ABB FlexTrack IRT501 Series User manual

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

Trace back information:
Workspace Systems version a6
Checked in 2019-01-15
Skribenta version 5.3.012

Product manual
FlexTrack IRT501-66/66R/90/90R
Document ID: 3HAW050008590-001
Revision: C
© Copyright 20042018 ABB. All rights reserved.
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.
© Copyright 20042018 ABB. All rights reserved.
Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
9Overview ...........................................................................................................................................
12Product documentation, M2004 .......................................................................................................
14How to read the product manual ......................................................................................................
151 Safety
151.1 Introduction ...................................................................................................... 161.2 General safety information .................................................................................. 161.2.1 Safety in the robot system ........................................................................ 171.3 Safety risks ...................................................................................................... 171.3.1 Safety risks during installation and service work on robot ............................... 191.3.2 Safety risks related to tools/workpieces ....................................................... 201.3.3 Safety risks related to pneumatic/hydraulic systems ...................................... 211.3.4 Safety risks during operational disturbances ................................................ 221.3.5 Risks associated with live electric parts ....................................................... 231.4 Safety actions ................................................................................................... 231.4.1 Safety fence dimensions ........................................................................... 241.4.2 Fire extinguishing .................................................................................... 251.4.3 Emergency release of the robots/manipulators axes ...................................... 261.4.4 Brake testing .......................................................................................... 271.4.5 Risk of disabling function "Reduced speed 250 mm/s" ................................... 281.4.6 Safe use of the Teach Pendant Unit ............................................................ 291.4.7 Work inside the manipulator's working range ................................................ 301.4.8 Translate the information on safety and information labels .............................. 311.5 Safety related instructions .................................................................................. 311.5.1 Safety signals, general ............................................................................. 331.5.2 DANGER - Moving manipulators are potentially lethal! ................................... 341.5.3 DANGER - First test run may cause injury or damage! ................................... 351.5.4 WARNING - The unit is sensitive to ESD! ..................................................... 361.5.5 WARNING - Safety risks during work with gearbox oil .................................... 371.5.6 Location of safety pictograms ....................................................................
392 Installation and commissioning
392.1 Introduction ...................................................................................................... 412.2 Unpacking and acceptance ................................................................................. 412.2.1 Unpacking ............................................................................................. 422.2.2 Acceptance inspection ............................................................................. 432.3 Handling .......................................................................................................... 432.3.1 Lifting FlexTrack IRT 501 .......................................................................... 482.3.2 Lifting weight .......................................................................................... 492.3.3 FlexTrack IRT 501 size and dimensions ....................................................... 532.3.4 Moving the carriage manually .................................................................... 562.4 Preparations for assembly .................................................................................. 562.4.1 Foundation ............................................................................................ 602.4.2 Recommendation for anchors .................................................................... 632.4.3 Screw joints ........................................................................................... 642.5 Assembly of the track ........................................................................................ 642.5.1 Procedure of assembly ............................................................................. 712.5.2 Recommendations for floor mounting ......................................................... 762.5.3 Geometric alignment of FlexTrack IRT 501 ................................................... 792.6 Assembly of the manipulator ............................................................................... 802.7 Cables, SMB box and cable chain ........................................................................ 802.7.1 Cabling of the FlexTrack ........................................................................... 812.7.2 Specifications of the movement cables ........................................................ 822.7.3 Specifications of the internal cable chain ..................................................... 842.7.4 Installation of the cable chain .................................................................... 872.7.5 SMB box ................................................................................................
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882.7.6 Cables connections ................................................................................. 902.7.7 Connectors on IRC5 controller ................................................................... 952.8 Software installation .......................................................................................... 952.8.1 Preparation for setup ............................................................................... 962.8.2 Load configuration files ............................................................................ 992.8.3 Modification of the Travel Direction of the track ............................................. 1002.8.4 Link robot and track ................................................................................. 1012.8.5 Robot orientation on the track .................................................................... 1042.8.6 Set Upper and Lower Limits Software Limits for track ..................................... 1112.9 Lubrication ....................................................................................................... 1122.10 Zone Division ................................................................................................... 1152.11 Setting up the FlexTrack limit switch for additional safety ......................................... 1172.12 Additional Function Support ................................................................................
