ABB FlexTrack IRT501 Series, Product Manual

Page 1: ...ROBOTICS Product manual FlexTrack IRT501 66 66R 90 90R ...

Page 2: ...Trace back information Workspace Systems version a6 Checked in 2019 01 15 Skribenta version 5 3 012 ...

Page 3: ...Product manual FlexTrack IRT501 66 66R 90 90R Document ID 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ... 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 ...

Page 5: ...s are potentially lethal 34 1 5 3 DANGER First test run may cause injury or damage 35 1 5 4 WARNING The unit is sensitive to ESD 36 1 5 5 WARNING Safety risks during work with gearbox oil 37 1 5 6 Location of safety pictograms 39 2 Installation and commissioning 39 2 1 Introduction 41 2 2 Unpacking and acceptance 41 2 2 1 Unpacking 42 2 2 2 Acceptance inspection 43 2 3 Handling 43 2 3 1 Lifting Fl...

Page 6: ... 5 Activities 1 Month 126 3 5 1 Linear guideways 128 3 5 2 Ball bearing blocks 130 3 5 3 Automatic lubrication system 135 3 5 4 Emergency stop and stroke limit system 136 3 5 5 Zone division system 138 3 5 6 Cables and connectors 139 3 6 Activity 3 and 12 months 139 3 6 1 Gear 141 3 7 Activities 36 Months 141 3 7 1 Replacement SMB Battery pack 143 4 Repair 143 4 1 Instruction 144 4 2 Replace the l...

Page 7: ...8 2 Track 189 8 3 Limit switch and calibration 190 8 4 Automatic lubrication system 191 8 5 Cable chains 194 8 6 Electrical spare parts and cables 197 8 7 Anti collision 199 9 Appendix 199 9 1 Wiring diagrams 201 Index Product manual FlexTrack IRT501 66 66R 90 90R 7 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved Table of contents ...

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Page 9: ...e following chapters Contents Chapter 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...

Page 10: ...d see Electrical spare parts and cables on page 194 A 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...

Page 11: ...ed in In struction on page 76 Expected life of cables updated in Expected life on page 122 Limits for expected life of cable chains updated in Expected life on page 122 Additional Function Support added in Additional Function Support on page 117 Added material disposing symbol and related description in Envir onmental information on page 180 Re described the method of geometric alignment and remov...

Page 12: ...tandards 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 and syntax for all RAPID instructions...

Page 13: ...roduction 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 Product manual FlexTrack IRT501 66 66R 90 90R 13 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights...

Page 14: ...n include references to equipment spare parts tools etc required for the different actions in the procedure The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information i e article number dimension The denomination in the procedure for the component or attachment point corresponds to the denomination...

Page 15: ...nd in General safety information on page 16 specific safety information pointed out in the procedure at the moment of the danger How to avoid and eliminate the danger is either detailed directly in the procedure or further detailed in separate instructions found in Safety related instructions on page 31 Product manual FlexTrack IRT501 66 66R 90 90R 15 3HAW050008590 001 Revision C Copyright 2004201...

Page 16: ...Manual Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices Via this interface an external safety function can interact with other machines and peripheral equipment This means that control signals can act on safety signals received from the peripheral equipment as well as from the r...

Page 17: ... working space Light beams or sensitive mats are suitable devices Turntables or the like should be used to keep the operator out of the robot s working space The axes are affected by the force of gravity when the brakes are released In addition to the risk of being hit by moving robot parts you run the risk of being crushed by the parallel arm Energy stored in the robot for the purpose of counterb...

Page 18: ...ts are removed e g secure the lower arm with fixtures if removing motor axis 2 Cabling Description Safety risk CAUTION The cable packs are sensitive to mechanical damage They must be handled with care especially the connect ors in order to avoid damaging them Cable packs are sensitive to mechanical damage Gearboxes and motors Description Safety risk CAUTION Whenever parting mating motor and gearbo...

Page 19: ...s by manual operation valves Safe design Grippers end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller CAUTION Ensure that a gripper is prevented from dropping a workpiece if such is used Product manual FlexTrack IRT501 66 66R 90 90R 19 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 1 Safety 1 3 2 ...

Page 20: ...atic and hydraulic systems must be released before starting to repair them Safe design Gravity may cause any parts or objects held by these systems to drop Dump valves should be used in case of emergency Shot bolts should be used to prevent tools etc from falling due to gravity 20 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved ...

Page 21: ...st only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken due to risks other than those associated with regular operation Such an interruption may have to be rectified manually Product manual FlexTrack IRT501 66 66R 90...

Page 22: ...VDC Note Capacitors The drive unit 700 VDC The drive system power supply 230 VAC The service outlets 115 230 VAC The customer power supply 230 VAC The power supply unit for tools or special power supply units for the machining process The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains Additional connections Voltage related risks ro...

Page 23: ...ximum speed Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell see Product Specification Description Robot Motion Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator Product manual FlexTrack IRT501 66 66R 90 90R 23 3HAW0500...

Page 24: ...N DIOXIDE CO2 extinguisher in the event of a fire in the robot manipulator or controller 24 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 1 Safety 1 4 2 Fire extinguishing ...

Page 25: ...n page 53 The robot arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the trapped person further increasing any injury Product manual FlexTrack IRT501 66 66R 90 90R 25 3HAW050008590 001 Revision C Copyright 20042018 AB...

Page 26: ...is to a position where the combined weight of the manipulator arm and any load is maximized max static load 1 Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller 2 Check that the axis maintains its position 3 If the manipulator does not change position as the motors are switched off then the brake function is adequate 26 Product manual FlexTrack IRT501 66...

Page 27: ... kinematic parameters from the Teach Pendant Unit or a PC This will affect the safety function Reduced speed 250 mm s Product manual FlexTrack IRT501 66 66R 90 90R 27 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 1 Safety 1 4 5 Risk of disabling function Reduced speed 250 mm s ...

Page 28: ... implemented The enabling device must never be rendered inoperative in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move The programmer must always bring the Teach Pendant Unit with him her when entering the robot s working space This is to prevent anyone else taking control of the robot without the programmer knowing 28 P...

Page 29: ...sition 250 mm s This should be the normal position when entering the working space The position 100 full speed may only be used by trained personnel who are aware of the risks that this entails Pay attention to the rotating axes of the manipulator Keep a distance to the axes in order not to get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or othe...

Page 30: ...arent sticker over the standard label with text added in a fourth language Drawings detailing the design text figure dimensions of the standard labels can be ordered from ABB Notice that each label is identified according to the article number located in the lower corner of the label Example of transparent sticker The figure below shows the location of the free space on one of the labels on the ro...

Page 31: ... not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING The electrocution or electrical shock symbol indic ates electrical hazards which could result in sev...

Page 32: ...ols direct you to specific instructions where to find additional information or how to perform a certain operation in an easier way TIP 32 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 1 Safety 1 5 1 Safety signals general Continued ...

Page 33: ...Before attempting to run the manipulator make sure all emergency stop equipment is correctly installed and connected 1 How to use the hold to run control in RobotWare 5 0 is detailed in section How to use the hold to run function in theOperating manu al IRC5 with FlexPendant If possible use the hold to run button whenever possible The hold to run button is used in manual mode not in automatic mode...

Page 34: ... installation or maintenance Action Remove all service tools and foreign objects from the robot and its working area 1 Install all safety equipment properly 2 Make sure all personnel are standing at a safe distance from the robot i e out of its reach behind safety fences etc 3 Pay special attention to the function of the part previously serviced 4 34 Product manual FlexTrack IRT501 66 66R 90 90R 3...

