COMAU Handbook Smart5 NJ4

Comau Robotics
Instruction handbook
SMART5 NJ4 170 – 2.5

SMART5 NJ4 175 – 2.2
SMART5 NJ4 170 – 2.9
SMART5 NJ4 220 – 2.7
SMART5 NJ4 220 – 2.4
SMART5 NJ4 220 – 3.0
SMART5 NJ4 270 – 2.7
Technical Specification
CR00757635-en_01/2011.03
The information contained within this manual is the property of COMAU S.p.A.
Any reproduction, even partial is forbidden without previous written authorisation from COMAU S.p.A.
COMAU reserves the right to modify without previous warning, the characteristics of the product presented in
this manual.
Copyright © 2009 by COMAU -

Summary
SUMMARY
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Symbols in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16

Robot SMART5 NJ4 family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Robot mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Interchangeability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3. TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...22

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4. OPERATING AREAS AND ROBOT OVERALL DIMENSIONS . . . . . . . . . . . . . . . . ...27

SMART5 NJ4 170 – 2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SMART5 NJ4 170 – 2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SMART5 NJ4 175 – 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SMART5 NJ4 175 – 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SMART5 NJ4 220 – 2.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SMART5 NJ4 220 – 2.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SMART5 NJ4 220 – 2.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SMART5 NJ4 220 – 2.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SMART5 NJ4 170 – 2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SMART5 NJ4 170 – 2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SMART5 NJ4 270 – 2.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Summary
SMART5 NJ4 270 – 2.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SMART5 NJ4 220 – 3.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SMART5 NJ4 220 – 3.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5. ROBOT FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43

Tool coupling flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6. LOADS AT WRIST AND ADDITIONAL LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..49

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Determination of max loads at wrist flange (QF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Additional loads (QS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7. PREPARATION FOR ROBOT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..63

Environment conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Environment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Operating space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Attachment to a Steel Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Standard Steel Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Attachment to a plate with adjustable level (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Secure plate to the floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Stress on supporting structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8. OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..74

APPLICABILITY OF OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Axis 1 work area partialization assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Axis 2 work area partialization assembly -
2 areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Axis 1 adjustable mechanical hard stop assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Axis 2 adjustable mechanical hard stop assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Relaese code CR82342500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Relaese code CR8234480 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Screws and pins kit for robot mounting (code CR82342700) . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Leveling plate unit for robot mounting
(code CR82342800). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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Summary
Non adjustable plate for robot mounting (code 82343100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Fall-prevention brackets assembly for ceiling attachment (code CR82348800) . . . . . . . . . . . . 89
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
NJ ceiling mounting and fall-prevention assembly - BRIC (code CR82344700) . . . . . . . . . . . . 92
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Axis 1 adjustable mechanical hard stop assembly (code CR82273200) . . . . . . . . . . . . . . . . . . 95
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Axis 2 adjustable mechanical hard stop assembly (code CR82273300) . . . . . . . . . . . . . . . . . . 98
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Axis 1 mechanical hard stop on-off assembly (lock pin - code CR82344300 . . . . . . . . . . . . . . 99
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Axis 1 mechanical hard stop on-off assembly - lock pin (code CR82273600). . . . . . . . . . . . . 101
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Axis 1 work area partialization assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Axis 2 work area partialization assembly -
2 areas (code CR82273400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Screws and pins kit for robot mounting (code 82314700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Leveling plate unit for robot mounting
(code 82314800) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Calibration tool (code 82314100). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Gauged tool assembly L=200 mm
(code 82109501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Fork liftable option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Distribution connection guard assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Guard assembly for ventilated motor ax1
(code 82309259) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
00/0000 3
Preface
PREFACE
Symbols in the manual

Find below the symbols highlighting WARNING, CAUTION and NOTES together with
their meaning
This symbol applies to operating procedures, technical information and

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

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

precautions that need necessarily to be highlighted.
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Preface
Reference documents
This document refers tol robot SMART5 NJ4 with standard outfitting.
The composition of the complete set of manuals containing the robot system and control
documentation is indicated in the following table:
Comau Robot Set Manuali

– Technical Specifications
SMART5 NJ4 – Transport and Installation
– Electrical diagram
SMART5 NJ4 170 – 2.5 – Maintenance
SMART5 NJ4 170 – 2.9
Comau
SMART5 NJ4 220 – 2.4
SMART5 NJ4 220 – 2.7
SMART5 NJ4 270 – 2.7
These manuals are to be integrated with the following documents:
C5G Control Unit – Technical Specifications

– Transport and installation
– Guide to integration, safeties, I/O and
communications
– Maintenance
Comau – Use of Control Unit.
– Electrical diagram
Programming – EZ PDL2 Easy programming environment
– PDL2 Programming Language Manual
– Move programming
– VP2 Visual PDL2
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General Safety Precautions
1. GENERAL SAFETY PRECAUTIONS
It deals with a general specification that apply to the whole Robot System. Due to
ist significance, this document is referred to unreservedly in any system
instruction manual.
This specification deals with the following topics:

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

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

conform to all national and local codes.
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1.2 Safety Precautions

1.2.1 Purpose
These safety precautions are aimed to define the behaviour and rules to be observed
when performing the activities listed in the Applicability section.
1.2.2 Definitions
Robot System (Robot and Control System)
The Robot System is a functional unit consisting of Robot, Control Unit, Programming
terminal and possible options.
Protected Area
The protected area is the zone confined by the safety barriers and to be used for the
installation and operation of the robot
Authorised Personnel
Authorised personnel defines the group of persons who have been trained and assigned
to carry out the activities listed in the Applicability section.
Assigned Personnel
The persons assigned to direct or supervise the activities of the workers referred to in
the paragraph above.
Installation and Putting into Service

The installation is intended as the mechanical, electrical and software integration of the
Robot and Control System in any environment that requires controlled movement of
robot axes, in compliance with the safety requirements of the country where the system
is installed.
Programming Mode
Operating mode under the control of the operator, that excludes automatic operation
and allows the following activities: manual handling of robot axes and programming of
work cycles at low speed, programmed cycle testing at low speed and, when allowed,
at the working speed.
Auto / Remote Automatic Mode

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

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

Putting out of service defines the activities involved in the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.
Integrator
The integrator is the professional expert responsible for the installation and putting into
service of the Robot and Control System.
Incorrect Use
Incorrect use is when the system is used in a manner other than that specified in the
Technical Documentation.
Range of Action
The robot range of action is the enveloping volume of the area occupied by the robot
and its fixtures during movement in space.
1.2.3 Applicability
These Specifications are to be applied when executing the following activities:
– Installation and Putting into Service;
– Programming Mode;
– Auto / Remote Automatic Mode;
– Robot axes release;
– Maintenance and Repairs;
– Putting Out of Service and Dismantling
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1.2.4 Operating Modes

Installation and Putting into Service
– Putting into service is only possible when the Robot and Control System has been
correctly and completely installed.
– The system installation and putting into service is exclusively the task of the
authorised personnel.
– The system installation and putting into service is only permitted inside a protected
area of an adequate size to house the robot and the fixtures it is outfitted with,
without passing beyond the safety barriers. It is also necessary to check that under
normal robot movement conditions there is no collision with parts inside the
protected area (structural columns, power supply lines, etc.) or with the barriers. If
necessary, limit the robot working areas with mechanical hard stop (see optional
assemblies).
– Any fixed robot control protections are to be located outside the protected area and
in a point where there is a full view of the robot movements.
– The robot installation area is to be as free as possible from materials that could
impede or limit visibility.
– During installation the robot and the Control Unit are to be handled as described in
the product Technical Documentation; if lifting is necessary, check that the
eye-bolts are fixed securely and use only adequate slings and equipment.
– Secure the robot to the support, with all the bolts and pins foreseen, tightened to
the torque indicated in the product Technical Documentation.
– If present, remove the fastening brackets from the axes and check that the fixing
of the robot fixture is secured correctly.
– Check that the robot guards are correctly secured and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– If applicable, connect the robot pneumatic system to the air distribution line paying
attention to set the system to the specified pressure value: a wrong setting of the
pressure system influences correct robot movement.
– Install filters on the pneumatic system to collect any condensation.
– Install the Control Unit outside the protected area: the Control Unit is not to be used
to form part of the fencing.
– Check that the voltage value of the mains is consistent with that indicated on the
plate of the Control Unit.
– Before electrically connecting the Control Unit, check that the circuit breaker on the
mains is locked in open position.
– Connection between the Control Unit and the three-phase supply mains at the
works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned
appropriately for the power installed on the Control Unit. See the product
Technical Documentation.
– The power supply cable is to enter the Control Unit through the specific fairlead and
be properly clamped.
– Connect the earth conductor (PE) then connect the power conductors to the main
switch.
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00/0710 9
– Connect the power supply cable, first connecting the earth conductor to the circuit
breaker on the mains line, after checking with a tester that the circuit breaker
terminals are not powered. Connect the cable armouring to the earth.
– Connect the signals and power cables between the Control Unit and the robot.
– Connect the robot to earth or to the Control Unit or to a nearby earth socket.
– Check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors could cause permanent damage to the
Control Unit components.
– The C5G Control Unit manages internally the main safety interlocks (gates,
enabling pushbuttons, etc.). Connect the C5G Control Unit safety interlocks to the
line safety circuits, taking care to connect them as required by the Safety
standards. The safety of the interlock signals coming from the transfer line
(emrgency stop, gates safey devices etc) i.e. the realisation of correct and safe
circuits, is the responsibility of the Robot and Control System integrator.
In the cell/line emergency stop circuit the contacts must be included of the control
unit emergency stop buttons, which are on X30. The push buttons are not
interlocked in the emergency stop circuit of the Control Unit.
– The safety of the system cannot be guaranteed if these interlocks are wrongly
executed, incomplete or missing.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic states; in Programming the power is cut out (power
contactors open) immediately. The procedure for the selection of the controlled
stop time (that can be set on SDM board) is contained in the Installation manual .
– When preparing protection barriers, especially light barriers and access doors,
bear in mind that the robot stop times and distances are according to the stop
category (0 or 1) and the weight of the robot.
Check that the controlled stop time is consistent with the type of Robot connected
to the Control Unit. The stop time is selected using selector switches SW1 and
SW2 on the SDM board.
– Check that the environment and working conditions are within the range specified
in the specific product Technical Documentation.
– The calibration operations are to be carried out with great care, as indicated in the
Technical Documentation of the specific product, and are to be concluded
checking the correct position of the machine.
– To load or update the system software (for example after replacing boards), use
only the original software handed over by COMAU Robotics & Service.
Scrupulously follow the system software uploading procedure described in the
Technical Documentation supplied with the specific product. After uploading,
always make some tests moving the robot at slow speed and remaining outside the
protected area.
– Check that the barriers of the protected area are correctly positioned.
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10 00/0710
Programming Mode
– The robot is only to be programmed by the authorised personnel.
– Before starting to program, the operator must check the Robot System (Robot and
Control System) to make sure that there are no potentially hazardous irregular
conditions, and that there is nobody inside the protected area.
– When possible the programming should be controlled from outside the protected
area.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the hand-held programming unit functions
correctly (slow speed, emergency stop, enabling device, etc.).
– During the programming session, only the operator with the hand-held terminal is
allowed inside the Protected Area.
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (Drive On) is always to be controlled from a position
outside the range of the robot, after checking that there is nobody in the area
involved. The Drive On operation is concluded when the relevant machine status
indication is shown.
– When programming, the operator is to keep at a distance from the robot to be able
to avoid any irregular machine movements, and in any case in a position to avoid
the risk of being trapped between the robot and structural parts (columns, barriers,
etc.), or between movable parts of the actual robot.
– When programming, the operator is to avoid remaining in a position where parts of
the robot, pulled by gravity, could execute downward movements, or move
upwards or sideways (when installed on a sloped plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at slow speed has been executed. The
test is to be controlled from a safe distance.
– Special attention is to be paid when programming using the hand-held terminal: in
this situation, although all the hardware and software safety devices are active, the
robot movement depends on the operator.
– During the first running of a new program, the robot may move along a path that is
not the one expected.
– The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the robot position out
of the path that links two steps of the program), could give rise to movements not
envisaged by the operator when testing the program.
– In both cases operate cautiously, always remaining out of the robot’s range of
action and test the cycle at slow speed.
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00/0710 11
Auto / Remote Automatic Mode

