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Product manual - IRL FlexLifter

1. 47 324 1 FlexLaft er cables oec nn erre Re Rr eb ever ee RN Peta 47 AZOTEA RE Eis 48 3 4 3 Position Sensors isses ee de exe e oU CANA ed o oder Von e poc 49 3 5 Robot controller technical requirements 50 Table of Contents 4 Unpacking and acceptance 41 Unpacking pits y den dt HER tie cds 4 2 Acceptance 1nspection ee Rr ce Ur Rig Rc Read cR RR a Lace RL Sob eave Boe AUR ut se a 5 Handling 9 1 Lifting weight ceci ni nn E E NIU ep erae qu ee RE dee ete 3 2 Laitting the FlexLifter IRL600 5 2 ce er a eng ces 5 3 Motor brake release RR a E ERI 5 3 1 Important information about the brake release 5 3 2 Brake release of the FlexLifter with the SMB box 5 3 3 Brake release of the FlexLifter with external 24V DC 6 Installation 6 1 Fixing the FlexLifter ocios a REIR Rd rx Farc e ne eT Ra x hr da m eR is 6 1 1 When used as a FlexTrack additional axis 6 1 2 When used as a stand alone unit 7 Electrical setup 7 4 Cabling of the FlexLift r 210 1 87 v LEE ee need mes mt ee 7 1 1 Stand alone configuration 7 1 2 FlexLitter on Flex Track ied EUR nr ii in 7 2 Architecture e
2. 76 The system has been tuned before delivery The calibration offset value is set to 0 and is stored in the controller data and the SMB Box No fine calibration is required on the FlexLifter IRL 600 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 8 Setup and commissioning 8 4 2 Calibration instructions 8 4 2 Calibration instructions Procedure This procedure must be applied at the first start after mechanical intervention e g motor or reducer replacement or if the contents of the revolution counter are changed or lost Steps Action Info Illustration 1 Using the FlexPendant jog the cylinder rod in order to align the grove with the seal e Mechanical unit FT900 1 ot de Axis Pavio load midi Joystick lock None o Increment None 1 Activate ES ver en2010110200028 2 The grove and the seal must appear aligned as shown on the figure E Grove Seal en2010110200029 3 On the FlexPendant tap on the ABB logo select Calibration ABR Pacos me EA be HotEdit te Backup and Restore ig Inputs and Outputs IG Calibration Le Jogging D Control Panel 8 Production Window 8 Event Log YR Program Editor l PlexPendant Explorer m Program Data Q system Info E tono Br ae en2010110200030 4 Select the external axis here FT900 ABBI B I TX In order to use the system all mechanic
3. 1 e Fieldbus air hose IOs please refer to the FlexLifter Standard Product Offer for part number Wiring diagram IRCS STATIC CABLES SMBBOX STATIC FIELD CABLES FLEXLIFTER resolver sm coc Ei O DE rcm cf T ANT i is ed gt U A E w s motor ID 3HAWO50008890 Revision 63 7 Electrical setup 7 1 2 FlexLifter on FlexTrack 7 1 2 FlexLifter on FlexTrack Description When the FlexLifter is used on top of a FlexTrack carriage flexible cables are required in FlexTrack s cable chain The SMB is usually located near the FlexTrack way It is possible to use standard robot cables from the SMB to the controller floor cables Wiring diagram IRC5 Stand Alone STATIC CABLES SMB BOX i MOVEMENT CABLES FLEXTRACK and FLEXLIFTER MOTORS resolvers H Da i 64 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 7 2 Architecture example 7 2 1 Overview 7 Electrical setup 7 2 1 Overview Please find below the necessary material for a typical configuration using 3 Flextrack amp 3 Flexlifters en2010110200021 The detailed cable chain 1 per Flextrack en2010110200022 Designation IRC5 6 axes 3V3W Static Measure link cable Power Cable SMB 6 axes Extension motor cable Extension resolver cable Mvt motors cable
4. 2 If not already done jog the axis to the zero position see Zero position on page 73 3 Lock the safety pin see Safety instructions during mechanical assembly on page 35 4 Switch off the power on the installation see Safety for electrical operations on page 36 74 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved Steps 3HAWO50008890 Revision 10 8 Setup and commissioning 8 3 1 Lubrication with basic delivery package Action Info lllustration Remove the protection cap from the cylinder Protection cap Locate the grease nipple and connect the grease pump Inject 14 cm of grease into the roller nut Disconnect the pump and put the protection cap back on Make sure that no tool has been left in the FlexLifter and unlock the safety pin Grease nipple Switch the controller on in manual mode and gently jog the FlexLifter to make sure that there is no mechanical interference 75 8 Setup and commissioning 8 4 1 Overview 8 4 Calibration 8 4 1 Overview General A i This chapter includes general information about the calibration method and also details procedures that do not require specific calibration equipment When the robot system must be recalibrated it is done according to the documentation enclosed with the calibration tools WARNING Check first that nobody stands in the Fl
5. 2 When used as a stand alone unit 6 1 2 When used as a stand alone unit WARNING VAN When used as a stand alone module the FlexLifter is secured to the tooling plate and the levelling is done using the levelling screws of the tooling No direct fixing on the floor is allowed The FlexLifter is not designed to be directly secured to the ground floor It is necessary to have a tooling slab under the baseplate in order to have levelling means en2010110200017 The FlexLifter is linked to the slab with 6 M12 screws the fixing mask in the lower plate is as follows 910 m 910 180 180 q en2010110200018 The levelling of the FlexLifter is depending on the levelling of the slab The FlexLifter inclination should not exceed 1mm for 1m The slab should also have one hole prepared for the cable routing 62 3HAWO050008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 7 Electrical setup 7 1 1 Stand alone configuration 7 Electrical setup 7 1 Cabling of the FlexLifter 7 1 1 Stand alone configuration Description FlexLifter is designed to be driven by the ABB IRCS robot controller However alternative control systems are possible please contact ABB The SMB is usually located near the FlexLifter base It is possible to use standard robot cables from the SMB to the controller floor cables Other standard cables are also available as options
6. 300mm lower 500 upper 300 en201011020009 48 3HAWO050008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 3 Technical details 3 4 3 Position sensors 3 4 3 Position sensors The FlexLifter IRL 600 is equipped with two position sensors to detect the up and down positions It is also possible to add other sensors to detect intermediate positions In addition the EPS option Electronic Position Switches of the controller can be used to safely monitor the FlexLifter position in case of manual operation in automatic mode For more information regarding EPS see product specification Controller IRC5 with FlexPendant and Application Manual Electronic Position Switches 3HAC027709 001 Down position Detector Upper position Detector en2010110200036 3HAWO50008890 Revision 49 3 Technical details 3 5 Robot controller technical requirements 3 5 Robot controller technical requirements When the FlexLifter is associated with an IRB 66007600 robot it behaves like an external axis However the robot controller must satisfy some requirements to get an optimum integration The FlexLifter unit has been designed for ABB IRCS controller for compatibility with other control systems please contact ABB Requirements in the robot controller The robot equipment must fulfil the following requirements to integrate an external axis Item Option Comm
7. Brake release of the FlexLifter with external 24V DC Instructions for brake release using external 24V DC If no controller is available or if the controller can not be powered and you need to release the brake proceed as described below Action 1 Unplug the FlexLifter movement motor power cable from the SMB box Using pins connect the 24VCC to the G pin see figure in Motor details on page 46 Connect the OVCC to the H pin see figure in Motor details on page 46 WARNING VAN The motor brakes of the FlexLifter are phase dependent Fault connection can cause damage to vital parts 60 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 6 Installation 6 1 1 When used as a FlexTrack additional axis 6 Installation 6 1 Fixing the FlexLifter 6 1 1 When used as a FlexTrack additional axis When the FlexLifter is used as an additional axis to the FlexTrack it is delivered already preassembled on the track carriage en2010110200015 Cable outlet Side with opening in Flextrack covers en2010110200016 NOTE i If you need to assemble the Flexlifter on the carriage take care of the positioning of the cable outlet a specific opening is prepared in the base plate in order to route the cables thru the FlexTrack internal cable chain see also Routing of the cables on page 67 3HAW050008890 Revision 61 6 Installation 6 1
