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3 Maintenance

3.1 Introduction

Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRBT
2005.

It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.

Each procedure contains all the information required to perform the activity,
including required tools and materials.

The procedures are gathered in different sections and divided according to the
maintenance activity.

Safety information

Observe all safety information before conducting any service work.

There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter

Safety on page 15

before performing any service

work.

Note

If the IRBT 2005 is connected to power, always make sure that the IRBT 2005 is
connected to protective earth before starting any maintenance work.

For more information see:

•

Product manual - IRC5

Product manual - IRBT 2005

149

3HAC051130-001 Revision: F

© Copyright 2015 - 2018 ABB. All rights reserved.

3 Maintenance

3.1 Introduction

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Summary of Contents for IRBT 2005

Page 1: ...ROBOTICS Product manual IRBT 2005 ...

Page 2: ...Trace back information Workspace R18 2 version a15 Checked in 2018 10 30 Skribenta version 5 3 012 ...

Page 3: ...Product manual IRBT 2005 IRC5 Document ID 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ess 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 A...

Page 5: ... or grease 36 1 4 Safety signals and symbols 36 1 4 1 Safety signals in the manual 38 1 4 2 Safety symbols on product labels 45 2 Installation and commissioning 45 2 1 Before starting the track motion 46 2 2 Operating requirements 48 2 3 Unpacking 48 2 3 1 Acceptance inspection 49 2 3 2 Storage 51 2 3 3 Unpacking 52 2 3 4 Lifting the track motion 52 2 3 4 1 Actions before lifting 53 2 3 4 2 Liftin...

Page 6: ...tenance schedule 153 3 2 3 Gearbox oil 154 3 2 4 Expected component life 155 3 3 Activities 100 km or 1 week 155 3 3 1 Cleaning the rack 157 3 3 2 Cleaning the linear guides 159 3 4 Activities 1 month 159 3 4 1 Inspecting the automatic lubrication system 162 3 4 2 Emergency stop and stroke limit system 163 3 4 3 Inspecting the cables and connectors 164 3 5 Activities 3 months 164 3 5 1 Inspecting ...

Page 7: ...ation 265 5 3 Update revolution counters 266 5 4 Defining base frame 267 6 Decommissioning 267 6 1 Environmental information 269 7 Reference information 269 7 1 Introduction 270 7 2 Applicable standards 272 7 3 Unit conversion 273 7 4 Screw joints 276 7 5 Standard tools 277 7 6 Special tools 278 7 7 Lifting accessories and lifting instructions 279 7 8 HILTI adhesive anchor 283 8 Spare parts 283 8 ...

Page 8: ...This page is intentionally left blank ...

Page 9: ...BT 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 Contents Chapter 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 avo...

Page 10: ...ubrication in gearboxes 3HAC050948 001 Technical reference manual System parameters i This manual contains all safety instructions from the product manuals for the manipulators and the controllers Revisions Description Revision 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 ...

Page 11: ...MB 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...

Page 12: ...ioning 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 ...

Page 13: ...s The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRBT 2005 13 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved Product documentation Continued ...

Page 14: ...ompleted 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 Illustration Action Art no is...

Page 15: ...rried 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 respon...

Page 16: ...orking 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...

Page 17: ...iew The protective stops and emergency stops are described in the product manual for the controller Product manual IRBT 2005 17 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 18: ...uishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 18 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 19: ...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 Product manua...

Page 20: ...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 20 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 2 3 Make sure that the main power has been switched off ...

Page 21: ...afety lock Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller If the robot is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a robot standing directly on the floor Energy stored in the robot for the pur...

Page 22: ...odifications to the robot Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment as...

Page 23: ... stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to ...

Page 24: ...fore it is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If ...

Page 25: ...in USA or Canada Pay attention to the rotating axes of the robot Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell Keep clear of moving parts so that limbs hands or fingers do not get trapped or crushed by the robot To prevent anyone else from taking control of the...

Page 26: ...anipulator switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to pre...

Page 27: ...risks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and 400 7...

Page 28: ...e live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 28 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 29: ...nics Safe handling Note Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static voltages and mus...

Page 30: ...your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic 30 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 3 8 Ho...

Page 31: ...re must be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause a...

Page 32: ...as described below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the robot does not change position as the motors are switched off then the brake function is adequate 32 Product manual IRBT 2005 3HAC051130 001 Revision F Co...

Page 33: ...plosion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Safe handling Use safety glasses when handling the batteries In the event of leakage wear rubber gloves and chemical apron In the event of fire use self contained breathing apparatus Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures...

Page 34: ...ion Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic re...

Page 35: ... time to heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained vol...

Page 36: ...e instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING Warns for electrical hazards which could result in severe personal injury or deat...

Page 37: ... conditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP Product manual IRBT 2005 37 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 38: ...lish German and French Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of c...

Page 39: ...Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page Product manual IRBT 2005 39 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights re...

Page 40: ...p over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page 40 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 41: ... 1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page Product manual IRBT 2005 41 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 42: ...001242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page 42 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 43: ...hat this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts Product manual IRBT 2005 43 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Conti...

Page 44: ...This page is intentionally left blank ...

Page 45: ...f track motion IRBT 2005 on page 96 Align and level the track 3 Assembling the manipulator and cable tray on page 108 Assemble the cable tray and manipulator for robot track 4 Electrical installation on page 118 Install the cable chain and connect all cables 5 Inspection of cables and covers prior to start up on page 122 Verify covers and cable chain 6 Electrical installation on page 118 Connect v...

Page 46: ...controller i At low environmental temperature 10o C is as with any other machine a warm up phase recommended to be run with the robot Otherwise there is a risk that the robot stops or run with lower performance due to temperature dependent oil and grease viscosity Relative humidity Relative humidity Description Max 95 at constant temperature Complete track during transportation and storage Max 95 ...

Page 47: ... load at emergency stop kN Endurance load in operation kN Robot Fz Fxy Fz Fxy 3 0 11 0 3 5 3 0 5 5 1 5 IRB 2600 with 1000 mm pedestal 3 0 15 0 3 5 3 0 7 0 1 5 IRB 4600 with 250 mm pedestal Product manual IRBT 2005 47 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 2 Operating requirements Continued ...

Page 48: ...ery inspect the identification plates and compare them to the delivery note The identification plates are shown in the figure xx1500000228 ABB logo 1 Rating label 2 Calibration label 3 Lifting label 4 Warning label 5 Instruction plate 6 48 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Acceptance inspection ...

Page 49: ...either be folded so that the chain is lying on itself or laid on its side xx1300000884 Method 2 rolled up For complete chains with or without strapping in place or strapping in place and the strapping plate not connected to the chain the chain can be rolled up and stored lying on its side xx1300000885 Continues on next page Product manual IRBT 2005 49 3HAC051130 001 Revision F Copyright 2015 2018 ...

Page 50: ...age To move the chain from storage to track see Lifting cable chain on page 59 50 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 2 Storage Continued ...

Page 51: ...ct ABB Contents As standard the track motion IRBT 2005 includes the following on delivery Track motion IRBT 2005 segments depending on the length Cleaning Before transport the track motion IRBT 2005 has been protected against rust by a thin film of oil that has been applied before packing Note Do not clean any of the pre lubricated linear guide and rack Illustration Note Action Wipe off any surplu...

Page 52: ...ng Illustration Note Action xx1500000127 A M6x12 Screw DIN6921 9ADA181 11 7pcs Remove the M6 socket head cap screws holding the cover plates and rack plates using standard tools 1 xx1500000129 If the carriage is not in the centered posi tion move it by hand to the midpoint of the track 2 For details see Moving the carriage manually on page 99 52 Product manual IRBT 2005 3HAC051130 001 Revision F C...

Page 53: ...track is longer the track has to be disassembled into smaller segments Never lift the track IRBT 2005 using an overhead crane without first removing the cover plates Lifting zones xx1400000234 WARNING Never place lifting straps wider than a combined angel of max 60 Continues on next page Product manual IRBT 2005 53 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installatio...

Page 54: ...8 sections 5 distance 1918 mm 5 distance 1918 mm 7 sections 4 distance 1418 mm 4 distance 1418 mm 6 sections 3 distance 918 mm 3 distance 918 mm 5 sections 3 distance 918 mm 3 distance 918 mm 4 sections 2 distance 418 mm 2 distance 418 mm 3 sections 1 distance 82 mm 1 distance 82 mm 2 sections Continues on next page 54 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All ...

Page 55: ...g an overhead crane Proceed as follows to lift the track motion IRBT 2005 using an overhead crane xx1500000592 Continues on next page Product manual IRBT 2005 55 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 4 2 Lifting and moving track motion IRBT 2005 Continued ...

Page 56: ...ound plates Depending on the length of the track motion the number of roller dollies varies See table for information xx1500000594 Continues on next page 56 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 4 2 Lifting and moving track motion IRBT 2005 Continued ...

Page 57: ...g Track motion length 2 pcs 4 pcs 9 sections 2 pcs 4 pcs 8 sections 2 pcs 4 pcs 7 sections 2 pcs 4 pcs 6 sections 4 pcs 5 sections 4 pcs 4 sections 4 pcs 3 sections 4 pcs 2 sections Product manual IRBT 2005 57 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 4 2 Lifting and moving track motion IRBT 2005 Continued ...

Page 58: ...le carriage track on page70 and Weight of double carriage track on page 71 WARNING Never lift the track IRBT 2005 in segments longer than 9 meters If the track is longer the track has to be disassembled into smaller segments Never lift the track IRBT 2005 using an overhead crane without first removing the cover plates 58 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB Al...

Page 59: ...e internal and external cable chains xx1400000479 Description Item Cable chain end unit A Cable chain pitch with divider B Cable chain pitch no divider C Cable chain 10 links D Continues on next page Product manual IRBT 2005 59 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 4 4 Lifting cable chain ...

Page 60: ... the chain and plan the job in advance in regard to the actual installation site To move the chain from storage to track use one of the methods described in this section Method 2 requires an overhead crane Required equipment Note Art No Equipment Quantity depends on track length Lifting slings standard Required if using lifting method 1 Required if using lifting method 2 Lifting sling extra wide 5...

Page 61: ... be placed so that both ends are in the middle of the track 4 There is no space for the lifting slings to stay fitted to the chain once it is lowered into the tray therefore these must be removed before the cable chain is placed inside the tray 5 Lower the fixed and movable ends first then continue lowering bit by bit until the complete chain is fitted into the tray while at the same time removing...

