaning and general inspection

Status: – The procedure must be carried out
with the system powered off: the main
switch of the Control Unit MUST be in
OFF position (turned off).
– Pneumatic power supply
disconnected and discharged.
Material: – Material and detergents for cleaning
If necessary:
– warning plates (see Tab. 4.6)
Equipment: – Torque ratchet wrench
– Set of bits and sockets for torque
wrench
If necessary:
– material and equipment for removing
Representative image illustrating Robot Rebel-S6-0.60
and fixing the warning signs
Fixing – ---
components:

– The frequency of intervention indicated in Tab. 4.5 - Preventive maintenance
plan on page 125 can vary depending on the environment and the type of
application.
– The procedure is divided into the following steps:
• Robot cleaning
• Check the structure and warning signs integrity
• Check of Robot fixing
Operating procedure
Robot cleaning
a. Clean the Robot parts.
Check the structure and warning signs integrity
b. Check integrity and good conservation state of all the Robot parts.
c. Check the presence and proper fixing of the warning signs. The warning signs
position is given in Fig. 4.3.
d. Check integrity and good conditions of the warning signs.
e. If the warning signs were no longer legible, replace them with signs having the
same features. The warning signs part numbers are listed in Tab. 4.6
126

Check of Robot fixing
f. Check proper tightening and integrity of connectors.
g. Check the proper tightening and integrity of wiring power supply pipes.
h. Check, by means of appropriate visual reference notches, the proper tightening

of the screws that fix the Robot to the floor or to the supporting structure.
i. Check, using suitable visual reference notches, the proper tightening of the
screws that fix the equipment on the Robot flange.
– Not necessary
Fig. 4.3 - Warning signs position
13 3 2 7 8 10 1 2 4 13
6
12 11
5
9
127
Tab. 4.6 - List of warning signs
Ref. Description Q.ty Comau Part No.

1 “Caution Falling / Dropping” label 1 CR82399801
2 “Rebel-S” logo label 2 CR82399802
3 “Red Line sx” label 1 CR82399803

4 “Red Line dx” label 1 CR82399804
5 Ax. identification label 1 1 CR82399805
9 “Collision warning” label 1 CR82399809

10 “Risk of limbs crushing” label 1 CR82399810
11 “See the instruction handbook” label 1 CR82392302
12 Transparent label 74x54 mm 1 CR82392306
13 Data plate Comau 104x15 - Aluminium 2 CR82399103
128
PREVENTIVE MAINTENANCE - ENCODER BATTERIES: REPLACEMENT
4.7.5 Encoder batteries: replacement

Status: – The procedure must be carried out
with the system powered off: the main
switch of the Control Unit MUST be in
OFF position (turned off).
– Pneumatic power supply
disconnected and discharged
Material: – Encoder batteries [see par. 4.11
Spare parts list on page 242]
Equipment: – 3 mm Allen wrench
Fixing – Hex socket button head screws
components: M5x10
Representative image illustrating Robot Rebel-S6-0.60 – Nuts M5

– The necessity of batteries replacement is signaled by the System Software
through the Virtual TP interface, on WinR1C or on the Teach Pendant (if
present).
– After the signalling, replace the batteries as quickly as possible.
– Replace the batteries only with original Comau spare parts.
Dispose the batteries respecting the environment and in accordance with
the regulations in force in the country where the Robot is installed.
Operating procedure
a. Unscrew and remove the six
fixing hex socket button head A
screws M5x10 (A).
129

b. Pull upwards the cover (B) so
as to remove it from the Robot
wrist. B
Be careful not to damage
the gasket (C).
C
c. Disconnect the two connectors
(D) of the batteries.
d. Unscrew and remove the two

hex socket button head screws
M5 (E) and the corresponding
M5 nuts that fix the battery
holder (F).
e. Remove the battery holder (F).
f. Remove the batteries (G).
G E F
g. Reposition the new batteries (G) in the corresponding holder (F).
h. Reposition and fix the battery holder, fixing it with the hex socket button head
screws M5 (E) and M5 nuts to the proper tightening torque.
The batteries' cables must come out on the left side, as shown in figure.
i.Reconnect the connectors (D) of the batteries.
j. Clamp using cable ties the batteries' cables to the cables harness already
present inside the Robot wrist.
130

k. Reposition the cover (B).
Be careful not to damage B

the gasket (C).
C
l. Tighten the six fixing hex socket
button head screws M5x10 (A) A
to the proper tightening torque.
– After the batteries replacement, carry out the Encoder recognition procedure as
described in par. 4.9 Software procedures following the maintenance on
page 214.
– Carry out the Robot calibration, as described in par. 4.10 Robot calibration on
page 219.
131
PREVENTIVE MAINTENANCE - LUBRICATION PROCEDURES
4.7.6 Lubrication procedures

– Precautions when using lubricants
– Remarks on lubrication operations
– Summary of lubrication points
4.7.6.1 Precautions when using lubricants

When assembled in Comau the Robot is supplied with lubricants that do not contain any
harmful to health substances, however, in some cases, repeated and prolonged
exposure to the product may cause skin irritation, or if swallowed, sickness.
In case of contact with eyes or skin: rinse the affected areas with copious amount of
water; if irritation persists, consult a doctor.
If swallowed, do not induce vomiting or administer anything by mouth; seek medical
advice immediately.
The lubrication operations shall be carried out with the lubricant type advised on the
label applied on the Robot.
It is forbidden to mix lubricants of different qualities.
4.7.6.2 Remarks on lubrication operations
Before starting the lubrication operations, carry out a general cleaning of the
surrounding parts of the lubrication point, in order not to allow the possible insertion of
dirt and/or impurities inside the machine body.
After lubrication operations, carry out a general cleaning of the parts surrounding the
lubrication point, in order to remove possible lubricant residues.
The quantity of lubricant indicated for the “first intervention” refers to filling after a new
unit has been installed.
The quantity indicated for “subsequent interventions” concerns the replenishment of the
lubricant.
The disposal of used oils and greases is to be carried out according to the legislation in
force in the country where the Robot is installed.
132
4.7.6.3 Summary of lubrication points
Frequency
1 1
---* L2 L1 ---*
180 d L3 180 d
h = hours
d = days

Gearbox Recirculating ball screw
Part to be
lubricated
Axis 1 Axis 2 Axis 3 / Axis 4
Intervention point L1 L2 L3
Type of lubricant
HARMONIC GREASE SK-1A THK AFB-LF
used
Identification
symbol
Type of intervention Surface lubrication using a brush

Frequency of Not necessary (lubrication carried out by Comau, exclusively when installing the Robot)*¹
180 days* (6 months, 2500 hours)
intervention
Q.ty 1°
42 g 19 g 12.7 g
intervention*²
Q.ty following
--- *¹ --- *¹ 9.18 g
interventions *³
Procedure detail --- --- par. 4.7.6.4
* Recommended frequency. The necessity of lubrication is also signaled by the System Software through the Virtual TP interface, on WinR1C
or on the Teach Pendant (if present).
*¹ Lubricated for life; check the presence of grease in case of motor replacement
*² Quantity concerning a filling carried out after a new unit assembly
*³ Quantity concerning the replenishment of the lubricant
133
4.7.6.4 Axes 3 and 4 recirculating ball screw lubrication

Status: – The procedure must be carried out with
the system powered off: the main switch
of the Control Unit MUST be in OFF
position (turned off).
– Pneumatic power supply disconnected
and discharged.
Material: – Grease:
• Type: THK AFB-LF
• Quantity: 9.18 g
Equipment: – 3 mm Allen wrench
– Brush
Fixing – Hex socket button head screws M5x10
components: (12.9)

– Before starting the lubrication operations, carry out a general cleaning of the
surrounding parts of the lubrication point, in order not to allow the possible
ingress of dirt and/or impurities inside the machine body.
– See Precautions when using lubricants and the Remarks on lubrication
operations.
– The necessity of lubrication is also signaled by the System Software through the
Virtual TP interface, on WinR1C or on the Teach Pendant (error: 62555/04
SYSTEM: Arm 1 the screw of the axis 3 require lubrication)
Operating procedure
hex socket button head screws A
M5x10 (A).
134

wrist. B
the gasket (C).
C
c. Using a brush, manually apply a
thin layer of grease THK
AFB-LF ( 9.18 total grams) on D
the outer surface of the screw
(D).
d. At the end of the lubrication operations, carry out a general cleaning of the parts
surrounding the lubrication point, in order to remove possible lubricant residues.
e. Reposition the cover (B).

the gasket (C).
135

f. Tighten the six fixing hex socket
136
SPECIAL MAINTENANCE
4.8 Special maintenance

– par. 4.8.1 Precautions before starting on page 137
– par. 4.8.2 Required equipment on page 137
– par. 4.8.3 Special maintenance plan on page 138

– Read carefully what described in par. 4.1 General requirements for the
maintenance on page 109.