8. Motor or gearbox failure In the situation where there is a failure to the EMC cylinder motor or gearbox it is possible to disassemble the complete electromechanical cylinder in order to maintain it easily In this procedure presume that it is no longer possible to move the lifter Y y G en2010110200038 Warning Risks of First shutdown the controller and isolate the FlexLifter electric shock from the main power en1011003 DANGER A There is a risk of deadly injuries for the operators and or irreversible damage to the product 1f the safety rules are not respected Steps Actions Info lllustration 1 Remove any load from the top plate of the FlexLifter 2 If possible jog the FlexLifter such as the safety pin can be engaged 3 Secure the top frame with a handling system or a crane Slightly pull up the upper frame in order to cancel the load constraint on the lower structure and the cylinder If possible engage the safety pin Use posts to prevent any drop of the top plate Safety posts specifically designed for the FlexLifter IRL 600 are available as spare parts 3HAW107703535 To install them remove the spring dampers and replace them with the safety posts and secure them the same sets of screws en2010110200039 Proceed one by one 4 Disconnect the motor cables 3HAWO50008890 Revision 91 11 Maintenance operations 11 1 Motor or gearbox failure 92 Steps 10 Acti
9. Mvt resolver cable Mvt 4 position switch cable 3HAWO50008890 Revision qty O Ecol IER MES ES IE In ne Rep O T1 M OOO gt 65 7 Electrical setup 7 2 1 Overview 66 Designation Air pipe Mvt profinet cable amp PS Mvt PE cable Static Laser cable Mvt Laser cable Anticollision option SMB Support aty 2000000 Rep z A Md EN ES 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 7 2 2 Routing of the cables 7 Electrical setup 7 2 2 Routing of the cables en2010110200023 3HAWO50008890 Revision 67 7 Electrical setup 7 2 3 SMB box 7 2 3 SMB box 68 SMB means Serial Measurement Board The SMB board is available in 3 versions for 1 3 amp 6 axis The cables from the axis motors FlexTrack FlexLifter are connected to the SMB box The SMB is connected to the controller with 2 static cables en2010110200024 NOTE Check that there s enough space to install the SMB box at layout time 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 8 Setup and commissioning 8 1 Pre requirements 8 Setup and commissioning 8 1 Pre requirements Hereunder are listed the required operations before starting up the FlexTrack setup Actions Info Illustration 1 Configure the controller Load the FlexLifter para
10. and the motor are firmly tighten and that there s no damage to the cable outlet 3HAWO50008890 Revision 89 10 Instructions for maintenance 10 2 5 SMB backup battery 10 2 5 SMB backup battery The SMB box includes a battery pack to save the resolver information in case of a power failure The reference of the battery pack is 3 HAC 16831 1 It is recommended to replace the backup battery every 3 months or when the following error code is displayed on the teach pendant screen 38213 More information about this error code can be found in the robot controller documentation 90 To replace the battery pack proceed as follow Steps Actions 1 Position first the carriage in the synchronization position align the synchronization gauges oa BR CO Io Switch off the power on the SMB box Open the SMB box and locate the battery see fig below Cutthe plastic straps Unplug the 2 wires cable from the board and remove the battery pack Place the new battery pack plug the connector on the board and secure the pack with straps 7 Close the SMB box switch on the power 8 calibrate the axis as described in Calibration on page 76 u uu rr al en2010110200037 3HAWO50008890 Revision Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 11 Maintenance operations 11 1 Motor or gearbox failure 11 Maintenance operations 11 1
11. 008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 8 Setup and commissioning 8 2 3 Zero position 8 2 3 Zero position The stroke limits parameters are related to the zero position which is indicated by a small grove in the cylinder shaft Align the grove with the seal when synchronizing the axis see fig below To move the axis to the zero position align the grove in the cylinder rod with the seal then follow the Calibration on page 76 seal grove en2010110200025 3HAWO50008890 Revision 73 8 Setup and commissioning 8 3 1 Lubrication with basic delivery package 8 3 Lubrication Only the roller screw nut needs to be lubricated on the Flexlifter 600 8 3 1 Lubrication with basic delivery package WARNING AN Use lithium soap flowable grease class NLGI 0 with a mineral oil base doped with 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 slides The roller screw nut is equipped with a standard grease port Inject the grease with a manual or air operated pump following the instructions below The required grease type is indicated below Supplier Lubricant CASTROL Longtime PD 0 KL BER Microlube GB 0 TOTAL MULTIS EP 0 Procedure Steps Action Info Illustration 1 Switch the robot controller to manual mode
12. 10 3HAWO05000861 3 015 3HAWO05000861 4 005 3HAWO05000861 4 010 3HAWO05000861 4 015 3HAWO05000861 5 005 3HAWO050008615 010 3HAWO05000861 5 015 3HAWO05000861 2 005 3HAWO050008612 010 3HAWO05000861 2 015 3HAWC107034 3HAWC116986 3HAWC116987 3HAWC116988 3HAWC116990 3HAWC116991 3HAWC116992 Description Servomotor SMB box 1 axis M2008 SMB box 3 axis M2008 SMB box 6 axis M2008 1 axis motor movement cable 5m 1 axis motor movement cable 10m 1 axis motor movement cable 15m 1 axis resolver movement cable 5m 1 axis resolver movement cable 10m 1 axis resolver movement cable 15m 1 axis motor static cable 5m 1 axis motor static cable 10m 1 axis motor static cable 15m 3 axis motor static cable 5m 3 axis motor static cable 10m 3 axis motor static cable 15m 6 axis motor static cable 5m 6 axis motor static cable 10m 6 axis motor static cable 15m 6 axis resolver static cable 5m 6 axis resolver static cable 10m 6 axis resolver static cable 15m Position sensor Movement sensor cable 5m Movement sensor cable 10m Movement sensor cable 15m Static sensor cable 5m Static sensor cable 10m Static sensor cable 15m 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Contact us ABB France Robotics Products Rue de l querre Zl des B thunes 95310 SAINT OUEN L AUMONE France www abb com Power and productivity for a better world 4 P 3HAW050008890 Rev en
13. 6 2008 ABB All rights reserved 1 Safety 1 8 1 Safety pin 1 8 Safety instructions during mechanical assembly 1 8 1 Safety pin The Flexlifter is equipped with an integrated safety pin in order to secure the lifter position during maintenance operations When the lifter is in the upper position simply engage the pin in the hole and make sure that the latch is engaged Action Info lllustration 1 Engage the latch The latch must be in this position The following position is forbidden 2 After maintenance pull the pin back in parking position WARNING A Make sure to pull back the pin in parking position after maintenance 3HAW050008890 Revision 35 1 Safety 1 8 2 Safety for electrical operations 1 8 2 Safety for electrical operations Tooling cabling Check that the tooling cables are secured in the dedicated cable trays and that they are not in touch with moving part to avoid wear of the cable The cabling of the tooling is the responsibility of the customer 36 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 Safety 1 8 3 Safety during setup amp commissioning 1 8 3 Safety during setup 8 commissioning Checking the working envelope Before moving the lifter it is important to check that nothing can interfere with the elevation This includes the inside of the lower frame in the moving arm area Ensure that no p
