Page 1 ROBOTICS Product manual IRT 510...
Page 2 Trace back information: Workspace 24B version a5 Checked in 2024-06-05 Skribenta version 5.5.019...
Page 4 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, damage to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Assembling the track sections (for tracks longer than 9 m) ......3.4.2 Orienting and securing ................3.4.3 Positioning the stand ................3.4.4 Geometric alignment of IRT 510 ..............3.4.5 Assembling the pedestal (option) ............... 3.4.6 Assembling the manipulator and cable tray ..........3.4.6.1 Assembling the manipulator ............
Page 6 ® 3.7.2 Configuration of grease pump MEMOLUB ..........Commissioning ....................3.8.1 Check list for IRT 510 before commissioning ..........Test run after installation, maintenance, or repair ............ Maintenance Introduction ...................... Maintenance schedule and expected component life ..........4.2.1 Specification of maintenance intervals ............
Page 7 Special tools ....................Lifting accessories and lifting instructions .............. HILTI adhesive anchor ..................Spare parts Spare part lists and illustrations ................10 Circuit diagrams Index Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
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Page 9: Overview Of This Manual
IRT 510 Product manual scope The manual covers all variants and designs of the IRT 510. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 Product manual - IRB 2600 3HAC035504-001 Product manual - IRB 4600 3HAC033453-001 Operating manual - RobotStudio 3HAC065036-001 Operating manual - OmniCore 3HAC032104-001 Revisions Revision Description First edition. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 11: Product Documentation
Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics 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.
Page 12 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 troubleshooters. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 13: How To Read The Product Manual
Likewise, certain work methods or general information that is valid for several product models, can be illustrated with illustrations that show a different product model than the one that is described in the current manual. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
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Page 15: Safety
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. The information does not cover how to design, install and operate a robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.
Page 16: Requirements On Personnel
The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 17: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 18 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 19: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 20 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 21 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 22 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx2400000736 xx1500002616 Brake release buttons xx0900000820 xx1000001140 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 23 No mechanical stop xx1000001144 Stored energy Warns that this part contains stored energy. Used in combination with Do not disassemble symbol. xx0900000825 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 24 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 25: Robot Stopping Functions
The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - OmniCore V250XT Type B • Product manual - OmniCore V400XT Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 26: Safety During Installation And Commissioning
When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 27 Water • Compressed air • Hydraulics End-effector hazards require particular attention for applications which involve close human collaboration with the robot. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 28 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 29: Safety During Operation
Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 31 Specified amount de- on how much has previously pends on drained been drained from the gearbox. volume Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 32 WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Related information See also the safety information related to installation and operation. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 33: Emergency Release Of The Robot Axes
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 34: Brake Testing
For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 35: Safety During Troubleshooting
The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. CAUTION Risk of hot surfaces that can cause burns. A risk assessment must be done to address both robot and robot system specific hazards.
Page 36: Safety During Decommissioning
Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered. A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 37: Track Description
2.1 About IRT 510 Introduction The IRT 510 is a linear track motion which is driven by the OmniCore V line controllers and programmed using the FlexPendant. It supports to work with IRB 1520, IRB 1600, IRB 2600 and IRB 4600 by providing carriage tables to fit the robots on.
Page 38 Linear guide End cover Rack CAUTION Do not step on the cable chain or top cover; otherwise, injure and/or damage to the product may occur. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 39: Technical Data
IP65 For mechanical parts and main electrical connections. Explosive environments The IRT 510 cannot be located or operated in an explosive environment. Requirements, foundation The table shows the requirements for the foundation where the weight of the installed robot is included.
Page 40 3494 3637 3780 3696 3839 4184 3898 4041 3982 4100 4243 4386 4302 4445 4588 4504 4647 4790 4706 4849 4992 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 41 Airborne noise level The sound pressure level outside the working space. Track type Level IRT 510 < 76 dB (A) / 1m Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 42: Storage Conditions
Robot Within specification for respective robot. The track power consumption is measured on the condition of IRT 510 with a largest supported robot, that is, IRB 4600-60/2.05. The actual power consumption may vary according to the actual installed robot and site conditions.
Page 43: Dimensions
1824.5 tion position Length of the external cable chain 0-490 that exceeds the end of the track Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 44 For robot with extra plate, the external cable chain cannot exceed the end of the track. The total length of IRT 510 depends on the quantity of modules, each of which is 1,000 mm long. IRT 510 can be assembled with a minimum of 2 modules and a maximum of 110 modules.
Page 45 Two holes circled in the following figure at each side of the carriage table are available for ground cables. xx1500001610 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 46 The following height models can be provided by the pedestal/pedestal combination: 250 mm, 500 mm, 750 mm and 1,000 mm. Note 500 mm, 750 mm and 1,000 mm risers are not applicable to IRB 4600. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 47: Travel Length
2 Track description 2.4 Travel length 2.4 Travel length Overview The travel length of the IRT 510 varies according to the quantity of carriages and robots fitted on the track. Carriage quantity Robot quantity Travel length (m) Single carriage Robot 0.8 to 19.8 (in steps of 1 m)
Page 48 Note: The two carriages on the robot track have the same travel length. Carriage 1 This carriage is always in standard mounting. Carriage 2 This carriage is always in mirrored mounting. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 49: The Unit Is Sensitive To Esd
The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
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Page 51: Installation And Commissioning
Note If the IRT 510 is connected to power, always make sure that the IRT 510 is connected to protective earth and a residual current device (RCD) before starting any installation work. For more information see: •...