Page 35: ...ested fre quently to ensure that they are not damaged and are operating cor rectly Use a wrist strap 1 The mat must be grounded through a current limiting resistor Use an ESD protective floor mat 2 The mat should provide a con trolled discharge of static voltages and must be grounded Use a dissipative table mat 3 Location of wrist strap button The wrist strap button is located in the top right cor...

Page 36: ... gearbox oil can lead to internal over pressure inside the gearbox which in turn may damage seals and gaskets com pletely press out seals and gas kets prevent the manipulator from moving freely Don not overfill When filling gearbox oil do not mix different types of oil unless specified in the instruction Al ways use the type of oil specified by the manufacturer Mixing types of oil may cause severe...

Page 37: ...re in jury to hands This pictogram must be positioned close to the timing mark xx1800002100 xx1800002089 DO NOT WALK The pictogram is located on the track covers xx1800002101 Product manual FlexTrack IRT501 66 66R 90 90R 37 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 1 Safety 1 5 6 Location of safety pictograms ...

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Page 39: ...he top plate receives the tooling robot Carriage The static part of the FlexTrack Track The track is delivered as modules to be assembled by the cus tomer as described in Assembly of the track on page 64 Maximum stroke of the carriage Travel length The Serial Measurement Board Box a control box which in cludes the SMB card for the FlexTrack axis as well as the re solver position backup battery SMB...

Page 40: ...reparations The following steps should be carried out before starting the FlexTrack IRT 501 Note Action Compare the delivery check to the identification plate and verify for acceptance according to Accept ance inspection on page 42 Unpacking and acceptance 1 Lifting FlexTrack IRT 501 using lifting slings see Acceptance in spection on page 42 Lifting 2 Preparation for assembly 3 Assemble the track ...

Page 41: ... less than 2 m long Cable chain The cable chain has been preassembled on the track when delivered Memolub auto lubrication system The Memolub auto lubrication system has been installed on the carriage and preset when delivered but it is not yet activated Cleaning Before transport the FlexTrack IRT 501 has been protected against rust by a thin film of oil that has been applied before packing This f...

Page 42: ...identification plate and compare it to the delivery note The identification plate is located on the carriage side see figure below and indicates the FlexTrack type the serial number and the weight of the complete track xx1800002093 42 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Acceptan...

Page 43: ...unted carriage Recommended equipment Type 4 U shackles shackle has to fit into the bail xx1800002090 IRT 501 66 and 90 4 Lifting I bolts with a M12 thread xx1800002091 2 lifting straps min 5 m with a load capacity of 1 tonne each 2 lifting straps min 5 m with a load capacity of 1 tonne each IRT 501 66 and 90 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 43 3HAW050008590 001 ...

Page 44: ...e below the sidemembers at both sides and through the second shackle The second strap should be used for the other side The shackle should act as a guidance only to prevent the straps from slipping The weight of the FlexTrack should be carried by the sidemembers xx1800002094 Continues on next page 44 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB ...

Page 45: ...s below the sidemembers at both sides and through the second shackle The second strap should be used for the other side xx1800002096 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 45 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting FlexTrack IRT 501 Continued ...

Page 46: ...ng FlexTrack with a lifting beam If there is a lifting beam available the strap should always be located at the middle of the sidemembers The picture shows 66 90 with a length of 3 m xx1800002098 Continues on next page 46 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting FlexTrack IRT...

Page 47: ...tion which can be handled using appropriate straps and M24 handling I bolts xx1800002099 Product manual FlexTrack IRT501 66 66R 90 90R 47 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting FlexTrack IRT 501 Continued ...

Page 48: ... 501 90 IRT 501 66R IRT 501 66 390 kg 326 kg 325 kg 275 kg 1 meter Section without carriage 618 kg 510 kg 516 kg 436 kg 2 meter section without carriage 848 kg 686 kg 712 kg 591 kg 3 meter section without carriage 1 020 kg 909 kg 853 kg 772 kg 2 meter section with carriage 48 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Ins...

Page 49: ... C Linear guideway D Cover bracket E Rack cover F Cover G End cover H Cable chain J Carriage K Rack L Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 49 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 3 3 FlexTrack IRT 501 size and dimensions ...

Page 50: ...rack IRT 501 90R IRT 501 90 IRT 501 66R IRT 501 66 Data 900 900 660 660 A 680 680 500 500 B 495 495 435 435 C 525 1050 525 1050 D 900 900 1150 1150 E 738 N 1050 L Continues on next page 50 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 3 3 FlexTrack IRT 501 size and dimensions Continued ...

Page 51: ...ocating The opening in the middle of the plate is for easy access to the motor connection box Dimensions for IRT501 66 IRT501 66R xx1800001864 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 51 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 3 3 FlexTrack IRT 501 size and dimensions Continued ...

Page 52: ...or various robot models and their bolting patterns match that of the robot 52 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 3 3 FlexTrack IRT 501 size and dimensions Continued ...

Page 53: ...e track Note Illustration Action Connect all cables to the controller as described in Cables connections on page 88 1 Start up the controller as described in Connectors on IRC5 controller on page 90 on page 2 xx1800001866 Press in the brake release button A shows in the figure 3 Release the brake Push the carriage by hand to the desired location 4 Continues on next page Product manual FlexTrack IR...

Page 54: ...e external 24V DC If there is no voltage to the motor 24V DC can be connected direct to the SMB box Action Unplug the Motor power cable from the SMB box that runs to the FlexTrack motor 1 Using pins connect the 24VCC to the G pin see fig 2 Connect the 0VCC to the H pin 3 Continues on next page 54 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All ...

Page 55: ... 501 are phase dependent Fault connection can cause damage to vital parts Product manual FlexTrack IRT501 66 66R 90 90R 55 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 3 4 Moving the carriage manually Continued ...

Page 56: ...nclination must not exceed 1mm meter in the translation direction and 0 5mm meter cross section The levelling screws can also compensate a poor flatness of the slab and small bumps up to 10 mm However the surface under the levelling screw must be flat A concrete surfacing grinder should be used to correct the flatness locally if necessary Static loads The following table shows the maximum payload ...

Page 57: ... 260 Riser 1 500 mm max Riser 1 500 mm max X X IRB 4400 Riser 1 500 mm max Riser 1 000 mm max IRB 4600 Riser 1 500 mm max Riser 1 500 mm max Riser 1 000 mm max Riser 500 mm max X IRB 460 Riser 1 500 mm max Riser 500 mm max Riser 500 mm max X X X IRB 6400R 6400RF No riser allowed X X IRB 6600 Riser 500 mm max No riser allowed X X IRB 6620 6640 Riser 500 mm max No riser allowed X X IRB 6700 Riser 50...

Page 58: ...namic loads generated by the FlexTrack and the robot should never accumulate To avoid this when the carriage is moving the robot should stand still or only move in the opposite direction Movement xx1800001871 Allowed xx1800001872 Not allowed Continues on next page 58 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation...

Page 59: ...De celeration Time s Acceleration Deceleration m s Max speed m s Gear ra tio Cycle time for 6 m stroke FlexTrack 1 0 1 0 2 0 2 0 2 0 10 4 4 sec IRT 501 66 1 25 0 83 1 2 1 8 1 5 16 5 4 sec IRT 501 66R 1 25 0 83 1 2 1 8 1 5 16 5 4 sec IRT 501 90 1 20 1 00 1 0 1 2 1 2 20 6 5 sec IRT 501 90R WARNING In the event that any of the static or dynamic loading rules are not followed the tracks warranty will ...