14. 8890 Revision The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel The robot s speed is limited to max 250 mm s when the operating mode selector is in position lt 250 mm s This should be the normal position when entering the working space The position 100 full speed may only be used by trained personnel who are aware of the risks that this entails Pay attention to the rotating axes of the manipulator Keep a distance to the axes in order not to get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell 27 1 Safety 1 4 8 Translate the information on safety and information labels 1 4 8 Translate the information on safety and information labels Labels on the product Both the manipulator and the controller are marked with several safety and information labels containing important information about the product The information is useful for all personnel handling the robot system e g during installation service or operation Translation possibilities The labels fitted to the product contain space for adding a fourth language underneath the three standard languages English German and French Add a local language to the label by using a transparent sticker over the st
15. 91 Product Manual for IRT 501 66 66R 90 90R 3HAW050008590 Product manual IRC5 Robot Controller 3HAC021313 001 Operating manual IRC5 with FlexPendant 3HAC16590 1 Operating manual Calibration Pendulum 3HAC16578 1 Service Information System IRC5 3HAC025709 001 Application manual Additional axes and stand alone controller 3HAC021395 001 System Parameters 3HAC17076 1 Revisions Revision Description First edition 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 0 0 2 Product documentation M2004 0 0 2 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 calibr
16. ABB Robotics viy JA UD ER Power and productivity for a better world PAID ap Copyright 2010 ABB All rights reserved Product manual FlexLifter IRL 600 Document ID 3HAW050008890 Revision 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 Additional copies of this manual may be obtained from ABB O Copyright 2011 ABB All rights reserved ABB France Robotics Products Rue de l querre Zl des B thunes 95310 SAINT OUEN L AUMONE France O Copyright 2010 ABB All rights reserved Table of Contents 0 0 LOYEVIEW ii A oe e edd eR e eh dee e t eaae 7 0 0 2 Product documentation M2004 9 0 0 3 How to read the product manual 1 11 1 Safety 13 L T Introduction esr RE Ar o PvE n e o ta QR 13 1 2 General safety informa
17. accident will occur if the instructions are not followed resulting in a serious or fatal injury and or severe damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death Warns that an accident may occur if the instructions are not followed that can result in injury and or damage to the product It also applies to warnings of risks that include burns eye injury skin injury hearing damage crushing or slipping tripping impact fall from height etc Furthermore it applies to warnings that include function requirements when fitting and removing equipment where there is a risk of damaging the product or causing a breakdown Continues on next page 3HAWO50008890 Revision 31 1 Safety 1 6 1 Safety signals in the manual Continued Symbol Designation Signification ELECTROSTATIC T
18. aintenance 10 1 3 Rollers 10 1 3 Rollers The lifter frames are guided using heavy duty rollers Those rollers are lubricated for the Flexlifter lifetime Visual inspection e Check that there s no wear or damages to the rollers e Check that there s no wear or damages to the rails 84 3HAWO050008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 10 Instructions for maintenance 10 1 4 Lifetime of main components 10 1 4 Lifetime of main components Roller screw 1 150 000 cycles one cycle lift up amp down e Dry bushings 4 595 567 cycles Rollers 50 000 000 cycles 3HAWO050008890 Revision 85 10 Instructions for maintenance 10 2 1 Verification of the emergency stop feature 10 2 Maintenance of electric equipments 10 2 1 Verification of the emergency stop feature The emergency stop feature must be checked every 6 months please proceed as follow Steps Actions Start with the lifter in lower position With the FlexLifter powered but not moving Press the emergency stop button The brake is applied you should hear the noise in the motor area If the brake is correctly applied the lifter stands still o o0 AO ND If not the lifter might move downward amp stop on the spring bumpers In this case check the cabling of the brake or replace the motor amp redo the test 7 Proceed with the required vali
19. al units must be calibrated etext the mechanical urit you want to calte ate Mecharer ad unit latus ROB 1 Calibrated roo Calibrated en2010110200031 3HAWO50008890 Revision 77 8 Setup and commissioning 8 4 2 Calibration instructions Steps Action 5 Tap the axis checkbox to highlight the axis to be calibrated 6 Tap Update 7 After a few seconds the FlexPendant indicates that the external axis has been calibrated 78 Info lllustration ABBIA cine sos F Calibration FTWOO Rare Counters Update Revolution Counters Mexhanical unit FT900 To update ect ams arat Lap Update MS YA 1 00 1 pre Revolution Counters Updated F Calibration F1900 Rev Counters Update Revolution Counters Mechanical unit FT900 To update select ams arat Lap Update LN Status gi 1 Revolution Counters Updated TER c ABB conos comment ions Calle ation FOOD Rav Counters Update Revolution Counters Mechanical unit Frooo To update select amos an tap Update SX IB statin E Revolution Counters Updated en2010110200034 3HAWO50008890 Revision Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 8 Setup and commissioning 8 5 Checklist before first run 8 5 Checklist before first run WARNING A Check carefully the working envelope of the Flexlifter unit manually be
20. amaged if excessive force is used Description Caution signal Caution Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 Safety 1 3 2 Safety risks related to tools workpieces 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 D Ensure that a gripper is prevented from dropping a workpiece if such is used 3HAWO50008890 Revision 17 1 Safety 1 3 3 Safety risks related to pneumatic hydraulic systems 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 val
21. andalone unit the FlexLifter can be safely handled using the appropriate lifting M12 hook amp straps en2010110200011 54 3HAWO050008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 5 Handling 5 2 Lifting the FlexLifter IRL600 Handling equipment for FlexLifter assembled on a FlexTrack IRT 501 66 or 66R Type Recommended equipment IRT 501 66 with Flexlifter 4 U shackles shackle has to fit into the bail IRL 600 4 Lifting l bolts with a M12 thread 2 lifting straps min 5 meters with a load capacity of 1 tonne each IRT 501 66R with Flexlifter 2 lifting straps min 5 meters with a load capacity of 1 tonne IRL 600 each Lifting FlexTrack IRT 501 66 with FlexLifter Unmount all covers including the carrier side covers and screw the I bolt in the outer holes located between the crossmembers en2010110200012 3HAWO50008890 Revision 55 5 Handling 5 2 Lifting the FlexLifter IRL600 In the following step one end of a lifting strap should be guided through the shackle below the sidemembers at both sides and through the second shackle The second strap should be used for the other side The shackle should act as a guidance only to prevent the straps from slipping The weight of the FlexTrack should be carried by the sidemembers The following picture shows a FlexTrack carrier without Flexlifter mounted on however the principle is i
22. andard label with text added in a fourth language Drawings detailing the design text figure dimensions of the standard labels can be ordered from ABB Notice that each label is identified according to the article number located in the lower corner of the label Example of transparent sticker The figure below shows the location of the free space on one of the labels on the robot where the fourth language can be added The figure also shows a transparent sticker containing the text in Swedish WARNING VARNING High temperature Hohe Temperatur Temp rature lev e H g temperatur xx0500002517 A Free space for adding a fourth language 28 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 Safety 1 5 1 What is an emergency stop 1 5 Safety stops 1 5 1 What is an emergency stop Definition of emergency stop An emergency stop is a state that overrides any other manipulator control disconnects drive power from the manipulator motors stops all moving parts and disconnects power from any potentially dangerous functions controlled by the manipulator system An emergency stop state means that all power is disconnected from the manipulator except for the manual brake release circuits You must perform a recovery procedure i e resetting the emergency stop button and pressing the Motors On button in order to return to nor