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

– In the absence of motive power, the robot axes movement is possible by means of
optional release devices and suitable lifting devices. Such devices only enable the
brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enable button) are cut out; also the robot
axes can move upwards or downwards because of the force generated by the
balancing system, or the force of gravity.
Before using the manual release devices, it is strongly recommended to sling the
robot, or hook to an overhead travelling crane.
– Enabling the brake releasing device may cause the axes falling due to gravity as
well as possible impacts due to an incorrect restoration, after applying the brake
releasing module. The procedure for the correct usage of the brake releasing
device (both for the integrated one and module one) is to be found in the
maintenance manuals.
– When the motion is enabled again following the interruption of an unfinished
MOVE, the track recovery typical function may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next automatic cycle
restarting. Avoid moving the Robot to positions that are far away from the ones
provided for the motion restart; alternatively disable the outstanding MOVE
programmes and/or instructions.
Maintenance and Repairs

– When assembled in COMAU Robotics & Service, the robot is supplied with
lubricant that does not contain substances harmful to health, however, in some
cases, repeated and prolonged exposure to the product could cause skin irritation,
or if swallowed, indisposition.
First Aid. Contact with the eyes or the skin: wash the contaminated zones with
abundant water; if the irritation persists, consult a doctor.
If swallowed, do not provoke vomiting or take anything by mouth, see a doctor as
soon as possible.
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12 00/0710
– Maintenance, trouble-shooting and repairs are only to be carried out by authorised

personnel.
– When carrying out maintenance and repairs, the specific warning sign is to be
placed on the control panel of the Control Unit, stating that maintenance is in
progress and it is only to be removed after the operation has been completely
finished - even if it should be temporarily suspended.
– Maintenance operations and replacement of components or the Control Unit are to
be carried out with the main switch in open position and locked with a padlock.
– Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages coming from connections to peripheral units or external
power sources (e.g. 24 Vdc inputs/outputs). Cut out external sources when
operating on parts of the system that are involved.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Faulty components are to be replaced with others having the same code, or
equivalent components defined by COMAU Robotics & Service.
After replacement of the SDM module, check on the new module that the setting
of the stop time on selector switches SW1 and SW2 is consistent with the type of
Robot connected to the Control Unit.
– Trouble-shooting and maintenance activities are to be executed, when possible,

outside the protected area.
– Trouble-shooting executed on the control is to be carried out, when possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards are to be observed
when operating with hazardous voltages present.
– Trouble-shooting on the robot is to be carried out with the power supply cut out
(Drive off).
– At the end of the maintenance and trouble-shooting operations, all deactivated
safety devices are to be reset (panels, protection shields, interlocks, etc.).
– Maintenance, repairs and trouble-shooting operations are to be concluded
checking the correct operation of the Robot System (Robot and Control System)
and all the safety devices, executed from outside the protected area.
– When loading the software (for example after replacing electronic boards) the
original software handed over by COMAU Robotics & Service is to be used.
Scrupulously follow the system software loading procedure described in the
specific product Technical Documentation; after loading always run a test cycle to
make sure, remaining outside the protected area
– Disassembly of robot components (motors, balancing cylinders, etc.) may cause
uncontrolled movements of the axes in any direction: before starting a disassembly
procedure, consult the warning plates applied to the robot and the Technical
Documentation supplied.
– It is strictly forbidden to remove the protective covering of the robot springs.
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00/0710 13
Putting Out of Service and Dismantling

– Putting out of service and dismantling the Robot and Control System is only to be
carried out by Authorised Personnel.
– Bring the robot to transport position and fit the axis clamping brackets (where
applicable) consulting the plate applied on the robot and the robot Technical
Documentation.
– Before stating to put out of service, the mains voltage to the Control Unit must be
cut out (switch off the circuit breaker on the mains distribution line and lock it in
open position).
– After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the distribution line,
first disconnecting the power conductors, then the earth. Disconnect the power
supply cable from the Control Unit and remove it.
– First disconnect the connection cables between the robot and the Control Unit,
then the earth cable.
– If present, disconnect the robot pneumatic system from the air distribution line.
– Check that the robot is properly balanced and if necessary sling it correctly, then
remove the robot securing bolts from the support.
– Remove the robot and the Control Unit from the work area, applying the rules
indicated in the products Technical Documentation; if lifting is necessary, check the
correct fastening of the eye-bolts and use appropriate slings and equipment only.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU Robotics & Service,
or one of its branches, who will indicate, according to the type of robot and Control
Unit, the operating methods in accordance with safety principles and safeguarding
the environment.
– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.
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14 00/0710
1.2.5 Performance
The performances below shall be considered before installing the robot system:
– Stop distances
– Mission time (typ. case).
Stop distances
– With Robot in programming modality (T1), if you press the sttop pushbutton (red
mushroom-shaped one on WiTP) in category 0 (secondo norma EN60204-1), you
will obtain:
Tab. 1.1 - Stop spaces in programming modality (T1)

Expected Stopping Stopping
Mode Case
speed time space
Nominal 120 ms 30 mm
T1 250 mm/s
Limit 500 ms 125 mm
Tab. 1.2 - Safety electronics reaction time in programming

modality (T1)
Expected Stopping
Mode Case
speed time
For the safety inputs of the SDM module (e.g.
stop pushbutton of TP in wired version)
For the stop stop and enabling device inputs 150 ms
from the TP in wireless version, when the
T1 250 mm/s
safety wire trasmission is active.
For the time-out of stop input and enabling
device from TP in wireless version, when the 350 ms
safety wire transmission is lost or interrupted.
– Considering the Robot in automatico modality, under full extension, full load and
maximmum speed conditions, if you press the stop pushbutton (red
mushroom-shaped one on WiTP) in category 1 (according to norm EN60204-1)
you will trigger the Robot complete stop with controlled deleration ramp.
Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 °
motion, that correspond to about 3000 mm movement measured on TCP flange.
Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5
seconds.
Mission time (typ. case)

– We remind you that the safety system efficiency covering is equal to 20 years
(mission time of safety-related parts of control systems (SRP/CS), according to
EN ISO 13849-1).
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00/0710 15
General Description
2. GENERAL DESCRIPTION
2.1 Robot SMART5 NJ4 family

The robot SMART5 NJ4 family consists of high payload machines for applications where
"point to point" or "path control" programming is required
The versions available in the SMART5 NJ4 family are listed in the table below:
– Tab. 2.1 - Robot SMART5 NJ4 versions available on page 17
mc-rc-NJ4_5_descr-gen_03.FM
16 00/0610
General Description
Tab. 2.1 - Robot SMART5 NJ4 versions available

Payload Reach
Robot Type Robot view
(kg) (mm)
SMART5 NJ4 170 - 2.5 170 2501
SMART5 NJ4 170 - 2.9; 170 2918
SMART5 NJ4 175 - 2.2 175 2205
00/0610 17
General Description
Tab. 2.1 - Robot SMART5 NJ4 versions available (Continued)

Payload Reach
Robot Type Robot view
(kg) (mm)
SMART5 NJ4 220 - 2.4 220 2417
SMART5 NJ4 220 - 2.7; 220 2738
SMART5 NJ4 220 - 3.0 220 3002
18 00/0610
General Description
Tab. 2.1 - Robot SMART5 NJ4 versions available (Continued)

Payload Reach
Robot Robot view
(kg) (mm)
SMART5 NJ4 270 - 2.7 270 2703
00/0610 19
General Description
2.2 Robot mechanical

Every robot is parallelogram type with 6 degrees of freedom.
The fixed base is secured to the floor by four M24 screws and precisely located in
relation to the mounting plate by means of two special Ø 30 mm pins.
On the fixed robot base a column rotates with vertical rotation axis (axis 1); the column
supports the motorisation of axes 2 and 3, consisting of a motor clamped directly on the
reduction unit.
The mechanical connection between column and forearm is obtained by the robot arm,
consisting of a body ending with forks. The lower fork interfaces:
– on one side with the reduction unit axis 2 driving shaft from which it receives
motion;
– on the opposite side, with the driving shaft of reduction unit axis 3 in idle mode,
without receiving motion.
The upper fork of the arm is fitted with two coaxial pins, on which the forearm is jointed.
The lever assembly uses a crank to transmit motion from the reduction unit of axis 3
(below) to the connecting rod with fulcrum on the forearm body located in the upper part
of the robot.
The upper fork of the arm is fitted with two coaxial pins, on which the forearm is jointed.
The lever assembly uses a crank to transmit motion from the reduction unit of axis 3
(below) to the connecting rod with fulcrum on the forearm body located in the upper part
of the robot.
Axis 5 is the rotating axis of the floating body on the body of the wrist that is fastened to
the forearm. Axis 6 is the rotating axis of the robot tool attachment flange
The robot axes are equipped with software limit stop (programmable) and /or
mechanical shock absorber stops supplied as standard or on request (see Tab. 2.2
- Axes limit switches and work area restrictors on page 20)
The reduction units are the type with limited backlash specifically for robotic
applications.
All the reduction units are oil lubricated to guarantee best robot efficiency with a wide
time-interval between lubrication operations.
The motors are of the AC brushless type and incorporate the brake and encoder.
Tab. 2.2 - Axes limit switches and work area restrictors

