ABB FlexTrack IRT501 Series Bedienungsanleitung

ROBOTICS

Product manual

FlexTrack IRT501-66/66R/90/90R

Trace back information:

Workspace Systems version a6

Checked in 2019-01-15

Skribenta version 5.3.012

Product manual

FlexTrack IRT501-66/66R/90/90R

Document ID: 3HAW050008590-001

Revision: C

Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not

be construed as a commitment by ABB. ABB assumes no responsibility for any errors

that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be

construed as any kind of guarantee or warranty by ABB for losses, damages to

persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from

use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB's

written permission.

Keep for future reference.

Additional copies of this manual may be obtained from ABB.

Original instructions.

Specifications subject to change without notice.

ABB AB, Robotics

Robotics and Motion

Se-721 68 Västerås

Sweden

Table of contents
9Overview ...........................................................................................................................................
12Product documentation, M2004 .......................................................................................................
14How to read the product manual ......................................................................................................
151 Safety
151.1 Introduction ...................................................................................................... 161.2 General safety information .................................................................................. 161.2.1 Safety in the robot system ........................................................................ 171.3 Safety risks ...................................................................................................... 171.3.1 Safety risks during installation and service work on robot ............................... 191.3.2 Safety risks related to tools/workpieces ....................................................... 201.3.3 Safety risks related to pneumatic/hydraulic systems ...................................... 211.3.4 Safety risks during operational disturbances ................................................ 221.3.5 Risks associated with live electric parts ....................................................... 231.4 Safety actions ................................................................................................... 231.4.1 Safety fence dimensions ........................................................................... 241.4.2 Fire extinguishing .................................................................................... 251.4.3 Emergency release of the robots/manipulators axes ...................................... 261.4.4 Brake testing .......................................................................................... 271.4.5 Risk of disabling function "Reduced speed 250 mm/s" ................................... 281.4.6 Safe use of the Teach Pendant Unit ............................................................ 291.4.7 Work inside the manipulator's working range ................................................ 301.4.8 Translate the information on safety and information labels .............................. 311.5 Safety related instructions .................................................................................. 311.5.1 Safety signals, general ............................................................................. 331.5.2 DANGER - Moving manipulators are potentially lethal! ................................... 341.5.3 DANGER - First test run may cause injury or damage! ................................... 351.5.4 WARNING - The unit is sensitive to ESD! ..................................................... 361.5.5 WARNING - Safety risks during work with gearbox oil .................................... 371.5.6 Location of safety pictograms ....................................................................
392 Installation and commissioning
392.1 Introduction ...................................................................................................... 412.2 Unpacking and acceptance ................................................................................. 412.2.1 Unpacking ............................................................................................. 422.2.2 Acceptance inspection ............................................................................. 432.3 Handling .......................................................................................................... 432.3.1 Lifting FlexTrack IRT 501 .......................................................................... 482.3.2 Lifting weight .......................................................................................... 492.3.3 FlexTrack IRT 501 size and dimensions ....................................................... 532.3.4 Moving the carriage manually .................................................................... 562.4 Preparations for assembly .................................................................................. 562.4.1 Foundation ............................................................................................ 602.4.2 Recommendation for anchors .................................................................... 632.4.3 Screw joints ........................................................................................... 642.5 Assembly of the track ........................................................................................ 642.5.1 Procedure of assembly ............................................................................. 712.5.2 Recommendations for floor mounting ......................................................... 762.5.3 Geometric alignment of FlexTrack IRT 501 ................................................... 792.6 Assembly of the manipulator ............................................................................... 802.7 Cables, SMB box and cable chain ........................................................................ 802.7.1 Cabling of the FlexTrack ........................................................................... 812.7.2 Specifications of the movement cables ........................................................ 822.7.3 Specifications of the internal cable chain ..................................................... 842.7.4 Installation of the cable chain .................................................................... 872.7.5 SMB box ................................................................................................
Product manual - FlexTrack IRT501-66/66R/90/90R 5
3HAW050008590-001 Revision: C
© Copyright 20042018 ABB. All rights reserved.
Table of contents