23. ation 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 3HAWO50008890 Revision 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 How to use the application Examples of how to use the application Continues on next page 9 0 0 2 Product documentation M2004 Continued Operating manuals The operating manuals describe hands on handling of the products T
24. ation plate and verify for acceptance according to Acceptance inspection on page 52 Lifting FlexLifter IRL 600 using lifting slings see Lifting the FlexLifter IRL600 on page 54 69 8 Setup and commissioning 8 1 Pre requirements Action 5 Assemble the manipulator 6 Electrical installation 7 Software installation 70 Note 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 8 Setup and commissioning 8 2 1 Loading the FlexLifter parameters 8 2 Configure the controller 8 2 1 Loading the FlexLifter parameters It is necessary to load the FlexLifter parameters in the controller using the floppy disk supplied in the delivery package This procedure is described in details in the robot controller operation manual Hereunder are listed the actions related to the FlexLifter specifics Actions 1 Select the menu option Add new parameters 2 Load the file MOC_Ta _DMb_Mc_Ld_Ne cfg NOTE i The filename contains information about the FlexLifter configuration a type of track b of drive module c of the motor d of the SMB e of the node used by the SMB 3HAWO50008890 Revision 71 8 Setup and commissioning 8 2 2 Offset parameters 8 2 2 Offset parameters The offset parameters for the FlexLifter IRL 600 are factory parameters and should not be modified on site 72 3HAWO50
25. battery battery page 90 80 3HAWO50008890 Revision Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 10 Instructions for maintenance 10 1 1 Lubrication of the roller screw nut 10 Instructions for maintenance 10 1 Maintenance of the mechanical components 10 1 1 Lubrication of the roller screw nut WARNING AN Use lithium soap flowable grease class NLGI 0 with a mineral oil base doped with 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 slides The roller screw nut is equipped with a standard grease port Inject the grease with a manual or air operated pump following the instructions below The required grease type is indicated below Supplier Lubricant CASTROL Longtime PD 0 KL BER Microlube GB 0 TOTAL MULTIS EP 0 Procedure Steps Action Info lllustration 1 Switch the robot controller to manual mode Grove Seal 2 If not already done jog the axis to the zero position see Zero position on page 73 3 Lock the safety pin see Safety instructions during mechanical assembly on page 35 3HAWO50008890 Revision 81 10 Instructions for maintenance 10 1 1 Lubrication of the roller screw nut 82 Steps Action Info lllustration Switch off the power on the installation see Safety for electrical operations on pa
26. ble lifting of a high payload inside a station In addition to his the Electromechnical cylinder EMC can be used as a stand alone module for other applications 38 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 2 Description 2 1 Overview 2 2 Concept The FlexLifter IRL600 is based on generic scissor lift table concept However the hydraulic actuator has been replaced by an Electro Mechanical Cylinder EMC to allow for fast movements and high payloads without the constraints of hydraulic actuators Using a proven servomotor the FlexLifter is driven by IRCS robot controller 3HAWO50008890 Revision 39 2 Description 2 2 1 Detailed views 2 2 1 Detailed views Overview 40 en201011020002 o MAN OA BR ON Base plate Electromechanical cylinder EMC Safety pin Spring damper Top plate Outer leg frame Inner leg frame Sensor Cable tray 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 2 Description 2 2 1 Detailed views Electromechanical cylinder EMC en201011020003 o oc fF WD Rod end with ball joint Rod Cylinder Grease port Reducer Servomotor Calibration mark EMC section view en201011020004 o c BR WDM 3HAWO50008890 Revision Front seal Rod Screw Nut Bearings Coupling 41 2 D
27. bling function Reduced speed 250 mm s NOTE i 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 3HAW050008890 Revision 25 1 Safety 1 4 6 Safe use of the Teach Pendant Unit 1 4 6 Safe use of the Teach Pendant Unit 26 NOTE The enabling device is a push button located on the side of the Teach Pendant Unit TPU which when pressed halfway in takes the system to MOTORS ON When the enabling device is released or pushed all the way in the robot is taken to the MOTORS OFF state To ensure safe use of the Teach Pendant Unit the following must be implemented The enabling device must never be rendered inoperative in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move The programmer must always bring the Teach Pendant Unit with him her when entering the robot s working space This is to prevent anyone else taking control of the robot without the programmer knowing 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 Safety 1 4 7 Work inside the manipulator s working range 1 4 7 Work inside the manipulator s working range WARNING VAN If work must be carried out within the robot s work envelope the following points must be observed 3HAWO5000
28. cables which are in motion during the working process may be damaged 20 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 Safety 1 4 1 Safety fence dimensions 1 4 Safety actions 1 4 1 Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell see Product Specification Description Robot Motion Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator 3HAWO50008890 Revision 21 1 Safety 1 4 2 Fire extinguishing 1 4 2 Fire extinguishing NOTE i Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the robot manipulator or controller 22 3HAW050008890 Revision Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 Safety 1 4 3 Emergency release of the robots manipulators axes 1 4 3 Emergency release of the robots manipulators axes Description In an emergency situation any of the robot s manipulat
29. cedures 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 Action Note lllustration 3 Fit a new sealing axis 2 to the gearbox Art no is specified in Required equipment on page xx 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 13 3HAW050008890 Revision 11 0 0 3 How to read the product manual 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 Safety 1 1 Introduction 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 a
30. cy Stop ev ecestee reb RE e ense esee ea e no 29 1 6 Safety related instructions 31 1 6 1 Safety signals in the manual 31 1 6 2 Location of the pictograms 33 1 7 Safety rules for unpacking and handling 34 17 1 Handling mstructionss sas sus sas ER gue 34 1 8 Safety instructions during mechanical assembly 35 LS I Safety Plis oes state Shows node dle ht tonte saine ee M FERES E D 35 1 8 2 Safety for electrical operations 36 1 8 3 Safety during setup amp commissioning 37 2 Description 38 ZA OVERVIEW eek Sik ppc ed peche eee ACH RU Rd ACRI RR S P RR eS We RAN 38 2 2 Concept wea ces nus aan a mans eve be eee Ea GR ee date dis a avenue 39 2 2 T Detailed Views 5 00 et el is Ai rece d t Ack site Suk dates 40 2 3 Terminology te a re ae Ate ie pe ue ere fn ra CR rd te de 42 2 3 1 Terms used in this manual srias ee a EIE 42 3 Technical details 43 3 T Performatces iii Dx EAR de t RET Ds AE ERR RUP SUE n dre d 43 3 2 Overall dimensions cc A da UU RUP ed OE RES RI AERA RII AAN 44 5 3 Motor detal ucc este oL en eg est eere ct RSS ipo gt eh als 46 3 4 Cables and position sensors
31. dations in the control system to switch back to auto mode 86 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 10 Instructions for maintenance 10 2 2 Position sensors 10 2 2 Position sensors It is necessary to verify that the position sensors are still active every 6 months Down position Detector Upper position Detector en2010110200036 Steps Actions 1 Switch to manual mode 2 With the teach pendant jog the lifter up amp down 3 Check that the sensors are detecting the lifter position LED on sensor signal in control system If not adjust the sensor position verify the cabling or replace the sensor 3HAWO50008890 Revision 87 10 Instructions for maintenance 10 2 3 Verification of the cables 10 2 3 Verification of the cables Every 6 month verify the Flexlifter cabling If you find a cable You should with damages or destruction of the Replace the cable remove the cause of the external envelope due to wear by rubbing on wear or route the cable in a different way a fixed part 88 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 10 Instructions for maintenance 10 2 4 Verification of the connectors 10 2 4 Verification of the connectors Once a month verify that all the connectors on the controller the SMB box