The minimum equipment required for Racer3 preventive maintenance is:
Tab. 4.7 - Required equipment

– Allen wrench of 2, 2.5, 3, 4 and 5 mm (with extensions)
– Torque wrench with bits of 2, 2.5, 3, 4 and 5 mm (with extensions)
– Mechanical removal tool for pins Ø6
– Q.ty 2 threaded bars M4 (length 80 mm minimum)
– 1.5 and 12 mm gauge blocks
– 1.5 mm thickness gauge
– Digital tensiometer for belts (frequency meter)
– Compression dynamometer (capacity > 15 kg)
– Plate for tensioning axis 4 belt (CR82392162)
– Manual greaser with pump
– Ring for axis 3 screw lubrication (part No. CR82417700)
– O-Ring gasket (Part No. 00301287)
– A pair of scissors
– Cable tie tool
137
SPECIAL MAINTENANCE
4.8.3 Special maintenance plan

Find in Tab. 4.8 the special maintenance plan.
Tab. 4.8 - Special maintenance plan
Intervention / Sheet Ref. *¹

AXIS 1 MOTOR: complete replacement S1
AXIS 3 BELT: complete replacement S5
AXIS 4 BELTS: complete replacement S6
AXIS 3 RECIRCULATING BALL SCREW: complete replacement S7
WIRING: complete replacement S8
*¹ The reference is given in Fig. 4.2 - Summary diagram of the maintenance operations
on page 123.
138
SPECIAL MAINTENANCE - AXIS 1 MOTOR
4.8.4 AXIS 1 MOTOR: complete replacement

and discharged
Material: – Axis 1 motor [See par. 4.11 Spare parts
list on page 242]
– Threadlocker Loctite 222
– Lubricating grease HARMONIC
GREASE SK-1A
– If necessary:
• O-ring gasket Ø60.05 x Ø1.78 (Part
No. 00301289)
No. 00301215)
Equipment: – 2.5, 3 and 4 mm mm Allen wrench
– Torque wrench with bits of 2.5, 3 and 5
mm
– Mechanical removal tool for pins Ø6
– Q.ty 2 threaded bars M4 (length 80 mm
minimum)
– 12 mm gauge blocks
– Rubber-headed mallet
Fixing – Socket hex head screws M6x20 mm
components: (8.8)
– Dowel pin with extraction hole B6x16
– Socket hex head screws M4x60 (12.9)
– Socket hex head screws M5x12 (12.9) -
ISO 4762
– Socket hex head screws M5x12 (8.8) -
ISO 4762
– Socket hex grub screws M5
– Washers Ø6 ISO 7089
– Blank washers 4x9x0.8

HIGH TEMPERATURES DANGER
Danger because of possible high temperature of the motor.
Before operating on the motor check its temperature. Wait till the
temperature is not dangerous and if it is necessary use appropriate gloves
for high temperatures.
Some components inside the motor could be damaged if subject to violent
impacts: do not use a hammer or beat against the motor during
disassembly and reassembly.
Improper use of hammers or other tools on the motor will undermine the
validity of the warranty.
139
Preliminary procedures / notes (Continued)

– Disconnect the electrical power supply (details in par. 4.4 How to disconnect the
electrical power supply on R1C-4 Control Unit on page 116).
– Disconnect and discharge the pneumatic power supply.
Operating procedure
a. Unscrew and remove the four
socket hex head screws M6x20
(A) with the corresponding
washers Ø6.
b. Pull out the wrist (B) from the

Robot, being careful not to B C
damage the centering dowel
pins and not to over-pull the
wiring (C).
c. Position the wrist (B) on a

stable support plane.
d. Unscrew and remove the

twelve socket hex head screws D
M6x20 (D) with the
corresponding blank washers
Ø4.
140

e. Lift and remove the axis 1 body
(E) with the spacer (F), where
present.
F E
f. Lift and remove the flange (G).

G
g. Remove the dowel pin Ø6 (H)

using a removal tool.
h. Unscrew and remove the six J

(J).
H
i. Lift the flange (K), including the
motor (M), from the Robot base. K
141

During the disconnection and connection of the motor connectors, operate
gently to avoid damaging the connectors.
j. Disconnect the encoder XSYN1

connector (L) of the axis 1
N
motor (M).
k. Disconnect the XMTR1

connector (N) from axis 1
motor.
l. Position the motor (M) on the

workbench.
m. Unscrew the four socket hex M

head screws M5x12 (P).
P
n. Disassemble the motor (M) with
the corresponding flange (Q) M
from the gearbox (R).
142

o. Unscrew the two socket hex
grub screws M5 (S). S
p. Remove the internal part of the

gearbox (T) from the driving
shaft.
T
q. Unscrew and remove the four

(U). U V
r. Remove the flange (V).
143

Check the preservation
state of the sealing
gasket Part No.
00301289 (W) present on
the flange (V). If
necessary, carry out the
replacement.
V W
When reassembling, on all the fixing screws with M5 size onwards, apply
Loctite 222 threadlocker.
s. Position the flange (V) on the

new motor (M).
U
t. Tighten the four socket hex
head screws M4x25 (U) to 6
Nm. torque.
M U V
u. Pre-screw the two socket hex
grub screws M3 (S) on the
internal part of the gearbox (T). T
144

v. Position gauge blocks (X) of 12
mm on the motor base. X T X
A
The internal part of the
gearbox (T) must be
positioned at a distance
of 12 mm from the plane
“A” of the motor.
12 mm
S
w. Position the internal part of the X
gearbox (T) of the driving shaft,
matching the fixing socket hex
grub screws (S) with the milling
present on the driving shaft.
x. Tighten the two socket hex grub

screws M3 (S) to 3 Nm. torque.
y. Remove the gauge blocks (X).

z. Apply HARMONIC GREASE
SK1A between the motor and
internal part of the gearbox, in
the area indicated in figure.
a. Position the motor (M) with the

corresponding flange (Q) on the M
gearbox (R).
The motor must be Q
positioned with the
connector facing the
calibration notch (Y) R
present on the gearbox
flange.
145

b. Fix the motor (M) tightening the
four socket hex head screws
M5x12 (P) to 6 Nm. torque.
M
P
c. Clean any grease residues.
d. Insert the pin Ø6 (H) on the

flange using a rubber-headed
mallet.
e. Move the motor in the vicinity of

the installation position, so as to
be able to connect the N
connectors XMTR1 (N) and
XSYN1 (L).
146

f. Position the motor inside the
Robot base, ensuring the
proper positioning of the
centering dowel pin. J
Make sure the
centering dowel pin (H) is
all inserted and the flange
reached the mechanical
stop on the Robot base.
g. Tighten the 6 socket hex head

screws M5x12 (L) to 6 Nm.
torque.
H
h. Reposition the cover flange (G).
Check the preservation

state of the sealing
gasket Part No.
00301215 (Z) present on
the flange.
If necessary, carry out the G
replacement.
Z
i. Screw the 2 threaded bars (AA)

M4 (length = 80 mm) in the 2 E
opposite holes on the Robot
base, as shown in figure.
j. Reposition the axis 1 body (E)

with the spacer (F), where
present, using the threaded F AA
bars as reference / centering.
147

k. Screw without tightening ten of
the twelve socket hex head D
screws M6x20 (D) with the
corresponding blank washers.
l. Remove the two threaded bars

previously used.
m. Tighten the remaining two

screws (D).
n. Tighten the twelve screws (D) to

5.4 Nm. torque.
Proceed with tightening 6 1 7
the screws in the order
5 8
shown in figure. 3 4
12 9
11 2 10
Top view
o. Reposition the wrist (B) on the

Robot, ensuring the correct B AB
centering of the dowel pins
(AB).
p. Tighten the four fixing socket

hex head screws M6x20 (A)
with the corresponding washers
to 10.4 Nm. torque.
148
– After the motor replacement, carry out the Encoder recognition procedure as
page 214.
– Carry out the calibration procedure, as described in par. 4.10.2 Calibration -
Operating procedures on page 223
– Check the correct functioning of the Robot running a slow speed work program.
149

and discharged
list on page 242]
– Grease HARMONIC GREASE SK-1A
– If necessary
No. 00301287)
(floor installation) Equipment: – 2.5, 3 and 4 mm mm Allen wrench
– Torque wrench with bits of 2.5, 3 and 4
mm
– 1.5 mm thickness gauge
components: (12.9)
– Socket hex head screws M5x12 mm (8.8)
– Socket hex grub screws M3

150
Operating procedure
screws M5x10 (A).

wrist. B
the gasket (C).
C
c. Cut the cable ties that fix the
cables to the axis 3 and 4
motors.
d. Unscrew and remove the six

fixing screws M4x12 (D) of the
holder (E) with the related
washers (where present).
E D
151

e. Lift the holder (E) being careful
not to over-pull the cables. E

f. Disconnect the XMTR2 (F) and

XSYN2 (G) connectors from the
axis 2 motor (H). G
g. Disconnect the XMTR3 and
XSYN3 connectors from the
axis 3 motor.
h. Disconnect the XMTR4 and

axis 4 motor. H
F
i. Unscrew and remove the 4
(J) that fix the axis 2 motor (H),
H
using an Allen wrench with
extension.
152

j. Lift and remove the axis 2 motor
(H). H
To facilitate the removal
of the motor, it is
recommended to slightly
swing it during the
extraction phases.
k. Bring the motor on the

workbench.
l. Unscrew the two socket hex

grub screws M3 (K). K
m. Remove the internal part of the

gearbox (L) from the driving L
shaft.
n. Remove the gasket (M) from

the motor.
o. Check the preservation state of

the gasket. If excessively worn,
replace it with a new one (Part
No. 00301287).
p. Position the gasket (M) on the

new motor.
153

q. Carefully clean the shaft of the

new motor and the related seat L
on the inside of the gearbox (L).
r. Position the internal part of the

gearbox on the new motor,
matching the security dowels
with the milling present on the
driving shaft.
s. Interpose between the motor