Page 52: Unpacking
Always try to determine if the goods are as ordered, and that the package is not damaged before unpacking. The IRT 510 has been pre-assembled in ABB factory. For delivery and storage's convenience, it would be divided into several segments as an unit depending on the length of the track when delivered.
Page 53 3 Installation and commissioning 3.2 Unpacking Continued Cleaning Before transportation, the IRT 510 has been protected against rust by a thin film of oil that has been applied before packing. Upon receiving the track, wipe off any surplus using a lint-free cloth. Note Do not clean any of the pre-lubricated linear guide and rack.
Page 54 Sections (pcs) Required space for installation (m) ii iii Robot Robot with extra Value of N plate 2.23 3.23 4.23 5.23 6.23 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 55 + Robot with extra plate 4.23 5.23 6.23 7.23 8.23 9.23 10.23 11.23 12.23 10.6 13.23 11.6 10.4 14.23 12.6 11.4 10.3 15.23 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 56 The measurement for the required space is valid when not using the external cable chain. iii How to calculate the required space is described in Formula for required space on page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 57: Lifting
Read through the safety instructions carefully before lifting the track IRT 510. WARNING Never lift the track IRT 510 in segments longer than 9 m. If the track is longer than 9 m, the track has to be disassembled into smaller segments.
Page 58: Lifting And Moving The Track
WARNING Never lift the track IRT 510 in segments longer than 9 m. If the track is longer than 9 m, the track has to be disassembled into smaller segments. Never lift the track IRT 510 using an overhead crane without first removing the cover plates.
Page 59 3 Installation and commissioning 3.3.2 Lifting and moving the track Continued 2-9 sections lift The figure shows the stand feet on the track IRT 510 where the lifting straps should be placed. xx1500000593 Track length Lifting stand foot from left...
Page 60 3.3.2 Lifting and moving the track Continued Lifting using fork lift Proceed as follows to lift the track IRT 510 using the fork lift. xx1500000591 Lifting using an overhead crane Proceed as follows to lift the track IRT 510 using an overhead crane.
Page 61 Continued Moving the track using roller dollies Lift the IRT 510 according to lifting instructions, and place roller dollies under the stand's ground plates. Depending on the length of the track, the number of roller dollies varies. See table for information.
Page 62 4 pcs 2 pcs 6 sections 4 pcs 2 pcs 5 sections 4 pcs 4 sections 4 pcs 3 sections 4 pcs 2 sections 4 pcs Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 63: Lifting Cable Chain
Item Description Cable chain end unit Cable chain pitch, with divider Cable chain pitch, no divider Cable chain, 10 links Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 64 Quantity depends on track length. Required if using lifting method 1. Lifting sling, extra wide (50 mm) Required if using lifting method 2. Overhead crane Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 65 Without cables, the internal cable chain weights 3.4 kg / meter and the external cable chain weights 8 kg / meter. All lifting accessories used must be sized accordingly! Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 66 Lower the cable chain into the cable tray. The ends of the chain should be in the middle of the track. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 67 3 Installation and commissioning 3.3.3 Lifting cable chain Continued CAUTION Make sure that the cable chain cannot come into contact with any moving parts. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 68: On-Site Installation
54. Use the following procedure to assemble the sections of the IRT 510. Positioning the sections Action Illustration/Note Mark up the required position of each IRT 510 section on floor. Note Make sure that the floor is clean before the assembly.
Page 69 B M12x40 Hex socket head cap screw, 3HAB3409-67 (10 pieces on each side) C Plate washer, 3HAC045077-001 D Joint bracket, 3HEA801652-001 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 70 Slightly tighten all the screws of the linear guides and finalize the horizontal alignment of the IRBT 2005 as described in Geometric alignment of IRT 510 on page Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A...
Page 71 Use a brush to lubricate the linear guides. Tightening the join brackets Action Illustration/Note Tighten the joint brackets with the fixing Tightening torque: 100 Nm screws. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 72 Remove the square locking washers and screws, which clamp the linear guides at the junction. xx1500003253 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 73 Fit the top cover support with screws. xx1400000229 A M6x16 Screw DIN6921, 9ADA181-12 Tightening torque: 10 Nm B Top cover support Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 74 A M6x12 Screw DIN6921, 9ADA181-11 (7 pcs) Tightening torque: 10 Nm B Top cover of the track C Rack cover of the track Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 75 Release the carriage brake again and push the carriage manually along the length of its stroke. Verify that no covers come into contact with the moving carriage. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 76: Orienting And Securing
However, in order to insure a good leveling, the foundation must be designed so that the IRT 510 can be fitted without the incline exceeding 0.5 mm/m in the direction of travel and 0.2 mm/m across this. The leveling screws can also compensate a poor flatness of the slab and small bumps up to 10 mm.
Page 77 Travel length Total length of the stand Quantity N 2.8 / 1.6 m 3.8 / 2.6 m 4.8 / 3.6 m etc. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 78 Tightening torque: 80 Nm The type and dimension of screws depend on the foundation conditions. See description for maximum floor loads in Forces on page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 79: Positioning The Stand
Assembling the track sections (for tracks longer than 9 m) on page xx1400001410 Adjust the horizontal level of the IRT 510 Leveling tool, Included in Installation tool with the M60 leveling screw using the lev- kit (3HAC091295-001). eling tool.
Page 80 Note It is recommended to use metric drills M16. If British Drills are used, the hole needs to be enlarged. xx1400000582 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 81 Action Illustration/Note Brush the inside of the hole. xx1400000583 Remove the dust after brushing the hole with a vacuum cleaner. xx1400000584 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 82 If necessary, refine the adjustment of the track leveling using the M60 screws, and then tighten the M16 notched nuts. See Geometric alignment of IRT 510 on page Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A...