32. dentical en2010110200013 Lifting FlexTrack IRT 501 66R with FlexLifter The lifting strap should be guided behind the second to last crossmembers below the sidemembers at both sides and through the second shackle The second strap should be used for the other side The following picture shows a FlexTrack carrier without Flexlifter mounted on however the principle is identical en2010110200014 56 3HAWO050008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 5 Handling 5 2 Lifting the FlexLifter IRL600 Never place lifting straps wider than a combined angle of max 60 WARNING AN Never lift a track longer than 3m at once If the track is longer the track has to be disassembled into smaller sections Lifting FlexTrack IRT 501 66R with FlexLifter using a lifting beam If there is a lifting beam available the strap should always be located at the middle of the sidemembers 3HAWO50008890 Revision 57 5 Handling 5 2 Lifting the FlexLifter IRL600 5 3 Motor brake release 5 3 1 Important information about the brake release General 58 You should not need to release the brake during the commissioning or the normal use of the product If it happens to be however necessary you can release the brake by either pressing the brake release button on the SMB box or by supplying 24V DC to the right pin of the FlexLifter movement motor power cabl
33. e Before releasing the brake of the FlexLifter it is necessary to secure the position of the top frame with a handling system or a crane If possible use posts to prevent any unexpected fall dawn of the FlexLifter Safety posts specifically designed for the FlexLifter IRL 600 are available as spare parts ABB reference 3HAW107703535 To install them remove the spring dampers and replace them with the safety posts and secure them with the same sets of screws Proceed one by one en2010110200039 WARNING Releasing the brake of the FlexLifter without taking the appropriate care can induce a risk of serious injury for the operators Before releasing the brake make sure that nobody is working on the FlexLifter or the Flex Track Do not release the brake when the FlexLifter is loaded There is a risk of brutal fall down 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 5 3 2 Brake release of the FlexLifter with the SMB box 5 Handling 5 2 Lifting the FlexLifter IRL600 Instructions for brake release using the SMB box Action Note lllustration 1 Make sure that all cables are connected as described in Electrical setup on page 63 2 Turn the controller on 3 To release the brake press the brake release button on the back of the SMB box 3HAWO50008890 Revision 59 5 Handling 5 2 Lifting the FlexLifter IRL600 5 3 3
34. e 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 Type of information Detailed in document Section Installation of safety devices Product manual for the robot Installation and commissioning Changing robot modes Operators manual Operating modes RobotWare 5 0 Restricting the working space Product manual for the robot Installation and commissioning 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 3 Safety risks 1 Safety 1 3 1 Safety risks during installation and service work on robot 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 button
35. e 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 betrained 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 Content Safety Safety information that must be read through before performing any installation or service work on the FlexLifter Contains general safety aspects as well as more specific information about how to avoid personal injuries and damage to the product Description and technical Specifications and characteristics of the FlexLifter 600 details Unpacking acceptance Information relative to the steps following the reception of the and handling FlexLifter until its installation Maintenance Step by step procedures that describe how to perform maintenance of the FlexLifter 600 Based on a maintenance schedule that may be used in the work of planning periodical maintenance Spare parts List of the spare parts available for the FlexLifter 600 Continues on next page 3HAWO50008890 Revision 7 0 0 1 Overview Continued References Reference Document ID Product specification IRL 600 3HAWO050008891 Product specification IRT 501 66 66R 90 90R 3HAW0500085
36. ectromechanical cylinder back in position in the lifter following the steps 9 to 5 in reverse order Make sure that not tool has been left in the lifter frame en2010110200045 Connect the cables to the motor Unlock the safety pin and remove the safety posts Slowly release the load from the crane Run a test at low speed Calibrate the FlexLifter as described in section Calibration on page 76 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 12 Spare parts for maintenance 12 1 Mechanical spare parts 12 Spare parts for maintenance 12 1 Mechanical spare parts ABB part reference no 3HAW107703535 3HAW107703590 3HAWC117059 3HAWC117034 3HAWC117040 3HAWL000401 3HAW107703518 3HAWC117048 3HAWC103477 3HAWO50008890 Revision Description Set of 4 safety posts Complete electro mechanical cylinder includes servomotor Reducer Coupling Ball joint for cylinder end Seal for cylinder end Manual lock cylinder Latch for manual lock cylinder Hard stop bumper for spring damper 95 12 Spare parts for maintenance 12 2 Electrical spare parts 12 2 Electrical spare parts 96 ABB part reference no 3HAWC116592 3HAWO050008604 3HAWO050008605 3HAWO050008606 3HAWO050008608 005 3HAWO050008608 010 3HAWO050008608 015 3HAWO050008609 005 3HAWO050008609 010 3HAWO50008609 015 3HAWO50008613 005 3HAW050008613 0
37. ent IRB 6600 7600 770 4 Motor drive W type Drive module IRC5 controller Floppy drive If the lifter parameters have to be loaded in the controller using a floppy drive this optional device must be available It is therefore possible to load the parameters in the controller if this one is not equipped with a floppy drive please check the controller operation manual TIP In case of application with IRB 4400 robot or smaller performances are reduced speed acceleration Please contact ABB 50 3HAWO050008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 4 Unpacking and acceptance 4 1 Unpacking 4 Unpacking and acceptance 4 1 Unpacking Inspection The FlexLifter IRL 600 is wrapped in plastic Unpack it and check for any visible transport damage If the FlexLifter is damaged contact ABB Contents You should find in the standard delivery package not including options The Flexlifter The motor cables The product manual Cleaning Before transport the FlexLifter IRL 600 has been protected against rust by a thin film of oil that has been applied before packing This film of oil must be wiped off before installation NOTE i Wipe off any surplus oil using a lint free cloth 3HAW050008890 Revision 51 4 Unpacking and acceptance 4 2 Acceptance inspection 4 2 Acceptance inspection Y TIP e Q Always try to d
38. erson is standing on the top plate before moving the lifter Check also that nothing is left on the top of the lifter 1 e tools 3HAWO50008890 Revision 37 2 Description 2 1 Overview 2 Description 2 1 Overview The FlexLifter IRL600 is designed to increase the robot working envelope by adding a programmable degree of freedom to the FlexTrack IRT501 66 or 66R It is possible to use the unit to position a part tooling in front of the process robots material handling applications The unit can be used also as a stand alone module High performance The FlexLifter IRL600 integrates a powerful and compact servomotor equipped with a high quality gear allowing high accelerations amp speeds Ease of use The upper plate of the lifter is adapted to material handling applications The lower plate of the lifter is designed to adapt directly on FlexTrack IRT501 66 or 66R carriage The FlexLifter movements are programmed like a conventional axis using the robot controller interface Technical specifications FlexLifter Max payload Average speed Vertical stroke mm s mm IRL 600 600 kg 200 600 Modularity The FlexLifter is module of the FlexLean product range It can be used an additional axes of the robot and work in coordinated motion with an ABB robot or in conjunction with the ABB FlexTrack allowing the system to pickup and drop off a load The FlexLifter can also be used as a stand alone unit allowing programma
