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ABB FlexPLP IRPLP 220 Product Manual
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ABB FlexPLP IRPLP 220 Product Manual

ABB FlexPLP IRPLP 220 Product Manual

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ROBOTICS
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FlexPLP IRPLP 220

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Summary of Contents for ABB FlexPLP IRPLP 220

  • Page 1 ROBOTICS Product manual FlexPLP IRPLP 220...
  • Page 2 Trace back information: Workspace Systems version a10 Checked in 2019-04-12 Skribenta version 5.3.012...
  • Page 3 Product manual FlexPLP IRPLP 220 Document ID: 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Mechanical installation ..................4.2.1 Introduction .................... 4.2.2 Mounting surface (fastening of the FlexPLP IRPLP 220 to the floor plate) ..4.2.3 Mounting surfaces (fastening of an axis or customer equipment) ..... Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C...
  • Page 6 10.2 Spare parts - Ballscrew type ................10.3 Spare parts - Rack & Pinion type ................10.4 Covers ......................10.5 Cables ......................Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 7: Overview

    • spare parts Usage This manual should be used when working during: • installation, from lifting the FlexPLP IRPLP 220 to its work site and securing it to the foundation, to making it ready for operation • maintenance work •...
  • Page 8 Environmental information about the FlexPLP IRPLP 220. Reference information Reference information may be useful for the understanding of this manual. Spare parts List of the spare parts available for the FlexPLP IRPLP 220. References Reference (ABB manuals) Document ID Product manual - IRC5...

  • Page 9: Product Documentation, Irc5

    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 IRC5 robot systems.
  • Page 10 Getting started, IRC5 and RobotStudio • IRC5 with FlexPendant • RobotStudio • Introduction to RAPID • Trouble shooting, for the controller and manipulator. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 11: How To Read The Product Manual

    All procedures also include specific safety information when dangerous steps are to be performed. For more information, see Safety on page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
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  • Page 13: Safety

    How to avoid and eliminate the danger is either detailed directly in the procedure, or further detailed in separate instructions, found in Safety related instructions on page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 14: General Safety Information

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

  • Page 15: Safety Risks

    FlexPLP device 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 FlexPLP device, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 16 Gears may be damaged if excess- ive force is used! CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used! Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 17: Safety Risks Related To Tools/Workpieces

    CAUTION Ensure that an end effectors is prevented from dropping a workpiece, if such is used. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 18: Safety Risks Related To Pneumatic/Hydraulic Systems

    Dump valves should be used in case of emergency. • Shot bolts should be used to prevent tools, and so on, from falling due to gravity. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 19: Safety Risks During Operational Disturbances

    If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 20: Risks Associated With Live Electric Parts

    Tools, material handling devices, and so on may be live even if the FlexPLP control system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 21: Safety Actions Related To The Flexplp

    42). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the FlexPLP. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 22: Fire Extinguishing

    1.4.2 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the FlexPLP device (or controller)! Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 23: Emergency Release Of The Flexplp Device Axes

    In an emergency situation, any of the FlexPLP device axes may be released manually by pushing the brake release buttons on the device. How to release the brakes is detailed in the FlexPLP IRPLP 220 product manual. • The FlexPLP axes may be moved by using an crane or similar.

  • Page 24: Brake Testing

    3 Check that the axis maintains its position. If the FlexPLP device does not change position as the motors are switched off, then the brake function is adequate. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 25: Safe Use Of The Teach Pendant Unit

    FlexPLP device without the programmer knowing. • Do not change Transm. gear ratio or other kinematic parameters from the Teach Pendant Unit or a PC. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 26: Work Inside The Flexplp's Working Range

    Also be aware of any danger that may be caused by tools or other devices mounted on the device or inside the cell. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 27: Translate The Information On Safety And Information Labels

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

  • Page 28: Safety Stops

    If the stop is... then it is classified as... uncontrolled category 0 (zero) controlled category 1 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 29 Cabinet Controller).There can also be other types of emergency stops on your device, consult your plant or cell documentation to see how your FlexPLP system is configured. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 30: Safety Related Instructions

    The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 31 Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
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  • Page 33: Product Description

    Modularity FlexPLP IRPLP 220 is based on a modular concept and can be constituted of one to three or more linear axes: one or two horizontal axes, with or without a vertical axis, the vertical axis alone or combined horizontal axis one.

