ABB FlexTrack IRT501 Series Product Manual
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ABB FlexTrack IRT501 Series Product Manual

ABB FlexTrack IRT501 Series Product Manual

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

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Summary of Contents for ABB FlexTrack IRT501 Series

  • 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 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.

  • Page 5: Table Of Contents

    Specifications of the movement cables ............2.7.3 Specifications of the internal cable chain ............. 2.7.4 Installation of the cable chain ..............2.7.5 SMB box ....................Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 6 Motor and gear assembly ................. Replace the cable chain or the cable ..............Calibration Overview ......................Fine calibration ....................Update revolution counters ................. Decommissioning Introduction ...................... Environmental information .................. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 7 Limit switch and calibration ................. Automatic lubrication system ................Cable chains ....................Electrical spare parts and cables ................Anti collision ....................Appendix Wiring diagrams ....................Index Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview

    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: Chapter...
  • Page 10 171 • Spare parts updated in Spare parts on page 187 • Electrical diagrams added in Appendix on page 199 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 11 Geometric alignment of FlexTrack IRT 501 on page 76 • Replace the paint related reference manual to SafeMove2 in Ref- erence on page 117. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 12: Product Documentation, M2004

    All documents listed can be ordered from ABB on a DVD. The documents listed are valid for M2004 manipulator systems. Product manuals...
  • Page 13 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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 14: How To Read The Product Manual

    All procedures also include specific safety information when dangerous steps are to be performed. Read more in Safety on page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 15: Safety

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

  • Page 16: General Safety Information

    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...

  • Page 17: Safety Risks

    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 •...
  • Page 18 Gears may be damaged if excess- ive force is used! CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 19: Safety Risks Related To Tools/Workpieces

    CAUTION Ensure that a gripper is prevented from dropping a workpiece, if such is used. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 20: Safety Risks Related To Pneumatic/Hydraulic Systems

    • Dump valves should be used in case of emergency. • Shot bolts should be used to prevent tools, etc., from falling due to gravity. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 21: Safety Risks During Operational Disturbances

    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/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 22: Risks Associated With Live Electric Parts

    Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 23: Safety Actions

    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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 24: Fire Extinguishing

    1.4.2 Fire extinguishing 1.4.2 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot (manipulator or controller)! Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 25: Emergency Release Of The Robots/Manipulators Axes

    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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 26: Brake Testing

    Check that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 27: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    Do not change Transm. gear ratio or other 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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 28: Safe Use Of The Teach Pendant Unit

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

  • Page 29: Work Inside The Manipulator's Working Range

    Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 30: Translate The Information On Safety And Information Labels

    Using a transparent 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.

  • Page 31: Safety Related Instructions

    ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 32 Note symbols alert you to important facts and condi- tions. Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 33: Danger - Moving Manipulators Are Potentially Lethal

    - IRC5 with FlexPendant Make sure no personnel are present within the manipulator working range before pressing the start button. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 34: Danger - First Test Run May Cause Injury Or Damage

    Make sure all personnel are standing at a safe distance from the robot, i.e. out of its reach behind safety fences, etc.! Pay special attention to the function of the part previously serviced! Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 35: Warning - The Unit Is Sensitive To Esd

    Location of wrist strap button The wrist strap button is located in the top right corner as shown in the illustration below. xx1800002086 Wrist strap button Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 36: Warning - Safety Risks During Work With Gearbox Oil

    Specified amount de- gearbox. pends on drained volume! Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 37: Location Of Safety Pictograms

    This pictogram must be positioned close to the timing mark. xx1800002100 xx1800002088 DO NOT WALK! The pictogram is located on the track covers. xx1800002101 xx1800002089 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 38 This page is intentionally left blank...