Page 60: ...mmended to use chemical anchors with M16 threaded rods to secure the unit to the floor See Recommendations for floor mounting on page 71 Continues on next page 60 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Recommendation for anchors ...

Page 61: ...ntinues on next page Product manual FlexTrack IRT501 66 66R 90 90R 61 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Recommendation for anchors Continued ...

Page 62: ...exTrack anchor xx1800001875 62 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 4 2 Recommendation for anchors Continued ...

Page 63: ...d to the screws before assembly and tightening to their recommend torque Tightening torque Before tightening any screw note the following Determine whether a standard tightening torque or special torque is to be applied The standard torques is specified in the tables below Any special torques is specified in the Repair on page 143 Maintenance on page 119 or Installation procedure description Any s...

Page 64: ...astic mallet 1 Torque wrench 10 Nm 140 Nm 1 Ratchet head for torque wrench 1 2 1 Socket head cap 5 mm 8 mm 10 mm socket 1 2 bit L 20 mm 2 Hex head cap 13 mm 19 mm socket 1 2 bit L 20 mm 2 Picture Specific FlexTrack tools Qty xx1800001876 Rail Pressing Tool IRT501 66 66R 3HAW107700358 IRT501 90 90R 3HAW107700456 3 xx1800001877 Rack clamps 3HAW107700357 3 Continues on next page 64 Product manual Fle...

Page 65: ...embly of the IRT501 track Note Illustration Action Markup on a clean floor the FlexTrack axis 1 Markup also the position of each cross member with the following intervals IRT 501 66 90 1 050 mm steps IRT 501 66R 90R 525 mm steps Position the preassembled carriage track sec tion on the floor at the predetermined position 2 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 65 3HAW...

Page 66: ...this stage you can only check the horizontal alignment based on the sidemember upper sur face The final alignment will be given by the measurements done based on the linear guide ways position 5 Adjust the leveling screws until all leveling screws touch the ground 6 xx1800001884 Sidemember A Crossmember B Slightly tighten screws connecting the sidemem ber and the crossmember 7 Continues on next pa...

Page 67: ...scribed in Geometric alignment of FlexTrack IRT 501 on page 76 Tip All linear guideways are preassembled on track sections Note Use the rail pressing tool to make sure that the rails are pushed against the side member mount ing surface 10 xx1800001888 Unscrew one block from the carriage and use it to check the rails alignment if the rails are cor rectly aligned you should sense no step while passi...

Page 68: ...an the sidemember mounting before install the rack Check that the chamfer is located in front of the side member step check on preassembled sec tion if you are not sure 14 xx1800001890 Note Use the clamping and mounting racks at the ends of the rack section to make sure that the racks are pushed against the side member mounting surface and perfectly aligned with each other xx1800001891 When the al...

Page 69: ...not collide with any other fixed parts See section Release the brake on page 53 for in structions on how to release the motor brake 18 xx1800001894 Fix the small covers on top of the side members Fix the large cover s brackets on the opposite side members 19 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 69 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserv...

Page 70: ...ge brake and push the carriage manually along the length of its stroke Check that no covers come into contact with the moving carriage 21 70 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 5 1 Procedure of assembly Continued ...

Page 71: ... position see Update revolution counters on page 177 2 Drill the holes in the floor through the levelling screws opening see the following section 3 Install the anchors and secure the cross members to the floor 4 If the recommended anchors are not used you should check that the floor resistance and the selected anchors are compatible with the dynamic forces generated by the FlexTrack and the manip...

Page 72: ...ve the dust in the hole with a vacuum 6 cleaner xx1800001898 Brush the inside of the hole 7 Continues on next page 72 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Recommendations for floor mounting Continued ...

Page 73: ...ule is fluid 9 Insert the SPIT tool supplied with the anchor kit in a handheld electric punch drill s chuck 10 Insert the triangular extremity of the threaded rod in the SPIT tool Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 73 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Recommendations for floor mounting Co...

Page 74: ...C ambient 1 hour 20 C ambient 40 minutes 20 C ambient 12 xx1800001903 If necessary refine the adjustment of the track levelling using the M60 screws and then tighten the M16 notched nuts See Geometric alignment of FlexTrack IRT 501 on page 76 13 Continues on next page 74 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installa...

Page 75: ...tance that all screw joints be tightened with the correct torque Failure to do so may result in damage to the equipment or personal Product manual FlexTrack IRT501 66 66R 90 90R 75 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Recommendations for floor mounting Continued ...

Page 76: ...x1800001905 Absolute Tracker Reading must allow estimating 0 1 mm Example Leica AT960 Absolute Tracker xx1800001906 Reflector Example Leica Reflector xx1800001907 Magnetic block Example Leica Magnetic block ABB levelling tool 3HAW107700360 Continues on next page 76 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation a...

Page 77: ...highest points of the FlexTrack as reference It is easier to bring the crossmember to a higher level rather than to bring it to a lower level Use the ABB levelling tool 3HAW107700360 to adjust the levelling screws until all the measured points on both sides of the FlexTrack are at the same level The planarity tolerance is 0 1mm m in lateral and transverse 6 Once the alignment is correct tighten al...

Page 78: ...ge bracket and tighten its 4 pcs hexagon socket head cap M10x30 class 12 9 screws and narrow con tact lock washers M10 16 Tightening torque 77 Nm Use a brush to lubricate the linear guideways 10 78 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 5 3 Geometric alignment of FlexTrack IRT 501 Cont...

Page 79: ...ase contact ABB WARNING The robot should stand still while the carriage is moving in order to avoid any additional dynamic forces on the FlexTrack Robot position on the carriage 4 possibilities xx1800001911 xx1800001910 In line with the track 0 left or 180 right xx1800001913 xx1800001912 90 left or 270 right See Robot orientation on the track on page 101 on page 91 for details on how to link the r...

Page 80: ... from standard lengths based on the travel length of the carriage based on the total stroke of the carriage FlexTrack cables lengths The FlexTrack flexible and static cables power resolver are available in standard lengths of 5 m 10 m and 15 m lengths Robot cables If the FlexTrack is ordered prepared for a manipulator the cable chain should contain the suitable flexible movement cables Robot floor...

Page 81: ...ensors 3HAW050008611i 0 2 kg m 8 5 mm IRB2400 4400 6600 7600 movement resolver cable 3HEA802409i 0 2 kg m 7 8 mm IRB1410 1600 2600 4600 movement resolver cable 3HAC029834i 1 2 kg m 21 5 mm IRB1410 2400 movement power cable 3HAW050008617i 1 7 kg m 22 2 mm 22 2 mm IRB4400 movement power cable 3HAW050008622i 1 7 kg m 22 2 mm 22 2 mm IRB2600 4600 6600 7600 movement power cable 3HAW050008620i 0 7 kg m ...

Page 82: ...xx1800001915 Intrinsic chain weight t Pitch Bk Bi hG hi KR Bend ra dius Max total cables weight 2 85 kg m 90 5 mm 202 mm 175 mm 60 mm 44 mm 120 mm 10 kg m Between each cable a cable chain divider must be used every 8 links xx1800001916 aT aXmin ST hi 25 mm 25 mm 5 mm 44 mm Continues on next page 82 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB Al...

Page 83: ...e cables position xx1800001917 NZ BK Bi 14 mm 202 mm 175 mm Product manual FlexTrack IRT501 66 66R 90 90R 83 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 7 3 Specifications of the internal cable chain Continued ...