  • Page 34: Terminology

    The ballscrew is the mechanical component that transforms rotational movement from the motor into linear movement with little friction.The ballscrew mounted on FlexPLP IRPLP 220 are characterized by their stroke and their dimension D0 × P: 32 × 5. (D0: nominal diameter; P:...

  • Page 35: Principle Structure

    2 Product description 2.3.1 Modularity 2.3 Principle structure 2.3.1 Modularity Modularity FlexPLP IRPLP 220 is designed with high modularity what are constituted of the strokes, driving type, axis combination, vertical axis mounting method and cable chains direction. xx1800002106 Item Description...
  • Page 36 External cable chains are used for axes of FlexPLP IRPLP 220. Connection box Power and resolver cable connectors are inside. Each axis has a connection box installed. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 37: Axes Combinations

    2.3.2 Axes combinations Axis combinations FlexPLP IRPLP 220 can be constituted of one to three axes: one or two horizontal axes, with or without a vertical axis, or the vertical axis alone. For first horizontal axis, there can be one or more carriages or extended stroke by combined with additional module.

  • Page 38: Driving Types

    2.3.3 Driving types Driving types FlexPLP IRPLP 220 axes have two types of drive method: Ballscrew type and Rack & Pinion type that have same parts except the driving system. The horizontal axis can use either type of drive method. The vertical axis only use Ballscrew type.

  • Page 39: Vertical Axis Mounting And Cable Chain

    The cable chain of FlexPLP IRPLP 220 axes can be mounted both on left and right side. If the connector is not moving, there is no need to assemble the cable chain. However, for second horizontal axis and vertical axis, the mounting method of cable chain should consider the first horizontal axis cable chain mounting method for cables routing.

  • Page 40: Performances

    2 Product description 2.4.1 FlexPLP IRPLP 220 overall specifications 2.4 Performances 2.4.1 FlexPLP IRPLP 220 overall specifications General The table below are the overall specification of FlexPLP IRPLP 220. Specification Rack and Pinion Ballscrew Type type Horizontal axis First horizontal...

  • Page 41: Flexplp Irplp 220 Motor Specifications

    2.4.2 FlexPLP IRPLP 220 motor specifications 2.4.2 FlexPLP IRPLP 220 motor specifications General The Ballscrew type and Rack & Pinion type of FlexPLP IRPLP 220 are using the same servo motor. Below are the specifications of the motor used on FlexPLP IRPLP 220:...

  • Page 42: Dimensions

    2.5 Dimensions 2.5.1 Dimensions 1-axis FlexPLP IRPLP 220 FlexPLP IRPLP 220 - one horizontal axis The dimensions of FlexPLP IRPLP 220 - one horizontal axis depend on its stroke. The figure below shows the dimensions. S = Stroke. Ballscrew type: S = 190 mm, 270 mm, 350 mm, 430 mm, 510 mm, 590 mm or 670 Rack &...
  • Page 43 2.5.1 Dimensions 1-axis FlexPLP IRPLP 220 Continued S = 190 mm, 270 mm, 350 mm, 430 mm or 510 mm. xx1800002112 xx1800002113 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 44: Dimensions 2-Axis Flexplp Irplp 220