Page 83 It is of the utmost importance that all screw joints be tightened with the correct torque. Failure to do so may result in damage to the equipment or personal. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 84: Geometric Alignment Of Irt 510
3 Installation and commissioning 3.4.4 Geometric alignment of IRT 510 3.4.4 Geometric alignment of IRT 510 Align the track geometrically with a laser level Note The origin of coordinates is located in the manipulator’s base zero. The geometric alignment of the track is done in order to adjust the carriage horizontally along the entire travel length.
Page 85 3 Installation and commissioning 3.4.4 Geometric alignment of IRT 510 Continued Alignment in Z direction The figure shows the possible variation along the Z-axis. The track should be laser aligned to within 0.2 mm from the origin per meter, along the entire X-axis.
Page 86 3 Installation and commissioning 3.4.4 Geometric alignment of IRT 510 Continued Action Illustration/Note Tighten the fitting nut when the level of the complete track is adjusted. xx1400000464 A Fitting nut Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 87: Assembling The Pedestal (Option)
Lift the pedestal to the mounting position using The following is a pedestal ex- lifting slings and lower the pedestal to the track. ample. xx2000001769 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 88 Secure the pedestal with attachment screws and Hex socket head cap screw washers. M16x60, Steel 12.9 Gle 603 (6 pcs) Plain washer 17x30x3, Steel-A3F (6 pcs) Tightening torque: 250 Nm xx2000001770 Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 89: Assembling The Manipulator And Cable Tray
The following table shows the robot capability of IRT 510. Standard pedestals are generally allowed between the IRT 510 carriage and the robot but their height is limited and dependent on the type of the IRT 510 and the type of robot.
Page 90 IRB 2600 IRB 4600 Installing the insulation kit Insulation kits are delivered with the IRT 510 when arc welding options 4212-X or 4226-X are selected. The type of the actual delivered insulation kit depends on the selected robot type. Required parts and quantity...
Page 91 Place the bottom insulation washers w/o pin hole (2) on the mounting plate (C) of the track or the pedestal installed on the track. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 92 See the figures in previous table for ref- erence. Put top insulation washers (3) and top washers (4), and then secure the robot with M16 bolts (A). Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 93: Mounting Of Manipulator On The Track
0 degrees (in line) WORLD xx1400001911 xx1500000928 +90 degrees WORLD xx1500000928 xx1400001912 +180 degrees WORLD xx1400001909 xx1500000928 +270 degrees WORLD xx1500000928 xx1400001910 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 94: Robot Orientation With Mirrored Cable Chain
0 degrees (in line) WORLD xx1500000631 xx1500000927 +90 degrees WORLD xx1500000632 xx1500000927 +180 degrees WORLD xx1500000633 xx1500000927 +270 degrees WORLD xx1500000634 xx1500000927 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 95 The following figure shows guide bushing assembly positions on the carriage table of the robot track. xx1400002680 Guide bushing fitting hole for IRB 1520 Guide bushing fitting hole for IRB 1600/2600/4600 Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 96: Changing Manipulator Orientation
Guide the robot gently, using the screws while Make sure the robot base is correctly lowering it into its fitting position. fitted onto the guide bushings. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 97 Lift the robot from the pedestal to other posi- For how to lift the robot, according to tion. robot product manual. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 98 Refit the securing screws and plain washers in the attachment holes of the robot base. Tighten the bolts in a criss-cross pattern to ensure that the base is not distorted. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 99: Assembling The Cable Tray
A M10x30 Hex socket head cap screw, 3HAB3409-51 (4 pcs) Tightening torque: 47 Nm Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 100 Place the cable tray onto the brackets. xx1400001583 Fasten the external cable tray with screws. M6x12 Torx counters. head screw, 9ADA624-5 Tightening torque: 10 Nm Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 101: Moving The Carriage Manually
If there is no voltage to the motor, 24V DC can be connected directly to the motor. Action Unplug the motor power cable from the power static harness that runs to the IRT 510 motor. Using pins, connect the +24VCC to the A pin (see figure).
Page 102 Painting: Half black color. Except the mounting surface. Note Mating connectors are not offered. WARNING The motor breaks on the IRT 510 are phase dependent. Fault connection can cause damage to vital parts. Product manual - IRT 510 3HAC091203-001 Revision: A...
Page 103: Connecting Long Tracks
Moving the carriage manually on page 101. Push the carriage by hand to show the rack and linear guide of extension section. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 105 3HAC045755-001, 500 mm: 3HAC045755-002 B Ø12xØ32x4 Washer for rail, 3HAC047749-001 C M12x35 Hex socket head cap screw, 3HAB3409-66 Tightening torque: 125 Nm Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 106 For how to adjust the leveling of the track, see Geometric alignment of IRT 510 on page 84. If you have moved the carriage manually, you probably need to initialize the...
Page 107: Restricting The Working Range
3.4.9 Restricting the working range 3.4.9 Restricting the working range Mechanical stops There are no adjustable mechanical stops on the IRT 510. This needs to be considered during a risk assessment of the complete installation, the track can however be ordered in different lengths.
Page 108: Electrical Installation
Connectors connecting cable harness from the carriage and cable harness from the controller. Floor cables from the controller • Power cable, available for controller • Signal cable, available for controller Controller Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 109 FB7 on the robot base. The IRT 510 flexible power cable should be connected from the motor power connector to the IRT 510 fixed power harness, and then the IRT 510 fixed power cable should be connected to the X7 socket on the OmniCore controller.