  • Page 39: Installation And Commissioning

    Also known as linear block or linear guide block. The ball bearing block contains the recirculating balls which roll on the linear guideway. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 40 Lifting FlexTrack IRT 501 using lifting slings, see Acceptance in- spection on page Preparation for assembly. Assemble the track. Assemble the manipulator. Electrical installation. Software installation. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 41: Unpacking And Acceptance

    Inspection The FlexTrack IRT 501 is wrapped in plastic. Unpack the track and check for any visible transport damage. If the FlexTrack IRT 501 is damaged, contact ABB. Contents If the complete track contains more than 5 modules, it would be separated to more than 1 sections for packing’s convenience.

  • Page 42: Acceptance Inspection

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

  • Page 43: Handling

    IRT 501 - 66 and 90 2 lifting straps (min. 5 m ) with a load capacity of 1 tonne each Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 44 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 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 45 The second strap should be used for the other side. xx1800002096 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 46 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 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 47 Lifting 2 m FlexTrack with carriage The carriage comes assembled on a 2 m track section which can be handled using appropriate straps and M24 handling I-bolts. xx1800002099 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 48: Lifting Weight

    3 meter section 591 kg 712 kg 686 kg 848 kg without carriage 2 meter section with 772 kg 853 kg 909 kg 1,020 kg carriage Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 49: Flextrack Irt 501 Size And Dimensions

    FlexTrack overview xx1800001861 Cross member Levelling screw Side member Linear guideway Cover bracket Rack cover Cover End cover Cable chain Carriage Rack Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 50 Ball bearing block Gearbox Motor Dimensions of the FlexTrack Data IRT 501-66 IRT 501-66R IRT 501-90 IRT 501-90R 1050 1050 1150 1150 738+N×1050 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 51 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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 52 Continued Dimensions for IRT501-90 / IRT501-90R xx1800001865 Robot Plate Robot plates exist for various robot models and their bolting patterns match that of the robot. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 53: Moving The Carriage Manually

    Press in the brake release button (A) shows in the figure. xx1800001866 Release the brake Push the carriage by hand to the desired location. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 54 Unplug the Motor power cable from the SMB box that runs to the FlexTrack motor. Using pins, connect the +24VCC to the G pin (see fig). Connect the 0VCC to the H pin Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 55 2.3.4 Moving the carriage manually Continued xx1800001869 xx1800001870 WARNING The motor breaks on the FlexTrack IRT 501 are phase dependent. Fault connection can cause damage to vital parts. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 56: Preparations For Assembly

    The payloads listed above are estimated for a wide range of FlexTrack applications. For ModulFlex payload, please refer to ModulFlex specifications. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 57 Riser 500 mm IRB 660 √ √ No riser allowed Riser 1,500 mm IRB 760 √ √ No riser allowed Riser 1,000 mm Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 58 Movement Allowed xx1800001871 Not allowed xx1800001872 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 59 In the event that any of the static or dynamic loading rules are not followed, the tracks warranty will be void and no warranty claims of any sort will be valid. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 60: Recommendation For Anchors

    It is recommended to use chemical anchors with M16 threaded rods to secure the unit to the floor. See Recommendations for floor mounting on page Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 61 2 Installation and commissioning 2.4.2 Recommendation for anchors Continued xx1800001874 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 62 2 Installation and commissioning 2.4.2 Recommendation for anchors Continued Section view of the FlexTrack anchor xx1800001875 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 63: Screw Joints

    Screw class Class 12.9 screw is recommended by ABB for certain screw joints. These screws are high grade quality and extremely resistant to fatigue. Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw...