Page 62: ...xx1300000889 Lift the chain so that it is standing upright and in sert a wide lifting sling 50 mm through the center of the chain 2 Lift the cable chain to the installation position above the cable tray The chain should be placed so that both ends are in the middle of the track 3 Lower the cable chain into the cable tray The ends of the chain should be in the middle of the track 4 Continues on nex...

Page 63: ... cable chain cannot come into contact with any moving parts Product manual IRBT 2005 63 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 4 4 Lifting cable chain Continued ...

Page 64: ...carriages 1 3 to 16 3 in steps of 1 m Robot with extra plate Ro bot with extra plate Double carriages 0 8 to 19 8 in steps of 1 m Transfer Single car riage multiple carriages Transfer track For every independent trans fer track with a single carriage i Travel length is the maximum distance that the carriage s can move Single carriage xx1500001397 Description Item Total length of linear guide 230 1...

Page 65: ...the transfer track A1 Travel length in mm of carriage 2 on the transfer track A2 Carriage 1 C1 For robot track this carriage is always in standard mounting For transfer track refer to Mounting of manipulator on the track on page110 to acquire the mounting direction standard or mirrored of the carriage Continues on next page Product manual IRBT 2005 65 3HAC051130 001 Revision F Copyright 2015 2018 ...

Page 66: ...red of the carriage Carriage 2 C2 For transfer track refer to Mounting of manipulator on the track on page110 to acquire the mounting direction standard or mirrored of the carriage Carriage 3 C3 For transfer track refer to Mounting of manipulator on the track on page110 to acquire the mounting direction standard or mirrored of the carriage Required space for track installation Note The following t...

Page 67: ... 23 20 17 7 18 8 21 23 21 18 7 19 8 i The travel length is described in Travel length on page 64 ii The measurement for the required space is valid when not using the external cable chain iii How to calculate the required space is described in Formula for required space on page 66 Required space for installation of double carriage track without external cable chain The following table describes th...

Page 68: ...23 17 12 3 13 4 14 8 18 23 18 13 3 14 4 15 6 19 23 19 14 3 15 4 16 6 20 23 20 15 3 16 4 17 6 21 23 21 16 3 17 4 18 6 i The travel length is described in Travel length on page 64 ii The measurement for the required space is valid when not using the external cable chain iii How to calculate the required space is described in Formula for required space on page 66 Dimensions Without FlexLifter xx14000...

Page 69: ...tal length of the track without external cable chain or with ex ternal cable chain but the chain does not exceed the end of the trackiii L2 In which N indicates the number of sections N A 720 N x 1000 ii Total length of the track with one external cable chain exceed ing the end of the trackiii In which N indicates the number of sections N A 1210 N x 1000 ii Total length of the track with double ex...

Page 70: ...sfer W 232 x 2 202 x N Robot Robot W 232 375 202 x N Root Robot with extra plate W 375 x 2 202 x N Robot with extra plate Robot with extra plate W 249 x 2 202 x N Transfer Transfer W 249 x 3 202 x N Transfer Transfer Transfer Weight of single carriage track Weight kg Joined sections in transport Sections pcs Transfer Robot with extra plate Robot Value of N 653 779 636 1 2 855 981 838 1 3 1057 1183...

Page 71: ...ons pcs Transfer Transfer Robot with extra plate Robot with extra plate Robot Ro bot with ex tra plate Robot Ro bot Value of N 1306 1558 1415 1272 1 4 1508 1760 1617 1474 1 5 1710 1962 1819 1676 1 6 1912 2164 2021 1878 1 7 2114 2366 2223 2080 1 8 2316 2568 2425 2282 1 9 2518 2770 2627 2484 2 10 2720 2972 2829 2686 2 11 2922 3174 3031 2888 2 12 3124 3376 3233 3090 2 13 3326 3578 3435 3292 2 14 3528...

Page 72: ...1 5 1959 1 6 2161 1 7 2363 1 8 2565 1 9 2767 2 10 2969 2 11 3171 2 12 3373 2 13 3575 2 14 3777 2 15 3979 2 16 4181 2 17 4383 3 18 4585 3 19 4787 3 20 4989 3 21 Weight of pedestal Weight kg Pedestal height mm i 70 250 95 500 165 750 190 1000 i Heights 500 750 and 1000 are unavailable for IRB 4600 Airborne noise level The sound pressure level outside the working space is less than 76 dB A 1 m Contin...

Page 73: ...pe of movement Within specification for respective robot ISO Cube Product manual IRBT 2005 73 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 5 Technical data for track motion Continued ...

Page 74: ...f the table orientation Use the hole configuration for the manipulator when designing fixtures to be used on the track The figures below show the dimensions of the robot carriage table in mm Both tables on double carriage track are the same Eight M10 holes circled in the following figure are available for fastening the fixture on the carriage xx1400000467 Continues on next page 74 Product manual I...

Page 75: ... the dimensions of the transfer carriage table in mm Eight M10 holes circled in the following figure are available for fastening the fixture on the carriage xx1400001407 Continues on next page Product manual IRBT 2005 75 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Measures of the carriage table Continued ...

Page 76: ...following figure are available for ground cables xx1500001611 Continues on next page 76 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Measures of the carriage table Continued ...

Page 77: ... suitable pedestal pedestal combination to meet their requirements The following height models can be provided by the pedestal pedestal combination 250 mm 500 mm 750 mm and 1000 mm Note 500mm 750 mm and 1000 mm risers are not applicable to IRB 4600 Product manual IRBT 2005 77 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Measures of th...

Page 78: ...eding 0 5 mm m in the direction of travel and 0 2 mm m across this The leveling screws can also compensate a poor flatness of the slab and small bumps up to 10 mm However the surface under the leveling screw must be flat A concrete surfacing grinder should be used to correct the flatness locally if necessary Maximum payload The following table shows the maximum load that can be placed on the top p...

Page 79: ...the basis of the material the foundation is made of Choose mounting bolts so that they Are suitable for the foundation Can bear the dynamic loads Are able to bear the combined dynamic loads that can occur when the manipulator and carriage move Fit in the holes in the stand Ø18 5 mm Product manual IRBT 2005 79 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and ...

Page 80: ...h different travel lengths Quantity N Total length of the stand Travel length 4 4 m 2 8 1 6 m 5 5 m 3 8 2 6 m 6 6 m 4 8 3 6 m etc Continues on next page 80 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 4 3 Hole configuration ...

Page 81: ...and C Screws for fastening track to base Recommended screws for fastening the track to the base M16x125 mm Steel structure M16x125 mmi Concrete floor i The type and dimension of screws depend on the foundation conditions See description for maximum floor loads in Operating environment Product manual IRBT 2005 81 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation a...

Page 82: ...over I Carriage C Top cover support J Mechanical stop D End cover K Linear guide E Rack F CAUTION Do not step on the cable chain or top cover otherwise injure and or damage to the product may occur 82 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 4 4 Track motion IRBT 2005 overview ...

Page 83: ...Ratchet head for torque wrench 1 2 1 Special tools Illustration Art No Description Quantity Rack clamps 2 3HAC054535 001 Leveling tool 1 3HAC054534 001 Locking nut adjust ment tool 1 Continues on next page Product manual IRBT 2005 83 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Assembling the sections of the track motion IRBT 2005 Lon...

Page 84: ...rack motion IRBT 2005 Positioning the sections Illustration Note Action Note Make sure that the floor is clean before the assembly Mark up the required position of each IRBT 2005 section on floor 1 Position the pre assembled track sections ac cording to the markup 2 Level the 9 meter track sections with the M60 leveling screws as described in Geometric alignment of track motion IRBT 2005 on page 9...

Page 85: ...10 pieces on each side C Plate washer 3HAC045077 001 D Joint bracket 3HEA801652 001 Fit two positioning pins A using a hammer In order to reach the same acceptable accuracy as in the manufacturing process the joint bracket is drilled with two Ø 16 mm through holes and must be inserted with the two pins during assembling 3 Connect the sections with joint brackets D by fitting screws B and plate was...

Page 86: ...ightly tighten Install the racks When the alignment is correct tighten the screws one by one 6 Use a brush to lubricate the racks 7 xx1400000228 A Linear guide 1000 mm 3HAC045755 001 500 mm 3HAC045755 002 B Ø 12 x Ø 32 x 4 Plain washer for rail 3HAC047749 001 C M12x35 Hex socket head cap screw 3HAB3409 66 Tightening torque 125 Nm Fit the linear guides on sections by fitting the screws and plain wa...

Page 87: ...t the clearance into allowed scope 2 xx1400001751 A M10x20 Hex socket counter sunk screw DIN7991 3HAC051482 001 B Square locking washer 3HEA802935 001 C Upper right mark Tightening torque 40 Nm Secure the square locking washers with screws Note Start fixing lock washers from the rear end 3 Tightening torque 40 Nm When the alignment is correct tighten the fix ing screws of linear guides one by one ...

Page 88: ...ge 99 If required press the brake release button to manually move the carriage sideways 1 xx1500003251 Remove cover screws 2 xx1500003252 Remove the covers of the sections to be re moved Note End covers need to be removed only when sections are to be removed from the track end 3 xx1500003253 Remove the square locking washers and screws which clamp the linear guides at the junction 4 Continues on n...

Page 89: ...es with the next section module See Assembling sections on page 85 7 Fitting covers Illustration Note Action xx1400000229 A M6x16 Screw DIN6921 9ADA181 12 Tightening torque 10 Nm B Top cover support Fit the top cover support with screws 1 Continues on next page Product manual IRBT 2005 89 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 A...

Page 90: ...y other fixed parts See section Moving the carriage manually on page 99 for instructions on how to release the motor brake xx1400000231 A M6x12 Screw DIN6921 9ADA181 11 7 pcs Tightening torque 10 Nm B Top cover of the track C Rack cover of the track Fit the rack covers C on top of the section with screws A and fix the top cover B on the top cover support with screws A 4 Continues on next page 90 P...

Page 91: ...ered 5 Release the carriage brake again and push the carriage manually along the length of its stroke Verify that no covers come into contact with the moving carriage 6 Product manual IRBT 2005 91 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 4 5 Assembling the sections of the track motion IRBT 2005 Longer than 9 m Continued ...

Page 92: ...463 A Leveling screw Adjust the horizontality of the IRBT 2005 with the M60 leveling screw using the lev eling tool Art No 3HAC054535 001 2 Make sure that all the leveling screws are touching the floor 3 xx1400000464 A Fitting nut Tighten the M60 fitting nuts using the nut adjustment tool Art No 3HAC054534 001 4 Continues on next page 92 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright...