Page 84: ...ately at the end of the chain If necessary the edges of the cut tray area should be covered with rubber edge guard 1 xx1800001892 The cable tray should be absolutely free of any object cable screw etc The bottom of the cable tray must be perfectly flat without bump 2 xx1800001920 In the cable chain the cables should be separated by the separators at least every 8 links That the mass of the cables ...

Page 85: ...should be used to prevent the chain from running on the cables ex iting the cable chain If the cable chain appears to be rubbing the cables and no ramp is installed please order 1pc 3HAW107700646 and 1pc 3HAW107700647 from ABB 6 xx1800001925 Verify that there is be a clearance of approxim ately 2 mm between the rack covers and the pin ion see figure If not unscrew the cover screws and push the cov...

Page 86: ...chain is long enough to reach the ends of the stroke without damage At least 1 chain link should remain horizontal to avoid unne cessary pulling on the chain fixing element Verify again that the chain is parallel with the cable tray when unwind If not adjust the orientation of the fixed point of the chain as described in step5 9 86 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Re...

Page 87: ...B board robot option If there is no robot or if the robot is not equipped with a resolver socket for external axis on its base it is necessary to use an external SMB box xx1800001927 Note Check that there is enough space to install the SMB box at layout time Product manual FlexTrack IRT501 66 66R 90 90R 87 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and c...

Page 88: ... through an external SMB box the connections should be made as shown below Note Illustration Description xx1800001928 Connect the static resolver and power cables from the IRC5 to the SMB box xx1800001929 Connect the movement resolver and power cables from the car riage to the SMB Box For all signal sockets on the SMB box that are unused a PTC plug is required This plug bridges pin 7 and 8 Continu...

Page 89: ...cable B Ensure that the movement cables are properly connected to the mo tor Product manual FlexTrack IRT501 66 66R 90 90R 89 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 7 6 Cables connections Continued ...

Page 90: ...ots xx1800001931 XP 0 Mains connection A XS 1 Robot power connection B XS 7 Additional axes power connection C XS 58 Position switches D XS 8 Position switches E XS 13 XS 5 Customer power signals external connection F XS 10 Customer options G XS 11 Customer options H XS 12 Customer options J X3 Customer safety signals K XS 28 Network connection L XS 41 Additional axes SMB connection M XS 2 Robot S...

Page 91: ...power signals external connection F XS 10 Customer options G XS 11 Customer options H XS 12 Customer options J X3 Customer safety signals K XS 28 Network connection L XS 41 Additional axes SMB connection M XS 2 Robot SMB connection N Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 91 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and com...

Page 92: ...es B A5 X58 Position switches C A5 X5 Customer power signals external connection D A5 X 11 Customer options E A5 X 12 Customer options F A5 X 13 Customer options G A5 X 14 Customer options H A5 X3 Customer safety signals J A22 X1 FlexPendant connection K A5 X28 Network connection L Continues on next page 92 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 200420...

Page 93: ...ot power connection C A4 X7 External axes power connection D A4 XX Customer options E A4 XX Customer options F A4 XX Customer options G A4 XX Customer options H Communication cabling between Control Drive Module J Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 93 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 7 7 Con...

Page 94: ... XS41 Additional axes SMB connection L A4 XS2 Robot SMB connection M 94 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 7 7 Connectors on IRC5 controller Continued ...

Page 95: ...ibed in Lubrication on page 111 Lubrication system 3 If the FlexTrack is not equipped with an automatic lubrication sys tem you need to manually lubric ate the blocks and the rack see Racks and pinion on page 124 Manual lubrication 4 Like any other robot axis the Flex Track revolution counter must be updated using the FlexPendant see Update revolution counters on page 177 Revolution counter update...

Page 96: ...oad the files there are two methods load the MOC files onto a USB stick and load then directly on the IRC5 or use Robot Studio Online Below described only the USB method Note Illustration Action Make a System Backup before beginning 1 xx1800001936 Start the IRC5 and tap ABB 2 xx1800001937 From the ABB menu tap Control Panel 3 xx1800001938 Tap Configuration 4 Continues on next page 96 Product manua...

Page 97: ...se for the appropriate CFG files to add and tap OK Do not restart the controller yet 8 Repeat the steps for all CFG files that need to be loaded and then warm restart the controller 9 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 97 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 8 2 Load configuration files Continue...

Page 98: ...f the system enters System failure state it is necessary to perform a cold start This will restore the system to a default settings with no mechanical units or programs Then restore the original backup taken before loading the CFG files Then retry loading the CFG files 98 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Install...

Page 99: ... function of the mechanical gear ratio If you want the track to move in the negative add the sign before the transmission ratio 179 519 TRANSMISSION name TR2 transm_joint 179 519 Note There are different track transmission ratios depending on the type of track and the gear for each different model Product manual FlexTrack IRT501 66 66R 90 90R 99 3HAW050008590 001 Revision C Copyright 20042018 ABB ...

Page 100: ...o reach desired targets a long the length of the track by moving the robot on the track The declaration is in the MOC under the theme ROBOT in base_frame_coordinated In the example below we declare that the robot ROB1 is mounted on the Track TR1 ROBOT base_frame_coordinated TR1 100 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved...

Page 101: ..._frame_orient_u1 which corresponds to the quaternion Q2 base_frame_orient_u2 which corresponds to the quaternion Q3 base_frame_orient_u3 which corresponds to the quaternion Q4 Robot aligned with the Track xx1800001943 base_frame_orient_u0 1 base_frame_orient_u1 0 base_frame_orient_u2 0 base_frame_orient_u3 0 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 101 3HAW050008590 001...

Page 102: ...ot with a 180 rotation around Z on the Track xx1800001945 base_frame_orient_u0 0 base_frame_orient_u1 0 base_frame_orient_u2 0 base_frame_orient_u3 1 Continues on next page 102 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 8 5 Robot orientation on the track Continued ...

Page 103: ...0710678 base_frame_orient_u1 0 base_frame_orient_u2 0 base_frame_orient_u3 0 70710678 Product manual FlexTrack IRT501 66 66R 90 90R 103 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 8 5 Robot orientation on the track Continued ...

Page 104: ... Upper and Lower Limit of the track is the physical displacement distance from the zero position to the limit position in meters This depends on the length of the track and the location of the calibration pin Also referred to as the Zero position of the track The limits are in MOC CFG under the theme ARM The upper limit is called upper_joint_bound and the lower limit is called lower_joint_bound Bo...

Page 105: ...u tap Control Panel 1 xx1800001938 Tap Configuration 2 xx1800001949 Under Topics tap Motion 3 xx1800001950 Select Arm 4 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 105 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 8 6 Set Upper and Lower Limits Software Limits for track Continued ...

Page 106: ...below as an example The physical length of the track is 8 m The carriage is 0 8 m long The zero position of the track is in the middle of the track The MOC file would be as follows ARM upper_joint_bound 6 lower_joint_bound 1 xx1800001953 Continues on next page 106 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation an...

Page 107: ...e teach pendent Below is the process to identify the limits by experiment Note Illustration Action Before beginning ensure that the FlexTrack s re volution counter is calibrated 1 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 107 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 8 6 Set Upper and Lower Limits Software ...

Page 108: ...n as shown in the figure A minimum distance of 50 mm should be used between where the software limit is set and the actual mechanical stop In the jogging window read of the tracks current position Note that the distance is shown in milli meters and not meters In this example it is 9 950 1 mm Update the limit in the MOC file ARM upper_joint_bound 9 950 lower_joint_bound 1 4 xx1800001958 WARNING Thi...