7.6 Cables connections ................................................................................. 902.7.7 Connectors on IRC5 controller ................................................................... 952.8 Software installation .......................................................................................... 952.8.1 Preparation for setup ............................................................................... 962.8.2 Load configuration files ............................................................................ 992.8.3 Modification of the Travel Direction of the track ............................................. 1002.8.4 Link robot and track ................................................................................. 1012.8.5 Robot orientation on the track .................................................................... 1042.8.6 Set Upper and Lower Limits Software Limits for track ..................................... 1112.9 Lubrication ....................................................................................................... 1122.10 Zone Division ................................................................................................... 1152.11 Setting up the FlexTrack limit switch for additional safety ......................................... 1172.12 Additional Function Support ................................................................................
Maintenance
1 Introduction ...................................................................................................... 1203.2 Standard toolkit ................................................................................................ 1213.3 Maintenance schedule and expected component life ............................................... 1213.3.1 Specification of maintenance intervals ........................................................ 1223.3.2 Expected component life .......................................................................... 1233.3.3 Maintenance schedule ............................................................................. 1243.4 Activities 100 Km or one week ............................................................................. 1243.4.1 Racks and pinion .................................................................................... 1263.5 Activities 1 Month .............................................................................................. 1263.5.1 Linear guideways .................................................................................... 1283.5.2 Ball bearing blocks .................................................................................. 1303.5.3 Automatic lubrication system ..................................................................... 1353.5.4 Emergency stop and stroke limit system ...................................................... 1363.5.5 Zone division system ............................................................................... 1383.5.6 Cables and connectors ............................................................................. 1393.6 Activity 3 and 12 months ..................................................................................... 1393.6.1 Gear ..................................................................................................... 1413.7 Activities 36 Months ........................................................................................... 1413.7.1 Replacement, SMB Battery pack ................................................................
Repair
1 Instruction ....................................................................................................... 1444.2 Replace the linear guideways .............................................................................. 1484.3 Replace the ball bearing blocks ........................................................................... 1514.4 Replace the racks .............................................................................................. 1544.5 Motor and gear ................................................................................................. 1544.5.1 Overview ............................................................................................... 1554.5.2 Disassemble the bracket from the carriage ................................................... 1594.5.3 Replace motor ........................................................................................ 1604.5.4 Replace gear .......................................................................................... 1634.5.5 Motor and gear assembly ......................................................................... 1684.6 Replace the cable chain or the cable .....................................................................
Calibration
1 Overview ......................................................................................................... 1765.2 Fine calibration ................................................................................................. 1775.3 Update revolution counters .................................................................................
Decommissioning
1 Introduction ...................................................................................................... 1806.2 Environmental information ..................................................................................
Product manual - FlexTrack IRT501-66/66R/90/90R
3HAW050008590-001 Revision: C
© Copyright 20042018 ABB. All rights reserved.
Table of contents

1837 Reference information

1837.1 Introduction ...................................................................................................... 1847.2 Applicable safety standards ................................................................................ 1857.3 Unit conversion .................................................................................................

1878 Spare parts

1878.1 Carriage IRT501 ................................................................................................ 1888.2 Track .............................................................................................................. 1898.3 Limit switch and calibration ................................................................................. 1908.4 Automatic lubrication system ............................................................................... 1918.5 Cable chains .................................................................................................... 1948.6 Electrical spare parts and cables .......................................................................... 1978.7 Anti collision ....................................................................................................

1999 Appendix

1999.1 Wiring diagrams ................................................................................................

201Index

Product manual - FlexTrack IRT501-66/66R/90/90R 7

3HAW050008590-001 Revision: C

Table of contents

This page is intentionally left blank

Overview

About this manual

This manual contains instructions for:

• mechanical and electrical installation instructions for the FlexTrack

• maintenance instructions for the FlexTrack

• spare parts

Usage

This manual should be used when working during;

• installation, from lifting the robot to its work site and securing it to the

foundation, to making it ready for operation

• maintenance work

• repair work

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel

Prerequisites

A maintenance/repair/installation craftsman working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical and

electrical installation/repair/maintenance work.

Organization of chapters

The manual is organized in the following chapters:

ContentsChapter

Safety information that must be read through before performing

any installation or service work on the FlexTrack. Contains gen-

eral safety aspects as well as more specific information about

how to avoid personal injuries and damage to the product.

Safety

Required information about lifting and installation of the Flex-

Track.

Installation and commis-

sioning

Step-by-step procedures that describe how to perform mainten-

ance of the FlexTrack. Based on a maintenance schedule that

may be used in the work of planning periodical maintenance.

Maintenance

Procedures that does not require specific calibration equipment.Calibration information

References

Document IDDocument name

3HAW050008591Product specification - IRT 501 - 66/66R/90/90R

3HAC021313-001Product manual - IRC5 Robot Controller

Continues on next page

Product manual - FlexTrack IRT501-66/66R/90/90R 9

3HAW050008590-001 Revision: C

Overview

Document IDDocument name

3HAC16590-1Operating manual - IRC5 with FlexPendant

3HAC16578-1Operating manual - Calibration Pendulum

3HAC025709-001Service Information System - IRC5

3HAC021395-001Application manual - Additional axes and stand alone controller

3HAC17076-1System Parameters

3HAC052610-001Application manual - Functional safety and SafeMove

Revisions

DescriptionRevision

First edition.-

Changes made in:

• Clarity improved and pictures added in Disassemble the bracket

from the carriage on page 155. Instructions for the coupling of the

motor and the gearbox updated, see Motor and gear assembly

on page 163.

• Names of spare cables updated, see Electrical spare parts and

cables on page 194.

Changes made in:

• Standard top plate drawings are updated in Standard top plate on

page 51

• Robot capacities updated in Static loads on page 56

• FlexTrack on site installation procedures updated in Procedure

of assembly on page 64

• Add more detailed information about 1, 2 and 4 position switch in

Zone Division on page 112

•Change the verification step of the tightening torque in Verification

of the tightening torque on page 140

• Procedures about how to change a cable in the cable chain is

added inReplace cables on page 171

• Spare parts updated in Spare parts on page 187

• Electrical diagrams added in Appendix on page 199

Continues on next page

10 Product manual - FlexTrack IRT501-66/66R/90/90R

3HAW050008590-001 Revision: C

Overview

Continued

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