Page 93: ... through the leveling screw Ø 18 5 mm 125 mm deep 1 xx1400000583 Brush the inside of the hole 2 Continues on next page Product manual IRBT 2005 93 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Positioning the stand Continued ...

Page 94: ...ide the capsule is fluid 4 Insert the HILTI tool supplied with the an chor kit in the chuck of a handheld electric punch drill 5 Insert the triangular extremity of the threaded rod in the HILTI tool Continues on next page 94 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 4 6 Positioning the stand Continued ...

Page 95: ...the track leveling using the M60 screws and then tighten the M16 notched nuts See Geometric alignment of track motion IRBT 2005 on page 96 7 xx1400000587 Tightening torque 160 Nm Use the supplied washers then tighten the nuts 8 WARNING It is of the utmost importance that all screw joints be tightened with the correct torque Failure to do so may result in damage to the equipment or personal Product...

Page 96: ... horizontally along the entire travel length Use a laser level Required equipment Note Art No Equipment Laser level Directions xx1400001830 Track alignment in different directions Note The origin of coordinates is located in the manipulator s base zero Continues on next page 96 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commiss...

Page 97: ...should be laser aligned to within 0 5 mm from the origin per meter along the entire X axis xx1400001474 Leveling screw adjustment method Illustration Note Action xx1400000463 A Leveling screw Screw the leveling screw A in or out to raise or lower the machining in question 1 Continues on next page Product manual IRBT 2005 97 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 In...

Page 98: ... the fitting nut when the level of the complete track is adjusted 2 98 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 4 7 Geometric alignment of track motion IRBT 2005 Continued ...

Page 99: ...ibed in Releasing the brake with external 24 V DC on page 100 Note If the carriage is moved manually without connection to the IRC5 but by simply connecting directly 24 V DC to the motor to release the brake a recalibration is needed Illustration Note Action Connect all cables to the controller as de scribed in The cabling from the controller on page 118 1 Start up the controller as described in C...

Page 100: ...he calibration pin as well as at the location where the rack and pinion mesh Users should remain clear of these locations when moving the track Releasing the brake with external 24 V DC If there is no voltage to the motor 24 V DC can be connected directly to the brake release Note If the carriage is moved manually without connection to the IRC5 but by simply connecting directly 24 V DC to the moto...

Page 101: ...Connect 0 V DC to pin f 9 for con nector XP7 or XP1 12 for connector XP1 Note Be careful not to interchange the 24 V and 0 V pins If they are mixed up damage can be caused to the brake release unit and the system board 3 Pin location on connector XP7 for the transfer track with 3 axis SMB box xx1500000763 WARNING Incorrect connections can cause all brakes to be released simultaneously Pin location...

Page 102: ...ttons on 6 axis SMB box xx1500000766 Note The 3 axis SMB box has three buttons for controlling the axes brakes and the 6 axis SMB box has six buttons The buttons are numbered according to the numbers of the axes Push the carriage to the desired location by hand 6 The brake will function again as soon as the button is released 7 102 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 ...

Page 103: ...ered track extension B Procedures of long track connection Removing one end section of the track A track motion has two end sections A and B in the following figure Remove one of the end section as required xx1400002676 Illustration Note Action Remove the top cover and rack cover of the end section 1 Continues on next page Product manual IRBT 2005 103 3HAC051130 001 Revision F Copyright 2015 2018 ...

Page 104: ...ection 1 xx1400000465 Press the brake release button of extension section as shown in the figure 2 Push the carriage by hand to show the rack and linear guide of extension section 3 Removed the cover on extension section if the section is covered track extension 4 Remove the bolts that are used as temporary stops on both sides of the extension section WARNING A track that is divided in sections ha...

Page 105: ... 3HAC054532 001 Install the racks Fit the companion rack fix block and companion rack to the section and the rack to make sure the racks are positioned correctly in vertical plane 7 xx1400000184 Fit the clamping tools at both ends of the rack to make sure that the racks are aligned with each other 8 Note This clamping tool is for reference only Prepare clamping tools based on actual situation Cont...

Page 106: ... guide or more linear guide until gap between all linear guides are less than 0 7 mm 12 xx1400000228 A Linear guide 1000 mm 3HAC045755 001 500 mm 3HAC045755 002 B Ø12xØ32x4 Washer for rail 3HAC047749 001 C M12x35 Hex socket head cap screw 3HAB3409 66 Tightening torque 140 Nm Fit the linear guides on sections by fitting the screws and plain washer 13 Note Use the rail pressing tool to make sure tha...

Page 107: ...y and verify the leveling with a leveling device or a laser tracker The levelness of the top plate must be satisfying in the translation direction but also cross section For how to adjust the leveling of the track see Geometric alignment of track motion IRBT 2005 on page 96 If you have moved the carriage manually you probably need to initialize the resolver position see Update revolution counters ...

Page 108: ...n There are two orientations to fit the cable chain Side view xx1500000597 Standard cable chain orientation Top view xx1400001952 Side view xx1500000630 Mirrored cable chain orienta tion Top view xx1400001951 Robot capacity The following table shows the robot capability of IRBT 2005 Standard pedestals are generally allowed between the IRBT 2005 carriage and the robot but their height is limited an...

Page 109: ...licable 1000 mm pedes tal 750 mm pedestal 500 mm pedestal 250 mm pedestal Robot x x x x IRB 1520 x x x x IRB 1600 x x x x IRB 2600 N A N A N A x IRB 4600 Product manual IRBT 2005 109 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 5 1 Assembling the manipulator Continued ...

Page 110: ...n different directions with the standard cable chain The positive X direction is the positive motion direction of the track The positive Y direction is the direction of the cabling outlet on the carriage Y Z X WORLD xx1500000928 xx1400001911 0 degrees in line Y Z X WORLD xx1500000928 xx1400001912 90 degrees Y Z X WORLD xx1500000928 xx1400001909 180 degrees Y Z X WORLD xx1500000928 xx1400001910 270...

Page 111: ...sitive Y direction is the opposite direction of the cabling outlet on the carriage Y Z X WORLD xx1500000927 xx1500000631 0 degrees in line Y Z X WORLD xx1500000927 xx1500000632 90 degrees Y Z X WORLD xx1500000927 xx1500000633 180 degrees Y Z X WORLD xx1500000927 xx1500000634 270 degrees Continues on next page Product manual IRBT 2005 111 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights...

Page 112: ...itions on the carriage table of the robot track xx1400002680 Guide bushing fitting hole for IRB 1520 A Guide bushing fitting hole for IRB 1600 2600 4600 B 112 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 5 2 Mounting of manipulator on the track Continued ...

Page 113: ...bot product manual Lift the robot to other position 2 xx1400002681 A Guide bushing Fit two guide bushings to the hole on the car riage table of the robot track according to the orientation of robot For the guide bushing assembly positions see Assembly position on page 112 3 Make sure the robot base is correctly fitted onto the guide bushings Guide the robot gently using the screws while lowering i...

Page 114: ... robot from the pedestal first and then adjust the pedestal orientation Illustration Note Action XX1500000490 A M16x60 Hex socket head cap screw 3HAB3409 86 6 pcs B Ø30xØ17x3 plain washer 3HAA1001 186 6 pcs Remove the securing screws and plain wash ers in the holes of robot base 1 For how to lift the robot according to robot product manual Lift the robot from the pedestal to other posi tion 2 Cont...

Page 115: ...rrectly fitted onto the guide bushings Guide the pedestal gently using the screws while lowering it into its fitting position 5 Refit the securing screws and plain washers in the attachment holes of the pedestal 6 Lift the robot back and gently put it onto the pedestal Refit the securing screws and plain washers in the attachment holes of the robot base 7 Tighten the bolts in a criss cross pattern...

Page 116: ... friction between the cable chain when the moving end of the cable chain moves passing the fixed end xx1400001580 Installing the cable tray Installing the external cable tray Illustration Note Action xx1400001936 A M10x30 Hex socket head cap screw 3HAB3409 51 4 pcs Tightening torque 47 Nm Fix the connection bracket for the external cable tray on the top plate of the carriage by screws 1 Continues ...

Page 117: ...able tray onto the brackets 3 M6x12 Torx counters head screw 9ADA624 5 Fasten the external cable tray with screws 4 Tightening torque 10 Nm Product manual IRBT 2005 117 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 5 4 Assembling the cable tray Continued ...

Page 118: ...d as the connection between the cable harness from the track flexible cables and the cable harness from the controller floor cables CAUTION The floor cables must be grounded based on the requirements described in section Circuit diagrams on page285 Single stranded copper wires with a diameter larger than 7 mm are recommended to be used as customer grounding cables which will connect the cable grou...

Page 119: ...le grounding and hoses etc Connectors connecting cable harness from the carriage and cable harness from the controller i E Floor cables from the controller F Power cable available for IRC5 Signal cable available for IRC5 Controller available for IRC5 G i For the transfer track this would be an SMB box Product manual IRBT 2005 119 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserve...

Page 120: ... Connections The wiring diagrams are described in section Circuit diagrams on page 285 120 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 6 2 1 Introduction ...

Page 121: ...001852 Description XP 0 Mains connection A Earth connection point B XS 1 Robot power connection C XS 7 Additional axes power connection D XS 13 XS 5 Customer power signals external connection E XS 10 Customer options F XS 11 Customer options G XS 12 Customer options H X3 Customer safety signals J XS 28 Network connection K XS 41 Additional axes SMB connection L XS 2 Robot SMB connection M Product ...

Page 122: ...the moving and fixed end need to be strapped individually at least twice in order to strain relief correctly If there are not enough holes available in the connection plates for individual strapping the cables should be secured in such a way that they can not move 2 Make sure no floor cables are in risk of collision with moving parts 3 Guide channel inspection No Yes Inspection Guide channel free ...

Page 123: ...dio System status after startup After startup only the manipulator is configured in the controller It will not be possible to jog or program using the track motion To activate the track motion it is necessary to use RobotStudio to create a new system with the track motion settings and download the new system to the robot controller see Creating and downloading a system on page 124 Product manual I...

Page 124: ... Installation Manager in RobotStudio 1 In the Products tab click Add and select the RobotWare and TrackMotion product manifests 2 In the Licenses tab add the license for RobotWare The track motion does not require a license 3 In the Options tab Drive Modules pane add the additional drive unit ADU that controls your track motion 4 In the Options tab Drive Modules pane select and modify the options ...

Page 125: ...ct length 10 Verify that the selected robot orientation on the track motion matches the physical configuration see Base frame configuration on page 133 11 For more detailed instructions on using the Installation Manager see Operating manual RobotStudio Product manual IRBT 2005 125 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 7 2 Creating ...

