ABB IRBT 2005 Bedienungsanleitung

ROBOTICS

Product manual

IRBT 2005

Trace back information:

Workspace R18-2 version a15

Checked in 2018-10-30

Skribenta version 5.3.012

Product manual

IRBT 2005

IRC5

Document ID: 3HAC051130-001

Revision: F

Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not

be construed as a commitment by ABB. ABB assumes no responsibility for any errors

that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be

construed as any kind of guarantee or warranty by ABB for losses, damages to

persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from

use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB's

written permission.

Keep for future reference.

Additional copies of this manual may be obtained from ABB.

Original instructions.

Specifications subject to change without notice.

ABB Engineering (Shanghai) Ltd.

Robotics and Motion

No. 4528 Kangxin Highway

PuDong District

SHANGHAI 201319

CHINA

Table of contents
9Overview of this manual ...................................................................................................................
12Product documentation ....................................................................................................................
14How to read the product manual ......................................................................................................
151 Safety
151.1 General safety information .................................................................................. 151.1.1 Limitation of liability ................................................................................. 171.1.2 Protective stop and emergency stop ........................................................... 181.2 Safety actions ................................................................................................... 181.2.1 Fire extinguishing .................................................................................... 191.2.2 Emergency release of the robot axes .......................................................... 201.2.3 Make sure that the main power has been switched off .................................... 211.3 Safety risks ...................................................................................................... 211.3.1 Safety risks during installation and service work on robots .............................. 231.3.2 Moving robots are potentially lethal ............................................................ 241.3.3 First test run may cause injury or damage .................................................... 251.3.4 Work inside the working range of the robot .................................................. 261.3.5 Enabling device and hold-to-run functionality ............................................... 271.3.6 Risks associated with live electric parts ....................................................... 291.3.7 The unit is sensitive to ESD ....................................................................... 301.3.8 Hot parts may cause burns ....................................................................... 311.3.9 Safety risks related to pneumatic/hydraulic systems ...................................... 321.3.10 Brake testing .......................................................................................... 331.3.11 Safety risks during handling of batteries ...................................................... 341.3.12 Safety risks during work with gearbox lubricants (oil or grease) ....................... 361.4 Safety signals and symbols ................................................................................. 361.4.1 Safety signals in the manual ...................................................................... 381.4.2 Safety symbols on product labels ...............................................................
452 Installation and commissioning
452.1 Before starting the track motion ........................................................................... 462.2 Operating requirements ...................................................................................... 482.3 Unpacking ....................................................................................................... 482.3.1 Acceptance inspection ............................................................................. 492.3.2 Storage ................................................................................................. 512.3.3 Unpacking ............................................................................................. 522.3.4 Lifting the track motion ............................................................................. 522.3.4.1 Actions before lifting .................................................................... 532.3.4.2 Lifting and moving track motion IRBT 2005 ....................................... 582.3.4.3 Lifting weight .............................................................................. 592.3.4.4 Lifting cable chain ........................................................................ 642.3.5 Technical data for track motion .................................................................. 742.3.6 Measures of the carriage table ................................................................... 782.4 On-site installation ............................................................................................ 782.4.1 Foundation ............................................................................................ 792.4.2 Mounting bolts ........................................................................................ 802.4.3 Hole configuration ................................................................................... 822.4.4 Track motion IRBT 2005 overview .............................................................. 832.4.5 Assembling the sections of the track motion IRBT 2005 (Longer than 9 m) ......... 922.4.6 Positioning the stand ............................................................................... 962.4.7 Geometric alignment of track motion IRBT 2005 ............................................ 992.4.8 Moving the carriage manually .................................................................... 1032.4.9 Connecting long tracks ............................................................................. 1082.5 Assembling the manipulator and cable tray ............................................................ 1082.5.1 Assembling the manipulator ...................................................................... 1102.5.2 Mounting of manipulator on the track ..........................................................
Product manual - IRBT 2005 5
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© Copyright 2015 - 2018 ABB. All rights reserved.
Table of contents