39. escription 2 3 1 Terms used in this manual 2 3 Terminology 2 3 1 Terms used in this manual 42 You ll find in the table hereunder some explanations regarding the terms used in this manual Designation Robotic system Robot Manipulator Controller Translation unit Carriage Track SMB SMB Box Definition The robot and the track motion The manipulator and the controller The 6 axis mechanical unit of the robot The motion system used to control the manipulator amp track motion i e ABB IRC5 The complete carriage assembly including all moving parts cable chain lubrication system sensors The moving part of the track motion The top plate receives the tooling robot The static part of the track motion The track is delivered as modules to be assembled by the customer as described in When used as a FlexTrack additional axis on page 61 The Serial Measurement Board is an integrated circuit board used to measure and store the position of each robot axes The Serial Measurement Board Box a control box which includes the SMB card for the FlexLifter axis as well as the resolver position backup battery 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 3 Technical details 3 1 Performances 3 Technical details 3 1 Performances FlexLifter IRL 600 The following table summarizes the main informatio
40. etermine if the goods are as ordered and that the package is not damaged before unpacking the unit Identification plate To identify the delivery check the identification plate and compare it to the delivery note The identification plate is located on the baseplate side see fig below and indicates the FlexLifter type the serial number and the weight en2010110200010 52 O O 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 5 Handling 5 1 Lifting weight 5 Handling 5 1 Lifting weight FlexLifter delivered as a standalone unit The weight of a FlexLifter IRL 600 without FlexTrack is 700 kg FlexLifter delivered assembled on a section of Flextrack 2 meter section with FlexLifter IRL 600 3 meter section with FlexLifter IRL 600 3HAWO50008890 Revision IRT 501 66 1336 kg 1491 kg IRT 501 66R 1516 kg 1612 kg 53 5 Handling 5 2 Lifting the FlexLifter IRL600 5 2 Lifting the FlexLifter IRL600 Actions before lifting CAUTION D Before lifting the FlexLifter IRL 600 read through the safety instructions carefully Handling equipment for FlexLifter delivered as a standalone unit Type Recommended equipment Flexlifter IRL 600 4 Lifting l bolts with a M12 thread 2 lifting straps with a load capacity of 1 tonne each Lifting the FlexLifter delivered as a standalone unit As a st
41. exLifter area and that nothing has been left i e tool inside the FlexLifter frame Make sure that the machines have been correctly installed NOTE The FlexLifter does not need to be calibrated during restart The resolvers only need to be calibrated when commissioning the system When to calibrate The FlexLifter axis must be calibrated each time the contents of the revolution counter are changed or lost If resolver values are changed the robot must be recalibrated using the calibration methods supplied from ABB Calibrate the FlexLifter IRL 600 carefully with standard calibration The resolver values will change when parts affecting the calibration position are replaced on the FlexLifter IRL 600 e g motor or part of transmission If the contents of the revolution counter memory are lost the counters must be updated This will occur when the battery is discharged aresolver error occurs the signal between a resolver and measurement board is interrupted arobot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and controller are connected at the first installation Power failure There s no need to calibrate the FlexLifter after a power failure the backup battery included in the SMB box will store the resolver position until power is restored NOTE The resolvers only need to be calibrated when commissioning the system Fine calibration
42. fore switching to auto 100 Checking the working envelope of the lifter Using the FlexPendant jog the carriage in order to verify that The lifter can reach the extreme positions without mechanical interference The sensors are detecting the lifter as required by the process Nocable is damaged rubbed or constrained by the lifter movements There is no abnormal noise or wear 3HAWO50008890 Revision 79 9 Periodical and preventive maintenance 9 1 Maintenance planning 9 Periodical and preventive maintenance 9 1 Maintenance planning Even if the Flexlifter 600 has been designed to require a very few maintenance operations it 1s important to check the points mentioned hereafter and respect the maintenance time intervals Time interval ltem Maintenance More info Every 3 months Roller Screw Lubrication of the roller screw Lubrication of the roller nut screw nut on page 81 Every 6 months Safety Lock Check the good condition of Safety instructions mechanical locking pin during mechanical assembly on page 35 Emergency stop Check that all safety features Verification of the feature are operational emergency stop feature on page 86 Cables and Visual inspection of cables amp Verification of the electrical electrical cabinets envelope cables on page 88 cabinets Every year Rollers Visual inspection of the rollers Rollers on page 84 amp rails Every 3 years SMB Backup Replace the SMB backup SMB backup battery on
43. ge 36 Remove the protection cap from the cylinder Protection cap Locate the grease nipple and connect the grease pump 7 Inject 14 cm of grease into the roller nut 8 Disconnect the pump and put the protection cap 10 back on Make sure that no tool has been left in the FlexLifter and unlock the safety pin Grease nipple Switch the controller on in manual mode and gently jog the FlexLifter to make sure that there is no mechanical interference 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 10 Instructions for maintenance 10 1 2 Reducer 10 1 2 Reducer The reducer is filled with synthetic oil for the internal lubrication The quantity of oil in the gear is planned for the gear s lifetime Reducer en2010110200035 However if you need to refill the gear with oil for any reason you must use one of the recommended synthetic oils below ISO VG 220 Supplier Reference MOBIL SHC 630 SHELL Omala HD 220 TOTAL Carter SH 220 The manufacturer of the gear is recommending the following actions After 500 hours Actions 1st use 3 months Every 3 months Every year Visual inspection X X X Verification of the X X X tightening torque Visual inspection e Check that there s no mark of wear or damages to the gear Check that there s no oil leak 3HAWO50008890 Revision 83 10 Instructions for m
44. he electrostatic discharge ESD symbol indicates DISCHARGE electrostatic hazards which could result in severe ESD damage to the product Electrostatic discharge ESD NOTE Note symbols alert you to important facts and n conditions Note TIP Tip symbols direct you to specific instructions where to i find additional information or how to perform a certain NJ neti t PO operation in an easier way Tip 32 3HAW050008890 Revision Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 Safety 1 6 2 Location of the pictograms 1 6 2 Location of the pictograms Location of pictograms on the FlexLifter en201011020001 Symbol Description Position Risk of severe injury to hands This pictogram must be positioned close to the scissor frame risk of severe injury when lifter is going Risk of severe injury to down hands Do not walk The pictogram is located on the top plate The top plate is not designed to be walkable Do not walk 3HAWO50008890 Revision 33 1 Safety 1 7 1 Handling instructions 1 7 Safety rules for unpacking and handling 1 7 1 Handling instructions Only the pre assembled FlexLifter is prepared for handling see Handling on page 53 TIP Read carefully the following instruction before unpacking the product 34 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 200
45. he 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 IRCS with FlexPendant RobotStudio Introduction to RAPID Trouble shooting for the controller and manipulator 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 0 0 3 How to read the product manual 0 0 3 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 Action Note lllustration 8 Remove the rear attachment screws Shown in the figure Location of gearbox gearbox on page xx Reference to required equipment The pro