Page 126: ...g example the upper limit is set to 5 8 m and the lower limit is set to 0 5 m ARM upper_joint_bound 5 8 lower_joint_bound 0 5 Example The following screenshot shows an example of the error message that is generated when the track is jogged beyond its software limit xx1400001913 Changing the limits WARNING This is an important safety feature to prevent damage to the track Make sure that the track d...

Page 127: ...4230 0 5 3 35 3 85 5 5230 0 5 4 35 4 85 6 6230 0 5 5 35 5 85 7 7230 0 5 6 35 6 85 8 8230 0 5 7 35 7 85 9 9230 0 5 8 35 8 85 10 10230 0 5 9 35 9 85 11 11230 0 5 10 35 10 85 12 12230 0 5 11 35 11 85 13 13230 0 5 12 35 12 85 14 14230 0 5 13 35 13 85 15 15230 0 5 14 35 14 85 16 16230 0 5 15 35 15 85 17 17230 0 5 16 35 16 85 18 18230 0 5 17 35 17 85 19 19230 0 5 18 35 18 85 20 20230 0 5 19 35 19 85 21 ...

Page 128: ...r Joint Bound m Upper Joint Bound m Travel L m Modules Total L mm 0 5 1 1 1 60 4 4230 0 5 2 1 2 60 5 5230 0 5 3 1 3 60 6 6230 0 5 4 1 4 60 7 7230 0 5 5 1 5 60 8 8230 0 5 6 1 6 60 9 9230 0 5 7 1 7 60 10 10230 0 5 8 1 8 60 11 11230 0 5 9 1 9 60 12 12230 0 5 10 1 10 60 13 13230 0 5 11 1 11 60 14 14230 0 5 12 1 12 60 15 15230 0 5 13 1 13 60 16 16230 0 5 14 1 14 60 17 17230 0 5 15 1 15 60 18 18230 0 5 ...

Page 129: ...nt Bound m Robot Lower Joint Bound m Robot Upper Joint Bound m Travel L m Modules Track L mm 0 34 1 1 0 5 0 9 1 44 5 5230 0 34 2 1 0 5 1 9 2 44 6 6230 0 34 3 1 0 5 2 9 3 44 7 7230 0 34 4 1 0 5 3 9 4 44 8 8230 0 34 5 1 0 5 4 9 5 44 9 9230 0 34 6 1 0 5 5 9 6 44 10 10230 0 34 7 1 0 5 6 9 7 44 11 11230 0 34 8 1 0 5 7 9 8 44 12 12230 0 34 9 1 0 5 8 9 9 44 13 13230 0 34 10 1 0 5 9 9 10 44 14 14230 0 34 ...

Page 130: ...35 12 85 0 5 13 35 13 85 0 5 14 35 14 85 0 5 15 35 15 85 0 5 16 35 16 85 0 5 17 35 17 85 0 5 18 35 18 85 0 5 19 35 19 85 Identifying the upper and lower limits by experiment If the actual value of the limit is not known it is possible to jog the track to the desired limit position and then read the limit value from the FlexPendant Note Action Before beginning make sure that the revolution counter ...

Page 131: ...t the controller 3 xx1400001923 Jog the mechanical unit to the desired limit position as shown in the figure Note A minimum distance of 20 mm should be used between where the software limit is set and the actual mechanical stop 4 In the jogging window read the current position for the track motion Note The distance is shown in millimeters 5 xx1400001922 Update the limit value in the MOC file In th...

Page 132: ...step should be carried out with great care If the software limit has not been set correctly the mechanical unit may hit the mechanical hard stop 8 Repeat the previous steps for the other limit 9 132 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 7 3 Setting upper and lower software limits for the track Continued ...

Page 133: ...meter in Technical reference manual System parameters Robot These parameters belongs to the type Robot in the topic Motion Description Parameter Base Frame x y z defines the direction of the robot base frame pos ition in relation to the world frame in meters Base Frame x Base Frame y Base Frame z Base Frame q1 q4 defines the quaternions of the robot base frame orientation in relation to the world ...

Page 134: ...tion to the world frame Base Frame q1 Base Frame q2 Base Frame q3 Base Frame q4 Use Joint defines which joint data to use for the track motion Use Joint 134 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 7 4 1 Introduction Continued ...

Page 135: ... Rotation track1 Use Joint IRB rotated 90 in relation to the World coordinate system Y Z X WORLD xx1500000928 xx1400001912 90 degrees Positive travel direction x in World coordinates Standard travel direction Track motion TRACK_1 Robot ROB_1 Parameter 1 0 707107 Base Frame q1 0 0 Base Frame q2 0 0 Base Frame q3 0 0 707107 Base Frame q4 1 570796 Gamma Rotation track1 Use Joint Continues on next pag...

Page 136: ...rotated 270 in relation to the World coordinate system Y Z X WORLD xx1500000928 xx1400001910 270 degrees Positive travel direction x in World coordinates Standard travel direction Track motion TRACK_1 Robot ROB_1 Parameter 1 0 707107 Base Frame q1 0 0 Base Frame q2 0 0 Base Frame q3 0 0 707107 Base Frame q4 1 570796 Gamma Rotation track1 Use Joint Continues on next page 136 Product manual IRBT 200...

Page 137: ...Joint IRB rotated 90 in relation to the World coordinate system xx1500000632 Y Z X WORLD xx1500000927 90 degrees Positive travel direction x in World coordinates Mirrored travel direction Track motion TRACK_1 Robot ROB_1 Parameter 1 0 707107 Base Frame q1 0 0 Base Frame q2 0 0 Base Frame q3 0 0 707107 Base Frame q4 1 570796 Gamma Rotation track1 lin Use Joint Continues on next page Product manual ...

Page 138: ...e Joint IRB rotated 270 in relation to the World coordinate system xx1500000634 Y Z X WORLD xx1500000927 270 degrees Positive travel direction x in World coordinates Mirrored travel direction Track motion TRACK_1 Robot ROB_1 Parameter 1 0 707107 Base Frame q1 0 0 Base Frame q2 0 0 Base Frame q3 0 0 707107 Base Frame q4 1 570796 Gamma Rotation track1 lin Use Joint 138 Product manual IRBT 2005 3HAC0...

Page 139: ...uring the boot process The standard pedestals with the height of 250 mm 500 mm 1000 mm and 1750 mm The additional carriage plate The robot However if for example an arc welding power source is fitted on the additional carriage plate then the system parameter Arm Load t1_load_1 must be updated with the correct center of gravity and mass Product manual IRBT 2005 139 3HAC051130 001 Revision F Copyrig...

Page 140: ...isconnect the cartridge power cable from the connector bracket on the carriage 2 xx1500000131 Screw the complete cartridge counterclockwise to remove it from its holder on the carriage 3 Opening the grease pump Illustration Note Action Place the grease pump on a flat and clean surface 1 Continues on next page 140 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights...

Page 141: ... grease cartridge Illustration Note Action Open the MEMOLUB as described before 1 xx1400001572 Pull up the black rubber seal Fill in the MEMOLUB with a manual grease pump This manual operation is required only if the MEMOLUB has been used without a cart ridge if the previous cartridge has run out of grease Place the pump nipple at the entry of the MEMOLUB and pump until you see grease coming out a...

Page 142: ...4 xx1400001577 Place the cartridge at the inlet of the pump verify that the cartridge is correctly inserted in the inlet of the pump 5 xx1400001576 Place the spring and the compression disc in side the transparent bell Put the bell back in place and verify that the compression disc is correctly lying on the top of the cartridge sur face 6 Close the MEMOLUB as described before 7 Continues on next p...

Page 143: ...on press one of the 3 connectors located on the base during a few seconds The grease pump is starting a dispensing cycle The completion of the cycle means that the battery and the control board of the grease pump are working well xx1400001578 Product manual IRBT 2005 143 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 8 1 Replacing the greas...

Page 144: ...y of strokes and the duration of a 240 mm cartridge at different combinations Duration of a 240 mm cartridge month s Frequency hour s 38 mm xx1600001022 44 mm xx1600001021 50 mm xx1600001020 24 48 x 12 24 x 8 16 x x 6 12 x 3 6 x x 1 2 x x 1 2 1 x x x Set of rings The figure shows the 3 rings disassembled from the grease pump MEMOLUB xx1600001023 144 Product manual IRBT 2005 3HAC051130 001 Revision...

Page 145: ... get damaged Cables secured and not hanging loosely Cable chain Description Verify that Does the robot carrier run up and down the entire length of track without hitting the trunking guarding etc Working correct in the entire length Is there any damage to the cable chain such as step damage twisted sections or brackets etc No damage Ensure cables are not twisted too tight or too loose inside cable...

Page 146: ...ortant to feel along guiderails where the ball elements run to ensure that there are not any markings In case of suspected problem look after jumping marks at the end of each section Track foundation Description Verify that Correct size bolts used Stretched cables will inevitably affect the shielding and cause feedback issues and other damage Track feet correctly packed to the floor If there is mo...

Page 147: ...identified to prevent incorrect fitting Verify that all brackets are in correct position Verify that all bolts and the locking pins are fitted and have the right torque Product manual IRBT 2005 147 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 2 Installation and commissioning 2 9 1 Check list for IRBT 2005 before commissioning Continued ...

Page 148: ...This page is intentionally left blank ...

Page 149: ...ections and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 15 before performing any service work Note If th...

Page 150: ...IRBT 2005 Calendar time specified in months regardless of whether the system is running or not Operating time specified in operating hours More frequent running means more frequent maintenance activities Travel distance specified in kilometers Intense use means more frequent maintenance activities 150 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 ...

Page 151: ...pection Every 12 months Complete track Adjustment of leveling When expected life is reached or if disturbances occur Linear guide Replacement When linear guides are re placed Ball bearing blocks Replacement When play can not be adjus ted to specified i level Felt gear gear wheel gear box and racks Replacement When gliding surface thick ness is 1 5 mm or less iii Glide shoes ii Replacement 36 month...

Page 152: ...ical lifetime of a new battery is 36 months if the robot is powered off 2 days week or 18 months if the robot is powered off 16 h day The lifetime can be extended with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions vi The connector is available only when the option 1475 1 Oil Detection sensor is chosen To make the sensor alert effective the customer ...

Page 153: ...earbox oil Please see Technical reference manual Lubrication in gearboxes 3HAC042927 001 for information about gearbox oil Product manual IRBT 2005 153 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 2 3 Gearbox oil ...