    FlexPLP IRPLP 220 - one horizontal and one vertical axis The dimensions of FlexPLP IRPLP 220 unit depend on its axes strokes. The dimensions of FlexPLP IRPLP 220 unit with vertical axis - body moving is same with vertical axis - carriage moving when they are at low position.
  • Page 45 S3 = Stroke of the vertical axis. S3 = 190 mm, 270 mm, 350 mm, 430 mm, or 510 xx1800002115 The figure below shows the dimensions of a two axes FlexPLP IRPLP 220 with vertical axis - carriage moving in low position with: S1 = Stroke of the first horizontal axis.
  • Page 46 2.5.2 Dimensions 2-axis FlexPLP IRPLP 220 Continued S3 = Stroke of the vertical axis. S3 = 190 mm, 270 mm, 350 mm, 430 mm, or 510 xx1800002116 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 47: Dimensions 3-Axis Flexplp Irplp 220

    The dimensions of FlexPLP IRPLP 220 unit depend on its axes strokes.The dimension of a FlexPLP IRPLP 220 unit with vertical axis - body moving is same that with vertical axis - carriage moving when they are in low position.
  • Page 48 2.5.3 Dimensions 3-axis FlexPLP IRPLP 220 Continued S3 = Stroke of the vertical axis. S3 = 190 mm, 270 mm, 350 mm, 430 mm, or 510 xx1800002118 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 49: Weight

    270 mm 37 kg Interface bracket 350 mm 39 kg Interface bracket 430 mm 43 kg Interface bracket 510 mm 46 kg Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
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  • Page 51: Unpacking And Handling

    FlexPLP. When these prerequisites have been met, FlexPLP may be taken to its storage or installation site. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 52: Unpacking And Acceptance

    IRPLP220X0000 - 00 for the first horizontal axes, IRPLP220Y0000 - 00 for the second horizontal axes, and IRPLP220Z0000 - 00 for the vertical axis. When FlexPLP IRPLP 220 has more than one axis, the digits are identical on all plates.
  • Page 53 3 Unpacking and handling 3.2 Unpacking and acceptance Continued The plates can be found on the sides of FlexPLP IRPLP 220: xx1800002119 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 54: Handling/Lifting

    Use lifting straps to lift FlexPLP with vertical axis by lifting the interface bracket. Tighten the eye bolts (A) to the unit as shown on the following picture: xx1800002122 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 55 Dimensions on page 42 Weight on page Note Before lifting FlexPLP IRPLP 220, the carriages of the horizontal axis must be at mid-stroke and the vertical axis must be in low position. Lifting the Interface bracket Use lifting straps to lift the interface bracket.
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  • Page 57: Installation And Commissioning

    See references to these procedures in the step- by-step instructions below. Bolts and screws and tightening torques Specified in Bolt, screws, tightening torques on page 133. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 58: Mechanical Installation

    4 Installation and commissioning 4.2.1 Introduction 4.2 Mechanical installation 4.2.1 Introduction Overview The FlexPLP IRPLP 220 can be mounted on a floor plate, a tooling frame or another FlexPLP IRPLP 220. The following picture shows the mounting surfaces. xx1800002123 Item Name...

  • Page 59: Mounting Surface (Fastening Of The Flexplp Irplp 220 To The Floor Plate)

    4.2.2 Mounting surface (fastening of the FlexPLP IRPLP 220 to the floor plate) 4.2.2 Mounting surface (fastening of the FlexPLP IRPLP 220 to the floor plate) Inclination If FlexPLP IRPLP 220 is mounted on a base plate, the base plate would be mounted horizontally on the ground. Robustness...
  • Page 60 Continued Floor Plate The FlexPLP IRPLP 220 must be secured on a floor plate or a tooling frame. ABB provide the option of standard floor plate. With the standard floor plate, it is convenient for replacement of a whole FlexPLP IRPLP 220 unit. Contact ABB if a floor plate is needed.
  • Page 61 4 Installation and commissioning 4.2.2 Mounting surface (fastening of the FlexPLP IRPLP 220 to the floor plate) Continued The figure below shows the dimensions of the floor plate. xx1800002126 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 62: Mounting Surfaces (Fastening Of An Axis Or Customer Equipment)