(H) and internal part of the L
gearbox (L), a shim (N) of 1.5
mm (e.g. gauge block). 1,5 mm
t. Tighten the two socket hex grub

screws M3 (K) to 3.1 Nm. K
torque.
u. Remove the shim (N) previously

used.
v. Evenly apply the Harmonic

Grease SK-1A on the internal
part of the gearbox (L).
154

w. Reposition the axis 2 motor (H)
inside the corresponding seat H
on the Robot wrist.
Position the motor with

the connector facing the
Robot base, as shown in
figure.
Wrist Robot base
Top view, with the wrist free of top cover (B) and bracket
(E).
x. Tighten the four socket hex
head screws M5x12 (J) that fix
the axis 2 motor (H) to 6 Nm.
H
torque, using a torque wrench
with extension.
155

y. Connect the XMTR2 (F) and
XSYN2 (G) connectors to the
axis 2 motor (H). G
z. Reconnect the XMTR3 and
XSYN3 connectors to the axis 3
motor.
a. Reconnect the XMTR4 and

motor. H
b. Block the axis 3 and 4 motor F
cables to the corresponding
motor, using a plastic cable tie.
c. Reposition the holder (E)
previously removed. E
d. Tighten the six fixing socket hex

head screws M4x12 (D), with
corresponding washers (on two
front side screws) to 3.1 Nm.
torque.
156

e. Reposition the cover (B).

the gasket (C).
C
f. Tighten the six fixing hex socket
page 214.
157

and discharged
list on page 242]
Equipment: – Allen wrench of 2, 3 and 4 mm (with
extensions)
– Torque wrench with bits of 2, 3 and 4 mm
(with extensions)
– Digital tensiometer for belts (frequency
(floor installation) meter)
– Compression dynamometer (capacity >
5kg)
– 1.5 mm gauge blocks
– Cable tie tool
components: (12.9)
– Socket hex grub screws M4x5 - 45H -
A3K - ISO 4026
– Blank washer 4x9x0.8

To perform some steps of the procedure, connect the Control Unit to the
power supply. During these operations, work with particular caution,
considering the possible risks arising from the presence of voltage on
Robot cables and connectors.
158
Operating procedure
screws M5x10 (A).

wrist. B
the gasket (C).
C
motors.

E D
159



XSYN3 (G) connectors from the G H
axis 3 motor (H).

axis 2 motor.

axis 4 motor.
F
(J) that fix the plate (K) and
related blank washers, using an
Allen wrench with extension.
160

j. Manually remove the belt from
the pulley (L).
H
k. Lift and remove the axis 3 motor
(H) including the plate (K).
l. Bring the motor on the

K
workbench. L
The pulley (L) is fixed on the driving shaft with 2 pairs of socket hex grub
screws M4, set at 90° to one another.
m. Unscrew and remove the two

external socket hex grub
screws M4 (M).
N M
n. Loosen the 2 internal socket

hex grub screws M4 (N).
o. Remove the pulley (L) from the

axis 3 motor (H).
H L
p. Clean the driving shaft seat
within the pulley.
161

q. Make a mark (P) on the plate
(K) in correspondence of the
motor connector position
(useful for the new motor
repositioning).
P
r. Unscrew and remove the two

(Q). H
s. Remove the plate (K) from the
motor (H).
Q K
t. Position the plate (K) on the

new motor.
Correctly orient the motor H
(H) using as reference the
previously marked notch
(see point q. of this
procedure). K Q
u. Tighten the two fixing screws
M4x8 (Q) to 3.1 Nm. torque.
162

v. Reposition the pulley (L) on the
driving shaft, matching the
fixing socket hex grub screws
with the milling present on the
driving shaft.
w. Interpose between the plate (K) K

and pulley (L), a shim (R) of 1.5
mm (e.g. gauge block). R
1,5 mm
L
x. Tighten the two internal socket
hex grub screws M4 (N) to 3.1
Nm. torque.
N M
y. Tighten the two external socket

hex grub screws M4 (M) to 3.1
Nm. torque.
z. Remove the shim (R) previously

used.
a. Insert the motor (H) inside the

related seat, manually fitting the
belt on the pulley (L). H
b. Loosely tighten the three

screws (J), with the related
blank washers.
163

c. Position a compression
dynamometer (S) on the axis 3 H
motor base (H).
d. Apply a pressure between 3.5

kg and 4.5 kg in the direction
indicated by the arrow, in order
to properly tension the axis 3
belt.
S
e. Maintain the pressure, then
tighten the fixing screws M4x12
(J) to 3.1 Nm. torque.
f. Reconnect only the XMTR3

connector to axis 3 motor.
g. Make sure that the connection

cables between Robot and
Control Unit are properly
connected.
h. Start the Control Unit.
i. Holding down the appropriate

push-button indicated in figure,
release the brake of the axis 3
motor (details in par. 4.5), then
manually move the belt in order
to trigger some rotations in
clockwise and anticlockwise
direction.
j. Shut down the Control Unit and disconnect the XMTR3 connector from axis 3
motor.
For details on the procedures of Control Unit power up and shutdown, refer
to the “Use of Control Unit” handbook.
164

k. Check the correct tensioning of
the axis 3 belt (T) as indicated
below: T
k.1 position the frequency meter
(U) in the vicinity of the belt
(about 1 cm)
k.2 using for example a

screwdriver, strike the belt (in
the vicinity of the midpoint
between the two pulleys) in
order to trigger its vibration
U
k.3 carry out the reading of the

frequency detected by the
frequency meter; the correct
frequency must be between 65
Hz and 85 Hz.
In case of new belt installation, tension the belt until obtaining a frequency
value between 75 Hz and 85 Hz.
l. In case the detected

frequency is incorrect:
l.1 loosen the screws (J)
l.2 repeat the operations from point

d. manually exerting a higher
pressure (in case of too low
frequency) or lower (in case of J
too high frequency).
l.3 repeat the operations from point

e. to point k.3.
m. Connect the XMTR3 (F) and

XSYN3 (G) connectors to the G H
axis 3 motor (H).
n. Connect the XMTR2 and

motor.
o. Connect the XMTR4 and

motor.
p. Block the axis 3 and 4 motor F

165

q. Reposition the holder (E).
E
r. Tighten the six socket hex head

screws M4x12 (D), with
corresponding washers
(present only on the two front
screws), to 3.1 Nm. torque.
D
s. Reposition the cover (B).

the gasket (C).
C
t. Tighten the six fixing hex socket
166
page 214.
167

and discharged.
list on page 242]
Equipment: – Allen wrench of 2, 3 and 4 mm (with
extensions)
– Torque wrench with bits of 2, 3 and 4 mm
(with extensions)
(floor installation) meter)
– Compression dynamometer (capacity > 6
kg)
– 1.5 mm gauge blocks
– Cable tie tool
– Plate for tensioning axis 4 belt
(CR82392162)
components: (12.9)
– Socket hex grub screws M4x5 - 45H -
A3K - ISO 4026

168
Operating procedure
screws M5x10 (A).

wrist. B
the gasket (C).
C
motors.

washers (present only on the
two front screws).
E D
169



XSYN4 (G) connectors from the G H
axis 4 motor (H).

axis 2 motor.

axis 3 motor.
F
(J) that fix the plate (K) and
related blank washers, using an
Allen wrench with extension.
170

j. Manually remove the belt from
the pulley (L).
k. Lift and remove the axis 4 motor H

(H) including the plate (K). K
l. Bring the motor on the
workbench.
L
The pulley (L) is fixed on the driving shaft with 2 pairs of socket hex grub
screws M4, set at 90° to one another.
m. Unscrew and remove the two

external socket hex grub
screws M4 (M).
M
N
n. Loosen the two internal socket
hex grub screws M4 (N).
N
M
o. Remove the pulley (L) from the
axis 3 driving shaft (H).
H
p. Clean the driving shaft seat
within the pulley.
171

q. Make a mark (P) on the plate
(K), in correspondence of the
motor connector position
(useful for the new motor
repositioning).
P
r. Unscrew and remove the two
(Q).
H
s. Remove the plate (K) from the
motor (H).
Q
t. Position the plate (K) on the

new motor.
Correctly orient the motor
(H) using as reference the H
previously marked notch
(see point q. of this
procedure).
Q
u. Tighten the two fixing screws