Page 154: ...ations from this cycle will result in differences in expected life ii The track is dimensioned for a life of 4 years 302 400 cycles per year in a normal application iii The expected life can also be affected by assemblage of cabling other than standard options iv Due to process cycle variation and varying lengths of tracks the chains lifetime is calculated on two parameters gliding meters and bend...

Page 155: ...u clean the racks it is necessary to lubricate the racks manually Use one of the recommended lubricants Note Equipment KLÜBER Microlube GB0 Lubricant TOTAL Multis EP 0 Lubricant Lint free cloth Continues on next page Product manual IRBT 2005 155 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 1 Cleaning the rack ...

Page 156: ... C Rack cover of the track Remove IRBT 2005 upper covers and rack covers 1 Note Use lint free cloth Inspect the racks and the pinion clean them if necessary 2 Use a brush to lubricate the racks 3 Refit the covers 4 156 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 1 Cleaning the rack Continued ...

Page 157: ...u clean the linear guides it is necessary to lubricate them manually Use one of the recommended lubricants Note Equipment KLÜBER Microlube GB0 Lubricant TOTAL Multis EP 0 Lubricant Lint free cloth Continues on next page Product manual IRBT 2005 157 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 2 Cleaning the linear guides ...

Page 158: ...ove IRBT 2005 upper covers and rack covers 1 Note Use lint free cloth Inspect the linear guides clean them if ne cessary 2 If you have cleaned them use a brush to lubricate the linear guides 3 Move the carriage back and forth and re peat step 3 4 Refit the covers 5 158 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 3 2 Cleaning the li...

Page 159: ... though the system should apply the lubricant equally over a longer period Location of lubrication system The lubrication system is located as shown in the figure xx1400000478 Description Pos Lubrication pump EPS 240 A Polyamide tube 4x6 B Straight adaptor F1 4 D8 C Polyamide tube 6x8 D Male stud elbow white brass D8 G1 4 E Male stud elbow white brass D6 G1 8 F Male stud straight white brass D6 G1...

Page 160: ...ssary due to high loads on blocks Note Equipment KLÜBER Microlube GB0 Lubricant TOTAL Multis EP 0 Lubricant Inspecting the grease level and inspecting the pipes Use this procedure to inspect the grease level and inspect the pipes of the lubrication system Illustration Note Action Locate the cartridge 1 xx1400001754 A Checking lubrication cup level through the notch Check the level of lubricant if ...

Page 161: ...formance The automatic lubrication system should be checked that it can work properly For information about checking Memolub function see Test the grease pump MEMOLUB verify function on page 143 Product manual IRBT 2005 161 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 4 1 Inspecting the automatic lubrication system Continued ...

Page 162: ... the required validations in the control system to switch back to auto mode 6 Verification of the effectiveness of the stroke limit system A software limit prevents the carriage from moving beyond its acceptable upper and lower stroke limits The procedure below details how to ensure the software stroke limit is working correctly Illustration Note Action Switch the IRC5 to manual mode 1 With the te...

Page 163: ...ain relief of cables and hoses Marking should be close to the corresponding strap 3 If not pull the hose cable to the correct position and strap it Inspecting the connectors Check that the connectors at the robot base track motor and interchange to the floor cable are firmly secured and that there is no damage of cable outlet Inspecting the cable chain Once a month check that the cable track shows...

Page 164: ...ecting cables from the track and from IRC5 controller E Floor cables from the controller F IRC5 controller G Required equipment Note Art No Equipment Visual inspection Needed if the cable strapping needs to be improved 21662055 3 Cable ties Use heavy duty cable ties with minimum width 4 9 mm Loctite 243 Locking liquid Used if loose screws are de tected Continues on next page 164 Product manual IRB...

Page 165: ...s center line of the link of the chain as shown in the figure If cables are found to be too loose or too tight then they need to be adjusted 2 Repeat the check of the cables in the neutral axis with the carriage in the middle and at the other end 3 Make an overall inspection of the cables 4 If a cable is found to corkscrew it needs to be re placed immediately If cables have worn through the outer ...

Page 166: ...ide shoes on page 252 Make an overall inspection of the glide shoes Replace broken or missing shoes 2 Inspecting the strapping Illustration Note Action Check that strapping is in place Each cable is required to be individually strapped down and not bunched together 1 If insufficient holes are available in the connec tion plates for individual strapping with cable ties the cables should be secured ...

Page 167: ...hing plates and brackets If found to be loose they need to be removed have locking liquid applied to them and then be refitted and tightened 1 Product manual IRBT 2005 167 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 5 1 Inspecting the cable chain Continued ...

Page 168: ... Equipment Content is defined in section Standard tools on page 276 Standard toolkit Inspecting the felt gear Illustration Note Action Inspect the felt gear 1 If damaged replace it See Replacing the felt gear on page 233 168 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 5 2 Inspecting the felt gear ...

Page 169: ...pull the hose cable to the correct position and strap it Fault finding The following information is provided to assist fault finding Cables that have failed due to incorrect installation typically show the following symptoms Knotting of conductors underneath the cable jacket Cables twist around one another within a cable carriage system Cables are sticking out between the cable carriage crossbars ...

Page 170: ...ual inspection Inspecting the mechanical stops Use this procedure to inspect the mechanical stops Illustration Note Action xx1400001283 A Bumper B Mechanical stop Visually inspect the bumpers on mechanical stops for damage 1 If the mechanical stops are damaged replace them 2 170 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 6 2 Inspe...

Page 171: ...ar wheel gearbox and backlash Use this procedure to inspect the gear wheel gearbox and backlash Illustration Note Action Loosen the carriage from the drive train bracket 1 Remove the drive train 2 Inspect the backlash gear wheel and gearbox 3 If backlash is improper adjust it See Ad justing the gearbox backlash on page 229 4 Continues on next page Product manual IRBT 2005 171 3HAC051130 001 Revisi...

Page 172: ...crews class 12 9 3HAB3409 50 Required equipment Note Art No Equipment Content is defined in section Standard tools on page 276 Standard toolkit Inspecting the tightening torque of screws Use this procedure to inspect the tightening torque of the eight M10x40 hex socket head cap screws Illustration Note Action Remove the necessary track covers and carriage side covers 1 Screw specification M10x40 h...

Page 173: ...llow the procedure in Geometric alignment of track motion IRBT 2005 on page96 to adjust the leveling on the track Product manual IRBT 2005 173 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 6 4 Adjusting the leveling ...

Page 174: ...ctions for batteries Safety risks during handling of batteries on page33 Location of SMB battery xx1000001415 Continues on next page 174 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 3 Maintenance 3 7 1 Replacing SMB battery ...

Page 175: ...tery Make sure to order the correct spare parts Do not replace the battery contact Replacing SMB battery Use this procedure to replace the SMB battery Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page Product manual IRBT 2005 175 3HAC051130 001 Revision F Copyright ...

Page 176: ...s can cause shortage on the boards which can result in hazardous failures 3 Pull out the battery and disconnect the battery cable 4 Fit the new battery and connect the battery cable 5 Close the SMB box 6 See Calibration on page 263 Update the revolution counters 7 See Environmental information on page 267 Dispose of the old battery 8 176 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright...

Page 177: ...spective procedures The details of equipment are also available in different lists in the chapter Reference information on page 269 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sure to read through the chapter Safety on page 15 before ...

Page 178: ...dures include references to the tools re quired Other tools and procedures may be required See references to these procedures in the step by step in structions below Removing the linear guides Use this procedure to remove the linear guides Illustration Note Action xx1400000231 Remove all necessary IRBT 2005 top cov ers B and rack covers C around the lin ear guide to be replaced by removing screws ...

Page 179: ... A Linear guide B Ø 12xØ 32x4 Washer for rail l3HAC047749 001 C M12x35 Hex socket head cap screw 3HAB3409 66 Remove the linear guide by removing the screws and washers 3 Continues on next page Product manual IRBT 2005 179 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 2 Replacing the linear guides Continued ...

Page 180: ...uare locking washer 3HEA802935 001 C Ensure this mark is on the upper right corner of the lock washer Fit the square locking washer with screws Use standard tools slightly tighten 2 xx1400001752 A Ball bearing block B Linear guide Feel with a finger at the section joint to check the alignment of the linear guide if the linear guides are correctly aligned you should sense no step while passing the ...

Page 181: ... Once you have tightened a screw mark it with a white marker Make sure that the guide rail is aligned and then tighten the screw to locking washer 5 Tightening torque 45 Nm xx1400001752 Tightening torque 125 Nm Tighten the hex socket head cap screws M12x35 6 Fit the covers 7 Product manual IRBT 2005 181 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 2 Replacing th...

Page 182: ...are part number is specified in Spare parts on page 283 Ball bearings block The content is defined in Standard tools on page 276 Standard toolkit Jack 2t These procedures include references to the tools re quired Other tools and procedures may be required See references to these procedures in the step by step in structions below Continues on next page 182 Product manual IRBT 2005 3HAC051130 001 Re...

Page 183: ... for IRBT 2005 2 xx1400001679 A Lubrication tube connector Disconnect the lubrication tube connector for the ball bearing block 3 Use a jack to secure the height of the car riage plate don t rise it more than 1 mm WARNING Rising the carriage more than 1 mm can seriously damage the remaining three ball bearing blocks 4 Continues on next page Product manual IRBT 2005 183 3HAC051130 001 Revision F Co...

Page 184: ...slide out of the bracket and linear guide 6 Refitting the ball bearing block Illustration Note Action Remove the standard screws delivered with the block and replace with the grease pipe fitting taken from the old block 1 Continues on next page 184 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 3 Replacing the ball bearing blocks Continued...

Page 185: ...l meanwhile the black plastic protec tion B is pushed out 2 Note The fittings B must be on the inside of the carriage and the machined reference sur face A must be on the upper face of the block A Machined reference surface B Fittings C The other surface of the block has no reference line Continues on next page Product manual IRBT 2005 185 3HAC051130 001 Revision F Copyright 2015 2018 ABB All righ...

Page 186: ...tting of the ball bearing block 5 Refit the mechanical stop and the covers 6 See Fine calibration on page 264 Calibrate the track motion if the ball bearing block at the drive unit bracket has been replaced 7 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 24 8 186 Produc...

Page 187: ...on page 276 Standard toolkit 3HAC054531 001 Companion rack fix block 3HAC054532 001 Companion rack 3HAW107700357 Rack clamps These procedures include refer ences to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Continues on next page Product manual IRBT 2005 187 3HAC051130 001 Revision F Copyright 2015 2018...