    The flange includes an area (the shadowed area in the figure below) where the holes can be drilled according to the customer requirements. xx1800002128 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 63: Jogging Axes Of A Unit With Flexpendant

    Mechanical unit menu button Mechanical unit, a selected unit is highlighted • Using the Select mechanical unit button. Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 64 • Using the Jogging window on the ABB menu. On the ABB menu, tap Jogging. Then tap Mechanical unit.Tap the mechanical unit to be jogged, and then tap OK. The selected mechanical unit is active until you select another unit, even if you close the Jogging window.
  • Page 65 There are three ways to select the increment size. • Using the Quickset menu increments. Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 66 Jogging window. xx1800002134 Using the Jogging window on the ABB menu. Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 67 4 Installation and commissioning 4.2.4 Jogging axes of a unit with FlexPendant Continued One the ABB menu, tap Jogging. Then tap Increment.Tap the desired increment mode, and then tap OK. xx1800002135 Choose between small, medium or large increments. You can also define your own increment movement sizes.

  • Page 68: Fastening Of A Unit To The Floor Plate

    (A). xx1800002136 Remove the cover plate by sliding it from one end of FlexPLP IRPLP 220. xx1800002137 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 69 4.2.5 Fastening of a unit to the floor plate Continued Action Info/Illustration Lift FlexPLP IRPLP 220 and position it on the mounting surface. xx1800002138 Connect the power and resolver cables to the unit. If needed, use the controller’s FlexPendant to...

  • Page 70: Cabling And Control

    4.3 Cabling and control 4.3.1 Connectors and internal equipment wiring Connectors Each axis of FlexPLP IRPLP 220 has its own connection box which containing the power cable connector and the resolver cable connector. External harness FlexPLP IRPLP 220 integrates an external harness of one power cable and one resolver cable for the control of customer equipment.

  • Page 71: Control Architecture

    4.3.2 Control architecture 4.3.2 Control architecture Overview FlexPLP IRPLP 220 is driven by the IRC5 through a set of cables and a SMB box. The standard control system includes: • Controller: IRC5 (A). An IRC5 controller can control up to 36 axes, in up to 7 motion tasks.
  • Page 72 Extension cables are available in different lengths. xx1800002140 IRC5 Floor resolver cable Floor power cable SMB Box FlexPLP IRPLP 220 resolver cable FlexPLP IRPLP 220 power cable Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 73: Controller Capabilities

    This means that if the system configuration has more that seven FlexPLP IRPLP 220, two or more units must be grouped in one motion task. Read Application manual - Additional axes and stand alone controller (3HAC051016-001).
  • Page 74 Configuration in which two or more mechanical units must be grouped in one motion task. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 75: Examples Of Configurations

    Below is an example of configuration with one single cabinet IRC5 which controls one 3-axis FlexPLP IRPLP 220 through one 3-axis SMB box. Note that if the controller’s XS.1 and XS.2 are already occupied, and if the number of drive units in the controller is enough for all the mechanical units, it is possible to use a power cable for IRC5’s XS.7 (3-axis) and a resolver cable for XS.41.
  • Page 76 4.3.4 Examples of configurations Continued System example: Two 3-axis FlexPLP IRPLP 220 and three 1-axis FlexPLP IRPLP 220 Below is an example of configuration with one single cabinet IRC5 (with nine drive units) which controls two 3-axis FlexPLP IRPLP 220 and three 1-axis FlexPLP IRPLP 220 through respectively one 6-axis SMB box and one 3-axis SMB box.
  • Page 77 Ethernet cable and one safety cable. The IRC5 controls four 3-axis FlexPLP IRPLP 220 through two 6-axis SMB box. xx1800002144 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 78 Below is an example of configuration with one IRC5 (with nine drive units) equipped with one additional drive module (also with nine drive units). The IRC5 controls six 3-axis FlexPLP IRPLP 220 through two 6-axis SMB box, and two 3-axis SMB box. xx1800002145...
  • Page 79 Ethernet cables and two safety cables. The IRC5 controls eight 3- axis FlexPLP IRPLP 220 through three 6-axis SMB box, and two 3-axis SMB box. Since the system has eight FlexPLP IRPLP 220, three mechanical units or more are grouped in two motion tasks or more.
  • Page 80 4 Installation and commissioning 4.3.4 Examples of configurations Continued System example: Four 3-axis FlexPLP IRPLP 220, one 2-axis FlexPLP IRPLP 220, and two 1-axis FlexPLP IRPLP 220 Below is an example of configuration with one IRC5 (with nine drive units) equipped with one additional drive module (with seven drive units).