M4x8 (Q) to 3.1 Nm. torque. K
172

v. Reposition the pulley (L) on the
driving shaft, matching the
fixing socket hex grub screws
M4 with the milling present on
the driving shaft.
w. Interpose between the plate (K)

and pulley (L), a shim (R) of 1.5 K R
mm (e.g. gauge block).
1,5 mm
L
x. Tighten the two internal socket
hex grub screws M4 (N) to 3.1
Nm. torque.
M
N
y. Tighten the two external socket
hex grub screws M4 (M) to 3.1
Nm. torque.
L
z. Remove the shim (R) previously
used.
N
M
a. Insert the motor (H) inside the
related seat, manually fitting the
belt on the pulley (L).
H
K
b. Loosely tighten the three

screws M4x12 (J), with the
related blank washers.
173

c. Position the appropriate Plate
for tensioning axis 4 belt T H
(CR82392162) (S) on axis 4
transmission unit (T), then bring
the plate in contact with the
base of the axis 4 motor (H).
S
d. Position a compression
dynamometer (U) on the plate
side (S).
S
e. Apply a pressure between 4.5

indicated by the arrow, in order
to properly tension the first of
the 2 axis 4 belts.
U
f. Maintain the pressure, then
tighten the screws (J) to 3.1
Nm. torque.
174

g. Connect the XMTR4 (F) and
XSYN4 (G) connectors to the G H
axis 4 motor (H).
h. Connect the XMTR2 and

motor.
i. Reconnect the XMTR3 and

motor.
j. Block the axis 3 and 4 motor F

k. Reposition the holder (E).
E
l. Tighten the six socket hex head

corresponding washers where
present, to 3.1 Nm. torque.
175

m. Reposition the cover (B).

the gasket (C).
C
n. Tighten the six fixing hex socket
page 214.
176
SPECIAL MAINTENANCE - AXIS 3 BELT
4.8.8 AXIS 3 BELT: complete replacement

and discharged
Material: – Axis 3 belt [See par. 4.11 Spare parts list
on page 242]
Equipment: – 3 and 4 mm Allen wrench
– Torque wrench with bit of 3 and 4 mm
components: (12.9)


Danger because of possible high temperature of the motors in the vicinity
of the belts.
Before working on the belts check the motors temperature. Wait till the
Operating procedure
screws M5x10 (A).
177

wrist. B
the gasket (C).
C
motors.

E D
f. Remove the axis 3 motor (F) as

indicated in par. 4.8.6 AXIS 3 F G
MOTOR: complete
replacement on page 158.
g. Remove without disassembling

the axis 3 screw (G) as
indicated from point c. to point
h. of the par. 4.8.10 AXIS 3
RECIRCULATING BALL
SCREW: complete
replacement on page 187
178

h. Remove the axis 3 belt (H)
pulling it out from the Robot H
wrist.
i. Reposition the new axis 3 belt

(H). H
j. Reassemble the axis 3 motor

(F) as indicated in points a. and F G
b. in par. 4.8.6 AXIS 3 MOTOR:
complete replacement on
page 158.
k. Reassemble the axis 3 screw

(G) as indicated from point l. to
point q. of the par. 4.8.10 AXIS
3 RECIRCULATING BALL
SCREW: complete
l. Loosen the screws that fix the axis 3 motor.
m. Carry out the tensioning of the axis 3 belt as indicated from point c. to point l.3 of
the par. 4.8.6 AXIS 3 MOTOR: complete replacement on page 158.
In case of belt replacement, tension the belt until obtaining a frequency
value between 75 Hz and 85 Hz.
n. Loosen the fixing screws of the axis 4 motor and of the axis 4 bearing holder.
o. Carry out the tensioning of the axis 4 belts as indicated from point z. to point k.
of the par. 4.8.10 AXIS 3 RECIRCULATING BALL SCREW: complete
179

p. Block the axis 3 and 4 motor
cables to the corresponding E
q. Reposition the holder (E).
r. Tighten the six socket hex head

D
s. Reposition the cover (B).

the gasket (C).
C
t. Tighten the six fixing hex socket
180
– After the belt replacement, carry out the Encoder recognition procedure as
page 214.
181
4.8.9 AXIS 4 BELTS: complete replacement

and discharged
Material: – Axis 4 belts [See par. 4.11 Spare parts
list on page 242]
Equipment: – 3 and 4 mm Allen wrench
– Torque wrench with bits of 3 and 4 mm
components: (12.9)
Representative image illustrating Robot Rebel-S6-0.60 – Socket hex head screws M4x12 (8.8)
(floor installation) – Blank washer 4x9x0.8

Danger because of possible high temperature of the motors in the vicinity
of the belts.
Before working on the belts check the motors temperature. Wait till the
For the axis 4 motion transmission there are two driving belts: it is
recommended the simultaneous replacement of both axis 4 belts, for
collective wear.
Operating procedure
screws M5x10 (A).
182

wrist. B
the gasket (C).
C
motors.

E D
f. Remove the axis 4 motor (F) as

indicated in par. 4.8.7 AXIS 4 F G
MOTOR: complete
g. Remove without disassembling

the axis 3 screw (G) as
indicated from point c. to point
h. of the par. 4.8.10 AXIS 3
RECIRCULATING BALL
SCREW: complete
183

h. Unscrew and remove the three
(H).
H
i. Remove the bearing holder (J)
manually removing the axis 4
belts from the related pulleys. J
j. Remove the two axis 4 belts (L).

L
k. Reposition the two new axis 4

belts (L). L
184

l. Reposition the bearing holder
(J), by manually fitting the axis 4
belts on the related pulleys
(short belt on top pulley, long H
belt on lower pulley).
m. Screw but do not tighten the J

three socket hex head screws
M4x12 (H) with corresponding
blank washers.
n. Reassemble the axis 4 motor

(F) as indicated in par. 4.8.7 F G
AXIS 4 MOTOR: complete
o. Reassemble the axis 3 screw

(G) as indicated from point l. to
point q. of the par. 4.8.10 AXIS
3 RECIRCULATING BALL
SCREW: complete
p. Carry out the tensioning of the axis 3 belt as indicated from point c. to point l.3 of
the par. 4.8.6 AXIS 3 MOTOR: complete replacement on page 158.
q. Carry out the tensioning of the axis 4 second belt as indicated from point y. to
point j. of the par. 4.8.10 AXIS 3 RECIRCULATING BALL SCREW: complete
r. Carry out the tensioning of the axis 4 first belt as indicated from point c. to point
f. of the par. 4.8.7 AXIS 4 MOTOR: complete replacement on page 168.
s. Block the axis 3 and 4 motor
cables to the corresponding E
t. Reposition the holder (E).
185

u. Tighten the six socket hex head
D
v. Reposition the cover (B).

the gasket (C).
C
w. Tighten the six fixing hex socket
– After the belt replacement, carry out the Encoder recognition procedure as
page 214.
186
SPECIAL MAINTENANCE - AXIS 3 RECIRCULATING BALL SCREW
4.8.10 AXIS 3 RECIRCULATING BALL SCREW: complete

replacement
and discharged.
Material: – Axis 3 recirculating ball screw [See
par. 4.11 Spare parts list on page 242]
– Grease THK AFB-LF
– Cleaning product / generic degreaser
Equipment: – Allen wrench of 3 and 4 mm (with
extensions)
– Torque wrench with bits of 3 and 4 mm
(floor installation) (with extensions)
meter)
– Digital compression dynamometer
(capacity > 15 kg)
– Grease gun
– Lubrication ring (Part No. CR82417700)
– O-Ring gasket (Part No. 00301287)
– Tool for ball screw disassembly
(CR82392144)
components: (12.9)

Danger because of possible high temperature of the motors installed in the
vicinity of the axis 3 screw.
Before intervening check the motors temperature. Wait till the temperature
is not dangerous and if it is necessary use appropriate gloves for high
temperatures.
187
Preliminary procedures / notes (Continued)

Some components inside the axis 3 screw could be damaged if subject to
violent impacts: do not use the hammer or do not beat against the screw
during disassembly and reassembly operations.
Improper use of hammers or other tools on the screw will undermine the
To perform some steps of the procedure, connect the Control Unit to the
power supply. During these operations, work with particular caution,
considering the possible risks arising from the presence of voltage on
Robot cables and connectors.
Operating procedure
screws M5x10 (A).

wrist. B
the gasket (C).
188

c. Unscrew and remove the three
(D).
d. Remove the lower guard (E).
e. Unscrew and remove the six