Page 109: ... set correctly the mechanical unit may hit the mech anical hard stop Repeat the previous steps for the other limit 7 Offset parameters The offset parameters for the FlexTrack IRT 501 are manufacturer parameters and must not be modified on site Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 109 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installat...

Page 110: ...x1800001960 Use a Ø8 mm pin or the calibration tool to accurately setup the FlexTrack zero position then follow the instruction in Fine calibration on page 176 110 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 8 6 Set Upper and Lower Limits Software Limits for track Continued ...

Page 111: ...the cartridge Note Illustration Action xx1800001961 Introduce the battery and the cartridge LONGTIME PD 0 in the port The timer is activated once the battery is inserted See Memolub manual on page132 for instructions about MEMOLUB 1 xx1800001962 The grease is pushed in the piping by the pump a valve is sequencing the distribution to each port 2 Product manual FlexTrack IRT501 66 66R 90 90R 111 3HA...

Page 112: ...on regarding EPS see Product specification Controller IRC5 with FlexPendant and Application Manual Electronic Position Switches Document ID 3HAC027709 001 The wiring of the zone division is subject to the system layout Hence the design of the circuit is left to the system integrator Refer to the wiring diagram developed by the system integrator for details on how the zone division sensors are used...

Page 113: ...on Usually 1 position switch is used at the end of the track to detect if the track reaches the limit position 2 position and 4 position switch can be used when 2 particular positions and 4 particular positions are needed to be detected in the track stroke Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 113 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserve...

Page 114: ...are used on the same track setup the cam positions on rails in order to secure the working range Two types of cam would be used xx1800002103 114 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commissioning 2 10 Zone Division Continued ...

Page 115: ...turns off the motors immediately stopping all motion At the same time Error 20209 External Contactor Open is generated on the FlexPendant Note Illustration Action xx1800001970 Connect the signal cable from the limit switch to the IRC5 cabinets Contactor Board to A43 X24 This connection is described below The board is located as shown 1 xx1800001969 xx1800001971 Remove the terminal connector A43 X2...

Page 116: ...nd manually push the carriage away from the sensor Then update the revolution counters before attempting to run the track when necessary For more information please see Product manual IRC5 Option 2 Wiring the limit switch into the safety PLC Note This option should be used for more complex systems where a safety PLC is controlling the complete station and additional safety to guarantee that the ca...

Page 117: ...exTrack Independent FlexTrack with standalone controller Reference Regarding software and hardware options installation and commissioning safety etc please follow the instructions in Application manual Functional safety and SafeMove2 3HAC052610 001 Product manual FlexTrack IRT501 66 66R 90 90R 117 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 2 Installation and commission...

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Page 119: ...tivity e g required tools and materials The procedures are gathered in different sections divided according to the maintenance activity Safety information Before any service work is commenced it is extremely important that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describe danger and safety risks w...

Page 120: ... the sum of the standard toolkit and any tools listed in the instruction Contents standard toolkit Tool Qty Ring open end spanner 8 22 mm 1 Socket head cap 2 5 mm 4 mm 5 mm 6 mm 8 mm and 10 mm 1 Small flat tip screwdriver 1 Plastic mallet 1 Torque wrench 10 Nm 140 Nm 1 Ratchet head for torque wrench 1 2 1 Socket head cap 5 mm 8 mm 10 mm socket 1 2 bit L 20 mm 2 Hex head cap 13 mm 19 mm socket 1 2 ...

Page 121: ... of the FlexTrack IRT 501 66 66R 90 90R Calendar time specified in months regardless of whether the FlexTrack system is run or not Operating time specified in operating hours meters cycles More frequent running of the FlexTrack means more frequent maintenance activities Product manual FlexTrack IRT501 66 66R 90 90R 121 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 3 Maint...

Page 122: ...ight of the internal cables and tubes 3 the actual travel length 4 the speed and acceler ation will have a great impact on the actual life 10 000 000 m Cable chain The expected life is given for the ball bear ings of a six meter longstroke FlexTrack 12 meters per cycle operating 1 000 maximum load cycles a day 1 000 000 cycles Ball bearing blocks Over 10 years Gear and pinion 122 Product manual Fl...

Page 123: ...cation system on page 130 1 month Automatic lubrica tion system Inspect and re fill if neces sary If automatic lubrication See Emergency stop and stroke limit system on page 135 1 month Emergency stop and stroke limit sys tem Inspection See Zone division system on page 136 1 month Zone division sys tem Inspection See Cables and connectors on page 138 1 month Cables connectors and electrical cabin ...

Page 124: ...uipped with an automatic lubrication system it is necessary to lubricate the racks and the pinion manually every 100 km or every week Location The figure below shows the location of the gear racks and pinion xx1800001972 Pinion A Rack B Continues on next page 124 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 3 Maintenance 3 4 ...

Page 125: ... lubrication system Note Use lint free cloth Note Illustration Action Remove the FlexTrack upper covers and rack covers 1 Inspect the racks and the pinion clean them if necessary 2 If you have cleaned them use a brush to lubricate the racks and the pinion 3 Move the carriage back and forth and repeat step3 4 Re attach the covers 5 xx1800001973 Every week or 100 km if the FlexTrack is not equipped ...

Page 126: ...A Required equipment When you clean the linear guideways it is necessary to lubricate them manually Use one of the recommended lubricants Note Equipment CASTROL Longtime PD0 Lubricant KLÜBER Microlube GB0 Lubricant TOTAL Multis EP 0 Lubricant Lint free cloth Continues on next page 126 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reser...

Page 127: ...rack upper covers and rack covers 1 Inspect the linear guideways clean them if neces sary 2 If you have cleaned them use a brush to lubricate the linear guideways 3 Move the carriage back and forth and repeat step 3 4 Re attach the covers 5 Product manual FlexTrack IRT501 66 66R 90 90R 127 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 3 Maintenance 3 5 1 Linear guideways ...

Page 128: ...Grease manifold B Required equipment Use one of the recommended lubricants Note Equipment CASTROL Longtime PD0 Lubricant KLÜBER Microlube GB0 Lubricant TOTAL Multis EP 0 Lubricant Lint free cloth Lubricate the ball bearing blocks The procedure below details how to lubricate the ball bearing blocks Note Use lint free cloth Continues on next page 128 Product manual FlexTrack IRT501 66 66R 90 90R 3HA...

Page 129: ...the ball bearing block when you see the grease pouring out you have applied enough grease In average one should inject 1 gram of lubricant per block and per month 2 Repeat the step1 and step2 for each block port on the manifold 3 Product manual FlexTrack IRT501 66 66R 90 90R 129 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 3 Maintenance 3 5 2 Ball bearing blocks Continue...

Page 130: ...valve is sequencing the distribution to each port The level of the lubricant should be checked once a month even though the system should apply the lubricant equally over a longer period Location The figure below shows the location of the lubrication system xx1800001977 Grease cartridge A Control unit grease pump B Oil dispatcher C Continues on next page 130 Product manual FlexTrack IRT501 66 66R ...

Page 131: ...nt TOTAL Multis EP 0 Lubricant WARNING Battery packs should be changed every time the lubricant cartridge is replaced to assure proper voltage to the system and each battery pack should only be used once only A new battery pack should be supplied with each replacement cartridge purchased Checking grease level and inspect the pipes The procedure below details how to check the grease level and inspe...

Page 132: ... block and on the pinion 3 Memolub manual The procedure below is based on the Memolub HPS user manual It details how to replace the grease cartridge Opening and closing the Memolub Note Action xx1800001980 Opening the Memolub First place the Memolub on a flat and clean sur face Push firmly with one hand on top of the Memolub With the other hand hold the black base and turn counterclockwise Pull th...