Page 110 Following figure shows an installation example of the brake release box on the fixing bracket, which requires four M6x25 screws to secure the brake release box (tightening torque: 10 Nm). xx2400000907 Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 111: Connectors On The Omnicore Controller
Clean or replace any damaged parts. Connectors on OmniCore V250XT controllers The following details the connection interface on the OmniCore V250XT controller. xx2200001457 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 112 Incoming mains connector Ethernet outlet connector, LAN3 Ethernet outlet connector, WAN Cable grommet for Connected Services antenna (3G/4G/WiFi) ADU (additional drive unit) connector Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 113 Ethernet outlet connector, MGMT (Management) FlexPendant connector (HMI) Motor connector Manipulator signal connector (SMB) Cable grommet assembly Incoming mains connector Ethernet outlet connector, LAN3 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 114 Continued Description Ethernet outlet connector, WAN Cable grommet for Connected Services antenna (3G/4G/WiFi) ADU (additional drive unit) connector, 1-3 ADU (additional drive unit) connector, 4-6 Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 115: Inspection Of Cables And Covers Prior To Start-Up
Channel internal width > 2 mm and < 6 mm than chain outside width? Channel joints arranged flush and unobstructed? Guide channel running parallel to the moving end guide? Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 116: Software Installation
To activate the track, it is necessary to use RobotStudio to update the system with the track settings and download the updated system to the robot controller, see Creating and downloading a system on page 117. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 117: Creating And Downloading A System
(ADU) that controls your track motion. On the Options tab, in the IRT 510 group under the Tracks category, select and modify the options that suits your track motion. Click Apply to accept the changes.
Page 118 Mounting of manipulator on the track on page For more detailed instructions on using the dialog Modify Installation, see Operating manual - Integrator's guide OmniCore. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 119: Setting Upper And Lower Software Limits For The Track
Travel L (m) Upper Joint Lower Joint Bound (m) Bound (m) 2230 0.85 0.35 -0.5 3230 1.85 1.35 -0.5 4230 2.85 2.35 -0.5 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 120 -0.34 16230 13.69 13.35 -0.34 17230 14.69 14.35 -0.34 18230 15.69 15.35 -0.34 19230 16.69 16.35 -0.34 20230 17.69 17.35 -0.34 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 121 -0.34 13230 8.28 7.94 -0.34 14230 9.28 8.94 -0.34 15230 10.28 9.94 -0.34 16230 11.28 10.94 -0.34 17230 12.28 11.94 -0.34 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 122 FlexPendant. Action Note Before beginning, make sure that the revolution counter for the IRT 510 is updated. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A...
Page 123 This step should be carried out with great care. If the software limit has not been set correctly the mechanical unit may hit the mechanical hard stop. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 124 3 Installation and commissioning 3.6.3 Setting upper and lower software limits for the track Continued Action Note Repeat the previous steps for the other limit. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 125: Base Frame Configuration
Base Frame x,y,z defines the direction of the track base frame pos- ition in relation to the world frame (in meters). Base Frame y Base Frame z Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 126 Base Frame q2 Base Frame q3 Base Frame q4 Use Joint Use Joint defines which joint data to use for the track. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 127: Configuration Examples
Track (TRACK_1) Base Frame q1 0.707107 Base Frame q2 Base Frame q3 Base Frame q4 0.707107 Gamma Rotation 1.570796 Use Joint track1 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 128 Track (TRACK_1) Base Frame q1 0.707107 Base Frame q2 Base Frame q3 Base Frame q4 -0.707107 Gamma Rotation -1.570796 Use Joint track1 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 129 Track (TRACK_1) Base Frame q1 0.707107 Base Frame q2 Base Frame q3 Base Frame q4 0.707107 Gamma Rotation 1.570796 Use Joint track1-lin Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 130 Parameter Robot (ROB_1) Track (TRACK_1) Base Frame q1 0.707107 Base Frame q2 Base Frame q3 Base Frame q4 -0.707107 Gamma Rotation -1.570796 Use Joint track1-lin Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 131: Configuration Of Additional Load
However, if for example an arc welding power source is fitted on the additional carriage plate, then the system parameter Arm Load t1_load_1 must be updated with the correct center of gravity and mass. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 132: Lubrication
Opening the grease pump Action Illustration/Note Place the grease pump on a flat and clean surface. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 133 , and pump until you see grease coming out at the outlet. Two strokes of the manual pump are usually enough. xx1400001572 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 135 The completion of the cycle means that the battery and the control board of the grease pump are working well. xx1400001578 Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 136: Configuration Of Grease Pump Memolub
Duration of a 240 mm cartridge hour(s) month(s) xx1600001022 xx1600001021 xx1600001020 Set of rings ® The figure shows the 3 rings disassembled from the grease pump MEMOLUB xx1600001023 Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 137: Commissioning
Is shielding visible? Cables need to be tied to prevent this from happening. Spare ABB cable also needs to be tied out of the way. Cables secured and not Robot cables need securing because they are loose down hanging loosely.
Page 138 3 Installation and commissioning 3.8.1 Check list for IRT 510 before commissioning Continued Verify that... Description No step damage Is there any step damage to any of the cable chain channel or support brackets, are they twisted causing cable chain...
Page 139: Connection Bracket
3 Installation and commissioning 3.8.1 Check list for IRT 510 before commissioning Continued Verify that... Description Verify the torque on the bolts Connection bracket Verify that... Description Verify that all brackets are in correct position Brackets which connect track sections are dowelled and number identified to prevent incorrect fitting.
Page 140: Test Run After Installation, Maintenance, Or Repair
Verify the application in the operating mode manual reduced speed. Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before initiating motion. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 141: Maintenance
Note If the IRT 510 is connected to power, always make sure that the IRT 510 is connected to protective earth and a residual current device (RCD) before starting any maintenance work.
