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ABB IRB 390, Product Manual

The ABB IRB 390 is a cutting-edge industrial robot designed to enhance productivity and efficiency. With its advanced technology and versatility, this high-performance machine guarantees optimal results in various applications. You can easily access the detailed Product Manual for free download at manualshive.com, enabling users to maximize their experience with this top-notch automation solution.

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Table of contents

9

Overview of this manual ...................................................................................................................

11

Product documentation ....................................................................................................................

13

How to read the product manual ......................................................................................................

15

1

Safety

15

1.1

Safety information .............................................................................................

15

1.1.1

Limitation of liability .................................................................................

16

1.1.2

Requirements on personnel ......................................................................

17

1.2

Safety signals and symbols .................................................................................

17

1.2.1

Safety signals in the manual ......................................................................

19

1.2.2

Safety symbols on manipulator labels .........................................................

25

1.3

Robot stopping functions ....................................................................................

26

1.4

Installation and commissioning ............................................................................

29

1.5

Operation ........................................................................................................

29

1.5.1

Unexpected movement of robot arm ...........................................................

30

1.6

Maintenance and repair ......................................................................................

30

1.6.1

Maintenance and repair ............................................................................

33

1.6.2

Brake testing ..........................................................................................

34

1.7

Troubleshooting ................................................................................................

35

1.8

Decommissioning ..............................................................................................

37

2

Technical data

37

2.1

Technical data ..................................................................................................

40

2.2

Working range .................................................................................................

42

2.3

The unit is sensitive to ESD .................................................................................

43

2.4

Robot specific labels (rating label, calibration label and UL label) ...............................

45

3

Installation and commissioning

45

3.1

Introduction to installation and commissioning .......................................................

46

3.2

Unpacking .......................................................................................................

46

3.2.1

Pre-installation procedure .........................................................................

47

3.3

On-site installation ............................................................................................

47

3.3.1

Transport ...............................................................................................

48

3.3.2

Brief installation procedure .......................................................................

49

3.3.3

Minimum required free space above the robot ..............................................

50

3.3.4

Securing the robot frame .........................................................................

52

3.3.5

Orienting, assembling and securing the manipulator ......................................

67

3.3.6

First test run may cause injury or damage ....................................................

68

3.3.7

Manually releasing the brakes ...................................................................

71

3.3.8

Loads fitted to the robot, stopping time and braking distances .........................

72

3.3.9

Signal lamp (option) .................................................................................

73

3.3.10 Fitting equipment on the robot (robot dimensions) .........................................

80

3.4

Electrical connections ........................................................................................

80

3.4.1

Robot cabling and connection points ..........................................................

83

4

Maintenance

83

4.1

Introduction ......................................................................................................

84

4.2

Maintenance schedule and expected component life ...............................................

84

4.2.1

Specification of maintenance intervals ........................................................

85

4.2.2

Maintenance schedule .............................................................................

87

4.2.3

Expected component life .........................................................................

88

4.3

Inspection activities ...........................................................................................

88

4.3.1

Inspecting the telescopic shafts .................................................................

90

4.3.2

Inspecting the information labels ...............................................................

92

4.3.3

Inspecting the lower arms ........................................................................

Product manual - IRB 390

5

3HAC066566-001 Revision: B

© Copyright 2020 - 2021 ABB. All rights reserved.

Table of contents

Summary of Contents for IRB 390

Page 1: ...ROBOTICS Product manual IRB 390 ...

Page 2: ...Trace back information Workspace 21A version a11 Checked in 2021 03 19 Skribenta version 5 4 005 ...

Page 3: ...Product manual IRB 390 15 1300 IRB 390 10 1300 IRC5 Document ID 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty by ABB for losses damage to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained f...

Page 5: ...acking 46 3 2 1 Pre installation procedure 47 3 3 On site installation 47 3 3 1 Transport 48 3 3 2 Brief installation procedure 49 3 3 3 Minimum required free space above the robot 50 3 3 4 Securing the robot frame 52 3 3 5 Orienting assembling and securing the manipulator 67 3 3 6 First test run may cause injury or damage 68 3 3 7 Manually releasing the brakes 71 3 3 8 Loads fitted to the robot s...

Page 6: ...ilt arm 236 5 6 Motors and gears 236 5 6 1 Replacing the axis 1 axis 2 and axis 3 motor 247 5 6 2 Replacing the axis 4 motor 256 5 6 3 Replacing the axis 5 motor 265 5 6 4 Replacing the axis 4 gear unit pre stage 281 5 6 5 Replacing the axis 5 gear unit pre stage 297 6 Calibration 297 6 1 Introduction to calibration 297 6 1 1 Introduction and calibration terminology 298 6 1 2 Calibration methods 2...

Page 7: ... robot 331 9 Reference information 331 9 1 Introduction 332 9 2 Applicable standards 334 9 3 Unit conversion 335 9 4 Weight specifications 336 9 5 Standard toolkit 337 9 6 Special tools 340 9 7 Lifting accessories and lifting instructions 341 Index Product manual IRB 390 7 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved Table of contents ...