Page 133: ...t Two strokes of the manual pump are usually enough 2 xx1800001983 Pull up the black strap to reveal the battery case Insert a new Memolub battery hold it by the black plastic strap insert it in the Memolub respecting the instructions on the label If the battery is cor rectly inserted the motor is activated during 1 sec to check that the motor is working properly Put the black rubber seal back in ...

Page 134: ...olub as described before 8 Test the Memolub Check Function Note Action xx1800001988 To check that the Memolub is working well after a maintenance operation press one of the 3 con nectors located on the base during a few seconds The Memolub is starting a dispensing cycle The completion of the cycle means that the battery control board of the Memolub are working well It is important that you run thi...

Page 135: ...dations in the con trol system to switch back to auto mode 6 Verification of the effectiveness of the stroke limit system A software limit prevents the carriage from moving beyond its acceptable upper and lower stroke limits The procedure below details how to ensure the software stroke limit is working correctly Note Illustration Action Switch the IRC5 to manual mode 1 With the teach pendant try t...

Page 136: ...the effectiveness of the zone division sensor If a 1 position 2 position or 4 position limit switch is used to divide the track into zones then the following procedure should be followed to ensure it is functioning correctly Note Illustration Action Power off the IRC5 and activate the E Stop 1 Activate the limit switch sensor using an adhesive tape 2 Reset the E Stop button and power on the 3 IRC5...

Page 137: ...witch is triggered 4 For example if the limit switch is wired to a lamp then the lamp should be illuminated Power off the IRC5 and activate the E Stop 5 Remove the adhesive tape and reset the E Stop button and power on the IRC5 Product manual FlexTrack IRT501 66 66R 90 90R 137 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 3 Maintenance 3 5 5 Zone division system Continued...

Page 138: ...n against sharp edges Check the connector Check monthly All the connectors on the controller the SMB box and the motor are firmly tighten and that there s no damage to the cable outlet Inspection of the cable chain Once a month check that the cable track shows no trace of excessive wear due to rub on a fixed part If one element is damaged it is possible to replace it without removing the whole cha...

Page 139: ...ed for the gear s lifetime However if you need to refill the gear with oil for any reason you must use one of the recommended oil below ISO VG 220 Reference Supplier SHC 630 MOBIL Omala HD 220 SHELL Carter SH 220 TOTAL Note The oil in the gear does not need to be changed during life of the gear Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 139 3HAW050008590 001 Revision C Co...

Page 140: ...htening torque Every year make sure that the tightening torque of the hexagon socket head cap M6x25 class 12 9 screws that secure the gear to the bracket is 16 5 Nm Note Illustration Action Separate the carriage bracket holding the gearbox and motor from the carriage and move the car riage away For the procedure about how to move the carriage away see Disassemble the bracket from the carriage on p...

Page 141: ...8 001 and a Battery pack RMU Ref 3HAC044075 001 The battery should be replaced every three years or when the battery is going flat This is generally shown by an error code on the FlexPendant screen 38213 Information about error codes can be found in the FlexPendant documentation Note In a new system the batteries are charged to full capacity after a few hours in STANDBY mode xx1800001993 Continues...

Page 142: ... the SMB box 2 Open the SMB box and locate the battery 3 Cut the plastic straps 4 Unplug the 2 wires cable from the board and re move the battery pack 5 Place the new battery pack plug the connector on the board and secure the pack with straps 6 Close the SMB box switch on the power 7 Update the revolution counters of the axis 8 142 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 R...

Page 143: ...formation Before any service work is commenced it is extremely important that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describe danger and safety risks when performing the procedures Read Safety on page 15 before performing any service work Product manual FlexTrack IRT501 66 66R 90 90R 143 3HAW050...

Page 144: ...orrect part number The figure below shows the location of the linear guideways xx1800001995 Linear guideways A Linear guideway of different supplier Linear guideway of ABB FlexTrack has two suppliers Rexroth and INA are not compatible with each other The figure below shows the differences of two different suppliers xx1800001996 Continues on next page 144 Product manual FlexTrack IRT501 66 66R 90 9...

Page 145: ...eways Loctite 243 When you install new linear guideways it is necessary to lubricate them manually Use one of the recommended lubricants Note Equipment CASTROL Longtime PD0 Lubricant KLÜBER Microlube GB0 Lubricant TOTAL Multis EP 0 Lubricant Lint free cloth Disassemble Follow the directions below to disassemble the linear guideway Note Action As the linear guideway screws should have been tightene...

Page 146: ... do then push the rail against the sidemember step using the rail pressing tool and check that there s no clearance between the rails When the alignment is correct tighten the screws one by one after applying Loctite 243 on its thread Tightening torque 132 Nm 2 xx1800002000 If necessary re assemble the block in the carriage bracket and tighten its 4 pcs screws Tightening torque 77 Nm WARNING If yo...

Page 147: ...n Action Re assemble the FlexTrack covers 5 Product manual FlexTrack IRT501 66 66R 90 90R 147 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 4 Repair 4 2 Replace the linear guideways Continued ...

Page 148: ...p supports rubber hard stop E End cover F Required equipment Note Equipment The content is defined in Standard toolkit Standard toolkit Lubrication gun Jack 2t Use one of the recommended lubricants Note Equipment CASTROL Longtime PD0 Lubricant KLÜBER Microlube GB0 Lubricant TOTAL Multis EP 0 Lubricant Lint free cloth Continues on next page 148 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW0500...

Page 149: ...hree ball bearing blocks Remove the 4 pcs hexagon head bolt M10X30 class 12 9 screws and 4 pcs M10 16 narrow con tact lock washers 4 xx1800002024 Let the block slide out of the bracket and linear guideway 5 Assemble Note Illustration Action xx1800002025 Remove the standard screws delivered with the blocks and replace them with the grease pipe fit tings taken from the previous blocks The fittings m...

Page 150: ...ing the operation watch the seals at the ball bearing block when you see the grease pouring out you have applied enough grease 3 Let the bearings block slide into the bracket and tighten the 4 pcs hexagon head bolt M10X30 class 12 9 screws s and 4 pcs M10 16 narrow contact lock washers 4 Tightening torque 77 Nm Remove the jack 5 Re connect the lubrication pipe 6 Re assemble the mechanical stop and...

Page 151: ...essary to assemble the FlexTrack Rack clamps 3HAW107700357 See Procedure of assembly on page 64 The mounting rack is part of the kit of tools necessary to assemble the FlexTrack Mounting rack 3HAWL000011 See Procedure of assembly on page 64 Apply Loctite 243 on the screws that hold the racks Loctite 243 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 151 3HAW050008590 001 Revi...

Page 152: ...s the rack screws should have been tightened with Loctite 243 you may have to apply high force on the wrench Remove all necessary FlexTrack covers and dis assemble all hexagon head bolt M8x55 screws class 12 9 with contact lock washers M8 18 and plain washers 8x25x3 that hold the rack to the sidemember 1 xx1800002029 Remove the rack 2 Continues on next page 152 Product manual FlexTrack IRT501 66 6...

Page 153: ...face and perfectly aligned with each other Use standard tools slightly tighten 1 xx1800002031 When you are confident that the alignment is correct tighten the screws one by one after ap plying Loctite 243 on their thread 2 Tightening torque 40 Nm xx1800002032 Once you have tightened a screw mark it with a white marker 3 Use a brush to lubricate the racks 4 Re assemble the FlexTrack covers 5 Produc...

Page 154: ...tooling robot on top It is recommended to have 2 technicians to work together Location The figure below shows the location of the motor and the gear xx1800002033 Bracket A Gear B Motor C 154 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 4 Repair 4 5 1 Overview ...