Page 142: Maintenance Schedule And Expected Component Life
4.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRT 510: • Calendar time: specified in months regardless of whether the system is running or not.
Page 143: Maintenance Schedule
For grease splitter with 8 outputs, the signal configured for the lubrication detection sensor changes value when the dispatcher pumps every 6 times. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 144 4 Maintenance 4.2.2 Maintenance schedule Continued The pumping times can be modified according to actual application. If the pumping doesn't work as configured, the alert reports. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 145: Gearbox Oil
4.2.3 Gearbox oil Where to find information about gearbox oil Please see Technical reference manual - Lubrication in gearboxes (3HAC042927-001) for information about gearbox oil. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 146: Expected Component Life
A gliding meter is described as the chain making contact with itself or the glide bars. Chains on tracks shorter than 6 meters travel distance do not have gliding contact. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 147: Activities 100 Km Or 1 Month
When you clean the racks, it is necessary to lubricate the racks manually. Use one of the recommended lubricants: Equipment Note Lubricant TOTAL CERAN CA Lubricant TOTAL Multis EP 0 Lint free cloth Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 148 Continued Lubricating the racks Use this procedure to lubricate the racks and pinion. Action Illustration/Note Remove IRT 510 upper covers and rack covers. xx1400000231 A Screw DIN6921 M6x12 B Top cover of the track C Rack cover of the track Inspect the racks and the pinion, clean them if necessary.
Page 149: Cleaning The Linear Guides
When you clean the linear guides, it is necessary to lubricate them manually. Use one of the recommended lubricants: Equipment Note Lubricant TOTAL CERAN CA Lubricant TOTAL Multis EP 0 Lint free cloth Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 150 Continued Cleaning the linear guides Use this procedure to clean and, if necessary, lubrication of the linear guides. Action Illustration/Note Remove IRT 510 upper covers and rack covers. xx1400000231 A Screw DIN6921 M6x12 B Top cover of the track C Rack cover of the track Inspect the linear guides, clean them if ne- cessary.
Page 151: Activities 1 Month
4.4.1 Inspecting the automatic lubrication system Overview There is an automatic lubrication system in IRT 510. An electric pump will deliver the correct quantity of grease from a cartridge to the ball bearing blocks and to the pinion at required time intervals (one cycle per day). The grease is pushed in the piping by the pump;...
Page 152 Replacing the grease cartridge in grease pump MEMOL- ® EPS on page 132. xx1400001754 A Checking lubrication cup level through the notch Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 153 The automatic lubrication system should be checked that it can work properly. For information about checking Memolub function, see Test the grease pump ® MEMOLUB (verify function) on page 135. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 154: Emergency Stop And Stroke Limit System
The procedure below details how to ensure the effectiveness of the motor brake in case of emergency stop. Action Illustration/Note Ensure that the IRT 510 is powered, but not moving. Press the emergency stop button. The brake is applied; you should hear the noise in the motor area.
Page 155: Inspecting The Cables And Connectors
Once a month check that the cable track shows no trace of excessive wear due to rub on a fixed part. If one element is damaged, it is possible to replace it without removing the whole chain from IRT 510. Product manual - IRT 510 3HAC091203-001 Revision: A ©...
Page 156: Activities 3 Months
Use heavy duty cable ties with minimum width: 4.9 mm. Locking liquid Loctite 243 Used if loose screws are de- tected. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 157 If cables have worn through the outer cover they must be replaced. Some dust can be expected from the cables as they rub against the dividers in the chain. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 158 156. If strapping has been replaced ensure that a paint pen is used to mark both sides of the cable tie. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 159: Inspecting The Fasteners
Loctite 243 and brackets. If found to be loose they need to be removed, have locking liquid applied to them and then be refitted and tightened. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 160: Inspecting The Felt Gear
Standard tools on page 272. Inspecting the felt gear Action Illustration/Note Inspect the felt gear. If damaged, replace it. See Replacing the felt gear on page 224. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 161: Activities 12 Months
Cables are packed too tight inside the carriage cavities. • Cables are not properly adjusted (see Inspection of cables and covers prior to start-up on page 115). Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 162: Inspecting The Mechanical Stops
Action Illustration/Note Visually inspect the bumpers on mechanical stops for damage. xx1400001283 A Bumper B Mechanical stop If the mechanical stops are damaged, replace them. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 163: Inspecting The Gear Wheel, Gearbox And Backlash
Inspect the backlash, gear wheel and gearbox. If backlash is improper, adjust it. See justing the gearbox backlash on page 220. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 164 Screw specification: M10x40 hexagon tightening torque of the screws that secure socket head cap screw, class 12.9 the gear to the bracket is 70 Nm. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 165: Adjusting The Leveling
Leveling shall be checked every 12 months. Leveling adjustment is required only when there is subsidence happened, which affects the track levelling. Follow the procedure in Geometric alignment of IRT 510 on page 84 to adjust the leveling on the track.
Page 166 This page is intentionally left blank...
Page 167: Repair
Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRT 510, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 168: Cut The Paint Or Surface On The Robot Before Replacing Parts
Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 169: Replacing The Linear Guides
Removing the linear guides Use this procedure to remove the linear guides. Action Illustration/Note Remove all necessary IRT 510 top covers (B) and rack covers (C) around the linear guide to be replaced by removing screws (A). xx1400000231...