(F).
F F
f. Unscrew the four socket hex
head screws M4x12 (G). G G
g. Lift and remove the complete

screw (J), with the plate (H), J
manually removing the axis 3
and axis 4 belts from the related H
pulleys (K).
K
h. Bring the screw on the
workbench.
189

i. Unscrew the socket hex head
screw M4x12 (L) and remove
the mechanical limit switch (M)
on the upper part of the screw.
M L
j. Position the appropriate Tool
for ball screw disassembly
(CR82392144) (N), inserting it
from the upper side of the
screw.
N
k. Move upwards the axis 3
bearing / pulley unit (P), until it N
is fully positioned on the P N
appropriate tool (N) previously
installed (free screw). P
l. Remove the tool (N) with axis 3

bearing / pulley unit (P) from the N
screw, pulling it out from above. N
J
P P
m. Position the tool with bearing /
pulley unit on the workbench.
190

n. Unscrew and remove the six
socket hex head screws M5x16 M Q
(Q).
o. Remove the axis 4 pulley (R) R

and the plate (S).
p. Remove and set aside the two S

mechanical limit switches (M)
installed on the ends of the
screw.
M
q. On the axis 3 bearing / pulley

unit, unscrew and remove the V V
four socket hex head screws
M5x20 (T) then remove and
recover the axis 4 pulley (U).
H
r. Unscrew and remove the five
(V) then remove and recover
the plate (H).
U
T T
s. On the new screw, position the

appropriate Tool for ball screw
disassembly (CR82392144)
(N), inserting it from the upper
side of the screw.
191

t. Move upwards the axis 3
bearing unit (W), until it is fully N
positioned on the appropriate W N
tool (N) previously installed.
W
u. Position the plate (S) and the

pulley (R) on the axis 4 bearing Q
(X).
v. Tighten the six fixing socket hex R

head screws M5x16 (Q) to 6
Nm. torque.
X S
w. Reassemble the pulley (U) on

the axis 3 bearing (W).
x. Tighten the socket hex head

screws M5x20 (T) to 6 Nm.
torque.
W
U
T T
y. Slide the axis 3 bearing / pulley

unit (P), up to bring it back on N
the screw. P N
P
192

a. Recover the mechanical limit
switches (M) previously
removed from the damaged
screw.
b. Reposition the mechanical limit

switch (M) on the upper end of
the screw (flush with the upper
end). Tighten the socket hex
head screw M4x12 (L) to 3.1
Nm. torque.
M L
40
c. Position and fix the second
mechanical limit switch (M) 40
mm from the lower edge of the
screw.
d. Clean the screw with detergent

/ generic degreaser.
e. On the axis 3 bearing / pulley
unit (P) insert the O-ring gasket
Part No. 00301287 (Y) until
positioning it in the appropriate P
seat.
f. Insert the appropriate

lubrication ring (Z) on the axis 3
bearing / pulley unit (P),
positioning the lubrication P
nozzle in correspondence of the
hole on the bearing.
193

g. Insert the THK AFB-LF grease
inside the bearing using the
grease gun, until the grease is
forced out from the top of the
bearing.
h. Remove the lubrication ring and the O-ring gasket, then repeat the operations
from point e. to point g. also on the axis 4 bearing.
i. At the end of the operations, remove the lubrication ring and the O-ring gasket
from the axis 4 bearing.
j. Manually apply a thin layer of THK AFB-LF grease (about 12.7 grams) on the
external surface of the screw.
k. Manually move the axis 3 and axis 4 bearing / pulley units, in order to obtain an
even distribution of the grease all along the screw and inside the nut screw.
l. Reposition the screw (J) in the
corresponding seat on the J
Robot wrist, by manually fitting
the axis 3 and axis 4 belts on
the respective pulleys.
Position the screw (J) in
the correct direction, so
as to match the fixing
holes with the holes on
the Robot wrist.
m. Tighten the six socket hex head

screws M4x16 (F) to 3.1 Nm.
torque.
F F
194

n. Check the correct positioning of
the belts on the pulleys.
o. Reposition the plate (H)

between pulley and axis 3
bearing.
V V
p. Fix the plate tightening the five
(V) to 3.1 Nm. torque.
H
q. Tighten the four socket hex
head screws M4x12 (G) to 3.1 G G
Nm. torque.
r. Check the correct tensioning of the axis 3 belt and, if necessary, adjust it as
indicated in the procedure AXIS 3 MOTOR: complete replacement (see par.
4.8.6 on page 158).
s. Check the correct tensioning of
the axis 4 second belt (AA), as
indicated below:
s.1 position the frequency meter

(AB) in the vicinity of the belt
(about 1 cm)
s.2 strike the belt (in the vicinity of

the midpoint between the two
pulleys) using for example a
screwdriver, in order to trigger
its vibration AA AB
s.3 carry out the reading of the Representative image illustrating only the axis 4
frequency detected by the transmission, without guards.
frequency meter; the correct
frequency must be between
120 Hz and 145 Hz.
In case of new belt installation, the frequency value must be between 130
Hz and 145 Hz.
195

t. In case the frequency is
incorrect:
u. Cut the cable ties that fix the

motors.
v. Disconnect the XMTRx and

XSYNx connectors from the
axis 2, 3 and 4 motors.
w. Unscrew and remove the six

socket hex head screws M4x12 AD AC
(AC) and the related washers
that fix the holder (AD).
x. Lift the holder (AD) being
careful not to over-pull the AD
cables.
y. Loosen the three screws (AE)

that fix the axis 4 transmission
unit.
AE
z. Place a digital compression

dynamometer (AF) on the axis
4 transmission unit (AG).
a. Apply a pressure between 12.5

AF
indicated by the arrow, in order AG
to properly tension the axis 4
second belt.
b. Maintain the pressure, then Representative image illustrating only the axis 4
tighten the three socket hex transmission, without guards.
head screws M4x12 (AE) to 3.1
Nm. torque.
196

c. Reconnect only the XMTR4
connector to axis 4 motor.
d. Make sure that the connection

cables between Robot and
Control Unit are properly
connected.
e. Start the Control Unit.
f. Holding down the appropriate

push-button indicated in figure,
release the brake of the axis 4
motor (details in par. 4.5), then
manually move the belt in order
to trigger some rotations in
clockwise and anticlockwise
direction.
g. Shut down the Control Unit and disconnect the XMTR4 connector from axis 4
motor.
For details on the procedures of Control Unit power up and shutdown, refer
to the “Use of Control Unit” handbook.
h. Check again the belt tension as indicated in point s..

i. In case the detected frequency is still incorrect, repeat the operations from point
y. to point b. manually exerting a pressure:
i.1 greater, in case of too low frequency
i.2 lower, in case of too high frequency.

j. Check again the belt tension as indicated in point s.and, if necessary, repeat the
operations from point i. to point i.2.
k. Carry out the tensioning of the axis 4 first belt as indicated in the procedure AXIS
4 MOTOR: complete replacement (see par. 4.8.7 on page 168).
l. Obtained the correct tensioning
of all the belts, reconnect the AB
XMTRx and XSYNx connectors
to the corresponding axis 2, 3
and 4 motors.
m. Block the axis 3 and 4 motor

n. Reposition the holder (AB).
197

o. Tighten the six socket hex head
screws M4x12 (AA), with
corresponding washers
screws), to 3.1 Nm. torque.
AA
p. Reposition the lower guard (E).
q. Tighten the three socket hex

head screws M4x12 (D) to 1.5
Nm. torque.
r. Reposition the cover (B).

the gasket (C).
C
s. Tighten the six fixing hex socket
198
– After the recirculating ball screw replacement, carry out the Encoder recognition
procedure as described in par. 4.9 Software procedures following the
maintenance on page 214.
199
SPECIAL MAINTENANCE - WIRING
4.8.11 WIRING: complete replacement

and discharged
Material: – Wiring [See par. 4.11 Spare parts list on
page 242]
Equipment: – 6, 36, 41 mm open-end wrench
– Torque wrench
– Set of bits and sockets for torque wrench
– Cable tie tool
Representative image illustrating Robot Rebel-S6-0.60 Fixing – Socket hex countersunk screws M4x8
(floor installation) components: (x.x)
– Hex socket button head screws M5x10
(12.9)
– Screws Mxx
– Nuts Mxx
– Nuts Mxx

The cables are not to be twisted and the connectors are to be protected
against impacts.
During the disconnection and connection of the connectors, operate gently

to avoid damaging the connectors.
Before proceeding with the wiring disassembly, make sure that the
pneumatic power supply is disconnected and the compressed air circuit is
discharged.
The following are the operations needed to carry out:
• Operating procedure - Wiring disassembly
• Operating procedure - Wiring assembly
200
Operating procedure - Wiring disassembly

a. Unscrew and remove the four
socket hex countersunk screws
M4x8 (A) that fix the plate (B).
For added convenience,

it is recommended the
removal also of the Robot
lower plate, indicated in
figure (in case of wall
installation, remove the
side plate).
b. Move the plate (B) away from

the Robot base.
c. Remove the pneumatic piping

(C) from the quick coupling
fittings AIR 1, AIR 2 and AIR 3.
201
Operating procedure - Wiring disassembly (Continued)

d. Disconnect the XMTR1
connector (D) from the related
connector (E) present on cable
(F) of the Robot axis 1 motor.
Representative image illustrating Robot base without

lower guard.
e. Disconnect the two MTRx
connectors from the related
connectors present on the end
of the motor cable coming from
the Control Unit:
e.1 Disconnect the MTR1/MTR2

connector (G) intended for
Robot Axis 1 and Axis 2 motors.
e.2 Disconnect the MTR3/MTR4

connector (H) intended for
f. Disconnect the two SYNx
connectors (J) from the related
of the encoder cable coming
from the Control Unit:
f.1 Disconnect the SYN1/SYN2

connector intended for Robot
Axis 1 and Axis 2 motors
encoder.
f.2 Disconnect the SYN3/SYN4

encoder.
202

g. Using a socket wrench of 5 mm
block the fixing nuts (K) M3.
h. Using a wrench of 6 mm,

unscrew and remove the two
hex head screws (L) M3
(Harting 09670009924)
recovering the nuts (K) with the
related washers and Grover.
i. Remove the X50 connector (M)

from the plate (B).
j. Disconnect the axis 1 motor

encoder connector (N).