46. in this process a threaded hole in the axis is prepared for the extractor The axis should easily slide out otherwise it means that there is still a constraint from the load above en2010110200041 Remove the locking plate securing the clevis B A en2010110200042 Pull out the clevis axes you do not have to completely remove the axes in order to free the clevis Here also the axes are prepared for extractor with a treaded hole en2010110200043 Xx en2010110200044 Pull out the complete cylinder from the lifter structure The weight of the electromechanical cylinder is 82 kg Lay down the complete electromechanical cylinder on a workbench Unclamp the shrink disc of the coupling between motor amp reducer en2010110200045 93 11 Maintenance operations 11 1 Motor or gearbox failure 94 Steps 11 12 13 14 15 16 17 18 19 Actions Info lllustration Remove the 4 screws and pull out the motor en2010110200046 Ifthe problem comes from the reducer remove the 4 screws and pull it out en2010110200047 Remove the reducer flange Remove the coupling and install the new reducer The tightening torque of the coupling shrink disc is 6Nm en2010110200048 Install the new motor and reducer The threaded pin of the coupling must be tightened to TA1 45 Nm Width across flats of threaded pin B 6mm en2010110200045 Install the el
47. ing or connecting units The mains supply to the robot must be connected in such a way that it can be turned off outside the robot s working space Voltage related risks controller IRC5 A danger of high voltage is associated with the following parts Be aware of stored electrical energy DC link Ultra Cap unit in the controller Units inside the controller e g I O modules can be supplied with power from an external source The mains supply mains switch The transformers The power unit The control power supply 230 VAC The rectifier unit 400 480 VAC and 700 VDC Note Capacitors The drive unit 700 VDC The drive system power supply 230 VAC The service outlets 115 230 VAC The customer power supply 230 VAC The power supply unit for tools or special power supply units for the machining process The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains Additional connections Voltage related risks robot A danger of high voltage is associated with the robot in The power supply for the motors up to 800 VDC The user connections for tools or other parts of the installation max 230 VAC see chapter Installation and commissioning in the Product manual Voltage related risks tools material handling devices etc Tools material handling devices etc may be live even if the robot system is in the OFF position Power supply
48. ipping 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 3HAWO50008890 Revision 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 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 Continues on next page 15 1 Safety 1 3 1 Safety risks during installation and service work on robot Continued Complete robot Safety risk Hot components Removed parts may result in collapse of robot Description Caution signal Caution Motors and gears are HOT after running the robot Touching the motors and gears may result in burns A Warning signal 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 Safety risk Cable packs are sensitive to mechanical damage Description Caution signal Caution The cable packs are sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them Gearboxes and motors 16 Safety risk Gears may be d
49. mal operation The manipulator system can be configured so that the emergency stop results in either Anuncontrolled stop immediately stopping the manipulator actions by disconnecting power from the motors Acontrolled stop stopping the manipulator actions with power available to the motors so that the manipulator path can be maintained When completed power is disconnected The default setting is uncontrolled stop However controlled stops are preferred since they minimize extra unnecessary wear on the manipulator and the actions needed to return the manipulator system back to production Please consult your plant or cell documentation to see how your manipulator system is configured NOTE The emergency stop function may only be used for the purpose and under the conditions for which it is intended NOTE The emergency stop function is intended for immediately stopping equipment in the event of an emergency NOTE Emergency stop should not be used for normal program stops as this causes extra unnecessary wear on the manipulator Classification of stops The safety standards that regulates automation and manipulator equipment defines categories in which each type of stop applies If the stop is then it is classified as uncontrolled category 0 zero controlled category 1 Continues on next page 3HAWO50008890 Revision 29 1 Safety 1 5 1 What is an emergency stop Continued Emergency s
50. meters and configure the controller as described in Loading the FlexLifter parameters on page 71 2 Installation of the FlexLifter Check that the FlexLifter is installed and levelled as described in Fixing the FlexLifter on page 61 3 Manual lubrication FlexLifter is lubricated at ABB facility during assembly However if you need to manually lubricate the roller screw see Lubrication on page 74 4 Synchronization Like any other robot axis the FlexLifter motor must be calibrated using the FlexPendant see Calibration on page 76 5 Checklist The Checklist before first run on page 79 gives instructions about points to check before switching to auto mode Ambient temperature Description Standard Option Temperature During operation Standard 5 C 41 F to 50 C 122 F For the controller Standard 5 41 F to 45 C 113 F For the controller Option 5 C 41 F to 52 C 126 F For short periods not Standard up to 70 C 158 F exceeding 24 hours Relative humidity Description During transportation and storage During operation Relative humidity Max 95 at constant temperature Max 95 at constant temperature Preparations The following steps should be carried out before starting the FlexTrack IRT 501 Action 1 Unpacking and acceptance 2 Lifting 3 Preparation for assembly 4 Assemble the lifter 3HAWO50008890 Revision Note Compare the delivery check to the identific
51. n regarding the FlexLifter IRL600 per formances Feature Vertical stroke Speed Deceleration time Unidirectional repeatability Weight of the unit Max payload Index of protection According to ISO 9283 test 3HAWO50008890 Revision Performances 600 mm 200 mm s 0 4 s 1mm 700 kg 600 kg IP 54 43 3 Technical details 3 2 Overall dimensions 3 2 Overall dimensions Lower position 660 320 en201011020005 Upper position 920 en201011020006 Fixing mask on top plate 6 holes M12 850 850 500 en201011020007 44 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 3 Technical details 3 2 Overall dimensions Example of configuration FlexTrack with 2 carriages FlexLifter en201011020008 3HAWO50008890 Revision 45 3 Technical details 3 3 Motor details 3 3 Motor details Motor specifications 46 Motor Voltage Rated Torque Brake Voltage Brake torque Connection socket Resolver Connection socket 400 volts 15 9 N m at 3000tr min 24 volts 13 5 Nm REF MS 3102A20 18P REF MS 3106A20 29P MOTOR MS3102A20 18P p ENCODER MS3102A20 29P amp 110h7 9 035 L mm 241 Output Shaft A mm 26h6 Shat B mm 28 Attached spigot C Mm 6 View D D View F F e
52. n2010110200016 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 3 Technical details 3 4 1 FlexLifter cables 3 4 Cables and position sensors 3 4 1 FlexLifter cables General When the FlexLifter is mounted onto a standard FlexTrack no modification of the FlexTrack cabling is required You do however need to order specific flexible movement FlexLifter cables to be added in the cable chain of the FlexTrack In the case of a standalone configuration movement cables or static field cables can be used to connect the FlexLifter to the SMB box See Cabling of the FlexLifter on page 63 Dimensions The FlexLifter static and movement cables are available with lengths of 5 10 and 15 meters distance from the controller to the SMB box static cables and distance from the SMB box to the FlexLifter motor movement cable Diameter of the movement cables Designation Diameter 1 Resolver cableMotor Y 9 5 mm power cable Y 14 mm Position sensor cable 5 5 mm See Cabling of the FlexLifter on page 63 3HAWO50008890 Revision 47 3 Technical details 3 4 2 Cable tray 3 4 2 Cable tray The lower and upper frames of the FlexLifter are equipped with cable trays dedicated to route the cables for the customer s tooling See Routing of the cables on page 67 The trays are 50mm wide 30mm high and their lengths are respectively 500mm and