  • Page 64: Assembly Of The Track

    Hex head cap 13 mm, 19 mm socket 1/2”bit L 20 mm Specific FlexTrack tools Picture Rail Pressing Tool IRT501-66 & 66R: 3HAW107700358 IRT501-90 & 90R: 3HAW107700456 xx1800001876 Rack clamps (3HAW107700357) xx1800001877 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 65 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. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 66 Adjust the leveling screws until all leveling screws touch the ground. Slightly tighten screws connecting the sidemem- ber and the crossmember. xx1800001884 Sidemember Crossmember Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 67 If so then push the rail against the side member step and check that there's no clearance between the rails. xx1800001888 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 68 Loctite 243 on their thread (Tightening torque: 40 Nm). Use a brush to lubricate the racks. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 69 Fix the small covers on top of the side members. Fix the large cover's brackets on the opposite side members. xx1800001894 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 70 Once again, release the carriage brake and push the carriage manually along the length of its stroke. Check that no covers come into contact with the moving carriage. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 71: Recommendations For Floor Mounting

    Adjust the horizontality of the FlexTrack with the M60 levelling screw. Check that all the levelling screws are touching the floor. Tighten the M60 nuts. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 72 18 mm, 125 mm deep. xx1800001897 Remove the dust in the hole with a vacuum cleaner. Brush the inside of the hole. xx1800001898 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 73 Insert the SPIT tool supplied with the anchor kit in a handheld electric punch drill's chuck. Insert the triangular extremity of the threaded rod in the SPIT tool. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 74 M60 screws, and then tighten the M16 notched nuts. Geometric alignment of FlexTrack IRT 501 on page 76 xx1800001903 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 75 It is of the utmost importance 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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 76: Geometric Alignment Of Flextrack Irt 501

    Example: Leica AT960 Absolute Tracker xx1800001905 Reflector Example: Leica Reflector xx1800001906 Magnetic block Example: Leica Magnetic block xx1800001907 ABB levelling tool (3HAW107700360) Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 77 M12 × 40 screws that attach the sidemembers to the crossmembers to facilitate the levelling. Use the ABB levelling tool 3HAW107700360 to It is recommended to use one of adjust the levelling screws until all the measured...
  • Page 78 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. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 79: Assembly Of The Manipulator

    7th axis. The robot should be ordered with an additional drive unit (907-1) for the FlexTrack motor, and optionally a resolver connection for 7th axis on the robot base (864-1). The FlexTrack unit has been designed for ABB IRC5 controller, for compatibility with other control systems please contact ABB. WARNING The robot should stand still while the carriage is moving, in order to avoid any additional dynamic forces on the FlexTrack.

  • Page 80: Cables, Smb Box And Cable Chain

    It is important to indicate the robot mounting orientation in the order form in order to get the correct robot cable length. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 81: Specifications Of The Movement Cables

    Water and Air pipe DN12 19 mm 0.2 kg/m quantity) Water and Air pipe DN16 23.5 mm 0.4 kg/m The exact reference depends on the length of the cable. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 82: Specifications Of The Internal Cable Chain

    Between each cable, a cable chain divider must be used every 8 links: xx1800001916 44 mm 5 mm 25 mm 25 mm Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 83 2.7.3 Specifications of the internal cable chain Continued A strain relief comb is used at the carriage attachment point to fix the cables position: xx1800001917 175 mm 202 mm 14 mm Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 84: Installation Of The Cable Chain

    Having all heavy cables on the same side of the chain could cause prema- ture wear. xx1800001920 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 85 (see figure). If not, unscrew the cover screws and push the cover away from the pinion. Tighten the cover screws. xx1800001925 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 86 If not, adjust the orientation of the fixed point of the chain as described in step5. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 87: Smb Box

    2.7.5 SMB box Description The FlexTrack motor must be controlled through an ABB Serial Measurement Board. For FlexTrack used to move a manipulator, it is possible to connect the motor resolver to the manipulator’s integrated SMB board (robot option). If there...