Page 155: ...ains stationery B Motor remains stationery C Gear remains stationery D Pinion remains stationery E Cable chain remains stationery F Required equipment Note Equipment The content is defined in Standard toolkit on page 120 Standard toolkit The tightening torque of the hexagon socket head cap M6x25 class 12 9 screws that se cure the gear to the bracket is 16 5 Nm Torque wrench There are also specific...

Page 156: ...et in order to unload it 1 WARNING Turn off all electric power hydraul ic and pneumatic pressure supplies to the robot and for the FlexTrack IRT 501 xx1800002036 Loosen the 4 pcs M12x55 class 12 9 screws Use a ratchet wrench 2 xx1800002037 Extraction of the dowel Place the spacer on the dowel pin insert the longest screw with the thick washer and screw it to start extracting the dowel Use shorter ...

Page 157: ...cated near the pinion Loosen all the flanges circled in red on the pic ture to release the tubes from the bracket the tubes will be pushed away along with the car riage 6 xx1800002040 If present disconnect the cables from the tooling or robot mounted on the carriage Remove the upper part of the cable tray so that the connectors can pass through 7 Continues on next page Product manual FlexTrack IRT...

Page 158: ...t guide them through the cable tray while you push the carriage away 8 xx1800002042 Carriage A Motor bracket B Cable tray C xx1800002043 Motor A Gear B Pinion C Motor bracket D Remove the covers The drive unit is now access ible 9 158 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 4 Repair 4 5 2 Disassemble the bracket from the...

Page 159: ...it and separ ate the motor from the gear 2 Replace the motor 3 For instructions about how to reassemble the motor to the gear and issues that need attention see Motor and gear assembly on page 163 Use hexagon socket head cap M12x55 class 12 9 screws and contact lock washers M12 24 tightened at 132 Nm to secure the bracket Re assemble the bracket with the carriage Tightening torque 132 Nm Re connec...

Page 160: ...e section of rack with which the gear pinion is meshing 1 xx1800002047 Push the bracket and gear out of the rack section 2 CAUTION The complete gear weighs about 30 kg All lifting equipment used must be sized accordingly Remove the hexagon socket head cap M6x25 class 12 9 screws that secure the gear to the bracket and remove the gear 3 Replace the gear and tighten the hexagon socket head cap M6x25...

Page 161: ...ed again its mounting surface using on both of its ends the mounting rack section 3HAWL000011 xx1800002049 Re assemble the rack with the sidemember Tightening torque 40 Nm 6 and the clamps 3HAW107700357 xx1800002050 Follow the instructions see Motor and gear as sembly on page 163 7 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 161 3HAW050008590 001 Revision C Copyright 20042...

Page 162: ...ith the carriage Tightening torque 132 Nm Re connect the lubrication pipe to the block and secure it to the bracket with the flanges 8 See Fine calibration on page 176 Turn the power on and perform a fine calibration 9 162 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 4 Repair 4 5 4 Replace gear Continued ...

Page 163: ...e Slots of both parts must be in line for a maximum tightening force xx1800002051 The tightening screw of slotted coupling SW1 8 mm must be tightened to TA1 69 Nm The plug SW2 10 mm must be tightened to TA2 50 Nm SW width across flats See motor mounting instructions below for details Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 163 3HAW050008590 001 Revision C Copyright 200...

Page 164: ...r a maximum tightening force xx1800002053 The tightening screw of slotted coupling SW1 6 mm must be tightened to TA1 35 Nm The plug SW2 10 mm must be tightened to TA2 50 Nm SW width across flats See motor mounting instructions below for details Continues on next page 164 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 4 Repair 4...

Page 165: ... assembly manual Action Note Illustration xx1800002054 1 xx1800002055 2 xx1800002056 3 Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 165 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 4 Repair 4 5 5 Motor and gear assembly Continued ...

Page 166: ...002057 4 xx1800002058 5 xx1800002059 6 Continues on next page 166 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 4 Repair 4 5 5 Motor and gear assembly Continued ...

Page 167: ...Illustration xx1800002060 7 xx1800002061 8 Product manual FlexTrack IRT501 66 66R 90 90R 167 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 4 Repair 4 5 5 Motor and gear assembly Continued ...

Page 168: ...chain of ABB FlexTrack has two suppliers Kabelschlepp and IGUS are not compatible with each other The following table shows you the difference between two different suppliers Illustration Item xx1800002063 Cable chain link unit xx1800002064 Continues on next page 168 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 4 Repair 4 6 R...

Page 169: ...Required equipment Note Equipment The content is defined in section 3 2 stand ard toolkit Standard toolkit Cables Cable chain parts Continues on next page Product manual FlexTrack IRT501 66 66R 90 90R 169 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 4 Repair 4 6 Replace the cable chain or the cable Continued ...

Page 170: ...wo covers in the same zone to access both fixed moving points of the cable chain 1 xx1800002071 Remove two covers 2 xx1800002072 Remove screws at fixed point pull out cable chain help the cables through the carriage open ing 3 xx1800002073 Tip To facilitate assembly take a picture of the placement in the cable chain before removing cables 4 xx1800002074 Remove screws at fixed point pull the comple...

Page 171: ...ote Illustration Action xx1800002070 Move the track carriage in order to have it posi tioned just above the fixed point of the cable chain Doing so you just have to remove two covers in the same zone to access both fixed moving points of the cable chain 1 xx1800002071 Remove two covers 2 xx1800002072 Remove screws at fixed point pull out cable chain help the cables through the carriage open ing 3 ...

Page 172: ...ll facilitate reassembly 6 xx1800002073 Tip To facilitate assembly take a picture of the placement in the cable chain before removing damage cables 7 xx1800002076 Tiewrap plate of the fix end cable chain A End unit of the move end cable chain B Ties fixing cables C Cut off the ties that fix the cables to the tiewrap plate and cable chain end unit at the fix end and moving end of the cable chain 8 ...

Page 173: ... plate of the fix end cable chain A End unit of the move end cable chain B Ties fixing cables C Fix the cable on the tiewrap plate and the cable chain end unit with ties 13 xx1800001922 Reinstall the new cable chain and ensure the correct installation as described in Installation of the cable chain on page 84 14 Product manual FlexTrack IRT501 66 66R 90 90R 173 3HAW050008590 001 Revision C Copyrig...

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Page 175: ...refully with standard calibration The resolver values will change when parts affecting the calibration position are replaced on the FlexTrack IRT 501 e g motor or part of transmission This is detailed in Fine calibration on page 176 Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost the counters must be updated as detailed in Update revolut...

Page 176: ...rack until the calibration holes line up 2 xx1800001960 Insert the calibration pin 3HAW107700354 A dowel pin diameter 8 mm can also be used 3 Tap ABB on the top left of the FlexPendant 4 Tap Calibration 5 Select the desired mechanical unit 6 Tap Fine calibration 7 Select the desired axis 8 Tap Calibrate 9 176 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 2004...

Page 177: ...alibration marker with the line of the fixed part calibration marker 1 Tap ABB on the top left of the FlexPendant 2 Tap Calibration 3 Select the desired mechanical unit 4 Tap Update revolution counters 5 Select the desired axis 6 Tap Update 7 Product manual FlexTrack IRT501 66 66R 90 90R 177 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 5 Calibration 5 3 Update revolution...

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Page 179: ...y in which the robot and the control unit are installed If the robot or the control unit is partially or completely disposed of the various parts must be grouped together according to their nature that is all iron together and all plastic together and disposed of accordingly These parts must also be disposed of in accordance with the current legislation of the country in which the robot and contro...

