ABB IRL 600 FlexLifter Product manual

ABB Robotics

Product manual

FlexLifter

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.

© Copyright 2011 ABB All rights reserved.

ABB France Robotics Products

Rue de l'équerre

ZI des Béthunes

95310 SAINT-OUEN L'AUMONE

France

Table of Contents

0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

0.0.2 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

0.0.3 How to read the product manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Safety 13

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.4.3 Emergency release of the robots/manipulators axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.5.1 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

1.7.1 Handling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.8 Safety instructions during mechanical assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.8.1 Safety pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.8.2 Safety for electrical operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.8.3 Safety during setup & commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2 Description 38

2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.2 Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.2.1 Detailed views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.3 Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.3.1 Terms used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3 Technical details 43

3.1 Performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.2 Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.3 Motor details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.4 Cables and position sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.4.1 FlexLifter cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.4.2 Cable tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.4.3 Position sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.5 Robot controller technical requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3

Table of Contents

4 Unpacking and acceptance 51

4.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.2 Acceptance inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5 Handling 53

5.1 Lifting weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.2 Lifting the FlexLifter IRL600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.3 Motor brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.3.1 Important information about the brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.3.2 Brake release of the FlexLifter with the SMB box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.3.3 Brake release of the FlexLifter with external 24V DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

6 Installation 61

6.1 Fixing the FlexLifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.1.1 When used as a FlexTrack additional axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.1.2 When used as a stand alone unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

7 Electrical setup 63

7.1 Cabling of the FlexLifter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

7.1.1 Stand alone configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

7.1.2 FlexLifter on FlexTrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

7.2 Architecture example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7.2.2 Routing of the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.2.3 SMB box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8 Setup and commissioning 69

8.1 Pre-requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

8.2 Configure the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

8.2.1 Loading the FlexLifter parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

8.2.2 Offset parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

8.2.3 Zero position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

8.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

8.3.1 Lubrication with basic delivery package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

8.4 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

8.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

8.4.2 Calibration instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

8.5 Checklist before first run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

9 Periodical and preventive maintenance 80

9.1 Maintenance planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

10 Instructions for maintenance 81

10.1 Maintenance of the mechanical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

10.1.1 Lubrication of the roller screw nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

10.1.2 Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

10.1.3 Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

10.1.4 Lifetime of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

10.2 Maintenance of electric equipments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

10.2.1 Verification of the emergency stop feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

10.2.2 Position sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

4

10.2.3 Verification of the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

10.2.4 Verification of the connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

10.2.5 SMB backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

11 Maintenance operations 91

11.1 Motor or gearbox failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

12 Spare parts for maintenance 95

12.1 Mechanical spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

12.2 Electrical spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

5

6

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

• maintenance work

• repair work.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

A maintenance /repair/ installation craftsman working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work.

Organization of chapters

The manual is organized in the following chapters:

Chapter

Safety

Content

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.

Specifications and characteristics of the FlexLifter 600.

Description and technical details

Unpacking, acceptance and handling

Maintenance

Spare parts

Information relative to the steps following the reception of the

FlexLifter, until its installation.

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.

List of the spare parts available for the FlexLifter 600.

3HAW050008890 Revision: -

Continues on next page

7

0.0.1 Overview

Continued

References

Revisions

Reference

Product specification IRL 600

Product specification - IRT 501 - 66/66R/90/90R

Product Manual for IRT 501 - 66/66R/90/90R

Product manual - IRC5 Robot Controller

Operating manual - IRC5 with FlexPendant

Operating manual - Calibration Pendulum

Service Information System - IRC5

Application manual - Additional axes and stand alone controller

System Parameters

Document ID

3HAW050008891

3HAW050008591

3HAW050008590

3HAC021313-001

3HAC16590-1

3HAC16578-1

3HAC025709-001

3HAC021395-001

3HAC17076-1

-

Revision Description

First edition

8 3HAW050008890 Revision: -

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 (calibration, decommissioning).

• Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards).

• Parts list.

• Foldouts or exploded views.

• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe the manipulator software in general and contain relevant reference information.

• RAPID Overview: An overview of the RAPID programming language.