  • Page 88: Cables Connections

    For all signal sockets on the SMB box that are unused, a PTC plug is required. This plug bridges pin 7 and 8. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 89 2 Installation and commissioning 2.7.6 Cables connections Continued Description Note/Illustration Ensure that the movement cables are properly connected to the mo- tor. xx1800001930 Power cable Signal cable Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 90: Connectors On Irc5 Controller

    XS.11 Customer options XS.12 Customer options X3 Customer safety signals XS.28 Network connection XS.41 Additional axes SMB connection XS.2 Robot SMB connection Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 91 XS.11 Customer options XS.12 Customer options X3 Customer safety signals XS.28 Network connection XS.41 Additional axes SMB connection XS.2 Robot SMB connection Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 92 A5.X 12: Customer options A5.X 13: Customer options A5.X 14: Customer options A5.X3: Customer safety signals A22.X1: FlexPendant connection A5.X28: Network connection Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 93 A4.X7: External axes power connection A4.XX: Customer options A4.XX: Customer options A4.XX: Customer options A4.XX: Customer options Communication cabling between Control/Drive Module Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 94 2 Installation and commissioning 2.7.7 Connectors on IRC5 controller Continued Description Communication cabling between Control/Drive Module A4.XS41: Additional axes SMB connection A4.XS2: Robot SMB connection Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 95: Software Installation

    Hereunder are listed the actions related to the FlexTrack specifics: Action Select the menu option: Add new parameters. Load the file MOC.cfg. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 96: Load Configuration Files

    The files are specific to the system layout and configuration. If these files were not received, contact ABB. To load 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.
  • Page 97 OK. Do not restart the controller yet. xx1800001942 Repeat the steps for all *.CFG files that need to be loaded, and then warm restart the controller. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 98 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. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 99: Modification Of The Travel Direction Of The Track

    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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 100: Link Robot And 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" Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 101: Robot Orientation On The Track

    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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 102 Robot 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 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 103 2.8.5 Robot orientation on the track Continued Robot with a 270° rotation around Z on the Track xx1800001946 base_frame_orient_u0 = 0.70710678 base_frame_orient_u1 = 0 base_frame_orient_u2 = 0 base_frame_orient_u3 = -0.70710678 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 104: Set Upper And Lower Limits Software Limits For Track

    Both are expressed in meters. In the example below the upper limit is set to 6 m and the lower limit is set to -0.005 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 105 2.8.6 Set Upper and Lower Limits Software Limits for track Continued ARM : -upper_joint_bound 6 -lower_joint_bound -0.005 To change the limits using the teach pendent, do the following: Action Note/Illustration From the ABB menu, tap Control Panel. xx1800001948 Tap Configuration. xx1800001938 Under Topics, tap Motion. xx1800001949 Select Arm.
  • Page 106 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 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 107 Below is the process to identify the limits by experiment: Action Note/Illustration Before beginning, ensure that the FlexTrack’s re- volution counter is calibrated. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 108 If the software limit has not been set correctly the mechanical unit may hit the mech- anical hard stop. Perform a warm restart. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 109 Repeat the previous steps for the other limit. 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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 110 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. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 111: Lubrication

    MEMOLUB. xx1800001961 The grease is pushed in the piping by the pump; a valve is sequencing the distribution to each port. xx1800001962 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 112: Zone Division

    Refer to the wiring diagram developed by the system integrator for details on how the zone division sensors are used. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 113 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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 114 If two carriages 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 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 115: Setting Up The Flextrack Limit Switch For Additional Safety

    Pins 1 & 2 (Jumper between Pins 3 & 4 or Pin 5 & 6 can be used for each limit switch) xx1800001971 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 116 For details on how to connect to the safety PLC, please review the Product specification - PLC robot controller. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 117: Additional Function Support

    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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 118 This page is intentionally left blank...

  • Page 119: Maintenance

    Read Safety on page 15 before performing any service work. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 120: Standard Toolkit

    Socket head cap 5 mm, 8 mm, 10 mm socket 1/2" bit L 20 mm Hex head cap 13 mm, 19 mm socket 1/2" bit L 20 mm Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 121: Maintenance Schedule And Expected Component Life

    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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 122: Expected Component Life

    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. Gear and pinion Over 10 years Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 123: Maintenance Schedule

    (approx. 3 times) for longer production breaks by a battery shutdown service routine. See Operating manual - IRC5 with FlexPendant for instructions. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 124: Activities 100 Km Or One Week