Standard Optional
Robot Model Software limit Mechanical limit Mechanical mobile Work area restrictors
switch switch limit switch
Ax 1 ( da 1 a 3 aree)
SMART5 NJ4 Ax 1-2-3-4-5-6 Ax 1-2-3-5 Ax 1
Ax 2 ( da 1 a 2 aree)
20 00/0610
General Description
2.3 Interchangeability
The interchangeability of robots of the same version is a fundamental characteristic in
order to enable rapid substitution, or to transfer the same program to another robotic
station.
This characteristic is guaranteed by:
– adequate construction tolerances of all the parts that make up the structure
– precise robot location on the mounting plate by means of two pins (supplied with
the robot)
– possibility of bringing the axes to a known position (Calibration) using a specific tool
(the same for all axes and all models).
These features make it possible to transfer programs between robots of the same
version.
The above-mentioned characteristics are indispensable for effective “off-line
programming” executed in virtual environment.
2.4 Calibration
Calibration is the operation that makes it possible to bring the robot axes to a known
position to ensure the correct repetition of programmed cycles and interchangeability
between machines of the same version.
There are two calibration methods:
– Precise calibration: executed using a special tool that is the same for all axes and
all models. This operation must be executed after special maintenance operations
involving the separation of the kinematic chain between the motor and the robot
axis, or when particularly demanding cycles regarding precision have to be
executed.
– Calibration using location notches enables rapid but improper calibration with less
precision, and it may not restore robot movements with the precision that is
required by the specific application. Calibration by notches consists of bringing the
robot axes onto the calibration notches, aligning them with precision by sight,
without using specific tools, executing the calibration commands axis by axis.
00/0610 21
Technical Characteristics
3. TECHNICAL CHARACTERISTICS
3.1 Overview
The technical characteristics of the family robot SMART5 NJ4 are indicated in following
tables:
– Tab. 3.1 - SMART5 NJ4 170 – 2.5; SMART5 NJ4 175 – 2.2; Characteristics and
performance on page 23
– Tab. 3.2 - SMART5 NJ4 220 – 2.4; SMART5 NJ4 220 – 2.7; SMART5 NJ4 170 –
2.9; Characteristics and performance on page 24
– Tab. 3.3 - SMART5 NJ4 220 – 3.0; SMART5 NJ4 270 – 2.7; Characteristics and
performance on page 25
The operating area and overall dimensions of the robot versions are contained in
Chap.4. - Operating Areas and Robot Overall Dimensions on page 27.
mc-rc-NJ4_5-spt_01.FM
22 02/0611
Tab. 3.1 - SMART5 NJ4 170 – 2.5;

SMART5 NJ4 175 – 2.2;
Characteristics and performance
VERSION NJ4 170 – 2.5 NJ4 175-2.2
Parallelogram Parallelogram
Structure / n° axes
6 axes 6 axes
170 kg (1) 175 kg (1)
Load at wrist
(375 lb) (386 lb)
50 kg (2) 50 kg (2)
Additional load on forearm
(110 lb) (110 lb)
Torque axis 4 1010 Nm 1010 Nm
Torque axis 5 804Nm 804Nm
Axis 1 +/- 180° (110°/s) +/- 180° (110°/s)
Axis 2 +95° -75° (110°/s) +95° -75° (110°/s)
Axis 3 -10°/ -230° (110°/s) -10°/ -230° (110°/s)
Stroke / (Speed)
Axis 4 +/- 200° (180°/s) +/- 200° (180°/s)
Axis 5 +/- 200°(140°/s) +/- 200°(140°/s)
Axis 6 +/- 200° (190°/s) +/- 200° (190°/s)
2500 mm 2204 mm
Maximum horizontal reach
(98.5 in) (87in)
Repeatability +/- 0,1 mm +/- 0,1 mm
1100 kg 1080 kg
Robot weight
(2425 lb) (2381 lb)
ISO 9409 - 1 - A 125 ISO 9409 - 1 - A 125
Tool coupling flange
ISO 9409 - 1 - A 160 ISO 9409 - 1 - A 160
Motors AC brushless AC brushless
Position measurement system con encoder con encoder
Total power installed 8 kVA 8 kVA
Protection class IP65 IP65
Working temperature 0 ÷ + 45 °C 0 ÷ + 45 °C
Storage temperature - 40 °C ÷ + 60 °C - 40 °C ÷ + 60 °C
Colour of robot (standard) Red RAL 3020 Red RAL 3020
On the floor On the floor
Assembly position
From the ceiling From the ceiling
(1) See par. 6.2 Determination of max loads at wrist flange (QF) on page 50
(2) See Chap.6. - Loads at Wrist and Additional Loads on page 49 il par. 6.3 Additional loads (QS) on page 58
02/0611 23
Tab. 3.2 - SMART5 NJ4 220 – 2.4;

SMART5 NJ4 220 – 2.7;
SMART5 NJ4 170 – 2.9;
VERSION NJ4 220-2.4 NJ4 220-2.7 NJ4 170 – 2.9

Parallelogram Parallelogram Parallelogram
6 axes 6 axes 6 axes
220 kg (1) 220 kg (1) 170 kg (1)
Load at wrist
(485 lb) (485 lb) (375 lb)
25 kg (2) 25 kg (2) (3) 25 kg (2)
(55.1155 lb) (55.1155 lb) (55.1155 lb)
Torque axis 4 1320 Nm 1320 Nm 1010 Nm
Torque axis 5 950 Nm 950 Nm 804Nm
Torque axis 6 690 Nm 690 Nm 412 Nm
Axis 1 +/- 180° (100°/s) +/- 180° (100°/s) +/- 180° (110°/s)
Axis 2 -75° / +95° (90°/s) -75° / +95° (90°/s) +95° -75° (90°/s)
Axis 3 -10°/ -256° (110°/s) -10°/ -256° (110°/s) -10°/ -230° (110°/s)
Stroke / (Speed)
Axis 4 +/- 200° (130°/s) +/- 200° (130°/s) +/- 200° (130°/s)
Axis 5 +/- 200° (125°/s) +/- 200° (125°/s) +/- 200°(140°/s)
Axis 6 +/- 200° (170°/s) +/- 200° (170°/s) +/- 200° (190°/s)
2417 mm 2738 mm 2918 mm
(95.15719 in) (107.795 in) (114.8815 in)
Repeatability +/- 0,15mm +/- 0,15mm +/- 0,1mm
1260 kg 1290 kg 1240 kg
Robot weight
(2778 lb) (2844 lb) (2734 lb)
ISO 9409 - 1 - A 160 ISO 9409 - 1 - A 160 ISO 9409 - 1 - A 125
ISO 9409 - 1 - A 200 ISO 9409 - 1 - A 200 ISO 9409 - 1 - A 160
Motors AC brushless AC brushless AC brushless
Position measurement system con encoder con encoder con encoder
Total power installed 8 kVA 8 kVA 8 kVA
Protection class IP65 IP65 IP65
Working temperature 0 ÷ + 45 °C 0 ÷ + 45 °C 0 ÷ + 45 °C
Storage temperature - 40 °C ÷ + 60 °C - 40 °C ÷ + 60 °C - 40 °C ÷ + 60 °C
Colour of robot (standard) Red RAL 3020 Red RAL 3020 Red RAL 3020
On the floor On the floor On the floor
Assembly position
From the ceiling From the ceiling From the ceiling
(1) See par. 6.2 Determination of max loads at wrist flange (QF) on page 50
(2) See Chap.6. - Loads at Wrist and Additional Loads on page 49 il par. 6.3 Additional loads (QS) on page 58
(3) By loading a QF = 220 kg on the robot wrist, no extra QS load on the forearm can be applied.
24 02/0611
Tab. 3.3 - SMART5 NJ4 220 – 3.0;

SMART5 NJ4 270 – 2.7;
VERSION NJ4 220-3.0 NJ4 270 – 2.7

Parallelogram Parallelogram
6 axes 6 axes
220 kg (1) 270 kg (1)
Load at wrist
( 485 lb) (595 lb)
25 kg (2) 25 kg (2
(55 lb) (55 lb)
1320 Nm 1960 Nm
Torque axis 4
(2910 lb) (4321 lb)
Axis 1 +/- 180° (90°/s) +/- 180° (90°/s)
Axis 2 +75° / -75° (90°/s) +75° / -75° (90°/s)
Axis 3 -231°/ 0° (90°/s) -231°/ 0° (90°/s)
Stroke / (Speed)
Axis 4 +/- 200° (115°/s) +/- 200° (115°/s)
Axis 5 +/- 200° (125°/s) +/- 200° (125°/s)
Axis 6 +/- 200° (170°/s) +/- 200° (170°/s)
3002 mm 2703 mm
(118 in) (106 in)
Repeatability +/- 0,15mm +/- 0,15mm
2005 kg 1975 kg
Robot weight
(4420 lb) (4354 lb)
ISO 9409 - 1 - A 160 ISO 9409 - 1 - A 160
ISO 9409 - 1 - A 200 ISO 9409 - 1 - A 200
Motors AC brushless AC brushless
Position measurement system con encoder con encoder
Total power installed 8 kVA 8 kVA
Protection class IP65 IP65
Working temperature 0 ÷ + 45 °C 0 ÷ + 45 °C
Storage temperature - 40 °C ÷ + 60 °C - 40 °C ÷ + 60 °C
Colour of robot (standard) Red RAL 3020 Red RAL 3020
Assembly position On the floor On the floor
(1) See par. 6.2 Determinazione carichi max alla flangia del polso (QF) on page 48
(2) See Chap.6. - Carichi al Polso e Supplementari on page 47 il par. 6.3 Carichi supplementari (QS) on
page 56
02/0611 25
26 02/0611
Operating Areas and Robot Overall Dimensions
4. OPERATING AREAS AND ROBOT

OVERALL DIMENSIONS
This chapter describes the operating area and overall dimensions of the SMART5 NJ4
robot versions listed below:
– SMART5 NJ4 170 – 2.5
– SMART5 NJ4 175 – 2.2
– SMART5 NJ4 220 – 2.7