• RAPID Instructions, Functions and Data types: Description and syntax for all

RAPID instructions, functions, and data types.

• RAPID Kernel: A formal description of the RAPID programming language.

• System parameters: Description of system parameters and configuration workflows.

Application manuals

Specific applications (for example software or hardware options) are described in

Application manuals. An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful).

• What is included (for example cables, I/O boards, RAPID instructions, system parameters, CD with PC software).

• How to use the application.

• Examples of how to use the application.



9

0.0.2 Product documentation, M2004

Continued

Operating manuals

The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and trouble shooters.

The group of manuals includes:

• Emergency safety information

• General safety information

• Getting started, IRC5 and RobotStudio

• IRC5 with FlexPendant

• RobotStudio

• Introduction to RAPID

• Trouble shooting, for the controller and manipulator.

10 3HAW050008890 Revision: -

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.

8.

Action

Remove the rear attachment screws, gearbox.

Note/Illustration

Shown in the figure Location of gearbox

on page xx.

Reference to required equipment

The procedures often include references to equipment (spare parts, tools etc.) required for the different actions in the procedure. The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information, i.e. article number, dimension.

The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced list.

The table below shows an example of a reference to a list of required equipment, from a step in a procedure.

3.

Action Note/Illustration

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

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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 are found in

General safety information on page 14 .

• specific safety information, pointed out in the procedure at the moment of the danger.

How to avoid and eliminate the danger is either detailed directly in the procedure, or

further detailed in separate instructions, found in Safety related instructions on page

31 .

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1 Safety

1.2.1. 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 is installed.

The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system are designed and installed correctly.

Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. User's Guide and Product

Manual.

Connection of external safety devices

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

Limitation of liability

Any information given in this manual regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with.

Related information

Type of information Detailed in document Section

Installation of safety devices Product manual for the robot Installation and commissioning

Changing robot modes Operators manual

(RobotWare 5.0)

Operating modes

Restricting the working space Product manual for the robot Installation and commissioning

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1 Safety

1.3.1. Safety risks during installation and service work on robot

1.3 Safety risks

1.3.1. Safety risks during installation and service work on robot

Overview

This section includes information of general safety risks to be considered when performing installation and service work on the robot.

General risks during installation and service

• The instructions in the Product Manual - Installation and Commissioning must always be followed.

• Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly.

• Those in charge of operations must make sure that safety instructions are available for the installation in question.

• Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it.

Nation/region specific regulations

To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.

Non-voltage related risks

• Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices.

• Turntables or the like should be used to keep the operator out of the robot's working space.

• The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the parallel arm.

• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, are dismantled.

• When dismantling/assembling mechanical units, watch out for falling objects.

• Be aware of stored heat energy in the controller.

• Never use the robot as a ladder, i.e. do not climb on the robot motors or other part during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.

To be observed by the supplier of the complete system

• The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function.

• 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.


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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!

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

Safety risk

Gears may be damaged 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!

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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!

Ensure that a gripper is prevented from dropping a workpiece, if such is used.

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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 valves should be used in case of emergency.

• Shot bolts should be used to prevent tools, etc., from falling due to gravity.

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1 Safety

1.3.4. 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.

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1 Safety

1.3.5. 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 disconnecting 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 cables which are in motion during the working process may be damaged.

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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.

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1 Safety

1.4.2. Fire extinguishing

1.4.2. Fire extinguishing

NOTE!

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator or controller)!

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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/manipulators 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!

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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 performed to determine whether the brake can still perform its function.

How to test

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.

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1 Safety

1.4.5. Risk of disabling function "Reduced speed 250 mm/s"

1.4.5. Risk of disabling function "Reduced speed 250 mm/s"

NOTE!

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.

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1 Safety

1.4.6. Safe use of the Teach Pendant Unit

1.4.6. Safe use of the Teach Pendant Unit

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.

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1 Safety

1.4.7. Work inside the manipulator's working range

1.4.7. Work inside the manipulator's working range

WARNING!

If work must be carried out within the robot's work envelope, the following points must be observed:

• 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 < 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.

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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 standard label with text added in a fourth language.

Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

Example of transparent sticker

The figure below shows the location of the free space on one of the labels on the robot, where the fourth language can be added. The figure also shows a transparent sticker, containing the text in Swedish.

28 xx0500002517

A Free space for adding a fourth language


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 normal operation.

The manipulator system can be configured so that the emergency stop results in either:

• An uncontrolled stop, immediately stopping the manipulator actions by disconnecting power from the motors.

• A controlled 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... ... uncontrolled

controlled then it is classified as...

category 0 (zero) category 1



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1 Safety

1.5.1. What is an emergency stop?

Continued

Emergency stop devices

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.

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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:

• A caption 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.

• An instruction 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 danger warning

Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Signification

Warns that an 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.

Electrical shock

CAUTION caution

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.



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1 Safety

1.6.1. Safety signals in the manual

Continued

Symbol Designation

ELECTROSTATIC

DISCHARGE

(ESD)

Signification

The electrostatic discharge (ESD) symbol indicates electrostatic hazards which could result in severe damage to the product.

Electrostatic discharge (ESD)

NOTE Note symbols alert you to important facts and conditions.

Note

TIP Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way.

Tip

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1.6.2. Location of the pictograms

Location of pictograms on the FlexLifter

1 Safety

1.6.2. Location of the pictograms en201011020001

Symbol

Risk of severe injury to hands

Description

Risk of severe injury to hands

This pictogram must be positioned close to the scissor frame, risk of severe injury when lifter is going down.

Position

Do not walk

Do not walk

The pictogram is located on the top plate. The top plate is not designed to be walkable.

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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.

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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.

1.

Action

Engage the latch.

Info/Illustration

The latch must be in this position:

The following position is forbidden:

2.

After maintenance, pull the pin back in parking position.

WARNING!

Make sure to pull back the pin in parking position after maintenance.

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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.

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1 Safety

1.8.3. Safety during setup & commissioning

1.8.3. Safety during setup & 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 person is standing on the top plate before moving the lifter.

Check also that nothing is left on the top of the lifter (i.e. tools).

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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 & 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

IRL 600

Max payload

600 kg

Average speed

mm/s

200

Vertical stroke mm

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 programmable 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.

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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 IRC5 robot controller.

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2 Description

2.2.1. Detailed views

2.2.1. Detailed views

Overview

40

6

7

4

5

8

9

2

3 en201011020002

1 Base plate

Electromechanical cylinder (EMC)

Safety pin

Spring damper

Top plate

Outer leg frame

Inner leg frame

Sensor

Cable tray


Electromechanical cylinder EMC:

EMC section view:

6

7

4

5

2

3 en201011020003

1 Rod end with ball joint

Rod

Cylinder

Grease port

Reducer

Servomotor

Calibration mark

2 Description

2.2.1. Detailed views

4

5

6

2

3 en201011020004

1 Front seal

Rod

Screw

Nut

Bearings

Coupling

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2 Description

2.3.1. Terms used in this manual

2.3 Terminology

2.3.1. Terms used in this manual

You'll find in the table hereunder some explanations regarding the terms used in this manual:

Designation Definition

Robotic system

Robot

Manipulator

Controller

Translation unit

Carriage

Track

SMB

SMB Box

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 & 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.

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3 Technical details

3.1. Performances


3.1. Performances

FlexLifter IRL 600

The following table summarizes the main information regarding the FlexLifter IRL600 performances:

Feature Performances

Vertical stroke

Speed

Deceleration time

Unidirectional repeatability *

Weight of the unit

Max. payload

Index of protection

600 mm

200 mm/s

0.4 s

± 1mm

700 kg

600 kg

IP 54

* According to ISO 9283 test.

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3.2. Overall dimensions

3.2. Overall dimensions

Lower position:

Upper position: en201011020005 en201011020006

Fixing mask on top plate: 6 holes M12 en201011020007

44 3HAW050008890 Revision: -

Example of configuration: FlexTrack with 2 carriages + FlexLifter


3.2. Overall dimensions en201011020008

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3.3. Motor details

3.3. Motor details

Motor specifications

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 N/m

REF: MS 3102A20-18P

REF: MS 3106A20-29P

46 en2010110200016



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

1

2

3

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

Resolver cableMotor power cable

Position sensor cable

See Cabling of the FlexLifter on page 63

.