    100 km or every week. Location The figure below shows the location of the gear racks and pinion: xx1800001972 Pinion Rack Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 125 Check that no pipe has been damaged. xx1800001973 Pump to inject the grease in the piping. Inject 3 grams of lubricant for rack & pinion per week or 100 km. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 126: Activities 1 Month

    Use one of the recommended lubricants: Equipment Note Lubricant CASTROL Longtime PD0 Lubricant KLÜBER Microlube GB0 Lubricant TOTAL Multis EP 0 Lint free cloth Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 127 If you have cleaned them, use a brush to lubricate the linear guideways. Move the carriage back and forth and repeat step Re-attach the covers. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 128: Ball Bearing Blocks

    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 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 129 In average, one should inject 1 gram of lubricant per block and per month. Repeat the step1 step2 for each block port on the manifold. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 130: Automatic Lubrication System

    Location The figure below shows the location of the lubrication system. xx1800001977 Grease cartridge Control unit grease pump Oil dispatcher Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 131 EP (extreme pressure) additives. The base oil viscosity must be ISO VG68 to ISO VG 100. Grease doped with EP additives is absolutely necessary, due to high loads on blocks. Customers must use the following lubrication suggested by ABB or malfunction of the lubrication system may occur. Equipment Note...
  • Page 132 Push firmly with one hand on top of the Memolub. With the other hand, hold the black base and turn counterclockwise. Pull the transpar- ent bell to open. xx1800001980 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 133 Memolub program. Put the pa- per disc back in place in order to see the instruc- tions when the Memolub is closed. xx1800001984 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 134 Memolub are working well. It is important that you run this test cycle only if a cartridge is in place, otherwise you'll fill-in the pump with air. xx1800001988 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 135: Emergency Stop And Stroke Limit System

    If the software limits are functional, it should not be possible to go beyond the defined upper or lower end position, and it should not be possible to reach the hard stops. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 136: Zone Division System

    Activate the limit switch sensor using an adhesive tape. Reset the E-Stop button and power on the IRC5 in manual mode. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 137 Power off the IRC5 and activate the E-Stop. Remove the adhesive tape and reset the E-Stop button and power on the IRC5. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 138: Cables And Connectors

    If one element is damaged, it is possible to replace it without removing the whole chain from the FlexTrack. xx1800001990 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 139: Activity 3 And 12 Months

    TOTAL Carter SH 220 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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 140 The tightening torque of the hexagon socket head Section view: cap M6x25 class 12.9 screws that secure the gear to the bracket is 16.5 Nm. xx1800001992 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 141: Activities 36 Months

    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 on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 142 Place the new battery pack, plug the connector on the board, and secure the pack with straps. Close the SMB box, switch on the power. Update the revolution counters of the axis. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 143: Repair

    Read Safety on page 15 before performing any service work. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 144: Replace The Linear Guideways

    The figure below shows the location of the linear guideways: xx1800001995 Linear guideways 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...
  • Page 145 12x32x4 which hold the linear high force on the wrench. guideway to the sidemember. Remove the linear guideway xx1800001997 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 146 Once you have tightened a screw, mark it with a white marker. xx1800002021 Use a brush to lubricate the linear guideways. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 147 4 Repair 4.2 Replace the linear guideways Continued Action Note/Illustration Re-assemble the FlexTrack covers. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 148: Replace The Ball Bearing Blocks

    Use one of the recommended lubricants: Equipment Note Lubricant CASTROL Longtime PD0 Lubricant KLÜBER Microlube GB0 Lubricant TOTAL Multis EP 0 Lint free cloth Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 149 (with no marking) on the upper face of the block. xx1800002025 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 150 12.9 screws s and 4 pcs M10-16 narrow contact- lock washers. (Tightening torque: 77 Nm) Remove the jack. Re-connect the lubrication pipe. Re-assemble the mechanical stop and the covers. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 151: Replace The Racks

