ABB FlexPLP IRPLP 220 Bedienungsanleitung

ROBOTICS

Product manual

FlexPLP IRPLP 220

Trace back information:

Workspace Systems version a10

Checked in 2019-04-12

Skribenta version 5.3.012

Product manual

FlexPLP IRPLP 220

Document ID: 3HAW050041018-001

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
7Overview ...........................................................................................................................................
9Product documentation, IRC5 ..........................................................................................................
11How to read the product manual ......................................................................................................
131 Safety
131.1 Introduction ...................................................................................................... 141.2 General safety information .................................................................................. 141.2.1 Safety in the machine controller system ...................................................... 151.3 Safety risks ...................................................................................................... 151.3.1 Safety risks during installation and service work ........................................... 171.3.2 Safety risks related to tools/workpieces ....................................................... 181.3.3 Safety risks related to pneumatic/hydraulic systems ...................................... 191.3.4 Safety risks during operational disturbances ................................................ 201.3.5 Risks associated with live electric parts ....................................................... 211.4 Safety actions related to the FlexPLP .................................................................... 211.4.1 Safety fence dimensions ........................................................................... 221.4.2 Fire extinguishing .................................................................................... 231.4.3 Emergency release of the FlexPLP device axes ............................................ 241.4.4 Brake testing .......................................................................................... 251.4.5 Safe use of the Teach Pendant Unit ............................................................ 261.4.6 Work inside the FlexPLP's working range .................................................... 271.4.7 Translate the information on safety and information labels .............................. 281.5 Safety stops ..................................................................................................... 281.5.1 What is an emergency stop? ..................................................................... 301.6 Safety related instructions .................................................................................. 301.6.1 Safety signals in the manual ......................................................................
332 Product description
332.1 Product overview .............................................................................................. 342.2 Terminology ..................................................................................................... 352.3 Principle structure ............................................................................................. 352.3.1 Modularity .............................................................................................. 372.3.2 Axes combinations .................................................................................. 382.3.3 Driving types .......................................................................................... 392.3.4 Vertical axis mounting and cable chain ........................................................ 402.4 Performances ................................................................................................... 402.4.1 FlexPLP IRPLP 220 overall specifications .................................................... 412.4.2 FlexPLP IRPLP 220 motor specifications ..................................................... 422.5 Dimensions ...................................................................................................... 422.5.1 Dimensions 1-axis FlexPLP IRPLP 220 ........................................................ 442.5.2 Dimensions 2-axis FlexPLP IRPLP 220 ........................................................ 472.5.3 Dimensions 3-axis FlexPLP IRPLP 220 ........................................................ 492.6 Weight ............................................................................................................
513 Unpacking and handling
513.1 Pre-requisites for reception ................................................................................. 523.2 Unpacking and acceptance ................................................................................. 543.3 Handling/lifting .................................................................................................
574 Installation and commissioning
574.1 Introduction ...................................................................................................... 584.2 Mechanical installation ....................................................................................... 584.2.1 Introduction ............................................................................................ 594.2.2 Mounting surface (fastening of the FlexPLP IRPLP 220 to the floor plate) .......... 624.2.3 Mounting surfaces (fastening of an axis or customer equipment) .....................
Product manual - FlexPLP IRPLP 220 5
3HAW050041018-001 Revision: C
© Copyright 2016 - 2018 ABB. All rights reserved.
Table of contents

2.4 Jogging axes of a unit with FlexPendant ...................................................... 684.2.5 Fastening of a unit to the floor plate ............................................................ 704.3 Cabling and control ........................................................................................... 704.3.1 Connectors and internal equipment wiring ................................................... 714.3.2 Control architecture ................................................................................. 734.3.3 Controller capabilities .............................................................................. 754.3.4 Examples of configurations ....................................................................... 814.3.5 Configuration files ...................................................................................
Calibration
1 Introduction / When to calibrate ........................................................................... 845.2 Calibration points .............................................................................................. 855.3 Edit motor calibration offset ................................................................................ 875.4 Fine calibration ................................................................................................. 905.5 Update of the revolution counters .........................................................................
FlexPLP addin application GUI
1 Introduction ...................................................................................................... 946.2 Workflow of the FlexPLP addin ............................................................................ 946.2.1 Soft Calibration ....................................................................................... 1056.2.2 Shim Offset ............................................................................................
Maintenance
1 Introduction ...................................................................................................... 1157.2 Maintenance schedule ....................................................................................... 1167.3 Inspection ........................................................................................................ 1177.4 Lubrication ....................................................................................................... 1197.5 Driving belt (tension check, adjustment and replacement) ......................................... 1237.6 SMB Battery pack replacement ............................................................................ 1257.7 Repair information .............................................................................................
Decommissioning
Reference information
1 Introduction ...................................................................................................... 1329.2 Unit conversion ................................................................................................. 1339.3 Bolt, screws, tightening torques ........................................................................... 1349.4 Standard toolkit ................................................................................................ 1359.5 Special tools ....................................................................................................
Spare parts
1 Introduction ...................................................................................................... 13810.2 Spare parts - Ballscrew type ................................................................................ 14010.3 Spare parts - Rack & Pinion type .......................................................................... 14210.4 Covers ............................................................................................................ 14310.5 Cables ............................................................................................................
Product manual - FlexPLP IRPLP 220
3HAW050041018-001 Revision: C
© Copyright 2016 - 2018 ABB. All rights reserved.
Table of contents