Diameter

Ø 9.5 mm

Ø 14 mm

Ø 5.5 mm

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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 300mm.

en201011020009

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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).

en2010110200036

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3.5. Robot controller technical requirements

3.5. Robot controller technical requirements

When the FlexLifter is associated with an IRB 6600\7600 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 IRC5 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 Comment

IRB 6600 / 7600

Drive module

IRC5 controller

770-4 Motor drive « W » type.

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.

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4 Unpacking and acceptance

4.1. Unpacking


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!

Wipe off any surplus oil using a lint-free cloth.

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4.2. Acceptance inspection

4.2. Acceptance inspection

TIP!

Always try to determine 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 3HAW050008890 Revision: -

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

IRT 501-66

1336 kg

1491 kg

IRT 501-66R

1516 kg

1612 kg

3HAW050008890 Revision: - 53

5 Handling

5.2. Lifting the FlexLifter IRL600

5.2. Lifting the FlexLifter IRL600

Actions before lifting

CAUTION!

Before lifting the FlexLifter IRL 600, read through the safety instructions carefully.

Handling equipment for FlexLifter delivered as a standalone unit

Type

Flexlifter IRL 600

Recommended equipment

4 Lifting I-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 standalone unit, the FlexLifter can be safely handled using the appropriate lifting M12 hook & straps: en2010110200011

54 3HAW050008890 Revision: -

5 Handling


Handling equipment for FlexLifter assembled on a FlexTrack IRT 501-66 or 66R

Type

IRT 501–66 with Flexlifter

IRL 600

Recommended equipment

4 U-shackles (shackle has to fit into the bail)

4 Lifting I-bolts with a M12 thread

2 lifting straps (min 5 meters) with a load capacity of 1 tonne each

IRT 501–66R with Flexlifter

IRL 600

2 lifting straps (min 5 meters) with a load capacity of 1 tonne 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

3HAW050008890 Revision: - 55

5 Handling


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 identical: 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:

56 en2010110200014


5 Handling


Never place lifting straps wider than a combined angle of max. 60°.

WARNING!

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.

3HAW050008890 Revision: - 57

5 Handling


5.3 Motor brake release

5.3.1. Important information about the brake release

General

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 cable.

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.

58 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

FlexTrack.

Do not release the brake when the FlexLifter is loaded – There is a risk of brutal fall down.


5.3.2. Brake release of the FlexLifter with the SMB box

Instructions for brake release using the SMB box

Action

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.

Note/Illustration

5 Handling


3HAW050008890 Revision: - 59

5 Handling


5.3.3. 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.

2.

Using pins, connect the +24VCC to the G pin (see figure in Motor details on page 46

)

3.

Connect the 0VCC to the H pin (see figure in

Motor details on page 46 )

WARNING!

The motor brakes of the FlexLifter are phase-dependent. Fault connection can cause damage to vital parts.

60 3HAW050008890 Revision: -

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 en2010110200016

NOTE!

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

6.1.2. When used as a stand alone unit

6.1.2. When used as a stand alone unit

WARNING!

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.

62 en2010110200017

The FlexLifter is linked to the slab with 6 M12 screws, the fixing mask in the lower plate is as follows: 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.


7 Electrical setup

7.1.1. Stand alone configuration


7.1 Cabling of the FlexLifter

7.1.1. Stand alone configuration

Description

FlexLifter is designed to be driven by the ABB IRC5 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 (i.e.Fieldbus, air hose, IOs), please refer to the "FlexLifter Standard Product Offer" for part number.