Page 180: ...ent health or environmental hazards Example application Material Serial measurement board Batteries NiCad or Lithium Cables motors Copper Crossmembers linear carriage brackets Cast iron nodular iron Covers sidemembers carriage top plate screws Steel Brakes motors Neodymium Cables connectors hard stop bumper Plastic rubber PVC Lubrication system gearbox Oil grease Motor and gearbox housing Aluminiu...

Page 181: ...must be carried out under controlled conditions in accordance with local regulations Also note that Spills can form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination Product manual FlexTrack IRT501 66 66R 90 90R 181 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 6 D...

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Page 183: ...s general information complementing the more specific information in the different procedures in the manual Product manual FlexTrack IRT501 66 66R 90 90R 183 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 184: ... machinery safety related parts of the control system EN ISO 13849 1 2006 Generic standards Emission standard for industrial environments EN 61000 6 4 2007 EMC Part 6 4 Class A Radiated emission enclosure EN 55011 Class A Conducted emission AC Mains EN 55011 Generic standards Immunity for industrial environ ments EN 61000 6 2 2005 EMC Part 6 2 Electrostatic discharge immunity test EN 61000 4 2 Rad...

Page 185: ...8 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume Product manual FlexTrack IRT501 66 66R 90 90R 185 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

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Page 187: ...IRT501 66 3HAWC116589 1 B Gear pinion for IRT501 66R 90 3HAWC116590 Gear pinion for IRT501 90R 3HAWC116596 Ball bearing block Rexroth 3HAWL000021 4 C Ball bearing block INA 3HAWC116594 D6 M6 lubrication elbow fitting 3HAWL000049 4 D Product manual FlexTrack IRT501 66 66R 90 90R 187 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 8 Spare parts 8 1 Carriage IRT501 ...

Page 188: ...7700342 735 Upper cover for FlexTrack IRT 501 66 66R 3HAW107700343 D Upper cover for FlexTrack IRT 501 90 90R 3HAW107700431 Bracket for cover for FlexTrack IRT 501 66 66R 3HAW107700337 E Bracket for cover for FlexTrack IRT 501 90 90R 3HAW107700430 Cable chain guide L 1 050 mm 3HAW107700359 F Levelling screw M60 x 2 3HAW108201422 G Slotted round nut KM 12 3HAWC100857 H Note For how to identify cabl...

Page 189: ... B Limit switch cam tray L 1 200 mm 3HAW107700657 Cam on both ends of the FlexTrack 3HAWC116600 2 min C Hard stop bumper a pair on both ends of the FlexTrack 3HAWC106195 4 D Calibration gauge fixed on FlexTrack 3HAW107700344 1 E Calibration gauge mobile on carriage 3HAW107700540 Product manual FlexTrack IRT501 66 66R 90 90R 189 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserve...

Page 190: ...atic grease dispenser 3HAWC114278 1 C Set of washers for automatic oil dispenser output volume setting 3HAWL000050 1 D Tube D8x6 from dispenser to splitter only 3HAWC116980 0 2 m E Grease splitter 6 outputs 3HAWC116979 1 F Tube D6x4 3HAWL000032 25 m G 5 m are required in one carriage 190 Product manual FlexTrack IRT501 66 66R 90 90R 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights re...

Page 191: ...s 15 pcs A Cable chain link unit IGUS 3HAWL000051 Cable chain link unit Kabelschlepp 3HAWL000018 1 m chain requires 28 pcs B Cable chain link unit IGUS 3HAWL000053 Cable chain end units 1 mobile 1 fixed Ka belschlepp 3HAWL000019 1 C Tiewrap plate 1 per cable chain Kabelschlepp 3HAWL000020 1 D Cable chain end units 1 mobile 1 fixed Tiewrap plate 1 per cable chain IGUS 3HAWL000052 1 C D Note For how...

Page 192: ...IGUS 3HAWL000053 External cable chain end units 3HAWL000043 1 mobile 1 fixed C Kabelschlepp External cable chain end tiewrap plate 3HAWL000041 1plate per cable chain D Kabelschlepp Cable chain end units 1 mobile 1 fixed Tiewrap plate 1 per cable chain IGUS 3HAW107710234 1 mobile 1 fixed C D External cable chain bow orange 3HAW107700442 1 m chain requires 1 pcs E External cable chain bow graphite w...

Page 193: ...m chain requires 1 pcs G Note For how to identify cable chain from different supplier see Cable chain of different supplier on page 168 Product manual FlexTrack IRT501 66 66R 90 90R 193 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 8 Spare parts 8 5 Cable chains Continued ...

Page 194: ...on ABB part reference no SMB box 1 axis M2008 3HAW050008604 SMB box 3 axis M2008 3HAW050008605 SMB box 6 axis M2011 3HAW050008651 SMB Main board DSQC633 3HAC031851 001 Phased out Order instead the set 3HAC046686 001 board RMU101 battery pack RMU Battery pack for SMB board DSQC633 3HAC16831 1 For SMB boxes manufactured before 2015 only SMB Main board RMU101 3HAC044168 001 Battery pack for SMB board...

Page 195: ...ck controlled without external SMB box 3HAW050008635 005 1 Motor Static XP7 M2008 10 m for FlexTrack controlled without external SMB box 3HAW050008635 010 1 Motor Static XP7 M2008 15 m for FlexTrack controlled without external SMB box 3HAW050008635 015 6 axis motor static cable 5 m 3HAW050008612 005 Static cable resolver 6 axis motor static cable 10 m 3HAW050008612 010 6 axis motor static cable 15...

Page 196: ...on 5 m 3HAW050008610 005 Limit switch cable Limit switch cable 1 position 10 m 3HAW050008610 010 Limit switch cable 1 position 15 m 3HAW050008610 015 Limit switch cable 2 position 5 m 3HAW050008654 005 Limit switch cable 2 position 10 m 3HAW050008654 010 Limit switch cable 2 position 15 m 3HAW050008654 015 Limit switch cable 4 position 5 m 3HAW050008611 005 Limit switch cable 4 position 10 m 3HAW0...

Page 197: ... 3HAWC116985 Laser reflector bracket 3HAW107700584 Laser scanner 3HAW107710201 Laser bracket 1 2 3HAW107700582 Laser bracket 2 2 3HAW107700583 Product manual FlexTrack IRT501 66 66R 90 90R 197 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved 8 Spare parts 8 7 Anti collision ...

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Page 199: ... extension M2008 3HAW050008635 1 Motor Static XP7 M2008 No SMB box 3HAW050008636 1 Resolver Static M2008 No SMB box 3HAW050008628 Extension welding power cable 3HAW050008631 1 Motor power flex cable Electrical Spot Gun from SMB MP SMB MR to R1 SP 3HAW050008608 1 axis motor movement cable 3HAW050008609 1 axis resolver movement cable 3HAW050008610 Limit switch cable 1 position 3HAW050008654 Limit sw...

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Page 201: ... disposal 180 N neodymium disposal 180 NiCad disposal 180 nodular iron disposal 180 O oil disposal 180 P plastic disposal 180 R replacing xx 180 rubber disposal 180 S steel disposal 180 X xx replacing 180 Product manual FlexTrack IRT501 66 66R 90 90R 201 3HAW050008590 001 Revision C Copyright 20042018 ABB All rights reserved Index ...

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Page 204: ...elephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAW050008590 001 Rev C en Copyright 20042018 ABB All rights reserved Specifications subject to change without notice ...