Page 170 A Linear guide B Ø 12xØ 32x4 Washer for rail, l3HAC047749-001 C M12x35 Hex socket head cap screw, 3HAB3409-66 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 171 "step" while passing the linear guide's junction. xx1400001752 A Ball bearing block B Linear guide Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 172 Tightening torque: 45 Nm xx1400001752 Tighten the hex socket head cap screws Tightening torque: 125 Nm M12x35. Fit the covers. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 173: Replacing The Ball Bearing Blocks
These procedures include references to the tools re- required. See references to these quired. procedures in the step-by-step in- structions below. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 174 (don't rise it more than 1 mm). WARNING Rising the carriage more than 1 mm can seriously damage the remaining three ball bearing blocks. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 175 Illustration/Note Remove the standard screws delivered with the block and replace with the grease pipe fitting taken from the old block. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 176 (A) must be on the upper face of the block. A Machined reference surface B Fittings C The other surface of the block has no reference line. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 177 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section Test run after installation, maintenance, or repair on page 140. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 178: Replacing The Racks
These procedures include refer- may be required. See refer- ences to the tools required. ences to these procedures in the step-by-step instruc- tions below. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 179 Fit the rack with the screws and washers. Do not tighten the screws yet. xx1400000227 A M10x40 hexagon head bolt, class 12.9 B Ø17xØ11x2 washers C Rack Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 180 Repeat with following racks until all racks are aligned with each other. Once you have tightened a screw, mark it with a white marker. xx1400001752 Refit the covers. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 181: Replacing The Mechanical Stops
Spare part number is specified in Spare parts on page 281. Standard toolkit The content is defined in Standard tools on page 272. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 182 Fit the screws (C) and nuts (A). xx1400002686 A M20 hexagon nut, 9ADA267-11 B Mechanical stop C M20x100 Hex socket head cap screw, 3HAB3409-206 Tightening torque: 90 Nm Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 183: Replacing The Motor, Gearbox And Gear Wheel
Carriage - pushed away Motor bracket - remains stationery Gear wheel - remains stationery Felt gear - remains stationery Gearbox - remains stationery Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 184 (10 mm), and out- side diameter no bigger that the thick washer outside diameter. xx1500000635 xx1500000636 xx1500000637 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 185 Preparation Action Illustration/Note WARNING Turn off all electric power and pneumatic pressure supplies to the robot and for IRT 510. Remove the side cover of the carriage. xx1400001587 A M6x12 Screw DIN6921, 9ADA181-11 (4 pcs) Loosening the carriage from the drive train bracket...
Page 186 (the tube will be pushed away along with the carriage). xx1400001592 A Lubrication tube connector Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 187 Removing the drive train Action Illustration/Note Remove the covers above the drive train. xx1400000231 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 188 A M8 eye bolt (2 pcs) Disconnect the power and resolver connectors from the motor. Guide the cables in the tray area. xx1400001625 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 189 A Ø 17xØ 11x2 washer, 3HAB4233-1 B M10x40 hex socket head cap installation screw, 3HAB3409-50 C Cable chain support Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 190 A M8x30 Hex socket head cap screw, 9ADA183-38 (4 pcs) B Ø13xØ8.4x1.6 plain washer, 9ADA312-7 (4 pcs) Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 191 Fit the locating cylindrical pin to the motor us- ing a rubber mallet. Insert it completely. xx1400001637 A Ø10x32 Cylindrical pin with threaded hole, 3HAC043986- Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 192 For the mirrored cable chain orientation, refit the cable chain support with two screws. Reconnect the power and signal cables to the motor. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 193 Tighten the screws. Tightening torque: 100 Nm Connect the lubrication tube connectors of the ball bearing block. xx1400001592 A Lubrication tube connector Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 194 Refit the side cover of the carriage. xx1400001587 A M6x12 Screw DIN6921, 9ADA181-11 (4 pcs) Refit the top cover. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 195: Replacing The Gearbox
Gearbox - remains stationery Required equipment Equipment Art. No. Note Standard toolkit The content is defined in Standard tools on page 272. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 196 (10 mm), and out- side diameter no bigger that the thick washer outside diameter. xx1500000635 xx1500000636 xx1500000637 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 197 Preparation Action Illustration/Note WARNING Turn off all electric power and pneumatic pressure supplies to the robot and for IRT 510. Remove the side cover of the carriage. xx1400001587 A M6x12 Screw DIN6921, 9ADA181-11 (4 pcs) Loosening the carriage from the drive train bracket...
Page 198 (the tube will be pushed away along with the carriage). xx1400001592 A Lubrication tube connector Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 199 Removing the drive train Action Illustration/Note Remove the covers above the drive train. xx1400000231 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 200 A M8 eye bolt (2 pcs) Disconnect the power and resolver connectors from the motor. Guide the cables in the tray area. xx1400001625 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 201 A Ø 17xØ 11x2 washer, 3HAB4233-1 B M10x40 hex socket head cap installation screw, 3HAB3409-50 C Cable chain support Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 202 M8x30 hex socket head cap screws (Art. No. 9ADA183-38). xx1400001639 Refitting the gearbox Refitting the gearbox Action Illustration/Note Inject lubricant into the gearbox until it is filled. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 203 Attach the lifting chains to the eye bolts on the motor and lift the motor into position on the track with guidance from the locating cylindrical pin. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 204 Reconnect the power and signal cables to the motor. Reinstalling the carriage to the drive train bracket Action Illustration/Note Push the carriage back above the drive train. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 205 A Lubrication tube connector Connect the lubrication tube connector of the pinion. xx1400001596 A Lubrication tube connector Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 206 Refit the side cover of the carriage. xx1400001587 A M6x12 Screw DIN6921, 9ADA181-11 (4 pcs) Refit the top cover. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 207: Replacing The Gear Wheel
Gearbox - remains stationery Required equipment Equipment Art. No. Note Standard toolkit The content is defined in Standard tools on page 272. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 208 (10 mm), and out- side diameter no bigger that the thick washer outside diameter. xx1500000635 xx1500000636 xx1500000637 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 209 Preparation Action Illustration/Note WARNING Turn off all electric power and pneumatic pressure supplies to the robot and for IRT 510. Remove the side cover of the carriage. xx1400001587 A M6x12 Screw DIN6921, 9ADA181-11 (4 pcs) Loosening the carriage from the drive train bracket...