  • Page 81: Configuration Files

    Operating manual - IRC5 with FlexPendant (3HAC050941-001) Once the parameters are properly set in the system, calibrate the unit(s) as described in Calibration on page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
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  • Page 83: Calibration

    Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 84: Calibration Points

    Calibration pin Calibration hole on base Note As FlexPLP IRPLP 220 with calibration index system has flexible installation methods for both parts and axes combination, there are only one calibration index system for each axis. Here are the location of the calibration holes on the index system of FlexPLP IRPLP 220.

  • Page 85: Edit Motor Calibration Offset

    Edit Motor Calibration Offset..., a pop-up warning dialog box is displayed. Tap Yes to pro- ceed. xx1800002152 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 86 For detailed procedure, see Update of the revolu- tion counters on page Note After replacing the drive system, reset the resolver value. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 87: Fine Calibration

    Calibration Pin, with calibration index system The fine calibration of the FlexPLP with calibration index system must be done with a Ø8 x 50 mm calibration pin. You can order a calibration pin from ABB under the reference number 3HAW050041930. See Special tools on page 135.
  • Page 88 A warning that updating the revolution counters can change. Programmed FlexPLP IRPLP 220 positions are also displayed. Tap Yes to proceed. xx1800002152 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 89 To cancel the calibration, tap Cancel xx1800002158 The axis is calibrated and the sys- tem returns to the list of available mechanical units. xx1800002159 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 90: Update Of The Revolution Counters

    Calibration. xx1800002150 All mechanical units connected to the system are shown along with their calibration status. xx1800002151 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 91 Tap Update to proceed. Tap Cancel to cancel. xx1800002163 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 92 5.5 Update of the revolution counters Continued Action Info/Illustration Tap Update to update the selected revolution counters and remove the tick from the list of axes. xx1800002164 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 93: Flexplp Addin Application Gui

    Overview FlexPLP addin is an additional software package running in the ABB IRC5 Robot system and design to operate the FlexPLP Product. It will be run under ABB robot system. For more information of installing addin in RobotStudio, see Operating manual - RobotStudio.

  • Page 94: Workflow Of The Flexplp Addin

    Note Select Control Panel to set and configure parameters. xx1800003157 Select FlexPendant to configure the FlexPendant system. xx1800003158 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 95 The user must login to the system prior to any commissioning task. Note User can only execute fine calibration in manual mode. Fine calibration is disabled in automatic mode. Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 96 Select Change... on the right bottom of the screen to change the old password to a new one. xx1800003151 xx1800003124 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 97 Afterwards, the robot will move to 8 endpoints in the base frame one by one, which are (0,0,0), (0,0,z), (x,0,0), (x,0,z), (x,y,0), (x,y,z), (0,y,0), and Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 98 OK to con- firm the value of new transmission. xx1800003167 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 99 Select Set Arm Angle. xx1800003170 Press the START button to continue the processes. xx1800003206 Select OK for the next step. xx1800003207 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 100 MOC according to the measurement of base frame. Action Note Select Set Frames. xx1800003212 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 101 Move to CalibPos: With this command, the robot will move to the calibration position through jointing its axes to zero. Action Note Select Move to CalibPos. xx1800003223 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 102 Action Note Select Move to ZeroPos. xx1800003217 Choose 2- Base Zero, select OK to confirm the setting. xx1800003218 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 103 If you want to calibrate all the axes, please input 0. Select OK before moving on to the next step. xx1800003115 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 104 Soft Calibration would be in failure be- cause of PLP mechanical problems. To remove this issue, see Installation and commissioning on page xx1800003219 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 105: Shim Offset