Wiring diagram

3HAW050008890 Revision: - 63


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

64 3HAW050008890 Revision: -


7.2.1. Overview

7.2 Architecture example

7.2.1. Overview

Please find below the necessary material for a typical configuration using 3 Flextrack & 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

Mvt resolver cable

Mvt 4 position switch cable

3HAW050008890 Revision: - qty

6

6

4

4

3

1

1

1

1

Rep

E

F

O

P

G

C

D

A

B

65


7.2.1. Overview

Designation

Air pipe

Mvt profinet cable & PS

Mvt PE cable

Static Laser cable

Mvt Laser cable

Anticollision (option)

SMB Support qty

6

6

1

3

6

3

6

Rep

L

M

N

J

K

I

H

66 3HAW050008890 Revision: -

7.2.2. Routing of the cables


7.2.2. Routing of the cables en2010110200023

3HAW050008890 Revision: - 67


7.2.3. SMB box

7.2.3. SMB box

SMB means Serial Measurement Board. The SMB board is available in 3 versions, for 1,3 &

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.

68 3HAW050008890 Revision: -

8 Setup and commissioning

8.1. Pre-requirements


8.1. Pre-requirements

Hereunder are listed the required operations before starting up the FlexTrack setup :

Actions Info/Illustration

1

2

3

4

5

Configure the controller

Installation of the FlexLifter Check that the FlexLifter is installed and levelled as

described in Fixing the FlexLifter on page 61 .

Manual lubrication

Synchronization

FlexLifter is lubricated at ABB facility during assembly.

However if you need to manually lubricate the roller

screw, see Lubrication on page 74

.

Like any other robot axis, the FlexLifter motor must be

calibrated using the FlexPendant, see Calibration on page 76 .

Checklist

Load the FlexLifter parameters and configure the controller as described in

Loading the FlexLifter parameters on page 71 .

The

Checklist before first run on page 79

gives instructions about points to check before switching to auto mode.

Ambient temperature

Description

During operation

For the controller

For the controller

For short periods (not exceeding 24 hours)

Standard/Option

Standard

Standard

Option

Standard

Temperature

+ 5°C (41°F) to + 50°C (122°F)

+ 5°C (41°F) to + 45°C (113°F)

+ 5°C (41°F) to + 52°C (126°F) up to + 70°C (158°F)

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.

Note

Compare the delivery check to the identification 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

.

3. Preparation for assembly.

4. Assemble the lifter.

3HAW050008890 Revision: - 69


8.1. Pre-requirements

Action

5. Assemble the manipulator.

6. Electrical installation.

7. Software installation.

Note

70 3HAW050008890 Revision: -


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

2

Select the menu option : Add new parameters.

Load the file MOC_Ta _DMb_Mc_Ld_Ne.cfg .

NOTE!

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.

3HAW050008890 Revision: - 71


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 3HAW050008890 Revision: -


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

.

en2010110200025

3HAW050008890 Revision: - 73


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!

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

CASTROL

KLÜBER

TOTAL

Lubricant

Longtime PD 0

Microlube GB 0

MULTIS EP 0

Procedure

Steps Action

1. Switch the robot controller to manual mode.


2. If not already done, jog the axis to the zero position (see

Zero position on page 73 )

74

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 )



8.3.1. Lubrication with basic delivery package

Steps Action

5. Remove the protection cap from the cylinder.


6. Locate the grease nipple and connect the grease pump.

7. Inject 14 cm³ of grease into the roller nut.

8. Disconnect the pump and put the protection cap back on.

9. Make sure that no tool has been left in the

FlexLifter and unlock the safety pin.

10. Switch the controller on in manual mode and gently jog the FlexLifter to make sure that there is no mechanical interference.

3HAW050008890 Revision: - 75


8.4.1. Overview

8.4 Calibration

8.4.1. Overview

General

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 FlexLifter 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

• a resolver error occurs

• the signal between a resolver and measurement board is interrupted

• a robot 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

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.

76 3HAW050008890 Revision: -


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

1.

Using the FlexPendant, jog the cylinder rod in order to align the grove with the seal.

Info/IIIustration

2.

The grove and the seal must appear aligned as shown on the figure.

en2010110200028

3.

On the FlexPendant, tap on the

ABB logo : select « Calibration ».

en2010110200029

4.

Select the external axis (here,

FT900).

en2010110200030 en2010110200031

3HAW050008890 Revision: - 77


8.4.2. Calibration instructions

Steps Action

5.

Tap the axis checkbox to highlight the axis to be calibrated.

Info/IIIustration

6.

Tap « Update ».

en2010110200032

7.