Page 188: ... 1 C Rack Remove screws and plain washers that hold the rack to the sections 2 Refitting the racks Use the procedure to refit the racks Illustration Note Action xx1400000227 A M10x40 hexagon head bolt class 12 9 B Ø17xØ11x2 washers C Rack Fit the rack with the screws and washers Do not tighten the screws yet 1 Continues on next page 188 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright ...

Page 189: ...gnments are correct and then tighten the screws one by one 4 Loosen the screws of the rack located next to the replaced rack fit the clamping tool to the junction in order to align the loosened rack to the rack located next to it and then re tighten the screws 5 Repeat with following racks until all racks are aligned with each other xx1400001752 Once you have tightened a screw mark it with a white...

Page 190: ...tside of the software limit of the track xx1400000499 Mechanical stops left A Mechanical stops right B Required equipment Note Equipment Spare part number is specified in Spare parts on page 283 Mechanical stops The content is defined in Standard tools on page 276 Standard toolkit Continues on next page 190 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reser...

Page 191: ...cal stop by removing hexagon nuts A and screws C 1 Refitting the mechanical stops Use this procedure to refit the mechanical stops Illustration Note Action xx1400002686 A M20 hexagon nut 9ADA267 11 B Mechanical stop C M20x100 Hex socket head cap screw 3HAB3409 206 Tightening torque 90 Nm Fit the screws C and nuts A 1 Product manual IRBT 2005 191 3HAC051130 001 Revision F Copyright 2015 2018 ABB Al...

Page 192: ...o technicians to work together The figure below shows how to push the carriage away from the motor bracket and expose the motor gearbox gear wheel felt gear and cable chain connection point This makes the following components accessible for maintenance xx1400002684 Name Item Cable chain remains stationery A Motor remains stationery B Carriage pushed away C Motor bracket remains stationery D Gear w...

Page 193: ...For the cylindrical pin extraction M6 screws of different lengths For example M6x10 M6x15 M6x35 The following figures are for your refer ence about how to use the equipment xx1500000635 xx1500000636 xx1500000637 1 thick washer inside diameter 6 mm 1 spacer 30 mm long inside diameter no smaller than the pin diameter 10 mm and out side diameter no bigger that the thick washer outside diameter Contin...

Page 194: ...2 Loosening the carriage from the drive train bracket Illustration Note Action Remove the bracket for brake release Cut the cable ties that secure the brake release cables 1 xx1400001588 A M12x40 Hex socket head cap screws 3HAB3409 67 4 pcs Loosen the screws Use a ratchet wrench 2 Continues on next page 194 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reser...

Page 195: ...lindrical pin is extracted from the top plate Note It is not necessary to extract the pin from the bracket 4 xx1400001591 A M12x40 Hex socket head cap screw 3HAB3409 67 4 pcs B Ø21xØ13x2 Washer 3HAA1001 632 4 pcs Remove the screws and plain washers Use a ratchet wrench 5 xx1400001592 A Lubrication tube connector Disconnect the lubrication tube from the fitting of the ball bearing block to release ...

Page 196: ...nnectors can pass through 8 Note Pay attention to the cables and their connectors You must guide them through the cable tray while you push the carriage away Push the carriage away from the drive train bracket The bracket gear and pinion motor cable chain support and cable chain stay stationery 9 Removing the drive train Illustration Note Action xx1400000231 Remove the covers above the drive train...

Page 197: ...001626 A M8 eye bolt 2 pcs Fit two eye bolts on the drive train for lifting 3 xx1400001625 Disconnect the power and resolver connectors from the motor Guide the cables in the tray area 4 Continues on next page Product manual IRBT 2005 197 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing the motor Continued ...

Page 198: ... an overhead crane 7 Remove the remaining two screws from the drive train 8 xx1400001627 A Ø 17xØ 11x2 washer 3HAB4233 1 B M10x40 hex socket head cap installation screw 3HAB3409 50 C Cable chain support Remove the drive train from the bracket CAUTION The drive train weighs 33 kg All lifting accessor ies used must be sized accordingly 9 Continues on next page 198 Product manual IRBT 2005 3HAC051130...

Page 199: ...ards 1 xx1400001639 A M8x30 Hex socket head cap screw 9ADA183 38 4 pcs B Ø13xØ8 4x1 6 plain washer 9ADA312 7 4 pcs Remove the motor by unscrewing the screws and removing washers 2 Continues on next page Product manual IRBT 2005 199 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing the motor Continued ...

Page 200: ...it with screws and washers Tip The motor integrates the driving pinion article No 3HAC047333 001 and O ring article No 3HAB3772 110 as a complete spare part 1 Refitting the drive train Illustration Note Action xx1400001637 A Ø10x32 Cylindrical pin with threaded hole 3HAC043986 001 Fit the locating cylindrical pin to the motor us ing a rubber mallet Insert it completely 1 Continues on next page 200...

Page 201: ...n bracket with the screws and plain washers Note Do not tighten the screws yet 3 Adjust the backlash of the gear motor For how to adjust the gear motor backlash see Adjust ing the gearbox backlash on page 229 4 xx1400001630 Tighten the screws and plain washers in se quence shown in the illustration 5 Tightening torque 70 Nm For the mirrored cable chain orientation refit the cable chain support wit...

Page 202: ...d hole 3HAC043986 001 Adjust the position of the carriage until the cylindrical pin in the 10 mm positioning hole of the drive train bracket can be inserted into the positioning hole in the top plate of the car riage 3 Tightening torque 100 Nm Tighten the screws 4 xx1400001592 A Lubrication tube connector Connect the lubrication tube connectors of the ball bearing block 5 Continues on next page 20...

Page 203: ...he upper part of the cable tray so that the connectors can pass through Refit the bracket for brake release and secure brake release cables with cable ties 8 xx1400001587 A M6x12 Screw DIN6921 9ADA181 11 4 pcs Refit the side cover of the carriage 9 Refit the top cover 10 Product manual IRBT 2005 203 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing the ...

Page 204: ...away from the motor bracket and expose the motor gearbox gear wheel felt gear and cable chain connection point This makes the following components accessible for maintenance xx1400002684 Name Item Cable chain remains stationery A Motor remains stationery B Carriage pushed away C Motor bracket remains stationery D Gear wheel remains stationery E Felt gear remains stationery F Gearbox remains statio...

Page 205: ...f different lengths For example M6x10 M6x15 M6x35 The following figures are for your refer ence about how to use the equipment xx1500000635 xx1500000636 xx1500000637 1 thick washer inside diameter 6 mm 1 spacer 30 mm long inside diameter no smaller than the pin diameter 10 mm and out side diameter no bigger that the thick washer outside diameter Continues on next page Product manual IRBT 2005 205 ...

Page 206: ...2 Loosening the carriage from the drive train bracket Illustration Note Action Remove the bracket for brake release Cut the cable ties that secure the brake release cables 1 xx1400001588 A M12x40 Hex socket head cap screws 3HAB3409 67 4 pcs Loosen the screws Use a ratchet wrench 2 Continues on next page 206 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reser...

Page 207: ...indrical pin is extracted from the top plate Note It is not necessary to extract the pin from the bracket 4 xx1400001591 A M12x40 Hex socket head cap screw 3HAB3409 67 4 pcs B Ø21xØ13x2 Washer 3HAA1001 632 4 pcs Remove the screws and plain washers Use a ratchet wrench 5 xx1400001592 A Lubrication tube connector Disconnect the lubrication tube from the fitting of the ball bearing block to release t...

Page 208: ...nectors can pass through 8 Note Pay attention to the cables and their connectors You must guide them through the cable tray while you push the carriage away Push the carriage away from the drive train bracket The bracket gear and pinion motor cable chain support and cable chain stay stationery 9 Removing the drive train Illustration Note Action xx1400000231 Remove the covers above the drive train ...

Page 209: ...01626 A M8 eye bolt 2 pcs Fit two eye bolts on the drive train for lifting 3 xx1400001625 Disconnect the power and resolver connectors from the motor Guide the cables in the tray area 4 Continues on next page Product manual IRBT 2005 209 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing the gearbox Continued ...

Page 210: ...an overhead crane 7 Remove the remaining two screws from the drive train 8 xx1400001627 A Ø 17xØ 11x2 washer 3HAB4233 1 B M10x40 hex socket head cap installation screw 3HAB3409 50 C Cable chain support Remove the drive train from the bracket CAUTION The drive train weighs 33 kg All lifting accessor ies used must be sized accordingly 9 Continues on next page 210 Product manual IRBT 2005 3HAC051130 ...

Page 211: ...he motor by unscrewing the four M8x30 hex socket head cap screws Art No 9ADA183 38 2 Refitting the gearbox Refitting the gearbox Illustration Note Action Inject lubricant into the gearbox until it is filled 1 Continues on next page Product manual IRBT 2005 211 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing the gearbox Continued ...

Page 212: ...Ø10x32 Cylindrical pin with threaded hole 3HAC043986 001 Fit the locating cylindrical pin to the motor us ing a rubber mallet Insert it completely 1 CAUTION The motor weighs 11 kg All lifting accessories used must be sized accordingly 2 Attach the lifting chains to the eye bolts on the motor and lift the motor into position on the track with guidance from the locating cylindrical pin Continues on ...

Page 213: ...arbox backlash on page 229 4 xx1400001630 Tighten the screws and plain washers in se quence shown in the illustration 5 Tightening torque 70 Nm For the mirrored cable chain orientation refit the cable chain support with two screws 6 Reconnect the power and signal cables to the motor 7 Reinstalling the carriage to the drive train bracket Illustration Note Action Push the carriage back above the dri...

Page 214: ...itioning hole of the drive train bracket can be inserted into the positioning hole in the top plate of the car riage 3 Tightening torque 100 Nm Tighten the screws 4 xx1400001592 A Lubrication tube connector Connect the lubrication tube connectors of the ball bearing block 5 xx1400001596 A Lubrication tube connector Connect the lubrication tube connector of the pinion 6 Continues on next page 214 P...

Page 215: ...tors can pass through Refit the bracket for brake release and secure brake release cables with cable ties 8 xx1400001587 A M6x12 Screw DIN6921 9ADA181 11 4 pcs Refit the side cover of the carriage 9 Refit the top cover 10 Product manual IRBT 2005 215 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing the gearbox Continued ...

Page 216: ...away from the motor bracket and expose the motor gearbox gear wheel felt gear and cable chain connection point This makes the following components accessible for maintenance xx1400002684 Name Item Cable chain remains stationery A Motor remains stationery B Carriage pushed away C Motor bracket remains stationery D Gear wheel remains stationery E Felt gear remains stationery F Gearbox remains statio...