    FlexTrack. Procedure of assembly on page Loctite 243 Apply Loctite 243 on the screws that hold the racks. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 152 8x25x3 that hold the rack to the on the wrench. sidemember. Remove the rack. xx1800002029 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 153 (Tightening torque: 40 Nm) Once you have tightened a screw, mark it with a white marker. xx1800002032 Use a brush to lubricate the racks. Re-assemble the FlexTrack covers. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 154: Motor And Gear

    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 Gear Motor Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 155: Disassemble The Bracket From The Carriage

    16.5 Nm. There are also specific tightening torques for the motor shaft and gear assembly. See the details in maintenance instructions. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 156 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 screws when necessary. xx1800002037 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 157 Remove the upper part of the cable tray so that the connectors can pass through. xx1800002040 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 158 Carriage Motor bracket Cable tray Remove the covers. The drive unit is now access- ible. xx1800002043 Motor Gear Pinion Motor bracket Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 159: Replace Motor

    132 Nm to secure the secure it to the bracket with the flanges. bracket. Turn the power on and perform a fine calibration. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 160: Replace Gear

    Replace the gear and tighten the hexagon socket head cap M6x25 class 12.9 screws and contact- lock washers M6-12 with a torque wrench. (Tightening torque: 16.5 Nm) Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 161 3HAWL000011: xx1800002049 and the clamps 3HAW107700357: xx1800002050 Follow the instructions see Motor and gear as- sembly on page 163. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 162 132 Nm to secure the secure it to the bracket with the flanges. bracket. Turn the power on and perform a fine calibration. Fine calibration on page 176. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 163: Motor And Gear Assembly

    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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 164 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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 165 4.5.5 Motor and gear assembly Continued Motor assembly The following instructions are based on the Alpha gear and motor assembly manual: Action/Note/Illustration xx1800002054 xx1800002055 xx1800002056 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 166 4 Repair 4.5.5 Motor and gear assembly Continued Action/Note/Illustration xx1800002057 xx1800002058 xx1800002059 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 167 4 Repair 4.5.5 Motor and gear assembly Continued Action/Note/Illustration xx1800002060 xx1800002061 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 168: Replace The Cable Chain Or The Cable

    2 technicians to work together. xx1800002062 Cable chain of different supplier Cable 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:...
  • Page 169 Required equipment Equipment Note Standard toolkit The content is defined in section 3.2, stand- toolkit. Cables Cable chain parts Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 170 To facilitate assembly, take a picture of the placement in the cable chain before removing cables. xx1800002073 Remove screws at fixed point, pull the complete chain out. xx1800002074 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 171 Remove two covers. xx1800002071 Remove screws at fixed point, pull-out cable chain, help the cables through the carriage open- ing. xx1800002072 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 172 Tiewrap plate of the fix end cable chain End unit of the move end cable chain Ties fixing cables Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 173 Ties fixing cables Reinstall the new cable chain, and ensure the correct installation as described in Installation of the cable chain on page xx1800001922 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
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  • Page 175: Calibration

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the FlexTrack IRT 501 carefully with standard calibration. The resolver values will change when parts affecting the calibration position are replaced on the FlexTrack IRT 501, e.g.

  • Page 176: Fine Calibration

    Insert the calibration pin (3HAW107700354). A dowel pin diameter 8 mm can also be used. xx1800001960 Tap ABB on the top left of the FlexPendant Tap Calibration. Select the desired mechanical unit. Tap Fine calibration. Select the desired axis.

  • Page 177: Update Revolution Counters

    Align the sharp edge of the moving part of the calibration marker with the line of the fixed part calibration marker. xx1800002078 Tap ABB on the top left of the FlexPendant. Tap Calibration. Select the desired mechanical unit. Tap Update revolution counters.
  • Page 178 This page is intentionally left blank...