After a few seconds, the

FlexPendant indicates that the external axis has been calibrated.

en2010110200032 en2010110200034

78 3HAW050008890 Revision: -


8.5. Checklist before first run

8.5. Checklist before first run

WARNING!

Check carefully the working envelope of the Flexlifter unit manually before 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

• No cable is damaged, rubbed or constrained by the lifter movements

• There is no abnormal noise or wear.

3HAW050008890 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 is important to check the points mentioned hereafter and respect the maintenance time intervals.

Time interval Item Maintenance More info.

Every 3 months

Every 6 months

Roller Screw

Safety Lock

Emergency stop feature

Lubrication of the roller screw nut

Lubrication of the roller screw nut on page 81.

Check the good condition of mechanical locking pin

Check that all safety features are operational

Safety instructions during mechanical assembly on page 35

.

Verification of the emergency stop feature on page 86

Every year

Cables and electrical cabinets.

Rollers

Visual inspection of cables & electrical cabinets envelope

Verification of the cables on page 88

Every 3 years SMB Backup battery

Visual inspection of the rollers

& rails

Rollers on page 84

Replace the SMB backup battery

SMB backup battery on page 90

80 3HAW050008890 Revision: -

10 Instructions for maintenance

10.1.1. Lubrication of the roller screw nut


10.1 Maintenance of the mechanical components

10.1.1. Lubrication of the roller screw nut

WARNING!

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

CASTROL

KLÜBER

TOTAL

Lubricant

Longtime PD 0

Microlube GB 0

MULTIS EP 0

Procedure

Steps Action

1. Switch the robot controller to manual mode.


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 )

3HAW050008890 Revision: - 81


10.1.1. Lubrication of the roller screw nut

Steps Action

4. Switch off the power on the installation (see

Safety for electrical operations on page 36 )

5. Remove the protection cap from the cylinder.


6. Locate the grease nipple and connect the grease pump.

7. Inject 14 cm³ of grease into the roller nut.

8. Disconnect the pump and put the protection cap back on.

9. Make sure that no tool has been left in the

FlexLifter and unlock the safety pin.

10. Switch the controller on in manual mode and gently jog the FlexLifter to make sure that there is no mechanical interference.

82 3HAW050008890 Revision: -


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.

Visual inspection 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

SHELL

TOTAL

SHC 630

Omala HD 220

Carter SH 220

The manufacturer of the gear is recommending the following actions :

Actions 1st use

After 500 hours /

3 months

Every 3 months Every year

Visual inspection

Verification of the tightening torque

X

X

X

X

X

X

• Check that there's no mark of wear or damages to the gear

• Check that there's no oil leak.

3HAW050008890 Revision: - 83


10.1.3. Rollers

10.1.3. Rollers

Visual inspection

The lifter frames are guided using heavy duty rollers. Those rollers are lubricated for the

Flexlifter lifetime.

• Check that there's no wear or damages to the rollers.

• Check that there's no wear or damages to the rails.

84 3HAW050008890 Revision: -


10.1.4. Lifetime of main components

10.1.4. Lifetime of main components

• Roller screw: 1.150.000 cycles (one cycle = lift up & down)

• Dry bushings: 4.595.567 cycles

• Rollers: 50.000.000 cycles

3HAW050008890 Revision: - 85


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

1. Start with the lifter in lower position.

2. With the FlexLifter powered, but not moving.

3. Press the emergency stop button.

4. The brake is applied, you should hear the noise in the motor area.

5. If the brake is correctly applied, the lifter stands still.

6. If not, the lifter might move downward & stop on the spring bumpers. In this case check the cabling of the brake, or replace the motor & redo the test.

7. Proceed with the required validations in the control system to switch back to auto mode.

86 3HAW050008890 Revision: -


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: en2010110200036

Steps Actions

1.

2.

3.

Switch to manual mode

With the teach pendant, jog the lifter up & down .

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.

3HAW050008890 Revision: - 87


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 external envelope due to wear by rubbing on a fixed part.

Replace the cable, remove the cause of the wear, or route the cable in a different way.

88 3HAW050008890 Revision: -


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 and the motor are firmly tighten, and that there's no damage to the cable outlet.