1193 Maintenance
1193.1 Introduction ...................................................................................................... 1203.2 Standard toolkit ................................................................................................ 1213.3 Maintenance schedule and expected component life ............................................... 1213.3.1 Specification of maintenance intervals ........................................................ 1223.3.2 Expected component life .......................................................................... 1233.3.3 Maintenance schedule ............................................................................. 1243.4 Activities 100 Km or one week ............................................................................. 1243.4.1 Racks and pinion .................................................................................... 1263.5 Activities 1 Month .............................................................................................. 1263.5.1 Linear guideways .................................................................................... 1283.5.2 Ball bearing blocks .................................................................................. 1303.5.3 Automatic lubrication system ..................................................................... 1353.5.4 Emergency stop and stroke limit system ...................................................... 1363.5.5 Zone division system ............................................................................... 1383.5.6 Cables and connectors ............................................................................. 1393.6 Activity 3 and 12 months ..................................................................................... 1393.6.1 Gear ..................................................................................................... 1413.7 Activities 36 Months ........................................................................................... 1413.7.1 Replacement, SMB Battery pack ................................................................
1434 Repair
1434.1 Instruction ....................................................................................................... 1444.2 Replace the linear guideways .............................................................................. 1484.3 Replace the ball bearing blocks ........................................................................... 1514.4 Replace the racks .............................................................................................. 1544.5 Motor and gear ................................................................................................. 1544.5.1 Overview ............................................................................................... 1554.5.2 Disassemble the bracket from the carriage ................................................... 1594.5.3 Replace motor ........................................................................................ 1604.5.4 Replace gear .......................................................................................... 1634.5.5 Motor and gear assembly ......................................................................... 1684.6 Replace the cable chain or the cable .....................................................................
1755 Calibration
1755.1 Overview ......................................................................................................... 1765.2 Fine calibration ................................................................................................. 1775.3 Update revolution counters .................................................................................
1796 Decommissioning
1796.1 Introduction ...................................................................................................... 1806.2 Environmental information ..................................................................................
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1837 Reference information
1837.1 Introduction ...................................................................................................... 1847.2 Applicable safety standards ................................................................................ 1857.3 Unit conversion .................................................................................................
1878 Spare parts
1878.1 Carriage IRT501 ................................................................................................ 1888.2 Track .............................................................................................................. 1898.3 Limit switch and calibration ................................................................................. 1908.4 Automatic lubrication system ............................................................................... 1918.5 Cable chains .................................................................................................... 1948.6 Electrical spare parts and cables .......................................................................... 1978.7 Anti collision ....................................................................................................
1999 Appendix
1999.1 Wiring diagrams ................................................................................................
201Index
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Overview
About this manual
This manual contains instructions for:
• mechanical and electrical installation instructions for the FlexTrack
• maintenance instructions for the FlexTrack
• spare parts
Usage
This manual should be used when working during;
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel
Prerequisites
A maintenance/repair/installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
ContentsChapter
Safety information that must be read through before performing
any installation or service work on the FlexTrack. Contains gen-
eral safety aspects as well as more specific information about
how to avoid personal injuries and damage to the product.
Safety
Required information about lifting and installation of the Flex-
Track.
Installation and commis-
sioning
Step-by-step procedures that describe how to perform mainten-
ance of the FlexTrack. Based on a maintenance schedule that
may be used in the work of planning periodical maintenance.
Maintenance
Procedures that does not require specific calibration equipment.Calibration information
References
Document IDDocument name
3HAW050008591Product specification - IRT 501 - 66/66R/90/90R
3HAC021313-001Product manual - IRC5 Robot Controller
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Overview