– SMART5 NJ4 220 – 2.4
– SMART5 NJ4 170 – 2.9
– SMART5 NJ4 270 – 2.7

– SMART5 NJ4 220 – 3.0
00/0610 27
SMART5 NJ4 170 – 2.5
28 00/0610
SMART5 NJ4 170 – 2.5
Pos X Z Ax.2 Ax.3

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

Ax 1 Ax 2 Ax 3 Ax 4 Ax 5 Ax 6
0° 0° -90° 0° 0° 0°
00/0610 29
SMART5 NJ4 175 – 2.2
30 00/0610
SMART5 NJ4 175 – 2.2
Pos X Z Ax.2 Ax.3

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

0° 0° -90° 0° 0° 0°
00/0610 31
SMART5 NJ4 220 – 2.7
32 00/0610
SMART5 NJ4 220 – 2.7
Pos X Z Ax.2 Ax.3

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

0° 0° -90° 0° 0° 0°
00/0610 33
SMART5 NJ4 220 – 2.4
34 00/0610
SMART5 NJ4 220 – 2.4
Pos X Z Ax.2 Ax.3

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

0° 0° -90° 0° 0° 0°
00/0610 35
SMART5 NJ4 170 – 2.9
36 00/0610
SMART5 NJ4 170 – 2.9

0° 0° -90° 0° 0° 0°
00/0610 37
SMART5 NJ4 270 – 2.7
38 00/0610
SMART5 NJ4 270 – 2.7
Pos X Z Ax.2 Ax.3

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

0° 0° -90° 0° 0° 0°
00/0610 39
SMART5 NJ4 220 – 3.0
40 00/0610
SMART5 NJ4 220 – 3.0

0° 0° -90° 0° 0° 0°
00/0610 41
42 00/0610
Robot Flange
5. ROBOT FLANGE
5.1 Tool coupling flange

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

described in the applications manual.
– Fig. 5.1 - SMART5 NJ4 170 – 2.9; SMART5 NJ4 170 – 2.5; SMART5 NJ4 175 –
2.2; (ISO 9409-1- A125; ISO 9409-1- A160)- front view on page 44
2.2; (ISO 9409-1- A125; ISO 9409-1- A160)- lateral view on page 45
3.0; SMART5 NJ4 270 – 2.7; (ISO 9409-1- A160; ISO 9409-1- A200)- front view on
page 46
3.0; SMART5 NJ4 270 – 2.7 (ISO 9409-1- A160; ISO 9409-1- A200)-lateral view
on page 47
00/0610 43
Robot Flange
Fig. 5.1 - SMART5 NJ4 170 – 2.9;

SMART5 NJ4 170 – 2.5;
SMART5 NJ4 175 – 2.2;
(ISO 9409-1- A125; ISO 9409-1- A160)- front view
44 00/0610
Robot Flange
Fig. 5.2 - SMART5 NJ4 170 – 2.9;

SMART5 NJ4 170 – 2.5;
SMART5 NJ4 175 – 2.2;
(ISO 9409-1- A125; ISO 9409-1- A160)- lateral view
00/0610 45
Robot Flange
Fig. 5.3 - SMART5 NJ4 220 – 2.4;

SMART5 NJ4 220 – 2.7;
SMART5 NJ4 220 – 3.0;
SMART5 NJ4 270 – 2.7;
(ISO 9409-1- A160; ISO 9409-1- A200)- front view
46 00/0610
Robot Flange
Fig. 5.4 - SMART5 NJ4 220 – 2.4;

SMART5 NJ4 220 – 2.7;
SMART5 NJ4 220 – 3.0;
SMART5 NJ4 270 – 2.7
(ISO 9409-1- A160; ISO 9409-1- A200)-lateral view
00/0610 47
Robot Flange
48 00/0610
Loads at Wrist and Additional Loads
6. LOADS AT WRIST AND ADDITIONAL

LOADS
6.1 Overview
This chapter describes the procedures to determine the maximum load that can be
applied to the robot flange and any additional load applied on the forearm.
Load capacity on the flange according to the distance from the centre of gravity
– Fig. 6.2 - SMART5 NJ4 170 – 2.5; Maximum load capacity of the flange on
page 51
– Fig. 6.3 - SMART5 NJ4 175 – 2.2 Maximum load capacity of the flange on
page 52
page 53
page 54
– Fig. 6.6 - SMART5 NJ4 170 – 2.9; Maximum load capacity of the flange on
page 55
page 56
page 57
• Fig. 6.3 - SMART5 NJ4 175 – 2.2 Maximum load capacity of the flange on
page 52
Areas in which the centre of gravity position related to additional load is allowed
– Fig. 6.9 - Additional loads centre of gravity position on page 59
Centre distances and dimensions of holes to fasten any fixtures applied on the robot
forearm
– Fig. 6.10 - SMART5 NJ4 170 – 2.5; SMART5 NJ4 175-2.2 Drilling for fixtures
attachment on page 60
– Fig. 6.11 - SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7; SMART5 NJ4 170
– 2.9 Drilling for fixtures attachment on page 61
– Fig. 6.12 - SMART5 NJ4 220 – 3.0; SMART5 NJ4 270 – 2.7 Drilling for
fixtures attachment on page 62
Abbreviations
In this chapter the following abbreviations have been used:
– QF =Max. load applied to the flange;
– QS = Additional load applied to the forearm;
– QT =Max total load applied on the robot;
– LZ = Distance of load P centre of gravity from the flange axis;
– Lxy = Distance of load P centre of gravity from axis 6.
01/0311 49
Fig. 6.1 - Centre of gravity co-ordinates of the applied load
Z Ly
Lx
Y
Lx
X
P Lz y
6.2 Determination of max loads at wrist flange

(QF)
The maximum load that can be applied to the flange is defined using the wrist load
graphs, where the curves of maximum load QF are plotted according to co-ordinates LZ
and LY of the load centre of gravity.
The area below the load curve defines centre of gravity distances allowed for the
application of the load indicated on it.
50 01/0311
Fig. 6.2 - SMART5 NJ4 170 – 2.5;

Maximum load capacity of the flange
Lz [mm]
550
500
450
400
M = 140 kg
J 0= 30 kgm2 350
300
M = 150 kg
J 0= 35 kgm2 250
200
M = 160 kg
J 0= 38 kgm2 150
100
M = 170 kg
2 50
J = 40 kgm
0
0
0 50 100 150 200 250 300 350
Lxy [mm]
– M: Weight
– J0: Inertia
The inertia specified in the graph curves refers to the centre of gravity of the load
applied on the flange.
01/0311 51
Fig. 6.3 - SMART5 NJ4 175 – 2.2

J0
J0
J0
J0
– M: Weight
– J0: Inertia
52 01/0311
Fig. 6.4 - SMART5 NJ4 220 – 2.7

Lz [mm]
550
500
M = 150 kg
450
J0 = 68 kgm2
M = 160 kg 400
J0 = 73 kgm2
350
M = 175 kg
J0 = 80 kgm2
300
M = 190 kg 250
J0 = 86 kgm2
200
M = 205 kg
J0 = 93 kgm2 150
100
M = 220 kg
2
J0 = 100 kgm
50
0
0 50 100 150 200 250 300 350 400 450
Lxy [mm]
– M: Weight
– J0: Inertia
01/0311 53
Fig. 6.5 - SMART5 NJ4 220 – 2.4

Lz [mm]
550
500
M = 150 kg
450
J0 = 68 kgm2
M = 160 kg 400
J0 = 73 kgm2
350
M = 175 kg
J0 = 80 kgm2
300
M = 190 kg 250
J0 = 86 kgm2
200
M = 205 kg
J0 = 93 kgm2 150
100
M = 220 kg
2
J0 = 100 kgm
50
0
0 50 100 150 200 250 300 350 400 450
Lxy [mm]
– M: Weight
– J0: Inertia
54 01/0311
Fig. 6.6 - SMART5 NJ4 170 – 2.9;

Lz [mm]
550
500
450
400
M = 140 kg
J 0= 30 kgm2 350
300
M = 150 kg
J 0= 35 kgm2 250
200
M = 160 kg
J 0= 38 kgm2 150
100
M = 170 kg
2 50
J = 40 kgm
0
0
0 50 100 150 200 250 300 350
Lxy [mm]
– M: Weight
– J0: Inertia
01/0311 55
Fig. 6.7 - SMART5 NJ4 270 – 2.7

650
Lz [mm]
600
550
M = 210 kg
500
Jo = 130 kg m 2
450
M = 230 kg
Jo = 140 kg m 2 400
350
M = 250 kg 300
Jo= 150 kg m 2
250
M = 270 kg 200
Jo = 170 kg m 2
150
100
50
0
0 50 100 150 200 250 300 350
Lxy [mm]
– M: Weight
– J0: Inertia
56 01/0311
Fig. 6.8 - SMART5 NJ4 220 – 3.0

Lz [mm]
550
500
M = 150 kg
450
J0 = 68 kgm2
M = 160 kg 400
J0 = 73 kgm2
350
M = 175 kg
J0 = 80 kgm2
300
M = 190 kg 250
J0 = 86 kgm2
200
M = 205 kg
J0 = 93 kgm2 150
100
M = 220 kg
2
J0 = 100 kgm
50
0
0 50 100 150 200 250 300 350 400 450
Lxy [mm]
– M: Weight
– J0: Inertia
01/0311 57
6.3 Additional loads (QS)

Besides the load on the flange QF, an additional load QS can be applied on the robot
forearm; maximum loads applicable on the robot are those indicated in Tab. 6.1
- Maximum applicable loads on page 58.
The following indications are to be observed in every application,
– the centre of gravity of the load applied on flange QF is to be within the area
subtended by the curves of following graphs in Fig. 6.2 - SMART5 NJ4 170 – 2.5;
Maximum load capacity of the flange on page 51
– the centre of gravity of additional load QS has to be within the area of the graph
shown in Fig. 6.9 - Additional loads centre of gravity position on page 59.
To install special fixtures on the robot, the holes provided on the robot forearm can be
used seet following drawings:
– Fig. 6.10 - SMART5 NJ4 170 – 2.5; SMART5 NJ4 175-2.2 Drilling for fixtures
attachment on page 60
– Fig. 6.11 - SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7; SMART5 NJ4 170 – 2.9
Drilling for fixtures attachment on page 61
– Fig. 6.12 - SMART5 NJ4 220 – 3.0; SMART5 NJ4 270 – 2.7 Drilling for fixtures
attachment on page 62.
Tab. 6.1 - Maximum applicable loads

Max overall load that Max overall load that Max load additional on
SMART5 can be applied on robot can be applied on flange forearm
QT QF QS
NJ4 170 – 2.5 220 kg (485.02 lb) 170 kg (375 lb) 50 kg (110.23 lb)
NJ4 175 – 2.2 225 kg (496.04 lb) 175 kg (386 lb) 50 kg (110.23 lb)
NJ4 170 – 2.9 195 kg (430 lb) 170 kg (375 lb) 25 kg (55 lb)
220 kg (485.02 lb) 5 kg (11 lb)