lower guard.
k. Cut and remove the two plastic
cable ties (P) that fix the pipes
and cables harness.
203

l. Block using an open-end
wrench CH41 the collector (Q)
of the wiring in the upper part.
m. Unscrew the nut M32x1.5 (R)

using an open-end wrench
CH36 up to completely remove
it from the threaded part.
n. Draw out all cables and piping

upwards in order to be able to
remove the nut (R) and the
wiring from the Robot base.
o. Unscrew and remove the six

fixing hex socket button head
screws M5x10 (S).
p. Pull upwards the cover (T) so as

to remove it from the Robot
wrist.

the gasket (U).
204

q. Cut and remove the two plastic
cable ties (V) that fix the cables
to the axis 3 motor and to the
axis 4 motor.
r. Unscrew and remove the six

fixing screws M4x12 (W) with
the related washers (present
only on the two front screws).
s. Move upwards the holder (X)

being careful not to pull the
cables.
205

t. Disconnect the motors
connectors (Y, q.ty 3).
u. Disconnect the XMTR2

connector intended for the axis
2 motor
v. Disconnect the XMTR3

3 motor.
w. Disconnect the XMTR4

4 motor.
x. Disconnect the encoders
connectors (Z, q.ty 3):
x.1 disconnect the XSYN2

connector from axis 2 motor.


y. After having disconnected all

the cables/connectors, lift and
completely remove the holder
(X).
206
Operating procedure - Wiring assembly

a. Lay out the wiring (AA) on the
floor.
b. Reposition the holder on the

Robot, fixing it with the six fixing
(W) and the related washers
screws).
c. Tighten the screws to a 3.1 Nm

torque.
d. Connect the encoders

connectors (Z, q.ty 3):
d.1 connect the XSYN2 connector

to axis 2 motor.

to axis 3 motor.

to axis 4 motor.
207
Operating procedure - Wiring assembly (Continued)

e. Connect the motors connectors
(Y, q.ty 3):
e.1 connect the XMTR2 connector

intended for the axis 2 motor.


f. Connect the encoders powering

connectors (AB) coming from
the battery pack, to the
corresponding connectors
BATT1 and BATT2 of the
wiring.
g. Fix the connectors BATT1 and

BATT2 using a plastic cable tie
(AC).
h. Fix the encoder cables to the

axis 3 and axis 4 motors using 2
plastic cable ties (V).
208

i. Reposition the cover (T), by
inserting it from the opposite
end of the wiring (Robot base
side).

the gasket (U).
j. Fix the cover tightening the six

fixing hex socket button head
screws M5x10 (S) to the proper
tightening torque.
k. Reinsert the pipes and cables

harness inside the Robot base
through the appropriate hole.
l. Before inserting the pipes and

cables harness, make sure that
you have removed the plastic
cable tie (AD) used to maintain
the gasket in place.
209

m. Insert the nut (R), passing
through it all the wiring cables
and pipes.
n. Slide the nut (R) being careful

not to damage the wiring cables
and pipes.
o. Block using an open-end

wrench CH41 the collector (Q)
of the wiring in the upper part.
p. Screw the nut M32x1.5 (R)

using an open-end wrench
CH36 until obtaining the correct
locking of the wiring on the
Robot base.
q. Reposition carefully the wiring,
paying particular attention not
to excessively twist and/or bend
the cables and pipes:
q.1 position the motor and encoder

cables of the axis 1 motor
towards the axis 1 motor
q.2 place all the remaining cables

and pipes towards the Robot
distribution panel side.
r. Neatly fix the cables and pipes

to the appropriate bracket
inside the Robot base, using
two plastic cable ties (P).
s. Pass the axis 1 encoder cable
under the bracket, then connect
the encoder connector (N) to
the axis 1 motor.

lower guard.
210

t. Connect the XMTR1 connector
(D) to the related connector (E)
present on cable (F) of the
Robot axis 1 motor.

lower guard.
u. Position the rubber gasket (AE)
on the X50 connector.
v. Position the X50 connector on

the related seat on the plate (B).
w. Insert the 2 hex head screws (L)

M3 (Harting 09670009924) that
fix the X50 connector from the
external side.
x. Fix the X50 connector from the

internal side, using 2 grover
washers and 2 fixing nuts (K).
211

y. Connect the connectors of the
lamp (AF).
z. Reconnect the two SYNx

connectors (J) to the related
of the encoder cable coming
from the Control Unit:
z.1 connect the SYN1/SYN2

encoder.
z.2 connect the SYN3/SYN4

encoder.
a. Reconnect the two MTRx
connectors to the related
of the motor cable coming from
the Control Unit:
a.1 connect the MTR1/MTR2

connector (G) intended for
Robot axis 1 and axis 2 motors.
a.2 connect the MTR3/MTR4

connector (H) intended for
212

b. Connect the pneumatic piping
(C) to the corresponding quick
coupling fittings AIR 1, AIR 2
and AIR 3.
c. Reposition the plate (B) to the

Robot base.
If previously removed,
reassemble the Robot
lower plate, indicated in
figure (in case of wall
installation, reassemble
the side plate).
d. Fix the plate (B) to the Robot

base tightening the four socket
hex countersunk screws M4x8
(A).
– At the end of the activity, make sure the pipes and cables are not constricted or
inadequately curved.
– After the wiring replacement, carry out the Encoder recognition procedure as
page 214.
– Before restarting the production cycle, move the Robot at low speed, in order to
check the proper positioning of the wiring.
213
SPECIAL MAINTENANCE - SOFTWARE PROCEDURES
4.9 Software procedures following the maintenance

After some maintenance operations, it is necessary to perform some Software
operations, in order to restore the correct configurations and parameters on the Control
Unit.
Below is described the following procedure:
– Encoder recognition procedure
The need for any consequent Software procedures is indicated at the end of each
maintenance sheet of the Robot.
214
4.9.1 Encoder recognition procedure
The encoder recognition procedure must be performed following the disconnection and
reconnection of the encoder cable from the motor, or following the replacement of
encoder batteries.
The following paragraphs describe the encoder recognition procedure, using as

reference the video pages displayed on the Teach Pendant (optional). If there is no a
Teach Pendant, the operations can be performed through similar commands available
on Virtual TP interface of the WinR1C software.
a. From the “Home” page, Login to the Control

Unit with “Service” privileges.
b. Select the “Service” item, then “System”.
215
c. Select the “Root” application.
d. Select the concerned arm and the axis from

the respective “ARM” and “Axis” drop down
menu.
e. From the “Action” drop down menu, select

the “Service” item.
f. From the “Function” drop down menu, select

the “AbsEnc ResetTurn” item.
g. Confirm by pressing the “OK” key.
216
h. Confirm by pressing the “Run” key.
i. Repeat the operations from point b. to point h. for each axis. Select every time the desired axis from the
related “Axis” drop down menu.
j. From the “Function” drop down menu, select
the “AbsEnc ResetError” item.
k. Confirm by pressing the “OK” key.
l. Confirm by pressing the “Run” key.
m. Repeat the operations from point j. to point l. for each axis. Select every time the desired axis from the
related “Axis” drop down menu.
217
n. At the end of the operations, save the

settings by pressing the “Save” key.
o. Go to the Home Page of the Teach Pendant,

then restart the Control Unit by selecting
“Restart”, “Cold” item.
218
SPECIAL MAINTENANCE - SISTEMA ROBOTICO
4.10 Robot calibration

– Calibration - Basic concepts
– Calibration - Operating procedures
– Procedures following the calibration
4.10.1 Calibration - Basic concepts

– Calibration tool description
– Reference notches description and position
4.10.1.1 Calibration tool description

The calibration of the axes must be performed by using the specific Calibration tool
(CR82415200) (details in par. 2.10.3) consisting primarily of a mechanical key (for axes
1 and 2 calibration) and of the flange and bracket (for axes 3 and 4 calibration).
To carry out the calibration, the mechanical key must be inserted in the appropriate
notches:
– present on the Robot body (axes 1 and 2)
– available after the installation of the flange and bracket (axes 3 and 4).
Fig. 4.4 - Calibration tool
AX 3 and 4 B AX 1 and 2
– A: Mechanical key for axes 1 and 2 calibration

– B: Flange and bracket for axes 3 and 4 calibration
219
SPECIAL MAINTENANCE - ROBOT CALIBRATION
4.10.1.2 Reference notches description and position