3HAW050008890 Revision: - 89


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.

To replace the battery pack, proceed as follow:

Steps Actions

1. Position first the carriage in the synchronization position (align the synchronization gauges).

2. Switch off the power on the SMB box.

3. Open the SMB box and locate the battery (see fig. below).

4. Cut the plastic straps.

5. Unplug the 2 wires cable from the board and remove the battery pack.

6. 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


90 en2010110200037


11 Maintenance operations

11.1. Motor or gearbox failure


11.1. 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.

en2010110200038

Warning: Risks of electric shock

First shutdown the controller and isolate the FlexLifter from the main power.

en1011003

DANGER!

There is a risk of deadly injuries for the operators and/ or irreversible damage to the product if the safety rules are not respected.

Steps Actions Info/Illustration

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.

3HAW050008890 Revision: - 91



Steps Actions

5. Remove the locking plate securing the spherical joint axis.

Info/Illustration en2010110200040

6. 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.

7. Remove the locking plate securing the clevis axes (both sides).

en2010110200041

92

8. 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.

en2010110200042

9. Pull out the complete cylinder from the lifter structure. The weight of the electromechanical cylinder is 82 kg.

en2010110200043

10. Lay down the complete electromechanical cylinder on a workbench.

Unclamp the shrink disc of the coupling between motor & reducer.

en2010110200044 en2010110200045




Steps Actions

5. Remove the locking plate securing the spherical joint axis.

Info/Illustration en2010110200040

6. 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.

7. Remove the locking plate securing the clevis axes (both sides).

en2010110200041

8. 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.

en2010110200042

9. Pull out the complete cylinder from the lifter structure. The weight of the electromechanical cylinder is 82 kg.

en2010110200043

10. Lay down the complete electromechanical cylinder on a workbench.

Unclamp the shrink disc of the coupling between motor & reducer.

en2010110200044 en2010110200045

3HAW050008890 Revision: - 93



Steps Actions

11. Remove the 4 screws and pull out the motor.


94

12. If the problem comes from the reducer, remove the 4 screws and pull it out.

en2010110200046

13. Remove the reducer flange.

Remove the coupling, and install the new reducer.

The tightening torque of the coupling shrink disc is 6Nm.

en2010110200047

14. 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) en2010110200048

15. Install the electromechanical 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

16. Connect the cables to the motor

17. Unlock the safety pin and remove the safety posts.

Slowly release the load from the crane.

18. Run a test at low speed.

19. Calibrate the FlexLifter as described in section


.

en2010110200045


12 Spare parts for maintenance

12.1. Mechanical spare parts


12.1. Mechanical spare parts

ABB part reference no.

3HAW107703535

3HAW107703590

3HAWC117059

3HAWC117034

3HAWC117040

3HAWL000401

3HAW107703518

3HAWC117048

3HAWC103477

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

3HAW050008890 Revision: - 95


12.2. Electrical spare parts

12.2. Electrical spare parts

ABB part reference no.

3HAWC116592

3HAW050008604

3HAW050008605

3HAW050008606

3HAW050008608-005

3HAW050008608-010

3HAW050008608-015

3HAW050008609-005

3HAW050008609-010

3HAW050008609-015

3HAW050008613-005

3HAW050008613-010

3HAW050008613-015

3HAW050008614-005

3HAW050008614-010

3HAW050008614-015

3HAW050008615-005

3HAW050008615-010

3HAW050008615-015

3HAW050008612-005

3HAW050008612-010

3HAW050008612-015

3HAWC107034

3HAWC116986

3HAWC116987

3HAWC116988

3HAWC116990

3HAWC116991

3HAWC116992

Description

Servomotor

SMB box 1 axis M2008



1 axis motor movement cable 5m



1 axis resolver movement cable 5m



1 axis motor static cable 5m









6 axis resolver static cable 5m



Position sensor

Movement sensor cable 5m



Static sensor cable 5m



96 3HAW050008890 Revision: -

Contact us

ABB France Robotics Products

Rue de l'équerre

ZI des Béthunes

95310 SAINT-OUEN L'AUMONE

France www.abb.com

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