1132.5.3 Changing manipulator orientation ............................................................... 1162.5.4 Assembling the cable tray ......................................................................... 1182.6 Electrical installation .......................................................................................... 1182.6.1 The cabling from the controller .................................................................. 1202.6.2 Connections ........................................................................................... 1202.6.2.1 Introduction ................................................................................ 1212.6.2.2 Connectors on controller, IRC5 ...................................................... 1222.6.3 Inspection of cables and covers prior to start-up ........................................... 1232.7 Software installation .......................................................................................... 1232.7.1 Starting the system for the first time ........................................................... 1242.7.2 Creating and downloading a system ........................................................... 1262.7.3 Setting upper and lower software limits for the track ...................................... 1332.7.4 Base frame configuration .......................................................................... 1332.7.4.1 Introduction ................................................................................ 1352.7.4.2 Configuration examples ................................................................ 1392.7.5 Configuration of additional load ................................................................. 1402.8 Lubrication .......................................................................................................
140
2.8.1 Replacing the grease cartridge in grease pump MEMOLUB®EPS ...................
144
2.8.2 Configuration of grease pump MEMOLUB®.................................................
1452.9 Commissioning ................................................................................................. 1452.9.1 Check list for IRBT 2005 before commissioning ............................................
1493 Maintenance
1493.1 Introduction ...................................................................................................... 1503.2 Maintenance schedule and expected component life ............................................... 1503.2.1 Specification of maintenance intervals ........................................................ 1513.2.2 Maintenance schedule ............................................................................. 1533.2.3 Gearbox oil ............................................................................................ 1543.2.4 Expected component life .......................................................................... 1553.3 Activities 100 km or 1 week ................................................................................. 1553.3.1 Cleaning the rack .................................................................................... 1573.3.2 Cleaning the linear guides ......................................................................... 1593.4 Activities 1 month .............................................................................................. 1593.4.1 Inspecting the automatic lubrication system ................................................. 1623.4.2 Emergency stop and stroke limit system ...................................................... 1633.4.3 Inspecting the cables and connectors ......................................................... 1643.5 Activities 3 months ............................................................................................ 1643.5.1 Inspecting the cable chain ........................................................................ 1683.5.2 Inspecting the felt gear ............................................................................. 1693.6 Activities 12 months .......................................................................................... 1693.6.1 Inspecting the cables and connectors ......................................................... 1703.6.2 Inspecting the mechanical stops ................................................................ 1713.6.3 Inspecting the gear wheel, gearbox and backlash .......................................... 1733.6.4 Adjusting the leveling ............................................................................... 1743.7 Activities 36 months .......................................................................................... 1743.7.1 Replacing SMB battery .............................................................................
1774 Repair
1774.1 Introduction ...................................................................................................... 1784.2 Replacing the linear guides ................................................................................. 1824.3 Replacing the ball bearing blocks ......................................................................... 1874.4 Replacing the racks ........................................................................................... 1904.5 Replacing the mechanical stops ........................................................................... 1924.6 Replacing the motor, gearbox and gear wheel ........................................................ 1924.6.1 Replacing the motor ................................................................................ 2044.6.2 Replacing the gearbox ............................................................................. 2164.6.3 Replacing the gear wheel .......................................................................... 2294.7 Adjusting the gearbox backlash ...........................................................................
6 Product manual - IRBT 2005
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© Copyright 2015 - 2018 ABB. All rights reserved.
Table of contents