On axes 1 and 2, the Robot is fitted with seats within which is to be inserted the
calibration mechanical key; the coincidence of the two seats identifies the axis reference
notch (Fig. 4.5).
The reference notch of the axis taken into consideration, is composed of a fixed part (A)
and a mobile part (B) and their alignment makes possible the Robot calibration.
The axes 3 and 4 are free of calibration notches. For this reason it is necessary the
installation of the appropriate flange and bracket, included in Calibration tool
(CR82415200).
Fig. 4.5 - Aligned reference notch (axis 1)
By means of the Virtual TP on WinR1C (or on Teach Pendant, if present), move at low
speed the Robot axes up to coincide the movable notch with the fixed notch.
Insert the calibration mechanical key in the seat of the aligned reference notch. The
insertion must occur easily, without forcing. In case of even a minimum jam, remove the
calibration mechanical key, move the axis that is to be calibrated and try to insert again.
Fig. 4.6 - Example of gauge inserted on notch
AX 3 and 4 B AX 1 and 2
The following Tab. 4.9 are the points where it is necessary to insert the mechanical key
(T1) to perform the calibration of the various axes of the Robot.
220
The following figures represent the Robot Rebel-S6-0.60. On Robot Rebel-S6-0.60c

and Rebel-S6-0.75c the axis 1 calibration notch is placed on the opposite side.
Tab. 4.9 - Robot calibration notches location
Axis 1 calibration notch
T1
T1
T1
221
T1
The T1 key for axis 4 calibration can be installed without distinction in one of the two positions indicated in
figure
222
4.10.2 Calibration - Operating procedures

– Axis 3 and 4 calibration tool assembly
– Robot axis 1
– Axis 2 calibration
The calibration must be carried out on Robot free of loads applied to the axes, following
the sequence:
– Robot axis 1
– Axis 3 calibration.
To carry out the calibration it is necessary also to have the “SERVICE” access
privileges.
The following paragraphs describe the calibration procedures of the Robot axes, using
as reference the video pages displayed on the Teach Pendant (optional). If there is no
a Teach Pendant, the operations can be performed through similar commands
available on Virtual TP interface of the WinR1C software.
223
4.10.2.1 Axis 3 and 4 calibration tool assembly

Material: – Calibration tool (CR82415200)
Equipment: – ---
Fixing – Special screws (Part No.
components: CR82415201-B)
– Special screw (Part No. CR82415204)
– Socket hex head screws M4x12 - 8.8
– Dowel pins with extraction hole ISO 4762
Ø6x22 - B - St

– In order to make possible the axes 3 and 4 calibration, it is necessary to
assemble on the Robot wrist the appropriate flange and bracket included in
Calibration tool (CR82415200), operating as indicated below.
While assembling the axes 3 and 4 calibration tool, do not use hammers
and avoid shocks on flange and bracket. In case of damaging these
components, the calibration may be inaccurate.
224
Operating procedure
a. Unscrew the two socket hex
head screws M4x12 (A) present
on the bracket (B), so as to C
make the two dowel pins to
completely come out (C).
Section
Front view
A-A
b. Position the bracket (B) on the

lower part of the Robot wrist,
with the notch (D) facing the
axis 3 screw (E), as indicated in
figure.
The correct positioning is
guaranteed by the E B
insertion of the dowel pins
into the corresponding
holes on the Robot.
D
c. Fix the bracket (B) to the Robot
wrist manually tightening the
four screws (F), two for each
side.
225

d. Position the flange (G) on the
axis 3 screw (E).
The inscription “UP” on
the flange should face
upwards. H
E
e. Align the hole (H) present on
the flange (G) with the centering G
countersink present on the axis
3 screw.
G
f. Center and fix the flange (G) to
the axis 3 screw inserting and
tightening the screw (J).
J
226
4.10.2.2 Robot axis 1

b. Manually move the axis 1 in negative

direction, in order to misalign the calibration
notch.
c. Access the “Motion” page.
d. Access the “Advanced” tab.
e. Enable the “Incremental Jog” feed mode.
f. Under “Angular” item insert the value 0.05°.

In this way, each time you press the “JOG”
key, the concerned axis will rotate by 0.05°,
then will remain unchanged until the next
press.
g. Move the axis 1 in positive direction, by

pressing the “JOG” key.
h. Move the axis as long as it will be possible to

insert the calibration mechanical key (see
Axis 1 calibration notch in Tab. 4.9) without
forcing.
i. In the event of detecting a minimum forcing when inserting the key, repeat the procedure from step g.
j. Remove the T1 calibration mechanical key.
227
Do not move the Robot with the inserted mechanical key.
k. From the “Desktop” page, access the

“Setup” page.
l. Select the “Motion” item, then “Calib”.
m. Select the concerned axis.
n. Select “Calib”.
o. Confirm with “Yes”
p. Continue with the Axis 2 calibration as indicated below.
228
4.10.2.3 Axis 2 calibration


notch.

press.


forcing.
i. In the event of detecting a minimum forcing when inserting the key, repeat the procedure from step g.
229

“Setup” page.
230
a. Install on the Robot wrist the Calibration tool

(CR82415200) as indicated in the Axis 3 and
4 calibration tool assembly (see par.
4.10.2.1 on page 224) procedure.


notch.

press.


forcing.
i. In the event of detecting a minimum forcing when inserting the key, repeat the procedure from step h.
231

“Setup” page.
232
a. Install on the Robot wrist the Calibration tool

(CR82415200) as indicated in the Axis 3 and
4 calibration tool assembly (see par.
4.10.2.1 on page 224) procedure.
b. From the “Home” page, Login to the Control

c. Manually move the axis 3 in negative

notch.
d. Access the “Motion” page.
e. Access the “Advanced” tab.
f. Enable the “Incremental Jog” feed mode.
g. Under “Linear” item insert the value 0.05

mm. In this way, each time you press the
“JOG” key, the axis 3 will rotate by 0.05 mm,
press.
h. Move the axis 3 in positive direction, by

i. Move the axis as long as it will be possible to

forcing.
j. In the event of detecting a minimum forcing when inserting the key, repeat the procedure from step h.
k. Remove the T1 calibration mechanical key.
233
l. From the “Desktop” page, access the

“Setup” page.
m. Select the “Motion” item, then “Calib”.
n. Select the concerned axis.
o. Select “Calib”.
p. Confirm with “Yes”
234
4.10.3 Procedures following the calibration

In order to verify the correct and complete Robot calibration, it is necessary to perform
the following procedures:
– Calibration position check
– Calibration position check with Tool Master
– Saving the calibration file
4.10.3.1 Calibration position check
a. Manually move the Robot, so as to bring

each axis in a position different from the
calibration position.
b. From the “Desktop” page, access the

“Service” page, then select the “System”
item.
c. Select the “Execute” item.
d. Click 2 times the “Execute” field, then, from

the drop down menu, select the “Move to
$cal_sys” statement.
235
e. Confirm by pressing “OK”, then “Exec”.
f. You will see a dialogue window showing the

message “Operation in progress... And
move to $cal_sys”; wait until completion of
the operation.
g. At the end of the operations, the Robot will have to be placed in calibration position.
h. Visually check the alignment of all the calibration notches.
i. Insert the calibration mechanical key in each calibration notch (see Tab. 4.9 - Robot calibration notches
location on page 221); it must be possible to insert the calibration key without forcing.
j. Otherwise, repeat the calibration procedures, as described in par. 4.10.2 and the following.
k. Remove from the Robot wrist the Calibration tool (CR82415200), by reversing the steps indicated in the
Axis 3 and 4 calibration tool assembly (see par. 4.10.2.1 on page 224) procedure.
236
4.10.3.2 Calibration position check with Tool Master
It is recommended to perform this procedure in the following cases

–after the Robot calibration
–after a collision
–in all cases in which the Robot precision is insufficient.
The verification of the calibration position must be performed with no loads on the wrist.
To perform the procedure are required:
–ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149)
–Calibrated Tool Unit - Tool Master L=117 mm (81783801)
It is also required a “mechanical reference point” having the tip ø 6 mm (to be realized by the
integrator).
a. From the “Desktop” page, access the “Data”
page, then select the “Tool” item.
b. Check that the data relating to Robot “Tool

Master” are the following:
• X= -143
• Y= 0
• Z= 10.5
• A= 0
• E= 0
• R= 0
237
c. From the “Desktop” page, access the

“Motion” page, then select the “Basic” tab.
d. Enter in the appropriate fields the following

values:
• Tool = Master
• Frame = Frame0
• Base = Base0
• Payload = 0
e. Assemble the ISO tool coupling flange ISO 9409 - 1 - A40 (CR82392149) on the Robot, as indicated in
the related procedure in par. 3.5.1.
f. Screw the Calibrated Tool Unit - Tool Master L=117 mm (81783801) on the ISO tool coupling flange ISO
9409 - 1 - A40 (CR82392149) using an open-end wrench of 10 mm.
g. Manually move the Robot up to bring the tip
of the Tool Master (A) in contact with the tip
of the mechanical reference (B) on which to
perform the verification.
h. From the “Desktop” page, access the