53. ons Remove the locking plate securing the spherical joint axis Escape the axis from the spherical joint you do not have to completely remove the axis You can use an extractor to help you in this process a threaded hole in the axis is prepared for the extractor The axis should easily slide out otherwise it means that there is still a constraint from the load above Remove the locking plate securing the clevis axes both sides Pull out the clevis axes you do not have to completely remove the axes in order to free the clevis Here also the axes are prepared for extractor with a treaded hole Pull out the complete cylinder from the lifter structure The weight of the electromechanical cylinder is 82 kg Lay down the complete electromechanical cylinder on a workbench Unclamp the shrink disc of the coupling between motor amp reducer Info Illustration en2010110200041 A en2010110200042 en2010110200043 en2010110200044 en2010110200045 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 11 Maintenance operations 11 1 Motor or gearbox failure Steps Actions Info lllustration 3HAWO50008890 Revision 5 10 Remove the locking plate securing the spherical joint axis Escape the axis from the spherical joint you do not have to completely remove the axis You can use an extractor to help you
54. ors axes may be released manually by pushing the brake release buttons on the robot How to release the brakes is detailed in section Motor brake release on page 58 The robot arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the trapped person further increasing any injury 3HAWO50008890 Revision 23 1 Safety 1 4 4 Brake testing 1 4 4 Brake testing When to test During operation the holding brakes of each axis motor wear normally A test may be per formed to determine whether the brake can still perform its function How to test 24 The function of each axis motor holding brakes may be checked as detailed below 1 Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized max static load 2 Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller 3 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 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 Safety 1 4 5 Risk of disabling function Reduced speed 250 mm s 1 4 5 Risk of disa
55. re found in General safety information on page 14 e 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 3HAWO50008890 Revision 13 1 Safety 1 2 1 Safety in the robot system 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 1s 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 interfac
56. s 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 sl
57. ti0N oooooccocconencn eR n n n nn nn 14 1 2 1 Safety in the robot system e me hh eh 14 1 3 Safety rISKs it A A a ale rex 15 1 3 1 Safety risks during installation and service work on robot 15 1 3 2 Safety risks related to tools workpieces 17 1 3 3 Safety risks related to pneumatic hydraulic systems 18 1 3 4 Safety risks during operational disturbances 19 1 3 5 Risks associated with live electric parts 20 1 4 Safety actions wi cee eek ll lli den salons rl Ra ges rra moe a no NER a neue 21 1 4 1 Safety fence dimensions 21 14 2 Fare extinguishime eve bi Ree PERPE RS PEE E S PME eed TOS PPP tp 22 1 4 3 Emergency release of the robots manipulators axes 23 1 44 Brake testno seinan euh mess sas GUCCI CST AGER EL ER 24 1 4 5 Risk of disabling function Reduced speed 250 mm s 25 1 4 6 Safe use of the Teach Pendant Unit 26 1 4 7 Work inside the manipulator s working range 27 1 4 8 Translate the information on safety and information labels 28 1 5 Satelite Nate 29 1 5 1 What1s an emergen
58. time of main components 10 2 Maintenance of electric equipments 10 2 1 Verification of the emergency stop feature 10 2 2 Position sensots ever a a Ea cen de HR S 51 51 52 53 53 54 58 58 59 60 61 61 61 62 63 63 63 64 65 65 67 68 69 69 71 71 72 73 74 74 76 76 77 79 80 80 10 2 3 Verification of the cables 88 10 2 4 Verification of the connectors 89 10 2 5 SMB backup battery cocida UR Ce RI De RR de ee tal LE 90 11 Maintenance operations 91 11 1 Motor or gearbox fallure ii ete een OEE Ide See ee RER Es e 91 12 Spare parts for maintenance 95 12 1 Mechanical spare parts eV a a E 95 12 2 Electrical spare parts ue A A A 96 Copyright 2006 2008 ABB All rights reserved 0 0 1 Overview 0 0 1 Overview About this manual This manual contains instructions for the characteristics of the FlexLifter mechanical and electrical installation instructions for the FlexLifter maintenance instructions for the FlexLifter 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 maintenanc
59. top devices 30 In a manipulator system there are several emergency stop devices that can be operated in order to achieve an emergency stop There are emergency stop buttons available on the Flex Pendant and on the controller cabinet on the Control Module on a Dual Cabinet Controller There can also be other types of emergency stops on your manipulator consult your plant or cell documentation to see how your manipulator system is configured 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 Safety 1 6 1 Safety signals in the manual 1 6 Safety related instructions 1 6 1 Safety signals in the manual Introduction to safety signals This section specifies all dangers that may arise from performing the work detailed in the manual Each danger is detailed in its own section consisting of Acaption specifying the danger level DANGER WARNING or CAUTION and the type of danger A brief description of what will happen if the operator service personnel do not eliminate the danger Aninstruction of how to eliminate the danger to facilitate performing the activity at hand Danger levels The table below defines the captions specifying the danger levels used throughout this manual Symbol Designation DANGER danger WARNING warning ELECTRICAL SHOCK Electrical shock CAUTION caution Signification Warns that an
60. ves should be used in case of emergency Shot bolts should be used to prevent tools etc from falling due to gravity 18 3HAWO50008890 Revision O Copyright 2006 2008 ABB All rights reserved Copyright 2006 2008 ABB All rights reserved 1 Safety 1 3 4 Safety risks during operational disturbances 1 3 4 Safety risks during operational disturbances General The industrial robot is a flexible tool which can be used in many different industrial applications All work must be carried out professionally and in accordance with the applicable safety regulations Care must be taken at all times Qualified personnel Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken due to risks other than those associated with regular operation Such an interruption may have to be rectified manually 3HAWO050008890 Revision 19 1 Safety 1 8 5 Risks associated with live electric parts 1 3 5 Risks associated with live electric parts Voltage related risks general Although troubleshooting may on occasion have to be carried out while the power supply is turned on the robot must be turned off by setting the mains switch to OFF when repairing faults disconnecting electric leads and disconnect
61. xample 4444 44444 hh nn TL OV IVIEW A veter agiles cbe a le deae ede Ent 7 2 2 Ro ting ob th Cables ns sit serre roe Pp her AA EISE Pete de TLISMB DOK ii ete CL WE REO e Rer eb aiii 8 Setup and commissioning S T Pre requirements servos Sa hs Skate v ese LEE m os dane es hee EUR OVE T 9 2 Configure the controller ero a nente eee ale ea ac um eels 8 2 1 Loading the FlexLifter parameters 8 2 2 Offset parameters ec ce pere SRG NE e IR lente RC CHER OE e ERE 8 2 3 Zero POSITION cse nu eb ERE eb pee REPE SE SE E 8 3 Lubrication naire nn e m 8 3 1 Lubrication with basic delivery package 8 4 Calibration 0 a dd nine tent e Ra nck yn nt ncaa ea alle ea ua RUN OCA as 8A I A verte ce we EERIE Garand bea he AEN RIS SEE a tae orig a agere SAD Calibration instr ctilons a oer etre UI Rd ede emp mue ERES EE So Checklist before first r n Za o SEDE Pee esee eb tbe eder teque 9 Periodical and preventive maintenance 91 Maintenance plannings ses dise ce le ibn a she MUN be bete ne EDS dites IS 10 Instructions for maintenance 10 1 Maintenance of the mechanical components 10 1 1 Lubrication of the roller screw nut 10 12 ReduCer iii dr rs ei oda a Ets LOTS Rollers ui ii ERI ARE RR eee reo eee et ERN an 10 1 4 Life

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