2334.8 Replacing the felt gear ....................................................................................... 2334.8.1 Replacing the felt gear ............................................................................. 2414.9 Replacing the cable chain and cables ................................................................... 2414.9.1 Replacing the cable chain ......................................................................... 2504.9.2 Replacing the side links and glide shoes ..................................................... 2534.9.3 Replacing the cables ................................................................................ 2604.10 Replacing SMB board ........................................................................................ 2624.11 Cut the paint or surface on the robot before replacing parts ......................................
2635 Calibration
2635.1 Overview ......................................................................................................... 2645.2 Fine calibration ................................................................................................. 2655.3 Update revolution counters ................................................................................. 2665.4 Defining base frame ...........................................................................................
2676 Decommissioning
2676.1 Environmental information ..................................................................................
2697 Reference information
2697.1 Introduction ...................................................................................................... 2707.2 Applicable standards ......................................................................................... 2727.3 Unit conversion ................................................................................................. 2737.4 Screw joints .................................................................................................... 2767.5 Standard tools .................................................................................................. 2777.6 Special tools .................................................................................................... 2787.7 Lifting accessories and lifting instructions .............................................................. 2797.8 HILTI adhesive anchor .......................................................................................
2838 Spare parts
2838.1 Spare part lists and illustrations ...........................................................................
2859 Circuit diagrams
287Index
Product manual - IRBT 2005 7
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© Copyright 2015 - 2018 ABB. All rights reserved.
Table of contents

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Overview of this manual

About this manual

This manual contains instructions for:

• mechanical and electrical installation of the track

• maintenance of the track

• mechanical and electrical repair of the track.

Usage

This manual should be used during:

• installation, from lifting the robot to its work site and securing it to the

foundation, to making it ready for operation

• maintenance work

• repair work and calibration.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

Maintenance/repair/installation personnel working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical and

electrical installation/repair/maintenance work.

Product manual scope

The manual covers covers all variants and designs of the IRBT 2005. Some variants

and designs may have been removed from the business offer and are no longer

available for purchase.

Organization of chapters

The manual is organized in the following chapters:

ContentsChapter

Safety information that must be read through before performing

any installation or service work on robot. Contains general safety

aspects as well as more specific information on how to avoid

personal injuries and damage to the product.

Safety

Required information about lifting and installation of the track

and installation of cabling. Information about how to get the

system running, including information about some of the import-

ant parameters to set.

Installation and commis-

sioning

Step-by-step procedures that describe how to perform mainten-

ance of the track. Based on a maintenance schedule that may

be used to plan periodical maintenance.

Maintenance

Continues on next page

Product manual - IRBT 2005 9

3HAC051130-001 Revision: F

Overview of this manual

ContentsChapter

Step-by-step procedures that describe how to perform repair

activities of the track. Based on available spare parts.

Repair

Information about calibration of the system.Calibration

Environmental information about the track and its components.Decommissioning

Reference to the spare part list for the robot.Spare parts

Reference to the circuit diagram for the robot.Circuit diagram

References

Documentation referred to in the manual is listed in the table below.

Document IDDocument name

3HAC051132-001Product manual, spare parts - IRBT 2005

3HAC051131-001Product specification - IRBT 2005

3HAC031045-001Operating manual - General safety information i

3HAC047136-001Product manual - IRC5

3HAC050941-001Operating manual - IRC5 with FlexPendant

3HAC16578-1Operating manual - Calibration Pendulum

3HAC050944-001Operating manual - Service Information System

3HAC051016-001Application manual - Additional axes and stand alone controller

3HAC042927-001Technical reference manual - Lubrication in gearboxes

3HAC050948-001Technical reference manual - System parameters

iThis manual contains all safety instructions from the product manuals for the manipulators and the

controllers.

Revisions

DescriptionRevision

First edition.-

This revision contains the following updates:A • Grease name change (Longtime PD 0 → Tribol GR 100-0 PD)

• Corrected the contents on delivery. See Contents on page 51.

•Added bolts to prevent carriage slipping during the transportation,

which must be removed before track assembly. See Assembling

sections on page 85.

• Modified information of track dimensions. See Dimensions on

page 68.

•Modified the procedure how to shorten a long track. See Removing

sections if too long on page 88.

• Minor changes.

Published in release R16.2. The following updates are made in this revi-

sion:

•Corrected the procedures of refitting the carriage to the drive train

bracket.

• Added tightening torque to screws when refitting.

• Corrected the screws for fastening track to base to M16x125 mm.

See Hole configuration on page 80.

Continues on next page

10 Product manual - IRBT 2005

3HAC051130-001 Revision: F

Overview of this manual

Continued

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