Page 217: ... different lengths For example M6x10 M6x15 M6x35 The following figures are for your refer ence about how to use the equipment xx1500000635 xx1500000636 xx1500000637 1 thick washer inside diameter 6 mm 1 spacer 30 mm long inside diameter no smaller than the pin diameter 10 mm and out side diameter no bigger that the thick washer outside diameter Continues on next page Product manual IRBT 2005 217 3...

Page 218: ...2 Loosening the carriage from the drive train bracket Illustration Note Action Remove the bracket for brake release Cut the cable ties that secure the brake release cables 1 xx1400001588 A M12x40 Hex socket head cap screws 3HAB3409 67 4 pcs Loosen the screws Use a ratchet wrench 2 Continues on next page 218 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reser...

Page 219: ...ndrical pin is extracted from the top plate Note It is not necessary to extract the pin from the bracket 4 xx1400001591 A M12x40 Hex socket head cap screw 3HAB3409 67 4 pcs B Ø21xØ13x2 Washer 3HAA1001 632 4 pcs Remove the screws and plain washers Use a ratchet wrench 5 xx1400001592 A Lubrication tube connector Disconnect the lubrication tube from the fitting of the ball bearing block to release th...

Page 220: ...ctors can pass through 8 Note Pay attention to the cables and their connectors You must guide them through the cable tray while you push the carriage away Push the carriage away from the drive train bracket The bracket gear and pinion motor cable chain support and cable chain stay stationery 9 Removing the drive train Illustration Note Action xx1400000231 Remove the covers above the drive train 1 ...

Page 221: ...626 A M8 eye bolt 2 pcs Fit two eye bolts on the drive train for lifting 3 xx1400001625 Disconnect the power and resolver connectors from the motor Guide the cables in the tray area 4 Continues on next page Product manual IRBT 2005 221 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the gear wheel Continued ...

Page 222: ... overhead crane 7 Remove the remaining two screws from the drive train 8 xx1400001627 A Ø 17xØ 11x2 washer 3HAB4233 1 B M10x40 hex socket head cap installation screw 3HAB3409 50 C Cable chain support Remove the drive train from the bracket CAUTION The drive train weighs 33 kg All lifting accessor ies used must be sized accordingly 9 Continues on next page 222 Product manual IRBT 2005 3HAC051130 00...

Page 223: ...ds 1 xx1400001639 A M8x30 Hex socket head cap screw 9ADA183 38 4 pcs B Ø13xØ8 4x1 6 plain washer 9ADA312 7 4 pcs Remove the motor by unscrewing the screws and removing washers 2 Continues on next page Product manual IRBT 2005 223 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the gear wheel Continued ...

Page 224: ...fitting the gear wheel Refitting the gear wheel Illustration Note Action xx1400002645 A M10x35 Hex socket head cap screw 3HAB3409 52 Tightening torque 70 Nm B Pinion on rack 3HAC047375 001 Tighten the screws 1 Continues on next page 224 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the gear wheel Continued ...

Page 225: ...ws and washers Tip The motor integrates the driving pinion article No 3HAC047333 001 and O ring article No 3HAB3772 110 as a complete spare part 1 Refitting the drive train Illustration Note Action xx1400001637 A Ø10x32 Cylindrical pin with threaded hole 3HAC043986 001 Fit the locating cylindrical pin to the motor us ing a rubber mallet Insert it completely 1 Continues on next page Product manual ...

Page 226: ...bracket with the screws and plain washers Note Do not tighten the screws yet 3 Adjust the backlash of the gear motor For how to adjust the gear motor backlash see Adjust ing the gearbox backlash on page 229 4 xx1400001630 Tighten the screws and plain washers in se quence shown in the illustration 5 Tightening torque 70 Nm For the mirrored cable chain orientation refit the cable chain support with ...

Page 227: ...ole 3HAC043986 001 Adjust the position of the carriage until the cylindrical pin in the 10 mm positioning hole of the drive train bracket can be inserted into the positioning hole in the top plate of the car riage 3 Tightening torque 100 Nm Tighten the screws 4 xx1400001592 A Lubrication tube connector Connect the lubrication tube connectors of the ball bearing block 5 Continues on next page Produ...

Page 228: ...upper part of the cable tray so that the connectors can pass through Refit the bracket for brake release and secure brake release cables with cable ties 8 xx1400001587 A M6x12 Screw DIN6921 9ADA181 11 4 pcs Refit the side cover of the carriage 9 Refit the top cover 10 228 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing the gea...

Page 229: ...ash Note All fixing screws of the gearbox must be loosened before adjusting the backlash Illustration Note Action xx1400001661 A Locking screw B Locking screw C Locking screw Tightening torque 70 Nm Tighten the locking screws A B and C 1 Continues on next page Product manual IRBT 2005 229 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 Adjusting the gearbox backl...

Page 230: ...ssing the reset button A 4 xx1400001633 Push the carriage or the drive unit by hand in the opposite direction until the gear wheel is in contact with the next cog on the gear rack 5 X direction Note The indicator should show data between 0 07 0 13 mm Check the reading on the indicator clock 6 X direction Push the carriage 1000 mm 7 Continue with step 2 to step 7 8 Continues on next page 230 Produc...

Page 231: ...ock screws If the data is too small lower the gear motor a little and then secure the three lock screws If the gap is not OK loosen locking screws A B and C to adjust the gear motor using the adjustment tool Then repeat step 1 to step 10 Note During adjustment note that the cable chain should be assembled and cables to motor should be connected Continues on next page Product manual IRBT 2005 231 3...

Page 232: ...ighten all the screws and plain washer in a spread sequence 11 See Fine calibration on page 264 Calibrate the track motion Use previously measured reference values for the zero posi tion 12 232 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 7 Adjusting the gearbox backlash Continued ...

Page 233: ...ans to work together The figure below shows how to push the carriage away from the motor bracket and expose the motor gearbox gear wheel felt gear and cable chain connection point This makes the following components accessible for maintenance xx1400002684 Name Item Cable chain remains stationery A Motor remains stationery B Carriage pushed away C Motor bracket remains stationery D Gear wheel remai...

Page 234: ...r the cylindrical pin extraction M6 screws of different lengths For example M6x10 M6x15 M6x35 The following figures are for your refer ence about how to use the equipment xx1500000635 xx1500000636 xx1500000637 1 thick washer inside diameter 6 mm 1 spacer 30 mm long inside diameter no smaller than the pin diameter 10 mm and out side diameter no bigger that the thick washer outside diameter Continue...

Page 235: ...2 Loosening the carriage from the drive train bracket Illustration Note Action Remove the bracket for brake release Cut the cable ties that secure the brake release cables 1 xx1400001588 A M12x40 Hex socket head cap screws 3HAB3409 67 4 pcs Loosen the screws Use a ratchet wrench 2 Continues on next page Product manual IRBT 2005 235 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reser...

Page 236: ...ndrical pin is extracted from the top plate Note It is not necessary to extract the pin from the bracket 4 xx1400001591 A M12x40 Hex socket head cap screw 3HAB3409 67 4 pcs B Ø21xØ13x2 Washer 3HAA1001 632 4 pcs Remove the screws and plain washers Use a ratchet wrench 5 xx1400001592 A Lubrication tube connector Disconnect the lubrication tube from the fitting of the ball bearing block to release th...

Page 237: ...ush the carriage away Push the carriage away from the drive train bracket The bracket gear and pinion motor cable chain support and cable chain stay stationery 9 Removing the felt gear Illustration Note Action For the standard cable chain orientation re move the cable chain support by removing the two screws 1 xx1400002642 A Felt gear lubrication tube con nnector B M8x20 Hex socket head cap screw ...

Page 238: ...or 2 For the standard cable chain orientation refit the cable chain support with two screws 3 Reinstalling the carriage to the drive train bracket Illustration Note Action Push the carriage back above the drive train 1 xx1400001588 A M12x40 Hex socket head cap screws 3HAB3409 67 4 pcs Fit the carriage to the drive train bracket with the screws Note Do not tighten the screws yet 2 Continues on next...

Page 239: ...Connect the lubrication tube connectors of the ball bearing block 5 xx1400001596 A Lubrication tube connector Connect the lubrication tube connector of the pinion 6 Connect the cables from the tooling or robot fitted on the carriage 7 If necessary remove the upper part of the cable tray so that the connectors can pass through Refit the bracket for brake release and secure brake release cables with...

Page 240: ...x12 Screw DIN6921 9ADA181 11 4 pcs Refit the side cover of the carriage 9 Refit the top cover 10 240 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 8 1 Replacing the felt gear Continued ...

Page 241: ...s Loctite 243 Locking liquid Replace if damaged Plastic clips Replace with new nuts if removed NYLOC nuts can only be used once NYLOC nuts Content is defined in section Standard tools on page 276 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See references to these procedures in the step by step in structions below See Circui...

Page 242: ...ake release cables 7 Removing the cable chain Removing the internal cable chain Illustration Note Action Remove all cover plates 1 Move the carriage in order to have it positioned just above the fixed point of the cable chain 2 WARNING Turn off all electric power and pneumatic pres sure supplies to the robot and IRBT 2005 3 Take a note of how the cabling is strapped on the carriage Pay special att...

Page 243: ...he carriage on page 241 Move away the carriage 9 xx1400000523 A M6x20 Hex socket head cap screw 9ADA183 25 B Ø12xØ6 4x1 6 Plain washer 9ADA312 6 Remove the four screws and four plain washers that hold the moving end of the cable chain to the connecting plate on the carriage 10 xx1400001980 A M6x20 Hex socket head cap screw 9ADA183 25 Remove screws at the fixed end of the cable chain 11 Pull the co...

Page 244: ...om getting wet 5 Disconnect the connectors for power signal and media at the floor end of the cable chain Note Water may spill out 6 xx1400002001 Make a marking on the moving end of the chain to show its location relative to the connecting plate This will facilitate alignment during refit ting 7 Cut off straps that securing the cables to the connection plates on the carriage 8 Cut off straps that ...

Page 245: ...le chain Illustration Note Action Remove top covers of the track 1 xx1400000523 A M6x20 Hex socket head cap screw 9ADA183 25 B Ø12xØ6 4x1 6 Plain washer 9ADA312 6 Secure the movable end of the cable chain by securing the four screws and four plain washers that hold the moving end of the cable chain to the connecting plate on the carriage 2 xx1400001980 A M6x20 Hex socket head cap screw 9ADA183 25 ...

Page 246: ...k of the chain as shown in the figure To ensure that the cables are in the neutral axis move the carriage to one end and open the links in the bend of the chain Adjust cable length as necessary move the carriage to the opposite side and recheck 8 xx1400001755 Connect power cable and signal cable on the carriage Note It is essential to start with the stiffest cable and to strap it into position in ...