Document IDDocument name
3HAC16590-1Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC025709-001Service Information System - IRC5
3HAC021395-001Application manual - Additional axes and stand alone controller
3HAC17076-1System Parameters
3HAC052610-001Application manual - Functional safety and SafeMove
Revisions
DescriptionRevision
First edition.-
Changes made in:
• Clarity improved and pictures added in Disassemble the bracket
from the carriage on page 155. Instructions for the coupling of the
motor and the gearbox updated, see Motor and gear assembly
on page 163.
• Names of spare cables updated, see Electrical spare parts and
cables on page 194.
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 of the tightening torque in Verification
of the tightening torque on page 140
• Procedures about how to change a cable in the cable chain is
added inReplace cables on page 171
• Spare parts updated in Spare parts on page 187
• Electrical diagrams added in Appendix on page 199
B
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Overview
Continued

DescriptionRevision
Changes made in:
• Expected life of ball bearing blocks updated in Expected life on
page 122
• Different suppliers of linear guideways added inLinear guideway
of different supplier on page 144 and different suppliers of cable
chain added in Cable chain of different supplier on page 168
• Spare parts updated in Spare parts on page 187
• Robot capacities about IRB 6650/6650s/6660 removed in Robot
capabilities on page 57
• Adjustment of the FlexTrack using a laser tracker updated 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 removed
the table in Geometric alignment of FlexTrack IRT 501 on page 76
• Replace the paint related reference manual to SafeMove2 in Ref-
erence on page 117.
C
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Overview
Continued

Product documentation, M2004
Categories for manipulator documentation
The manipulator documentation 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 M2004 manipulator systems.
Product manuals
All hardware, manipulators and controllers will be delivered with a Product manual
that contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation,
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals).
• Repair (descriptions 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 and syntax for
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
workflows.
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, CD with PC software).
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Product documentation, M2004

• 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.
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Product documentation, M2004
Continued

How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material etc. The references
are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the robot/controller. The components or attachment points are marked
with italic text in the procedures and completed with a reference to the figure where
the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure FlexTrack
Carriage Overview on page 50.
Remove the rear attachment screws, gearbox.8
Reference to required equipment
The procedures often 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 in the referenced list.
The table below shows an example of a reference to a list of required equipment,
from a step in a procedure.
NoteAction
Art. no. is specified in Required
equipment on page 64.
Fit a new sealing, axis 2 to the gearbox.3
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in Safety on page 15.
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How to read the product manual

1 Safety
1.1 Introduction
Overview
The safety information in this manual is divided in two categories:
• general safety aspects, important to attend to before performing any service
work on the robot. These are applicable for all service work and are found
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.
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1 Safety
1.1 Introduction

1.2 General safety information
1.2.1 Safety in the robot system
Validity and responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment, which can influence the safety
of the total system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system are
designed and installed correctly. Personnel working with robots must be familiar
with the operation and handling of the industrial robot, described in the applicable
documents, e.g. User's Guide and Product 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 robot.
Limitation of liability
Any information given in this manual regarding safety, must not be construed as
a warranty by ABB that the industrial robot will not cause injury or damage even
if all safety instructions are complied with.
Related information
SectionDetailed in documentType of information
Installation and commission-
ing
Product manual for the robotInstallation of safety devices
Operating modesOperators manualChanging robot modes
(RobotWare 5.0)
Installation and commission-
ing
Product manual for the robotRestricting the working space
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1 Safety
1.2.1 Safety in the robot system

1.3 Safety risks
1.3.1 Safety risks during installation and service work on robot
Overview
This section includes information of general safety risks to be considered when
performing installation and service work on the robot.
General risks during installation and service
• The instructions in the Product Manual - Installation and Commissioning
must always be followed.
• Emergency stop buttons must be positioned in easily accessible places so
that the robot can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install the robot must have the appropriate training for the robot
system in question and in any safety matters associated with it.
Nation/region specific regulations
To prevent injuries and damage during the installation of the robot system, the
regulations applicable in the country concerned and the instructions of ABB robotics
must be complied with.
Non-voltage related risks
• Safety zones, which have to be crossed before admittance, must be set up
in front of the robot's 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 counterbalancing certain axes,
may be released if the robot, or parts thereof, are dismantled.
•When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored heat energy in the controller.
• Never use the robot as a ladder, i.e. do not climb on the robot motors or other
part during service work. There is a serious risk of slipping because of the
high temperature of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete system
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
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1 Safety
1.3.1 Safety risks during installation and service work on robot

• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Complete robot
DescriptionSafety risk
CAUTION
Motors and gears are HOT after running the robot!
Touching the motors and gears may result in burns!
Hot components!
Removed parts may result in col-
lapse of robot!
WARNING
Take any necessary measures to ensure that the robot
does not collapse as parts are removed, e.g. secure the
lower arm with fixtures if removing motor, axis 2.
Cabling
DescriptionSafety 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
DescriptionSafety risk
CAUTION
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!
Gears may be damaged if excess-
ive force is used!
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1 Safety
1.3.1 Safety risks during installation and service work on robot
Continued

1.3.2 Safety risks related to tools/workpieces
Safe handling
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts 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.
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1 Safety
1.3.2 Safety risks related to tools/workpieces

1.3.3 Safety risks related to pneumatic/hydraulic systems
General
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy
•Residual energy may be present in these systems. After shutdown, particular
care must be taken.
• The pressure in pneumatic 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.
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1 Safety
1.3.3 Safety risks related to pneumatic/hydraulic systems