ABB IRBT 2005 User manual

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
© Copyright 2015 - 2018 ABB. All rights reserved.
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.
© Copyright 2015 - 2018 ABB. All rights reserved.
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 ..........................................................
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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 ...........................................................................
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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
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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
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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:
B
•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
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Overview of this manual
Continued

DescriptionRevision
• Added section Configuration of grease pump MEMOLUB®on
page 144.
• Modified the replacing procedure for linear guide. See Replacing
the linear guides on page 178.
• Minor changes.
Published in release R17.1. The following updates are made in this revi-
sion:
C
• Remove grease Tribol GR 100-0 PD.
Published in release R17.2. The following updates are made in this revi-
sion:
D
• Updated list of applicable standards.
• Added replacement procedure of SMB battery and SMB board.
• Added sensor alert as a checking interval for the lubricant level
of the automatic lubrication system.
• Added configuration of additional load.
Published in release R18.1. The following updates are made in this revi-
sion:
E
• Added section, Cut the paint or surface on the robot before repla-
cing parts.
• Safety restructured.
• Information about myABB Business Portal added.
Published in release R18.2. The following updates are made in this revi-
sion:
F
• Removed information about Documentation DVD, which is re-
placed by myABB Business Portal.
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Overview of this manual
Continued

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.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Continues on next page
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Product documentation

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

How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 15.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
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How to read the product manual

1 Safety
1.1 General safety information
1.1.1 Limitation of liability
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 complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Nation/region specific regulations
To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.
To be observed by the supplier of the complete system
The integrator is responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Continues on next page
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1 Safety
1.1.1 Limitation of liability

The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered robot are prohibited. Without
the consent of ABB, it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength of the robot could
be affected.
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1 Safety
1.1.1 Limitation of liability
Continued

1.1.2 Protective stop and emergency stop
Overview
The protective stops and emergency stops are described in the product manual
for the controller.
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1 Safety
1.1.2 Protective stop and emergency stop

1.2 Safety actions
1.2.1 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the
manipulator or controller.
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1 Safety
1.2.1 Fire extinguishing

1.2.2 Emergency release of the robot axes
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
•Moving the carriage manually on page 99.
The robot may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.
Increased injury
Before releasing the brakes, make sure that the weight of the robot does not
increase the pressure on the trapped person, further increasing any injury.
DANGER
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.
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1 Safety
1.2.2 Emergency release of the robot axes

1.2.3 Make sure that the main power has been switched off
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
personal injuries, switch off the main power on the controller before proceeding
work.
Note
Switch off all main power switches in a MultiMove system.
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1 Safety
1.2.3 Make sure that the main power has been switched off