Overview

About this manual

This manual contains instructions for:

• the characteristics of the FlexPLP IRPLP 220

•mechanical and electrical installation instructions for the FlexPLP IRPLP 220

• maintenance instructions for the FlexPLP IRPLP 220

• spare parts

Usage

This manual should be used when working during:

• installation, from lifting the FlexPLP IRPLP 220 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 personnel working with an ABB FlexPLP IRPLP

220 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:

ContentChapter

Safety information that must be read through before performing

any installation or service work on the FlexPLP IRPLP 220.

Contains general safety aspects as well as more specific inform-

ation about how to avoid personal injuries and damage to the

product.

Safety

Specifications and characteristics of the FlexPLP IRPLP 220.Product description

Information relative to the steps following the reception of the

FlexPLP IRPLP 220, until its installation.

Unpacking and handling

Required information about lifting and installation of the FlexPLP

IRPLP 220 and installation of cabling.

Installation and commis-

sioning

Information about calibration of the system.Calibration

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

ance of the FlexPLP IRPLP 220. Based on a maintenance

schedule that may be used in the work of planning periodical

maintenance.

Maintenance

Continues on next page

Product manual - FlexPLP IRPLP 220 7

3HAW050041018-001 Revision: C

Overview

ContentChapter

Environmental information about the FlexPLP IRPLP 220.Decommissioning

Reference information may be useful for the understanding of

this manual.

Reference information

List of the spare parts available for the FlexPLP IRPLP 220.Spare parts

References

Document IDReference (ABB manuals)

3HAC021313-001Product manual - IRC5

3HAC050944-001Operating manual - Service Information System

3HAC051016-001Application manual - Additional axes and stand alone controllers

3HAC050941-001Operating manual - IRC5 with FlexPendant

3HAC050948-001Technical reference manual - System parameters

3HAC050917-001Technical reference manual - RAPID Instructions, Functions and

Data types

Revisions

DescriptionRevision

First edition.-

The following updates are done in this revision:

• Minor editorial changed.

• Calibration point, without calibration index system removed.

• Specification of rack & pinion updated.

• Spare parts updated.

•Edit Motor Calibration Offset added.

• Number of the motions changed.

Changes made in:

• FlexPLP addin is applied to improve the efficiency of calibration

and setting offset procedures, see FlexPLP addin application GUI

on page 93.

•Deleted the stroke information, and add protection detail in Product

overview on page 33.

• Changed the axis name of nominal payload in Robustness on

page 59.

• Added a contact strategy for customers, see Workflow of the

FlexPLP addin on page 94.

• Added material disposing symbol and related description in

Symbol on page 128.

Changes made in:

• Added warning about grease KLÜBER Microlube GB0.

8 Product manual - FlexPLP IRPLP 220

3HAW050041018-001 Revision: C

Overview

Continued

Product documentation, IRC5

Categories for user documentation from ABB Robotics

The user documentation from ABB Robotics is divided into a number of categories.

This listing is based on the type of information in the documents, regardless of

whether the products are standard or optional.

All documents listed can be ordered from ABB on a DVD. The documents listed

are valid for IRC5 robot systems.

Product manuals

All hardware, manipulators and controllers will be delivered with a Product manual

that contains:

• Safety information

• Installation and commissioning (description of mechanical installation,

electrical connections)

•Maintenance (description of all required preventive maintenance procedures

including intervals)

• Repair (description of all recommended repair procedures including spare

parts)

• Additional procedures, if any (calibration, decommissioning)

• Reference information (article numbers for documentation referred to in

Product manual, procedures, lists of tools, safety standards)

• Parts list.

• Foldouts or exploded views.

• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe the manipulator software in general and

contain relevant reference information.

•RAPID Overview: An overview of the RAPID programming language.

•RAPID Instructions,Functions and Data types: Description of all RAPID

instructions, functions and data types.

•RAPID Kernel: A formal description of the RAPID programming language.

•System parameters: Description of system parameters and configuration

workflow.

Application manuals

Specific applications (for example, software or hardware options) are described

in Application manuals. An application manual can describe one or several

applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful)

•What is included (for example, cables, I/O boards, RAPID instructions, system

parameters)

Continues on next page

Product manual - FlexPLP IRPLP 220 9

3HAW050041018-001 Revision: C

Product documentation, IRC5

• How to install included or required hardware.

• How to use the application

• Examples of how to use the application

Operating manuals

The operating manuals describe hands-on handling of the products. The manuals

are aimed at those having first-hand operational contact with the product, that is

production cell operators, programmers, and trouble shooters.

The group of manuals includes:

•Emergency safety information

•General safety information

•Getting started, IRC5 and RobotStudio

•IRC5 with FlexPendant

•RobotStudio

•Introduction to RAPID

•Trouble shooting, for the controller and manipulator.

10 Product manual - FlexPLP IRPLP 220

3HAW050041018-001 Revision: C

Product documentation, IRC5

Continued

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