Page 210 (the tube will be pushed away along with the carriage). xx1400001592 A Lubrication tube connector Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 211 Removing the drive train Action Illustration/Note Remove the covers above the drive train. xx1400000231 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 212 A M8 eye bolt (2 pcs) Disconnect the power and resolver connectors from the motor. Guide the cables in the tray area. xx1400001625 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 213 A Ø 17xØ 11x2 washer, 3HAB4233-1 B M10x40 hex socket head cap installation screw, 3HAB3409-50 C Cable chain support Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 214 A M8x30 Hex socket head cap screw, 9ADA183-38 (4 pcs) B Ø13xØ8.4x1.6 plain washer, 9ADA312-7 (4 pcs) Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 215 Tighten the screws. xx1400002645 A M10x35 Hex socket head cap screw, 3HAB3409- Tightening torque: 70 Nm B Pinion on rack, 3HAC047375-001 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 216 9ADA312-7 (4 pcs) Note The correct orientation of the motor is with the connectors pointing outwards, as shown in the figure. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 217 Fit the carriage to the drive train bracket with the screws. Note Do not tighten the screws yet. xx1400001588 A M12x40 Hex socket head cap screws, 3HAB3409-67 (4 pcs) Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 218 Refit the bracket for brake release and secure brake release cables with cable ties. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 219 5.7.3 Replacing the gear wheel Continued Action Illustration/Note Refit the side cover of the carriage. xx1400001587 A M6x12 Screw DIN6921, 9ADA181-11 (4 pcs) Refit the top cover. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 220: Adjusting The Gearbox Backlash
Tighten the locking screws (A), (B) and (C). xx1400001661 A Locking screw B Locking screw C Locking screw Tightening torque: 70 Nm Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 221 The indicator should show data between 0.07-0.13 mm. Push the carriage 1000 mm. X+ direction Continue with step to step 7. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 222 Note During adjustment, note that the cable chain should be assembled and cables to motor should be connected. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 223 B Ø17xØ11x2 Washer, 3HAB4233-1 Tightening torque: 70 Nm Calibrate the track. Use previously measured Fine calibration on page 258. reference values for the zero position. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 224: Replacing The Felt Gear
Carriage - pushed away Motor bracket - remains stationery Gear wheel - remains stationery Felt gear - remains stationery Gearbox - remains stationery Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 225 (10 mm), and out- side diameter no bigger that the thick washer outside diameter. xx1500000635 xx1500000636 xx1500000637 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 226 Preparation Action Illustration/Note WARNING Turn off all electric power and pneumatic pressure supplies to the robot and for IRT 510. Remove the side cover of the carriage. xx1400001587 A M6x12 Screw DIN6921, 9ADA181-11 (4 pcs) Loosening the carriage from the drive train bracket...
Page 227 Use a ratchet wrench. xx1400001591 A M12x40 Hex socket head cap screw, 3HAB3409-67 (4 pcs) B Ø21xØ13x2 Washer, 3HAA1001-632 (4 pcs) Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 228 Removing the felt gear Action Illustration/Note For the standard cable chain orientation, re- move the cable chain support by removing the two screws. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 229 Refit the lubrication tube to the felt gear tube connector. For the standard cable chain orientation, refit the cable chain support with two screws. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 230 Tighten the screws. Tightening torque: 100 Nm Connect the lubrication tube connectors of the ball bearing block. xx1400001592 A Lubrication tube connector Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 231 Refit the side cover of the carriage. xx1400001587 A M6x12 Screw DIN6921, 9ADA181-11 (4 pcs) Refit the top cover. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 232: Replacing The Cable Chain And Cables
Circuit diagram Circuit diagrams on page 283. Moving away the carriage Action Illustration/Note Remove all cover plates. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 233: Removing The Cable Chain
WARNING Turn off all electric power and pneumatic pres- sure supplies to the robot and IRT 510. Take a note of how the cabling is strapped on the carriage. Pay special attention to how the IRB power cable is routed.
Page 234 Remove screws at the fixed end of the cable chain. xx1400001980 A M6x20 Hex socket head cap screw, 9ADA183-25 Pull the complete cable chain out. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 235 WARNING Turn off all electric power and pneumatic pres- sure supplies to the robot and IRT 510. Take a note of how the cabling is strapped on the carriage. Pay special attention to how the IRB power cable is routed.
Page 236 Secure the fixing end of the cable chain on the cable tray by screws. xx1400001980 A M6x20 Hex socket head cap screw, 9ADA183-25 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 237 Refit top covers. Refitting the external cable chain Action Illustration/Note Move the carriage to the gliding side of the cable tray. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 239: Moving Back The Carriage
140. Perform a test run before powering up the track Test run on page 250. to full speed and duty cycle. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 241: Replacing The Side Links And Glide Shoes
Location of the side links The figure shows the location of the side links on the cable chain. xx1400001677 Side link Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 242 Standard tools on page 272. Removing the side link Action Illustration/Note Bend the links until two marks on the side line xx1300000939 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 243 Remove the glide shoes by pushing in the clips with a screwdriver and then pulling out the glide shoes. Refit the glide shoes by pushing it into place until it snaps. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 244: Replacing The Cables
Connectors connecting cable harness from the carriage and cable harness from the controller. Floor cables from the controller • Power cable, available for controller • Signal cable, available for controller Controller Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 245 5 Repair 5.10.3 Replacing the cables Continued If the IRT 510 is used together with IRB 1600, IRB 2600 or IRB 4600, and the CP/CS option is also selected, the cables must be arranged according to the following layout. Ø8.7 Ø14.5...