  • Page 179: Decommissioning

    These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 180: Environmental Information

    Covers, sidemembers, carriage top plate, screws Neodymium Brakes, motors Plastic/rubber (PVC) Cables, connectors, hard stop bumper Oil, grease Lubrication system, gearbox Aluminium Motor and gearbox housing Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 181 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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 182 This page is intentionally left blank...

  • Page 183: Reference Information

    7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 184: Applicable Safety Standards

    Immunity to conducted disturbances, induced by radi- ofrequency fields EN 61000-4-8 Power frequency magnetic field immunity test EN 61000-4-11 Voltage dips, short interruptions and voltage variations immunity test Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 185: Unit Conversion

    1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
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  • Page 187: Spare Parts

    Gear + pinion for IRT501-66R/ 90 3HAWC116596 Gear + pinion for IRT501-90R 3HAWL000021 Ball bearing block (Rexroth) 3HAWC116594 Ball bearing block (INA) 3HAWL000049 D6-M6 lubrication elbow fitting Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 188: Track

    3HAWC100857 Slotted round nut KM 12 Note For how to identify cable chain from different supplier, see Linear guideway of different supplier on page 144. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 189: Limit Switch And Calibration

    Cam (on both ends of the FlexTrack) 3HAWC106195 Hard stop bumper (a pair on both ends of the FlexTrack) 3HAW107700344 Calibration gauge (fixed, on FlexTrack) 3HAW107700540 Calibration gauge (mobile, on carriage) Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 190: Automatic Lubrication System

    3HAWC116980 Tube D8x6 (from dispenser to splitter only) 3HAWC116979 Grease splitter 6 outputs 25 m 3HAWL000032 Tube D6x4. 5 m are required in one carriage. Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 191: Cable Chains

    Tiewrap plate (1 per cable chain) (IGUS) Note For how to identify cable chain from different supplier, see Cable chain of different supplier on page 168. Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 192 1 m chain 3HAW107700443 External cable chain cover module - orange requires 3HAW107700443- External cable chain cover module - graphite 1 pcs white Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 193 External cable chain floor guide requires 1 pcs 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 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 194: Electrical Spare Parts And Cables

    For SMB boxes manufactured before 2015 only. 3HAC044168-001 SMB Main board RMU101 3HAC044075-001 Battery pack for SMB board RMU101 3HAW050008607 PTC shunt M2008 Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 195 3HAW050008625-005 1 Resolver M2008 5 m sion cable- 3HAW050008625-010 1 Resolver M2008 10 m resolver 3HAW050008625-015 1 Resolver M2008 15 m Continues on next page Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 196 Welding Power cable of robot 15 m Air pipe 3HAW050008638-005 Air pipe DN12 5 m 3HAW050008638-010 Air pipe DN12 10 m 3HAW050008638-015 Air pipe DN12 15 m Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.

  • Page 197: Anti Collision

    Anti collision spare parts ABB part reference no. Description 3HAWC116985 Laser reflector 3HAW107700584 Laser reflector bracket 3HAW107710201 Laser scanner 3HAW107700582 Laser bracket (1/2) 3HAW107700583 Laser bracket (2/2) Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 198 This page is intentionally left blank...

  • Page 199: Appendix

    Limit switch cable 4 positions 3HAW050008611 Power supply 24V DC output & communication flexible 3HAW050008633 cable 1 Resolver, Robot Axis 7 Feedback- motor resolver, 3HAW050008637 Track M2008 No SMB Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
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  • Page 201: Index

    180 disposal, 180 copper disposal, 180 replacing xx, 180 rubber grease disposal, 180 disposal, 180 steel Lithium disposal, 180 disposal, 180 neodymium replacing, 180 Product manual - FlexTrack IRT501-66/66R/90/90R 3HAW050008590-001 Revision: C © Copyright 20042018 ABB. All rights reserved.
  • Page 204 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 20042018 ABB. All rights reserved. Specifications subject to change without notice.

This manual is also suitable for:

Flextrack irt501-66Flextrack irt501-66rFlextrack irt501-90Flextrack irt501-90r

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