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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© Copyright 20042018 ABB. All rights reserved.
Table of contents

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 ..................................................................................
6 Product manual - FlexTrack IRT501-66/66R/90/90R
3HAW050008590-001 Revision: C
© Copyright 20042018 ABB. All rights reserved.
Table of contents

1837 Reference information
1837.1 Introduction ...................................................................................................... 1847.2 Applicable safety standards ................................................................................ 1857.3 Unit conversion .................................................................................................
1878 Spare parts
1878.1 Carriage IRT501 ................................................................................................ 1888.2 Track .............................................................................................................. 1898.3 Limit switch and calibration ................................................................................. 1908.4 Automatic lubrication system ............................................................................... 1918.5 Cable chains .................................................................................................... 1948.6 Electrical spare parts and cables .......................................................................... 1978.7 Anti collision ....................................................................................................
1999 Appendix
1999.1 Wiring diagrams ................................................................................................
201Index
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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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Product manual - FlexTrack IRT501-66/66R/90/90R 9
3HAW050008590-001 Revision: C
© Copyright 20042018 ABB. All rights reserved.
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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10 Product manual - FlexTrack IRT501-66/66R/90/90R
3HAW050008590-001 Revision: C
© Copyright 20042018 ABB. All rights reserved.
Overview
Continued