NJ4 220 – 2.7 225 kg (496.04 lb)
195 kg 25 kg (55 lb)
NJ4 220 – 2.4 245 kg (540 lb) 220 kg (485.02 lb) 25 kg (55 lb)
NJ4 270 – 2.7 295 kg (650 lb) 220 kg (485.02 lb) 25 kg (55 lb)
NJ4 220 – 3.0 245 kg (540 lb) 220 kg (485.02 lb) 25 kg (55 lb)
58 01/0311
Fig. 6.9 - Additional loads centre of gravity position
The diagram shown in the Figure can also be applied to ceiling installation.
01/0311 59
Fig. 6.10 - SMART5 NJ4 170 – 2.5; SMART5 NJ4 175-2.2

Drilling for fixtures attachment
60 01/0311
Fig. 6.11 - SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7;

SMART5 NJ4 170 – 2.9 Drilling for fixtures attachment
01/0311 61
Fig. 6.12 - SMART5 NJ4 220 – 3.0; SMART5 NJ4 270 – 2.7
Drilling for fixtures attachment
62 01/0311
Preparation for Robot Installation
7. PREPARATION FOR ROBOT

INSTALLATION
Before carrying out any type of installation operation carefully read Chap.1. -
General Safety Precautions on page 6.
The robot has to be coupled to the C4G Control Unit. No other use is permitted.
Any exceptions are to be explicitly authorised by COMAU Robotics & Service.
This chapter contains specifications and technical information required for the
robot installation. The installation operation procedure is described in the
specific TRANSPORT AND INSTALLATION manual.
7.1 Environment conditions

The environment for robot use is the usual workshop environment.
7.1.1 Environment data

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

The maximum overall dimensions of the robot operating area is indicated in the
Chap. OPERATING AREA AND ROBOT OVERALL DIMENSIONS in TECHNICAL
SPECIFICATIONS manual.
mc-rc-NJ4_5-pred-int_01.FM
00/0710 63
7.2 Attachment to a Steel Plate

7.2.1 Standard Steel Plate
The robot can be attached to a steel plate already drilled for the screws and pins. The
steel plate can be prepared by the robot integrator or otherwise it can be supplied as an
optional, see:
– Fig. 7.1 - SMART5 NJ4 170-2.5; SMART5 NJ4 170-2.9; SMART5 NJ4 175-2.2;
SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7 Fastening Plate (not adjustable
leveling) (code CR82343100) on page 66.
To anchor the robot to the plate an optional kit is available that contains the mechanical
components needed for the anchorage, see:
SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7- Screws and pins to mount the robot
(code CR82342700) on page 67
– Fig. 7.3 - SMART5 NJ4 220-3.0- SMART5 NJ4 270-2.7 Screws and pins to mount
the robot (code CR 82314700) ; on page 69
The robot is to be anchored on a flat horizontal surface with the following

planarity tolerance:
7.2.2 Attachment to a plate with adjustable level (optional)

The robot can be assembled using an optional assembly consisting of 4 floor attachment
plates and a steel plate fastened to the robot that can be adjusted in level through the
specific screws, see:
SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7 - Adjustable level plate for robot
mounting (code CR82342800) on page 70.
– Fig. 7.5 - SMART5 NJ4 220-3.0- SMART5 NJ4 270-2.7- Adjustable level plate for
robot mounting (code 82314800) on page 71
Tab. 7.1 - Fastening Plate Robot Applicability

SMART5 NJ4 170 – 2.5
SMART5 NJ4 170 – 2.9
SMART5 NJ4 220 – 3.0
Robot SMART5 NJ4 175 – 2.2
SMART5 NJ4 270 – 2.7
SMART5 NJ4 220 – 2.4
SMART5 NJ4 220 – 2.7
Assembly Code Reference Code Reference
Fastening Plate
CR82343100 Fig. 7.1 - -
( not adjustable level)
Level adjustment plate assy CR82342800 Fig. 7.4 82314800 Fig. 7.5
Screws and pins CR82342700 Fig. 7.2 CR82314700 Fig. 7.3
64 00/0710
7.2.3 Secure plate to the floor

Use chemical anchorage blocks to secure the plate to the floor.
Tab. 7.2 - Recommended components for securing the leveling

plate to the floor (not supplied
Hole depth
Component Reference Code Q.ty
diameter
Chemical
HILTI HVU M20x170 See
capsule Ø 24x 170 mm
Fig. 7.2
HAS-E (Ø 0.94 x 6.70 in)
Pin HILTI Fig. 7.3
M20x170/48
Please read the instructions before using the recommended fastening

components
To avoid any micro movements of the plate caused by repeated alternated stress
generated by the robot during normal work cycles, lay the plates on a layer of aligning
mortar specifically for metal on concrete applications.
The mounting of the plate to the floor is to ensure the possibility to level the robot
with a tolerance of ± 0.5/1000 mm and is to be able to support the stresses
indicated in the Fig. 7.6 - Stress on the robot supporting structure on page 72
00/0710 65

SMART5 NJ4 175-2.2; SMART5 NJ4 220-2.4;
SMART5 NJ4 220-2.7 Fastening Plate (not adjustable
leveling) (code CR82343100)
66 00/0710

SMART5 NJ4 175-2.2; SMART5 NJ4 220-2.4;
SMART5 NJ4 220-2.7-
Screws and pins to mount the robot (code CR82342700)
1. Centring Ø = 30 mm ( 1.18 in) L = 80 mm (q.ty = 1)

2. Centring Ø = 30 mm ( 1.18 in) L = 60 mm (q.ty = 1)
3. Socket head cap screw M 10 x 90 (8.8) (q.ty = 1)
5. Partially threaded hex head screw M 24 x 100 (8.8.) (q.ty = 6)
6. Split washer Ø = 24mm ( 0.94 in ) (q.ty = 6)
7. Flat washer Ø = 24 mm ( 0.94 in ) (q.ty = 6)
8. Fastening Plate
00/0710 67
Key: Fig. 7.3 - SMART5 NJ4 220-3.0- SMART5 NJ4 270-2.7 Screws and pins to mount
the robot (code CR 82314700) ; on page 69
1. Centring Ø = 30 mm ( 1.18 in) L = 80 mm ( 3.15in) (q.tà = 1)
2. Centring Ø = 30 mm ( 1.18 in) L = 60 mm ( 2.36 in) (q.tà = 1)
3. Socket head cap screw M 10 x 90 (8.8) (q.tà = 1)
4. Socket head cap screw M 10 x 70 (8.8) (q.tà = 1)
5. Partially threaded hex head screwM 24 x 100 (8.8.) (q.tà = 6)
6. Flat washer Ø = 24mm ( 0.94 in ) (q.tà = 6)
7. Flat washer Ø = 24 mm (0.94 in )( (q.tà = 6)
68 00/0710
Fig. 7.3 - SMART5 NJ4 220-3.0- SMART5 NJ4 270-2.7

Screws and pins to mount the robot
(code CR 82314700) ;
00/0710 69

SMART5 NJ4 175-2.2; SMART5 NJ4 220-2.4;
SMART5 NJ4 220-2.7 - Adjustable level plate for robot
mounting (code CR82342800)
1
1
1. Piastra livellabile (q.tà =1)

2. Piastra (q.tà = 4)
3. Regolo (q.tà = 8)
4. Vite TE INTERAMENTE FILETTATA M20x100-8.8 (q.tà = 4)
5. Dado esagonale M20 -8 FE/ZN 12 (q.tà = 4)
70 00/0710
Fig. 7.5 - SMART5 NJ4 220-3.0- SMART5 NJ4 270-2.7- Adjustable

level plate for robot mounting (code 82314800)
1. Leveling plate (q.ty =1)

2. Plate (q.ty = 4)
3. Straight edge (q.ty = 8)
4. Fully threaded hex head screw M20x100-8.8 (q.ty = 4
00/0710 71
7.3 Stress on supporting structure

The foundations where the robot is installed are not to suffer vibrations coming from
other machines (such as sledge hammers, presses, etc.). The values of the stress
generated by the robot on the supporting structure differ according to whether it is
installed on the floor or on the ceiling, as shown in the figures Fig. 7.6 .
Because of the considerable stress discharged to the ground by the robot, and
the need to have an appropriate supporting surface, direct fixing to the floor is not
foreseen. The robot mounting surface must be horizontal
Fig. 7.6 - Stress on the robot supporting structure
Robot on floor installation Robot on ceiling installation
Mr
Fo
Fv
Mk
Robot shown on figure is indicative.
72 00/0710
Tab. 7.3 - Stress values on the robot supporting structure
Robot Movement type Fv (N) Fo (N) Mr (Nm) Mk (Nm)

Accelerating 16300 6000 8000 22000
SMART5 NJ4 170-2.5
Emergency braking 17000 11200 16000 30000
Accelerating 17000 6000 8000 23000
SMART5 NJ4 170-2.9
Accelerating 15000 4200 8000 17200
SMART5 NJ4 175-2.2
Accelerating 18000 6000 8000 25000
SMART5 NJ4 220-2.4
Accelerating 18000 7000 8000 26000
SMART5 NJ4 220-2.7
Accelerating 25000 7000 12000 33000
SMART5 NJ4 220-3.0
Accelerating 26000 7000 12000 35000
SMART5 NJ4 270-2.7
00/0710 73
Optional Equipment
8. OPTIONAL EQUIPMENT
8.1 APPLICABILITY OF OPTIONS

For the Robot SMART5 NJ4 Family, multiple options are possible, depending on the
type of robot.
The list of available options for the types of robots breaks down in the following tables:
– Tab. 8.1 - SMART5 NJ4 170-2.5; SMART5 NJ4 175-2.2; SMART5 NJ4 170-2.9;
SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7 Options available on page 75
– Tab. 8.2 - SMART5 NJ4 220–3.0; SMART5 NJ4 270–2.7 Options available on
page 76
74 00/0610
Optional Equipment
Tab. 8.1 - SMART5 NJ4 170-2.5; SMART5 NJ4 175-2.2;

SMART5 NJ4 170-2.9;
SMART5 NJ4 220-2.4; SMART5 NJ4 220-2.7
Options available
Code COMAU
SMART5
Description Applicability
NJ4 170-2.9;
NJ4 170-2.5;
NJ4 220-2.4;
NJ4 175-2.2
NJ4 220-2.7
CR82343300 Axis 1 work area partialization assembly - 1 area 1