    Select the PlexPLP GUI, and the PlexPLP addin is opened. xx1800003104 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 106 The initial password is set by ABB. Please contact your local ABB service, flexlean.sales@cn.abb.com, for more in- formation. xx1800003123 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 107 Logout. Otherwise, password invalid warning message will come out. If turn off the PLP GUI application, Login will be expired. xx1800003125 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 108 User can modify the car body name through selecting Change Name..xx1800003153 PLP robots are listed for user to choose. xx1800003127 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 109 The limitation of shim offset value on x,y, and z is from -10 mm to 10 mm (only one decimal allowed). Both PLP General Shim Value and PLP Weight Shim Value are within this limitation. Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 110 Note Value of shim offsets is the sum of all types of shim offset that user defined. xx1800003139 Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 111 Select Logs to check the record of shim data values. It can help user tracking the change history xx1800003140 xx1800003224 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
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  • Page 113: Maintenance

    If required, the main switch should be locked. • Make sure that the pneumatic system is not pressurized. • Use only original ABB spare parts. The use of unauthorized parts or others than original parts will void the warranty. Required equipment Equipment...
  • Page 114 7.1 Introduction Continued Maintenance position Before proceeding any service work, FlexPLP IRPLP 220 must be in its maintenance position: horizontal axes carriages on their mid-stroke and vertical axis carriage in low position. The mounting method of the vertical axis showing below is carriage plate fixed with the triangle bracket.

  • Page 115: Maintenance Schedule

    7.2 Maintenance schedule 7.2 Maintenance schedule The FlexPLP IRPLP 220 must be maintained regularly to ensure proper function. The maintenance activities and intervals are described in the table below. Unexpected event may also give rise to inspections of the product. Any damage must be attended immediately! The inspection intervals do not specify the life of each component.

  • Page 116: Inspection

    7 Maintenance 7.3 Inspection 7.3 Inspection General A thorough inspection of the FlexPLP IRPLP 220 should be done at least once a year. All covers removed, clean the unit with a lint free cloth. CAUTION Before any intervention on the mechanical and electrical components, all power supplies to FlexPLP IRPLP 220 as well as to other machines within the danger zone must be turned off.

  • Page 117: Lubrication

    For Rack and Pinion type of FlexPLP IRPLP 220, each axis of FlexPLP IRPLP 220 has four lubrication points on the four ball bearing blocks and the rack needs lubrication.
  • Page 118 Ports 6 Flange Lubricate ports of Rack & Pinion type xx1800002167 Ports 1, Ball bearing blocks 2, 3, 4 Ports 5 Rack Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 119: Driving Belt (Tension Check, Adjustment And Replacement)

    Motor shaft pulley Driving belt Ballscrew shaft pulley Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 120 Ballscrew 185 Hz ± 5 Hz Rack & Pinion 175 Hz ± 5 Hz You can order a tension gauge (Continental CONTITECH VSM-1) from ABB under the reference number 3HAW050009048. See Special tools on page 135. Continues on next page...
  • Page 121 Continued Adjustment or replacement of the belt of Ballscrew unit Action Note FlexPLP IRPLP 220 must be in maintenance pos- ition (horizontal carriage at mid stroke, vertical axis in low position) For vertical axis, Remove the eight M8 screws and two dowel pins Ø 8 mm from the vertical axis and take it off the interface bracket.
  • Page 122 The locking device screws must be tightened in xx1800002172 a gradual uniform way, increasing the torque on each equally to 5 Nm. xx1800002174 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 123: Smb Battery Pack Replacement