Page 246: Required Equipment
Be careful not to damage the brake release cables. Removing the cable Action Illustration/Note Disconnect the motor cables and cut the cable straps. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 247 A Cable chain B Tie wrap plate C Separator for cables D Cable chain link Remove the cable to be replaced. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 248 Refit the upper part of the cable tray to the cable outlet if it is dismantled. Reconnect the motor cables. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 249 Right: if correctly installed the cable should fit comfortably in the chains cavity Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 250 Moving back the carriage Action Illustration/Note Move back the carriage and secure it to the drive train bracket with the screws. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 251 140. Perform a test run before powering up the track Test run on page 250. to full speed and duty cycle. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 252: Replacing The Lubrication Sensor And Sensor Cable
5.10.4 Replacing the lubrication sensor and sensor cable Location of lubrication sensor and sensor cable The figure shows the location of the lubrication sensor and its cable which is available if the IRT 510 has the option Grease Detection sensor selected. xx2300001653 Required equipment Equipment Art.
Page 253 Unscrew and remove the sensor cable connector. xx2300001654 Loosen the two hexagon screws to release the lubrication sensor. xx2300001656 Remove the sensor from the distributor. xx2300001655 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 254 Note Pay attention to the sensor orientation. If improper, loosen the screws to reorient the sensor and then tighten again. xx2300001689 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 255 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section Test run after installation, maintenance, or repair on page 140. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
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Page 257: Calibration
WARNING Make sure no persons are on IRT 510 when the carriage is in motion. Also make sure that IRT 510's cover plates are free from loose objects, otherwise they can get trapped between the carriage and the plates.
Page 258: Fine Calibration
Tap Calibrate on the right corner. A dialog box is displayed warning that the op- eration cannot be undone. Tap Calibrate to proceed. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 259: Update Revolution Counters
Tap Update to proceed. CAUTION If a revolution counter is incorrectly updated, it will cause incorrect track positioning, which in turn may cause damage or injury! Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 260: Defining Base Frame
6.4 Defining base frame 6.4 Defining base frame General To run coordinated axes, the base frame must be defined. See Application manual - Additional axes (Coordinated track motion). Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 261: Decommissioning
See also Environmental information on page 262. Transportation Prepare the robot or parts before transport, this to avoid hazards. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 262: Environmental Information
7.2 Environmental information 7.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
Page 263 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
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Page 265: Reference Information
8.1 Introduction 8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 266: Applicable Standards
– Emission standard for industrial environments ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems - Part 1: General principles for design, normative reference from ISO 10218-1 Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 267: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 268: Screw Joints
8.4 Screw joints 8.4 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
Page 269 Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm) Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric- ated ated Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 270 Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Lubricated with Molycote 1000, Gleitmo 603 or equivalent Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 271: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 272: Standard Tools
Hex bit socket head cap no. 6 socket 1/2", bit length=20 mm Hex bit socket head cap no. 8 socket 1/2", bit length=20 mm Plastic mallet Small screwdriver Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 273: Special Tools
Backlash adjustment tool 3HAC054528-001 Calibration pin 3HAC054533-001 Companion rack 3HAC054532-001 Companion rack fix block 3HAC054531-001 Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 274 1 and includes Leveling tool, Locking nut adjust- ment tool and Calibration pin. Leveling tool xx1500000397 Locking nut adjustment tool xx2400000904 Calibration pin xx1400000186 Laser tracker Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 275: Lifting Accessories And Lifting Instructions
The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. The instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 276: Hilti Adhesive Anchor
Tensile NRk HAS [kN] Design resistance: concrete C 20/25 – fck,cube = 25 N/mm², anchor HAS 36,0 Shear VRk HAS [kN] Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 277: Basic Design Tensile Resistance
Long-term elevated base material temperatures are roughly constant over significant periods of time. Short-term elevated base material temperatures are those that occur over brief intervals, e.g. as a result of diurnal cycling. Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 278 Installation equipment Anchor size Rotary hammer TE 2 - TE 16 Other tools blow out pump or compressed air gun, setting tools Continues on next page Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
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Page 281: Spare Parts
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.abb.com/myABB. All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manual - IRT 510 3HAC091203-001 Revision: A...
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Page 283: Circuit Diagrams
Article numbers for circuit diagrams Circuit diagram - IRB 1520 3HAC039498-007 Circuit diagram - IRB 1600/1660 3HAC021351-003 Circuit diagram - IRB 2600 3HAC029570-007 Circuit diagram - IRB 4600 3HAC029038-003 Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
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Page 285: Index
17 storage, 42 signals in manual, 17 symbols, 17 symbols on robot, 19 integrator responsibility, 26 test run, 140 safety devices, 27 safety signals labels Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 286 262 disposal, 263 users storage conditions, 42 requirements, 16 symbols safety, 17 system integrator requirements, 26 validity and responsibility, 15 temperatures weight, 41 Product manual - IRT 510 3HAC091203-001 Revision: A © Copyright 2024 ABB. All rights reserved.
Page 288 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2024 ABB. All rights reserved. Specifications subject to change without notice.

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