CR82343200 Axis 1 work area partialization assembly - 2 areas 1
CR82342200 Axis 1 work area partialization assembly - 3 areas 1
CR82342300 CR82344900 Axis 2 work area partialization assembly - 2 areas 1
CR82342400 Axis 1 adjustable mechanical hard stop assembly 1
CR82342500 CR82344800 Axis 2 adjustable mechanical hard stop assembly 1
CR82342700 Screws and pins kit for robot mounting (code CR82342700) 1
CR82342800 Leveling plate unit for robot mounting (code CR82342800) 1
CR82343100 Non adjustable plate for robot mounting (code 82343100) 1
Axis 1 mechanical hard stop on-off assembly (lock pin - code
CR82344300 1
CR82344300
Fall-prevention brackets assembly for ceiling attachment (code
CR82348800 1
CR82348800)
NJ ceiling mounting and fall-prevention assembly - BRIC (code
CR82344700 1
CR82344700)
CR82352200 Distribution connection guard assembly 1
82314100 Calibration tool (code 82314100) 1
82109501 Gauged tool assembly L=200 mm (code 82109501) 1
CR82351700 -
Fork liftable option 1
- CR82274800
00/0610 75
Optional Equipment
Tab. 8.2 - SMART5 NJ4 220–3.0;

SMART5 NJ4 270–2.7 Options available
Codice
COMAU
SMART5 Description Applicability

NJ4 220 – 3.0
NJ4 270 – 2.7
CR82273200 Axis 1 adjustable mechanical hard stop assembly (code CR82273200) 1
CR82273300 Axis 2 adjustable mechanical hard stop assembly (code CR82273300) 1
CR82273600 Axis 1 mechanical hard stop on-off assembly - lock pin (code CR82273600) 1
CR82325600 Axis 1 work area partialization assembly - 3 areas (code CR82325600) 1
CR82274800
Fork liftable option 1
CR82351700
82109501 Gauged tool assembly L=200 mm (code 82109501) 1
82314800 Leveling plate unit for robot mounting (code 82314800) 1
82314700 Screws and pins kit for robot mounting (code 82314700) 1
82314800 Leveling plate unit for robot mounting (code CR82342800) 1
CR82276800 Distribution connection guard assembly 1
82309259 Guard assembly for ventilated motor ax1 (code 82309259) 1
CR82273500 Springs guard assembly 1
CR82341605 Centering dia 100 / 125 1
76 00/0610
Optional Equipment
8.2 Axis 1 work area partialization assembly

(1 area, code CR82343300 - 2 areas, code CR82343200 - 3 areas, code
CR82342200)
1. Microswitch support
2. Microswitch with six pushbuttons
3. LH cam holder
4. RH cam holder
5. Micro switch
6. Cam
7. Stubbed socket head cap screw M6x10
8. Socket head cap screw M6x45
9. Socket grub screw
10. Low hex nut M6-0,5
11. Parallel pin Ø4x40
00/0610 77
Optional Equipment
8.2.0.1 Description
Restrictor assy for one or two area Restrictor assy for three areas
The axis 1 work area shut-off assembly makes it possible to electrically sector the robot
work area using pushbutton micro switches of different types according to the number
of areas to be sectored, in detail :
– for up to 3 work areas a six-pushbutton micro is used
– for up to 2 work areas a 4-pushbutton micro is used
– for a single work area a two-pushbutton micro switch is used.
The work areas are each controlled by two safety micro switches in conformity with the
most severe safety standards.
The assembly consists of:
• a pushbutton multiple microswitch with Harting connector;
• set of plastic cams.
The cams are to be cut to the required length for the application, then they are to be
inserted, positioned and locked on two cam holders fastened to the robot column instead
of the protection guard.
For the microswitch electrical connection the following is foreseen:
• for a three areas restrictor - a 32 pin Harting connector
• for a one or two areas restrictor - a 90° female 19-pin connector..
For the microswitch assembly internal electrical layout see the robot Circuit
Diagram.
78 00/0610
Optional Equipment
8.3 Axis 2 work area partialization assembly -

2 areas
1. LH cam holder
2. RH cam holder
3. Mechanical limit switch with six pushbuttons
4. Support
5. Transfer box
6. Cam holder support
8.3.1 Description
The axis 2 work area partialization assembly enables electrical partialization of up to 2
work areas, each of which is controlled by two safety micro-switches built to the strictest
safety standards.
• a 4-pushbutton multiple micro-switch with output to cable gland,
• a set of plastic cams to be cut to the length required for the specific application.
The cams must be inserted and blocked on the cam holders fastened to the robot by
means of the specific supports.
The free connector is supplied for the external connection.
The kit includes:
• Nr. 1 connector (supplied by FCI) 19 pins, type UTG1619SN;
00/0610 79
Optional Equipment
• Nr. 19 female contacts to be crimped, type SC20ML-1S6 for wires from AWG 20;
• Nr. 1 cable clamp with PG16 (for cables from Ø 8 mm2 to Ø 16 mm2).
To crimp the female pins onto the wires from AWG 20 it is recommended to use the FCI
"crimping tool" type Y14MTV or Y16SCM2.
For the circuitry diagram inside the microswitch assy, see the robot Circuit
Diagram.
Tab. 8.3 - Electrical characteristics of axis 1, axis 2 and axis 3

mechanical limit switch assembl
ELECTRICAL DATA
Type of switch BSE 85 per DIN EN 60204-1
Insulation Gruppo C (VDE 0110)
Maximum voltage 50 Vac
Maximum current 2A
Minimum load ≥ 20 mA
Contact resistance < 40 mΩ
Interruption current 2 A, cos ϕ=0,8
80 00/0610
Optional Equipment
8.4 Axis 1 adjustable mechanical hard stop

assembly
1. Stopper axis 1 (q.ty 2)

2. Socket head cap screw M20 x 90-12.9
00/0610 81
Optional Equipment
Tab. 8.4 - Stroke limitations can be obtained with the adjustable

mechanical limit switch assy of axis 1
Corsa ax1 negativa Corsa ax1 positiva

Ax.1 negative strok e Ax.1 positive strok e
Pos.
from [°] to [°] from [°] to [°]
1 -130 -180 -125 + 180

2 -115 -180 -110 + 180
3 -100 -180 -95 + 180
4 -85 -180 -80 + 180
5 -70 -180 -65 + 180
6 -55 -180 -50 + 180
7 -40 -180 -35 + 180
8 -25 -180 -20 + 180
9 -10 -180 -5 + 180
10 5 -180 +10 + 180
11 20 -180 +25 + 180
12 35 -180 +40 + 180
13 50 -180 +55 + 180
14 65 -180 +70 + 180
15 80 -180 +85 + 180
16 95 -180 +100 + 180
17 110 -180 +115 + 180
18 125 -180 +130 + 180
8.4.1 Description
The axis 1 adjustable mechanical limit switch unit limits the stroke of axis 1 in both work
directions in steps of 15°. The group consists of two stop buffers to be attached with the
screws supplied, in the specific seats on the robot base to limit the stroke of axis 1 in
both directions; if the stroke is to be limited in only one direction, only one of the two
stops will be used
The axis 1 adjustable mechanical limit switch assembly meets "man safety"
requirements since it is able to absorb all the axis kinetic energy.
Once the stop has been used (impact), the following parts must be replaced:
- mechanical hard stop, fastening screws and dowel pin;
-rubber stop blocks and fastening screws.
Also the integrity of the robot parts involved is to be checked, for example:
- the part of the base housing the assembly;
- the part of the column housing the stop;
- the equipment being used by the robot.
Failure to replace any damaged parts will undermine correct operation (and thus
stopping) in future.
After an impact, check the clearance on axis and correct any slackening of the
axis.
82 00/0610
Optional Equipment

assembly
8.5.1 Relaese code CR82342500
Applicable to robot NJ110-3.0; NJ 130-2.6; NJ4 170-2.5; NJ4 175 2.2
1. Front stopper axis 2 (code CR82000542) - GS500

2. Rear stopper axis 2 (code CR82000543) - GS500
3. Socket head cap screw M12 x 35 -12.9 [screw HSHC-ISO 4762]
00/0610 83
Optional Equipment
Tab. 8.5 - Stroke limitations can be obtained with the adjustable

mechanical limit switch assy of axis 2
Corsa asse 2 in senso negativo Corsa asse 2 in senso positivo

Pos. Axes 2 negative stroke Axes 2 positive stroke
from [°] to [°] from [°] to [°]
1 -65 -75 -55 +95
2 -50 -75 -40 +95
3 -35 -75 -25 +95
4 -20 -75 -10 +95
5 -5 -75 5 +95
6 10 -75 20 +95
7 25 -75 35 +95
8 40 -75 50 +95
9 55 -75 65 +95
10 70 -75 80 +95
8.5.2 Description
The axis 2 adjustable mechanical hard stop assembly can be used to limit the stroke of
axis 2 in both directions of work with steps of 15°.
The group consists of two sets of 2 blocks to be interposed between the column
structure and the rubber stop already installed on the robot. The stroke limitations
obtained according to the assembly position of the blocks are indicated in Tab. 8.5. The
axis 2 adjustable mechanical hard stop assembly satisfies “operator safety”
requirements as it can absorb all of the kinetic energy of the axis.
84 00/0610
Optional Equipment
8.5.3 Relaese code CR8234480
Applicable to robot NJ220-2.7; NJ 165-3.0; NJ4 170-2.9; NJ4 220-2.4; NJ4 220-2.7
1. Front stopper ax.2 (Q.ty 2)

2. Screw TCEI M12 x 45 -12.9 [Q.ty 12]
8.5.4 Description
The group consists of two sets of 2 blocks to be interposed between the column
structure and the rubber stop already installed on the robot. The axis 2 adjustable
mechanical hard stop assembly satisfies “operator safety” requirements as it can absorb
all of the kinetic energy of the axis.
00/0610 85
Optional Equipment
8.6 Screws and pins kit for robot mounting (code

CR82342700)
1. Location Ø = 30 mm L = 80 mm (q.ty = 1)
6. Split spring washer Ø = 24 mm (q.ty = 6)
7. Flat washer Ø = 24 mm (q.ty = 6)
8.6.0.1 Description
The kit consists of the screws and pins needed to secure the robot to a steel plate
provided with the relevant holes.
The steel plate and its arrangement to secure the robot is to be performed by the
installer.
86 00/0610
Optional Equipment
8.7 Leveling plate unit for robot mounting