“Motion” page, then select the “Advanced”
tab.
i. Enable the “Incremental Jog” item.
j. In the “Linear” field set the 2 mm. value.
238
k. Manually move the Robot axis 3 in order to move away of 2 mm the tip of the Tool Master from the tip of
the mechanical reference.
l. Subsequently, disable the “Incremental Jog” mode.
m. Press the “COORD” button on the Teach Pendant in order to select the TOOL mode. The mode selection
is indicated in the related field of the Status Bar.
n. On the Status Bar, select the GenOVR field
to access the quick setup of the General
Override value.
o. Set the value to 20%.
20%
p. Rotate the Tool Center Point (TCP hereinafter) around the mechanical reference point by 45° on Z axis,
pressing the JOG “6Z+” key.
q. During the rotation of the Tool around the mechanical reference point, observe the distance between the
TCP and the center of the mechanical reference. The maximum permitted deviation is ±3 mm in all
directions.
r. Rotate the TCP around the mechanical reference point until bringing it to the starting position, by pressing
the JOG “6Z-” key.
s. Rotate the TCP around the mechanical reference point by -45° on Z axis, pressing the JOG “6Z-” key.
t. During the rotation of the Tool around the mechanical reference point, observe the distance between the
TCP and the center of the mechanical reference. The maximum permitted deviation is ±3 mm in all
directions.
u. In case the TCP deviation is greater than 3 mm:

• Verify the prerequisites listed at the beginning of this procedure
• Verify the Robot configuration file (Robot type, SW version, etc.)
• Perform again the Robot calibration as indicated in par. 4.10.2.
• Repeat the Calibration position check with Tool Master. In case in which the error is still greater than
3 mm, the Robot must be overhauled.
239
4.10.3.3 Saving the calibration file
a. From the “Desktop” page, access the “Files”

page, then select the “SYS” and “CNFG”
folders.
b. Select the desired calibration file, carefully

verifying the name and the serial
number.
c. Touch or press “Enter” to open the file.
d. Verify that the information contained in the

“Program” statement, corresponds to the
name of the calibration file.
e. Go back to the “Desktop” page.
240
f. Access the “Setup” page, then select the

items “Motion” and “Calib”.
g. Select and hold for a few seconds the “Save”

item.
h. From the drop down menu select the

“Motors” item.
i. Confirm the saving by pressing “Yes”.
j. At the end of the procedure, in the “Status

Bar” will be displayed the message
“Command Executed”.
k. The calibration file has been successfully

saved into the Flash memory of the Robot
motors.
l. At the end of the calibration operations, perform a low-speed work program in order to verify the correct
operation of the Robot.
241
SPARE PARTS LIST
4.11 Spare parts list

In the following:
– Tab. 4.10 - Robot Rebel-S6 - Rel. 1.0 mechanical spare parts on page 242
– Tab. 4.11 - Robot Rebel-S6 - Rel. 1.0 plates unit spare parts on page 244
are indicated all spare parts available for the Robots Rebel S6 - Rel. 1.0, with
corresponding order part numbers.
Tab. 4.10 - Robot Rebel-S6 - Rel. 1.0 mechanical spare parts
R
K M
Q
L
P
2
is
Ax
D
Axi
F
s4
E
H
C
A
is 3
Ax
B
J L Ax
is 1
Axis
Pos. Comau Part No. Description Q.ty Weight
Robot
O-RING gasket
A 00301289 Ax 1 1 ---
AS 568 - Ø60.05xØ1.78 (N°036)
O-RING gasket
B 00301287 Ax 1 1 ---
AS 568 - Ø50.52xØ1.78 (N°033)
O-RING gasket
C 00301215 Ax 1 1 ---
AS 568 - Ø88.62xØ1.78 (N°043)
O-RING gasket
D 00301287 Ax 2 1 ---
AS 568 - Ø50.52xØ1.78
O-RING gasket
E 00300765 Ax 2 1 ---
AS 568 - Ø69.57XØ1.78 (N°039)
242
SPARE PARTS LIST
Axis
Robot
O-RING gasket
F 00301215 Ax 2 1 ---
AS 568 - Ø88.62xØ1.78
Driving toothed belt
G CR82399630 Ax 3 1 ---
100S3M573
H CR82399631 Ax 4 1 ---
100MTS3M231G
J CR82399632 Ax 4 1 ---
200MTS3M459G
Recirculating ball screw 0.55 Kg
K CR82399610 Ax 3-4 1
2020A+410LC5 (THK) (1.21 lb)
0.7 Kg
L CR82397901 Motor 0.32 NM - 100W Ax 3-4 2
(1.54 lb)
0.9 Kg
M CR82397911 Motor 0.64 NM - 200W Ax 2 1
(1.98 lb)
1.2 Kg
N CR82397915 Motor 1.27 NM - 400W Ax 1 1
(2.64 lb)
CR82416900 Wiring for Rebel S6-0.45 --- 1 ---
P CR82417000 Wiring for Rebel S6-0.60 --- 1 ---
CR82417100 Wiring for Rebel S6-0.75 --- 1 ---

Lithium Battery 1.5 Ah 3.6V
Q CR19220009 --- 2 ---
ACCU Italia Part No. 2217020102
R CR82399663 Battery case --- 1 ---
243
SPARE PARTS LIST
Tab. 4.11 - Robot Rebel-S6 - Rel. 1.0 plates unit spare parts
N C B G H K A B D N
F
M L
E
J
A CR82399801 “Caution Falling / Dropping” label 1 ---
B CR82399802 “Rebel-S” logo label 2 ---
C CR82399803 “Red Line sx” label 1 ---
D CR82399804 “Red Line dx” label 1 ---
E CR82399805 Ax. identification label 1 1 ---

F CR82399806 Ax. identification label 2 1 ---
G CR82399807 Ax. identification label 4 1 ---
H CR82399808 Ax. identification label 3 1 ---

J CR82399809 “Collision warning” label 1 ---
K CR82399810 “Risk of limbs crushing” label 1 ---
L CR82392302 “See the instruction handbook” label 2 ---
M CR82392306 Transparent label 74x54 mm 1 ---
N CR82399103 Data plate Comau 104x15 - Aluminium 2 ---
244
Original instructions
Made
in
Comau

Comau Robot Rebel s6 Technical Specifications Transport and Installation and Maintenance PDF

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Comau Robot Rebel s6 Technical Specifications Transport and Installation and Maintenance PDF

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Formats disponibles

Robot Rebel-S6

Description of the available versions and technical

Copyright © 2008-2016 by COMAU - Published on 11/2016

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

2. TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

AIR fittings features on Robot wrist base/body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

3. TRANSPORT AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..74

Lubrication procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Manufacturer Robot Set of Handbooks

These handbooks must be integrated with the following documents:

Manufacturer Description Set of Handbooks

Limits on the handbook contents

Symbols used in the handbook

GENERAL SAFETY REQUIREMENTS

1. GENERAL SAFETY REQUIREMENTS

This chapter deals with the following topics:

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

GENERAL SAFETY REQUIREMENTS

1.1.1 Essential safety requirements applied and fulfilled

1.2 Safety requirements

Installation and Startup

Functioning in Programming Mode

GENERAL SAFETY REQUIREMENTS

Functioning in Auto / Remote Mode

Maintenance and Repair

Decommissioning and Dismantling

GENERAL SAFETY REQUIREMENTS

1.2.4 Operating modes

GENERAL SAFETY REQUIREMENTS

– A wrong connection of the connectors may cause permanent damage to the

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

GENERAL SAFETY REQUIREMENTS

Functioning in Programming Mode

GENERAL SAFETY REQUIREMENTS

Functioning in Auto / Remote Mode

GENERAL SAFETY REQUIREMENTS

Maintenance and Repair

GENERAL SAFETY REQUIREMENTS

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

Decommissioning and Dismantling

2.1 Robot general description

2.2 Robot axes identification

Ax Robot axis Mtr4 Ax2

Robot Rebel-S6-0.45 representative image

Robot Rebel-S6-0.60c representative image

2.3 Declaration of incorporation of partly completed

The Declaration of incorporation of partly completed machinery is provided in

Fig. 2.1 - Robot identification plate (example)

B xxxx REL. xxx

– A: Name and address of the manufacturer

2.4 Name and address of the manufacturer

2.5 Available versions and technical features

2.5.1 Available versions

Tab. 2.1 - Robot Rebel-S6 available versions

Robot Rebel-S6-0.45 and Rebel-S6-0.60c representative image

2.5.2 Technical features

VERSION Rebel-S6-0.45 Rebel-S6-0.60 Rebel-S6-0.60c Rebel-S6-0.75 Rebel-S6-0.75c

2.5.3 Operational areas and Robot overall dimensions

Fig. 2.2 - Rebel-S6-0.45

669 Base mounting face

Fig. 2.3 - Rebel-S6-0.60

819 Base mounting face

Fig. 2.4 - Rebel-S6-0.60c