    Place the new battery pack, plug the connector on the board, and secure the pack with straps. Close the SMB box, switch on the power. Update the revolution counters of each axis. Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 124 7 Maintenance 7.6 SMB Battery pack replacement Continued xx1800002178 Battery Board Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 125: Repair Information

    Some critical components require to be replaced by properly trained ABB personnel. In the case of failure of the parts listed below, please contact ABB in order to arrange an onsite repair by an ABB technician, or send the unit (or axis) for “exchange repair”:...
  • Page 126 This page is intentionally left blank...

  • Page 127: Decommissioning

    Equipment Note Handling equipment Specified in Handling/lifting on page Standard toolkit Specified in Standard toolkit on page 134. Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 128 Cable, motor, and so on. Steel Gears, screws, nuts, and so on. Plastic / Rubber (PVC) Cables, connectors, belt, and so on. Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 129 Spills may form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired.Spillage may penetrate the soil causing ground water contamination. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 130 This page is intentionally left blank...

  • Page 131: Reference Information

    9 Reference information 9.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 132: Unit Conversion

    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 - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 133: Bolt, Screws, Tightening Torques

    10 Nm 20 Nm 20 Nm 15 Nm 25 Nm 40 Nm 30 Nm 50 Nm 70 Nm 55 Nm 90 Nm Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 134: Standard Toolkit

    Socket head cap 4 mm, 5 mm and 6 mm socket 1/4” bit L 20 mm (for socket head cap screws - ISO 4762) Plastic mallet Dowel Pin remover Mild thread-locker (Recommended: Loctite 243) Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 135: Special Tools

    The tools may be ordered separately and are also specified directly in concerned instructions in the Product manual. Tool Product Tension gauge 3HAW050009048 Calibration pin Ø8 x 50 mm 3HAW050041930 Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 136 This page is intentionally left blank...

  • Page 137: Spare Parts

    Electrical parts: SMB boxes, static cables. Some spare parts must be chosen according to the strokes of your PLP. In any case, contact ABB if you do not know what type of material is required for your PLP. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C ©...

  • Page 138: Spare Parts - Ballscrew Type

    3HAW050041856 Rail stroke 590 mm 3HAW050041857 Rail stroke 670 mm 3HAW050041895 Bearing 3HAW050041803 Chain link 14.3.038 3HAW050041825-7035 Tray Continues on next page Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 139 350 mm, 34 for stroke 430 mm, 36 for stroke 510 mm, 40 for stroke 590 mm and 42 for stroke 670 mm. Note Contact ABB if you do not know whether your FlexPLP requires: • Material for strokes •...

  • Page 140: Spare Parts - Rack & Pinion Type

    So here only the spare parts that are different with the Ballscrew type of FlexPLP IRPLP 220 will be described. For ABB reference no.of cable chain and other parts, please refer to Spare parts - Ballscrew type on page 138.
  • Page 141 The number of chain link depends on strokes: 26 for stroke 990 mm, 29 for stroke 1,150 mm, 37 for stroke 1,630 mm and 45 for stroke 2,110 mm. Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 142: Covers

    Cover stroke 350 mm 3HAW050041844-7035 Cover stroke 430 mm 3HAW050041845-7035 Cover stroke 510 mm 3HAW050041846-7035 Cover stroke 590 mm 3HAW050041847-7035 Cover stroke 670 mm Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.

  • Page 143: Cables

    1 per axis 3HAW050041980-010 1 Motor Static or Extension M2008 10 m 1 per axis 3HAW050041980-015 1 Motor Static or Extension M2008 15 m Product manual - FlexPLP IRPLP 220 3HAW050041018-001 Revision: C © Copyright 2016 - 2018 ABB. All rights reserved.
  • Page 146 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2016 - 2018 ABB. All rights reserved. Specifications subject to change without notice.

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