(code CR82342800)
1
1

2. Plate (q.ty 4)
4. M20x100 fully threaded hex head cap screw -8.8 (q.ty = 4)
5. M20 -8 FE/ZN 12 hex nut (q.ty = 4)
8.7.1 Description
The robot leveling plate assembly is used to ensure that the robot is anchored correctly
to the floor. This assembly satisfies the following requirements:
– it ensures good mounting plate levelness, to avoid any incorrect stresses on the
structure of the robot base
– a perfectly aligned robot assembly that facilitate "off-line programming"
applications.
– four steel plates that are anchored to the floor by means of chemical bolts (for a
total of 16 anchor bolts, which are not supplied)
– a leveling plate that is welded to the plates described above after using the specific
adjustment screws to obtain optimal robot leveling
00/0610 87
Optional Equipment
8.8 Non adjustable plate for robot mounting

(code 82343100)
1. Robot mounting plate
88 00/0610
Optional Equipment
8.9 Fall-prevention brackets assembly for ceiling

attachment (code CR82348800)
00/0610 89
Optional Equipment
1. Bracket
2. Bracket
3. Hex head screw M16x40
6. Flat washer for screw M16
7. Flat washer for screw M20
Brackets on base front Bracket on robot lower distribution
90 00/0610
Optional Equipment
8.9.1 Description
The fall-prevention brackets assembly for ceiling installation can be used when the robot
is attached to the ceiling, to sustain it in safety should the standard fastening screws
become loose.
The assembly consists of three strong steel brackets, two attached to the front of the
base and one on the rear above the lower distribution.
The brackets are clamped to the mounting base with 6 M16 screws. Fig. 8.1 - Plate
drilling diagram to fasten the fall-prevention brackets (codice CR82348800) on page 91
shows the centre distances and dimensions of the holes for the attachment of the
brackets to the robot support plate.
When assembling, lock all the screws to the torque indicated in the SMART
Maintenance Manual.
The procedure for robot ceiling assembly is contained in the Transport and
Installation Manual .
Fig. 8.1 - Plate drilling diagram to fasten the fall-prevention

brackets (codice CR82348800)
1. Robot fastening screws

2. Robot location pins
3. Plate fastening screws
00/0610 91
Optional Equipment
8.10 NJ ceiling mounting and fall-prevention

assembly - BRIC (code CR82344700)
8.10.1 Description
The fastening and fall-prevention assembly for NJ robot attachment to the ceiling (with
BRIC structure) is a variant of the assembly described in par. 8.9 Fall-prevention
brackets assembly for ceiling attachment (code CR82348800) on page 89. The
fall-prevention brackets and the robot base are fastened by six screws (4) passing
through the robot support plate and driven-in from the upper side of this.
The assembly consists of three strong steel brackets, two (1) of which are fastened to
the front of the robot and one (2) above the lower distribution on the rear of the robot.
Also four angle brackets (3) are provided, with welded nut (5) to lock the 4 through
screws that fasten the robot base to the support plate.
The support plate that sustains the robot has to be prepared with the specified holes for
the screws as indicated in Fig. 8.2 - Plate drilling diagram to fasten the fall-prevention
brackets - BRIC on page 94.
When assembling, lock all the screws to the torque indicated in the SMART NJ4
Maintenance Manual.
The procedure for robot ceiling assembly is contained in the SMART NJ4
Transport and Installation Manual.
92 00/0610
Optional Equipment
1. Staffa 10. Hex head screw M24x140

2. Bracket 11. Flat washer for screw M6
6. Centring 15. Spring washer for screw M24
7. Centring 16. Socket head cap screw
M6x16
17. Socket head cap screw
9. Hex head screw M20x40 M10x70
18. Socket head cap screw
M10x90
00/0610 93
Optional Equipment
Fig. 8.2 - Plate drilling diagram to fasten the fall-prevention

brackets - BRIC
1. Robot fastening screws

2. Robot location pins
3. Plate fastening screws
94 00/0610
Optional equipment

assembly (code CR82273200)
1. Mechanical hard stop (q.ty 2)

2. M20 x70 socket head cap screw (8.8) (q.ty 4)
3. M24 x80 socket head cap screw (8.8) (q.ty 4)
4. Block (q.ty 2)
00/0610 95
Optional equipment
Tab. 8.6 - Possible axis 1 stroke limitations

Pos.
Negative strok e axis 1 Positive strok e axis 1
da from [°] a to [°] da from [°] a to [°]
1 - - +150 -180
2 +135 +180 +135 -180
3 +105 (2x15°) +180 +105 (2x15°) -180
4 +90 +180 +90 -180
5 +75 +180 +75 -180
6 +60 +180 +60 -180
7 +45 +180 +45 -180
8 +30 +180 +30 -180
9 +15 +180 +15 -180
10 0 +180 0 -180
11 -15 +180 -15 -180
12 -30 +180 -30 -180
13 -45 +180 -45 -180
14 -60 +180 -60 -180
15 -75 +180 -75 -180
16 -90 +180 -90 -180
17 -105 +180 -105 -180
18 -120 +180 -120 -180
19 -135 +180 -135 -180
20 -150 +180 - -
After an impact, check the clearance on axis 1 and correct any slackening of the
axis.
-
- mechanical hard stop and fastening screws;
96 00/0610
Optional equipment
8.11.0.1 Description
The axis 1 adjustable mechanical limit switch unit limits the stroke of axis 1 in both work
directions in steps of 15° (except the base zone above the axis 1 reduction gear, where
the centre distance is 30°).
The assembly consists of two limit switch pads (1) to be attached in the seats provided
on the robot base using the screws supplied, and two blocks (4) for the attachment of
the pads (1) in the zone of the base provided to attach the microswitch units; if the stroke
is to be limited in one direction only, use only one of the two stops.
The axis 1 adjustable mechanical limit switch assembly meets "man safety"
requirements since it is able to absorb all the axis kinetic energy.
00/0610 97
Optional equipment

assembly (code CR82273300)
1. Rear block (q.ty 1)

2. Rear block (q.ty 1)
3. Front block (q.ty 1)
4. Front block (q.ty 1)
8.12.1 Description
The unit consists of two sets of blocks to insert between the column structure and the
stop pad already installed on the robot.
The stroke can be limited:
• in plus direction: to +60° or +45° using two front blocks (instead of the
+75°standard stroke)
• in minus direction: to -60° or -45° using two rear blocks (instead of the -60°standard
stroke).
The axis 2 adjustable mechanical hard stop assembly satisfies “operator safety”
requirements as it can absorb all of the kinetic energy of the axis.
98 00/0610
Optional equipment
8.13 Axis 1 mechanical hard stop on-off assembly

(lock pin - code CR82344300
00/0610 99
Optional equipment

Pos.
1 - - +150 -180
2 +135 +180 +135 -180
3 +105 (2x15°) +180 +105 (2x15°) -180
4 +90 +180 +90 -180
5 +75 +180 +75 -180
6 +60 +180 +60 -180
7 +45 +180 +45 -180
8 +30 +180 +30 -180
9 +15 +180 +15 -180
10 0 +180 0 -180
11 -15 +180 -15 -180
12 -30 +180 -30 -180
13 -45 +180 -45 -180
14 -60 +180 -60 -180
15 -75 +180 -75 -180
16 -90 +180 -90 -180
17 -105 +180 -105 -180
18 -120 +180 -120 -180
19 -135 +180 -135 -180
20 -150 +180 - -
The axis 1 mechanical hard stopmechanical hard stop on-off assembly can be used to
enable the temporary sectoring of the robot work area and can be positioned on the
whole of the axis 1 stroke with steps of 15°.
The assembly consists of a mechanical plug and a block to be attached in the coupling
surfaces provided on the robot base. With the block, the plug can be mounted also in
the base sector where the microswitch included in the group is mounted to divide the
area, maintaining the step constant.
The lock pin is operated by a rotating pneumatic actuator and is complete with safety
micro-switches and electrically-controlled solenoid valves.
Inserted in the context of appropriate cell safety devices (safety PLC, accessory safety
barriers, etc.), with the mechanical on-off limit switch assembly a situation of complete
"man safety" can be reached; the management of the plug has to be assigned to a safety
system for the control of the robot position (e.g. area shut-off assembly in work area can
be supplied by COMAU Robotics ).
A maximum of 2 groups can be used on the robot to divide 3 work areas.
100 00/0610
Optional equipment
8.14 Axis 1 mechanical hard stop on-off assembly

- lock pin (code CR82273600)
00/0610 101
Optional equipment

Pos.
1 - - +150 -180
2 +135 +180 +135 -180
3 +105 (2x15°) +180 +105 (2x15°) -180
4 +90 +180 +90 -180
5 +75 +180 +75 -180
6 +60 +180 +60 -180
7 +45 +180 +45 -180
8 +30 +180 +30 -180
9 +15 +180 +15 -180
10 0 +180 0 -180
11 -15 +180 -15 -180
12 -30 +180 -30 -180
13 -45 +180 -45 -180
14 -60 +180 -60 -180
15 -75 +180 -75 -180
16 -90 +180 -90 -180
17 -105 +180 -105 -180
18 -120 +180 -120 -180
19 -135 +180 -135 -180
20 -150 +180 - -
8.14.1 Description
The axis 1 mechanical hard stopmechanical hard stop on-off assembly can be used to
enable the temporary sectoring of the robot work area and can be positioned on the
whole of the axis 1 stroke with steps of 15°.
The assembly consists of a mechanical plug and a block to be attached in the coupling
surfaces provided on the robot base. With the block, the plug can be mounted also in
the base sector where the microswitch included in the group is mounted to divide the
area, maintaining the step constant.
The lock pin is operated by a rotating pneumatic actuator and is complete with safety
micro-switches and electrically-controlled solenoid valves.
Inserted in the context of appropriate cell safety devices (safety PLC, accessory safety
barriers, etc.), with the mechanical on-off limit switch assembly a situation of complete
"man safety" can be reached; the management of the plug has to be assigned to a safety
system for the control of the robot position (e.g. area shut-off assembly in work area can
be supplied by COMAU Robotics ).
A maximum of 2 groups can be used on the robot to divide 3 work areas.Sul robot
possono essere utilizzati fino ad un massimo di 2 gruppi per la parzializzazione di 3 aree
di lavoro.
102 00/0610
Optional equipment
Tab. 8.9 - Electrical characteristics of axis 1 mechanical limit

switch assembly
ELECTRICAL DATA SG1-SG2
Description Solid state switch
Type of connection With 3 WIRES
Output PNP
Applicable load IC circuits, RELAY, PLC
Power supply voltage from 4.5 Vdc to 28 Vdc
Current draw ≤ 10 mA
Load voltage ≤ 10 Vdc
Load current ≤ 80 mA
ELECTRICAL DATA SG3