Page 247: ...onnection plate on the external cable tray 6 Make sure the relative position of the cables to the connection plate is the same with before 1 2 xx1200000518 Check that all cable s and or hose s are not installed too tight or too loose inside the car riage system Optimally aim for the neutral axis center line of the link of the chain as shown in the figure To ensure that the cables are in the neutra...

Page 248: ... Adjust if needed The use of serrated lock washers snap rings and other locking means is not permitted in this part of the track Moving back the carriage Illustration Note Action Move back the carriage and secure it to the drive train bracket with the screws 1 Refit the brake release unit and strap the brake release cables to the carriage 2 See Fitting covers on page 89 Refit the covers 3 Mark the...

Page 249: ...ore space is created in the cable tray to suit for a longer cable chain More brackets and sheet metals may need to be swapped around if the chain is excessively long Adjusting the cable tray Illustration Note Action See Removing the cable chain on page 242 Remove the old cable chain 1 See Lifting cable chain on page 59 Fit the new cable chain to the cable tray 2 Attach the cable chain at both the ...

Page 250: ...ks The figure shows the location of the side links on the cable chain xx1400001677 Side link A Continues on next page 250 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 9 2 Replacing the side links and glide shoes ...

Page 251: ...t number is specified in Spare parts on page 283 Glide shoes Content is defined in section Standard tools on page 276 Standard toolkit Removing the side link Illustration Note Action xx1300000939 Bend the links until two marks on the side line up 1 Continues on next page Product manual IRBT 2005 251 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 9 2 Replacing the ...

Page 252: ...links together until they snap together 1 xx1300000942 Rotate the link to close it 2 Refitting the glide shoes Illustration Note Action Remove the glide shoes by pushing in the clips with a screwdriver and then pulling out the glide shoes 1 Refit the glide shoes by pushing it into place until it snaps 2 252 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reser...

Page 253: ...le for IRC5 Signal cable available for IRC5 F Controller available for IRC5 G i For transfer application this would be a SMB box Cable layout transfer track Cable layout in the transfer track is similar with the robot track Robot power and signal cables are replaced by transfer track power and signal cables Flexible cables are connected with floor cables by an SMB box Cable layout extra plate Cabl...

Page 254: ...n Remove all cover plates 1 Move the carriage so that the drive train and the grease distribution block is away from the fixed end of the cable chain 2 WARNING Turn off all electric power and pneumatic pressure supplies to the robot and for the track motion 3 Remove the brake release unit and cut the straps that hold the brake release cables to the carriage 4 Remove the bracket at the cable outlet...

Page 255: ...re removing damaged cables measure the length of the damaged cable projecting from the end of the cable chain This will facilitate refitting 6 xx1400000479 A Cable chain B Tie wrap plate C Separator for cables D Cable chain link Remove the damaged cables from the tie wrap plates Tip Before removing damaged cables note down the location on tie wrap plate This will facilitate refit ting 7 Remove the...

Page 256: ... the standard layouts could seriously reduce the expected component life of the chain Illustration Note Action Strap the connectors together in order to facil itate insertion of them under the carriage 1 Fold the cable chain and insert the moving end under the carriage to its support plate at the drive unit In the same time guide the connect ors through the cable outlet at the side of the carriage...

Page 257: ...se inside the car riage system when clamping them into place Optimally aim for the neutral axis center line of the link of the chain as shown in the figure To ensure that the cables are in the neutral axis move the carriage to one end and open the links in the bend of the chain Adjust cable length as necessary move the carriage to the opposite side and recheck 7 Wrong If cables bend radius is too ...

Page 258: ...e new cable s and connect it them to the fix end plate if all cables are in the right position as shown in the picture 2 Strap the fix end if cables hoses are in the right positon Adjust the carriage position or alignment if needed 3 Adjust the position and length of cables and or hoses if needed 4 If adjustments are made repeat steps 1 to 4 5 Tighten all screws 6 The track is now ready to be powe...

Page 259: ...GER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 24 5 See Test run on page 258 Perform a test run before powering up the track to full speed and duty cycle 6 Product manual IRBT 2005 259 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 9 3 Repl...

Page 260: ... DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 xx0200000023 2 WARNING The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 29 Open the cover on the SMB box CAUTION Clean cover from metal residues before opening Metal...

Page 261: ...Information Action Place the new SMB board on the mounting plate 1 Fasten the screws fully 2 Cross tighten the screws to make sure the sealing is tight Refit the plate and fasten the screws fully 3 Connect the cables and close the cover 4 See Calibration on page 263 Update the revolution counters 5 Product manual IRBT 2005 261 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4...

Page 262: ... Knife Lint free cloth Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 262 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 4 Repair 4 11 Cut the pa...

Page 263: ...lied by ABB Calibrate the track carefully with standard calibration The resolver values will change when parts affecting the calibration position are replaced on the track for example motors or parts of the transmission This is detailed in Fine calibration on page 264 The revolution counter memory is lost If the revolution counter memory is lost the counters must be updated See Update revolution c...

Page 264: ...000570 A Calibration notch on the carriage B Calibration hole on the section Move the track until the calibration notch on the carriage line up with the calibration hole on the section 2 Insert the calibration pin A dowel pin diameter 8mm can also be used 3 Tap ABB on the top left of the FlexPendant 4 Tap Calibration 5 Select the desired mechanical unit 6 Tap Fine calibration 7 Select the desired ...

Page 265: ... Align the sharp edge of the moving part of the calibration marker with the line of the fixed part calibration marker 1 Tap ABB on the top left of the FlexPendant 2 Tap Calibration 3 Select the desired mechanical unit 4 Tap Update revolution counters 5 Select the desired axis 6 Tap Update 7 Product manual IRBT 2005 265 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 5 Calibra...

Page 266: ...the base frame must be defined See Application manual Additional axes and stand alone controller Coordinated track motion 266 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 5 Calibration 5 4 Defining base frame ...

Page 267: ...ies NiCad or Lithium Cables motors Copper Track section Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearbox Oil grease Covers Aluminium Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulations Do not dis...

Page 268: ...o organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 268 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 269: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRBT 2005 269 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 270: ...15i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment of...

Page 271: ...R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRBT 2005 271 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 7 Reference information 7 2 Applicable standards Continued ...

Page 272: ...9 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 272 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 273: ...ld be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions ...

Page 274: ...air maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The ...

Page 275: ...ning torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRBT 2005 275 3HAC051130 001 Re...

Page 276: ...tandard toolkit and any tools listed in the instruction Contents standard tools Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Torque wrench 10 120 Nm 1 Ratchet head for torque wrench 1 2 1 Hex bit socket head cap no 5 socket 1 2 bit length 20 mm 1 Hex bit socket head cap no 6 socket 1 2 bit length 20 mm 1 Hex bit socket head cap no 8 socket 1 2 bit len...

Page 277: ...l tools Note Art No Tool Qty 3HAC054528 001 Backlash adjustment tool 1 3HAC054533 001 Calibration pin 1 3HAC054532 001 Companion rack 1 3HAC054531 001 Companion rack fix block 1 3HAW107700357 Laser tracker 1 3HAC054535 001 Leveling tool 1 3HAC054534 001 Locking nut adjustment tool 1 The actual rack clamp to be used should be pre pared based on actual situation Rack clamp 2 Product manual IRBT 2005...

Page 278: ...ing accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference 278 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 7 Reference information 7 7 Lifting accessories and lifting ...

Page 279: ...o 40 C M16 anchor 125 Typical embedment depth mm i 210 Base material thickness mm 5 8 Carbon steel strength class 75 6 Mean ultimate resistance concrete C 20 25 fck cube 25 N mm anchor HAS Tensile NRu m HAS kN 37 8 Mean ultimate resistance concrete C 20 25 fck cube 25 N mm anchor HAS Shear VRu m HAS kN 60 0 Characteristic resistance concrete C 20 25 fck cube 25 N mm anchor HAS Tensile NRk HAS kN 3...

Page 280: ... elevated base material temperature may lead to a reduction of the design bond resistance Maximum short term base material temper atureii Maximum long term base materialtemper aturei Base material temper ature Temperature range 40 C 24 C 40 C to 40 C Temperature range 1 80 C 50 C 40 C to 80 C Temperature range 2 120 C 72 C 40 C to 120 C Temperature range 3 i Long term elevated base material temper...

Page 281: ...ize TE 2 TE 16 Rotary hammer blow out pump or compressed air gun setting tools Other tools Continues on next page Product manual IRBT 2005 281 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 7 Reference information 7 8 HILTI adhesive anchor Continued ...

Page 282: ... the Hilti Technical advisory service Curing time for general conditions Curing time before anchor can be fully loaded Temperature of the base material 20 minutes 20 C to 40 C 30 minutes 10 C to 19 C 1 hour 0 C to 9 C 5 hour 5 C to 1 C 282 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 7 Reference information 7 8 HILTI adhesive anchor Continued ...

Page 283: ...ews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRBT 2005 283 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved 8 Spare parts 8 1 Spare part lists and illustrations ...

Page 284: ...This page is intentionally left blank ...

Page 285: ...t 3HAC026871 006 Circuit diagram IRC5 Panel Mounted Con troller 3HAC026871 020 Circuit diagram IRC5 Panel Mounted Con troller 3HAC024120 004 Circuit diagram Euromap Robots Article numbers for circuit diagrams Product 3HAC039498 007 Circuit diagram IRB 1520 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC029570 007 Circuit diagram IRB 2600 3HAC029038 003 Circuit diagram IRB 4600 IRBT 2005 Article ...

Page 286: ...This page is intentionally left blank ...

Page 287: ... 15 neodymium disposal 267 NiCad disposal 267 nodular iron disposal 267 O oil disposal 267 oil change safety risks 34 P pedestal installed on pedestal 21 plastic disposal 267 product standards 270 protective equipment 22 protective wear 22 R region specific regulations 15 release brakes 19 replacing 260 SMB battery 174 SMB board 260 responsibility and validity 15 robot labels 38 symbols 38 rubber ...

Page 288: ...EN 270 EN IEC 270 EN ISO 270 steel disposal 267 symbols safety 36 system integrator requirements 15 T testing brakes 32 three position enabling device 26 V validity and responsibility 15 288 Product manual IRBT 2005 3HAC051130 001 Revision F Copyright 2015 2018 ABB All rights reserved Index ...

Page 289: ......

Page 290: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC051130 001 Rev F en Copyright 2015 2018 ABB All rights reserved Specifications subject to change without notice ...

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