Description Microswitch with forced opening
contacts
Position of contacts 1 n.c. / 1 n.o.
Insulation Group C (VDE 0110)
Maximum nominal voltage 250 Vac
Maximum direct current 6A
Minimum load at 24 Vdc ≥ 20 mA
Interruption power 2A
ELECTRICAL DATA VD1-VD2

Description Solenoid for solenoid valve
Power supply voltage 24 Vdc
Maximum voltage fluctuation ± 10% of power supply voltage
Maximum power 0,5-0,55 W
ELECTRICAL DATA X80-X81

Description Loose female connector
(HARTING 09330102701)
Type of connection Screwed (2,5 mm2/AWG 14
maximum)
Cable inlet Cable clamp PG21,
Ø outside cable from 13 mm2 to
18 mm2
00/0610 103
Optional equipment
8.15 Axis 1 work area partialization assembly

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

2. RH cam holder
3. LH cam holder
4. Cam
7. Socket grub screw to secure cams M6x8
8. Low hex nut M6
9. Internal thread parallel pin with dia 6x20 type B
104 00/0610
Optional equipment
Axis 1 work area partialization assembly Axis 1 work area partialization assembly
1-2 areas 3 areas
The axis 1 work area shut-off assembly makes it possible to electrically sector the robot
work area using pushbutton micro switches of different types according to the number
of areas to be sectored, in detail :
– for up to 3 work areas a six-pushbutton micro is used
– for up to 2 work areas a 4-pushbutton micro is used
– for a single work area a two-pushbutton micro switch is used
The work areas are each controlled by two safety micro switches in conformity with the
most severe safety standards
• a multiple micro switch with Harting connector
• a set of plastic cams to be cut to the length required by the application and installed
on cam holder
The cams are to be inserted, positioned and clamped on the cam holders attached to
the robot column to substitute the protection guard
For the electrical connection of the microswitch the following is foreseen:

• with restrictor for three areas, a 32-pole HARTING connector
• with restrictor for one or two areas, a 90° 19-pole female connector.
For the microswitch assembly internal electrical layout see the robot Circuit
Diagram.
00/0610 105
Optional equipment
8.16 Axis 2 work area partialization assembly -

2 areas (code CR82273400)
1. Support
2. Micro Switch
3. Left cam holder
4. Right cam holder
6. Cam holder support
7. Cams
8. Parallel pin 4x20
11. Internal thread parallel pin 6x20
13. Socket grub screw M6x8
14. Low hex nut M6
15. Internal thread parallel pin 6x30
106 00/0610
Optional equipment
The axis 2 work area partialization assembly enables electrical partialization of up to 2

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

The kit includes:
• Nr. 1 connector (supplied by FCI) 19 pins, type UTG1619SN;
• Nr. 19 female contacts to be crimped, type SC20ML-1S6 for wires from AWG 20;
• Nr. 1 cable clamp with PG16 (for cables from Ø 8 mm2 to Ø 16 mm2).
To crimp the female pins onto the wires from AWG 20 it is recommended to use the FCI
"crimping tool" type Y14MTV or Y16SCM2.
00/0610 107
Optional equipment
Tab. 8.10 - Electrical characteristics of axis 1, axis 2 and axis 3

mechanical limit switch assembly
ELECTRICAL DATA
Type of switch BSE 85 per DIN EN 60204-1
Insulation Gruppo C (VDE 0110)
Maximum voltage 50 Vac
Maximum current 2A
Minimum load ≥ 20 mA
Interruption current 2 A, cos ϕ=0,8
8.17 Screws and pins kit for robot mounting (code

82314700)
8.17.1 Description
The kit consists of the screws and pins needed to secure the robot to a steel plate
provided with the relevant holes.
The steel plate and its arrangement to secure the robot is to be performed by the
installer, with reference to following Fig. 8.3 - Screws and pins kit for robot mounting on
page 109
Key: Fig. 8.3 - Screws and pins kit for robot mounting on page 109
3. M 10 x 90 socket head cap screw (8.8) (q.ty = 1)
4. M 10 x 70 socket head cap screw (8.8) (q.ty = 1)
6. Split spring washer Ø = 24mm (q.ty = 6)
7. Flat washer Ø = 24 mm (q.ty = 6)
108 00/0610
Optional equipment
Fig. 8.3 - Screws and pins kit for robot mounting
00/0610 109
Optional equipment
8.18 Leveling plate unit for robot mounting

(code 82314800)
110 00/0610
Optional equipment
Key Leveling plate unit for robot mounting (code 82314800)

2. Plate (q.ty 4)
4. M20x100 fully threaded hex head cap screw -8.8 (q.ty = 4)
5. M20 -8 FE/ZN 12 hex nut (q.ty = 4)
8.18.1 Description
The robot leveling plate assembly is used to ensure that the robot is anchored correctly
to the floor. This assembly satisfies the following requirements:
– it ensures good mounting plate levelness, to avoid any incorrect stresses on the
structure of the robot base.
– a perfectly aligned robot assembly that facilitate "off-line programming"
applications.
– four steel plates that are anchored to the floor by means of chemical bolts (for a
total of 16 anchor bolts, which are not supplied).
– a leveling plate that is welded to the plates described above after using the specific
adjustment screws to obtain optimal robot leveling.
8.19 Calibration tool (code 82314100)
1. Dial gauge holder

2. Tapered ring nut
3. Probe
4. Dial gauge
8.19.1 Description
The calibration kit with dial gauge is used to enable the correct manual calibration of
each robot axis.
The kit consists of a dial gauge holder that is screwed into the specific seats on each of
the robot axes and a centesimal dial gauge to find the correct calibration position.
00/0610 111
Optional equipment
Tab. 8.11 - Example of use of the calibration kit

SMART5 NJ4 220 – 2.4;
SMART5 NJ4 170 – 2.9 ;
SMART5 NJ4 220 – 2.7;
ROBOT SMART5 NJ4 170 – 2.5 ;
SMART5 NJ4 220 – 3.0;
SMART5 NJ4 175 – 2.2
SMART5 NJ4 270 – 2.7
a. Remove guards
from calibration
reference surfaces
and from seat for
dial gauge holder
fixture.
b. Align calibration
reference surfaces
by sight.
c. Assembly of dial
gauge holder
fixture.
d. Search for axis

calibration point.
112 00/0610
Optional equipment
8.20 Gauged tool assembly L=200 mm

(code 82109501)
8.20.1 Description
The gauged tool assembly is used to calculate the TCP (Tool Center Point) in relation
to the robot flange.
The assembly consists of a cylindrical test rod of a length that is defined so that the end
is at an exact position in relation to the center of the wrist.
The prod is screwed directly onto the axis 6 output flange in a radial position in relation
to the latter and there is no need to disassemble any tools that are installed on the
flange.
00/0610 113
Optional equipment
8.21 Fork liftable option
114 00/0610
Optional equipment
8.21.1 Description
The forks assembly is an option necessary to lift and handle the robot by means of a lift
truck.
The assembly consists of two electro-welded steel boxed section supports, fastened in
a pre-set position of the robot column by means of screws. The forks of the lift truck are
inserted into the boxed sections to handle the robot safely in a balanced position
Before using he forks assembly read the use information in the manual supply
with the assembly
8.22 Distribution connection guard assembly

SMART5 NJ4 220 3.0; SMART5 NJ4 270 2.7
Code CR82276800
SMART5 NJ4 170-2.5; SMART5 NJ4 175-2.2; SMART5 NJ4 170 2.9; SMART5 NJ4 220 2.4; SMART5 NJ4
220 2.7 Code CR82352200
8.22.1 Description
The assembly consists of a robust guard made out of sheet metal that is fastened to the
base of the robot to protect all the connectors connected to the robot distribution unit.
00/0610 115
Optional equipment
8.23 Guard assembly for ventilated motor ax1

(code 82309259)
8.23.1 Description
The assembly consists of a strong sheet metal guard that is secured to the robot axis 1
reduction unit to protect the electric connectors of axis 1 motor.
116 00/0610
COMAU Robotics services
Repair: repairs.robotics@comau.com
Training: training.robotics@comau.com
Spare parts: spares.robotics@comau.com
Technical service: service.robotics@comau.com
comau.com/robotics Original instructions

COMAU Handbook Smart5 NJ4

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COMAU Handbook Smart5 NJ4

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Comau Robotics

SMART5 NJ4 170 – 2.5

Copyright © 2009 by COMAU -

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

2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16

3. TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...22

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

SMART5 NJ4 270 – 2.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5. ROBOT FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..43

6. LOADS AT WRIST AND ADDITIONAL LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..49

7. PREPARATION FOR ROBOT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..63

8. OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..74

Non adjustable plate for robot mounting (code 82343100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Symbols in the manual

This symbol applies to operating procedures, technical information and

This symbol applies to operating procedures, technical information and

This symbol applies to operating procedures, technical information and

Comau Robot Set Manuali

These manuals are to be integrated with the following documents:

C5G Control Unit – Technical Specifications

1. GENERAL SAFETY PRECAUTIONS

This specification deals with the following topics:

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

The installation shall be made by qualified installation Personnel and should

1.2 Safety Precautions

Installation and Putting into Service

Auto / Remote Automatic Mode

Maintenance and Repairs

Putting Out of Service and Dismantling

1.2.4 Operating Modes

Auto / Remote Automatic Mode

Robot axes release

Maintenance and Repairs

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

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

Putting Out of Service and Dismantling

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

Tab. 1.2 - Safety electronics reaction time in programming

Mission time (typ. case)

2.1 Robot SMART5 NJ4 family

Tab. 2.1 - Robot SMART5 NJ4 versions available

SMART5 NJ4 170 - 2.5 170 2501

SMART5 NJ4 170 - 2.9; 170 2918

SMART5 NJ4 175 - 2.2 175 2205

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

SMART5 NJ4 220 - 2.4 220 2417

SMART5 NJ4 220 - 2.7; 220 2738

SMART5 NJ4 220 - 3.0 220 3002

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

SMART5 NJ4 270 - 2.7 270 2703

2.2 Robot mechanical

Tab. 2.2 - Axes limit switches and work area restrictors

Tab. 3.1 - SMART5 NJ4 170 – 2.5;

Tab. 3.2 - SMART5 NJ4 220 – 2.4;

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

Tab. 3.3 - SMART5 NJ4 220 – 3.0;

VERSION NJ4 220-3.0 NJ4 270 – 2.7

4. OPERATING AREAS AND ROBOT

– SMART5 NJ4 220 – 2.7

– SMART5 NJ4 170 – 2.9

– SMART5 NJ4 270 – 2.7

SMART5 NJ4 170 – 2.5

SMART5 NJ4 170 – 2.5

Pos X Z Ax.2 Ax.3