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

Page 9: ...ir maintenance work Product manual scope The manual covers covers all variants and designs of the IRB 390 Some variants and designs may have been removed from the business offer and are no longer available for purchase References Documentation referred to in the manual is listed in the table below Document ID Document name 3HAC066567 001 Product manual spare parts IRB 390 3HAC066568 001 Product sp...

Page 10: ...cle number for brake release push button and Mo lykote P1900 Added nipple dimension on telescopic shaft Updated images of refitting axis 4 gear unit pre stage Updated images that show axis 5 delta unit screw side due to changed amount of attachment screws B 10 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved Overview of this manual Continued ...

Page 11: ...sioning 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 12: ...ts The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 12 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved Product documentation Continued ...

Page 13: ... include specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 15 Illustrations The product is illustrated with general figures that does not take painting or protection type in consideration Likewise certain work methods or general information that is valid for several product models can be illustrated with illustrations that show a different...

Page 14: ...This page is intentionally left blank ...

Page 15: ...ration of the robot when the safety devices are defective not in their intended location or in any other way not working When instructions for operation and maintenance are not followed Non authorized design modifications of the robot Repairs on the robot and its spare parts carried out by in experienced or non qualified personnel Foreign objects Force majeure Spare parts and equipment ABB supplie...

Page 16: ...ence of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot The plant liable must make sure that the personnel is trained on the robot and on responding to emergency or abnormal situations Personal protective equipment Use personal protective equipment as stated in the product manual 16 Product manual IRB 390 3HAC066566 001 Revisio...

Page 17: ...ion which if not avoided will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous...

Page 18: ...ed to indicate where to find additional information or how to do an operation in an easier way TIP 18 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 19: ...ription 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 crushing impact fall from height etc Caution xx090000...

Page 20: ...o 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 20 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reser...

Page 21: ... over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 390 21 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 22: ...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 22 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 23: ...01242 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 Product manual IRB 390 23 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 24: ...at 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 24 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Cont...

Page 25: ...protective stops and emergency stops are described in the product manual for the controller For more information see Product manual IRC5 Product manual IRB 390 25 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 26: ...or released at maximum speed The maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator Consider exposure to hazards such as slipping tripping and falling Hazards due to the wo...

Page 27: ...essary to protect people working with the robot system are designed and installed correctly When integrating the robot with external devices to a robot system The integrator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards The integrator of the robot system must ensure that safety functions are interlocked in accordance with appl...

Page 28: ...safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level 28 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 1 Safety 1 4 Installation and commissioning Continued ...

Page 29: ... and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Product manual IRB 390 29 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 1 Safety 1 5 1 Unexpected movement of robot arm ...

Page 30: ...rking as intended Hot surfaces Surfaces can be hot after running the robot Touching the surfaces may result in burns Allow the parts to cool down before maintenance or repair Allergic reaction Elimination Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn When working with lubricants there is a risk of an allergic reac tion Allergic reaction Gearbox ...

Page 31: ...ously been drained from the gearbox Specified amount de pends on drained volume For lifetime reasons always drain as much oil as possible from the gearbox The magnetic oil plugs will gather residual metal chips Contaminated oil in gearboxes Hazards related to batteries Under rated conditions the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside T...

Page 32: ... perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety information related to installation and operation 32 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 1 Safety 1 6 1 Maintenance and repair Continued ...

Page 33: ...ight of the manipulator 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 manipulator does not change position as the motors are switched off then the brake function is adequate Note For robots with the option SafeMove the Cyclic Brake Check routine is recommended See the manual for SafeMove in Refere...

Page 34: ... engineers A risk assessment must be done to address both robot and robot system specific hazards WARNING Hazards due to the use of brake release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety informat...

Page 35: ...e release devices and or gravity beneath the manipulator shall be considered A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Product manual IRB 390 35 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 1 Safety 1 8 Decommissioning ...

Page 36: ...This page is intentionally left blank ...

Page 37: ...s on foundation robot xx2000000862 The table shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values also never reach their maximum at the same time Continues on next page Product manual IRB 390 37 3HAC066566 001 Revision B Copyright 2020 2021 ABB All right...

Page 38: ...onance frequency given should be interpreted as the frequency of the robot mass inertia robot assumed stiff when a foundation translational torsional elasticity is added i e the stiffness of the pedestal where the robot is mounted The minimum resonance frequency should not be interpreted as the resonance frequency of the building floor etc For example if the equivalent mass of the floor is very hi...

Page 39: ...achine 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 Protection classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP67 Manipulator protection type Standard Product m...

Page 40: ... a c b d e TCP 15kg 10 56 90 Y X Z 0 Z 0 xx1900001423 Dimensions Measurement e Measurement d Measurement c Measurement b Measurement a 650 mm 475 mm 1 063 mm 1 274 mm 1 463 mm Continues on next page 40 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 2 Technical data 2 2 Working range ...

Page 41: ...c b a 10 56 90 Y X Z 0 WCP Z 0 105 Axis 5 xx1900001422 Dimensions Measurement e Measurement d Measurement c Measurement b Measurement a 650 mm 380 mm 1 118 mm 1 329 mm 1 518 mm Product manual IRB 390 41 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 2 Technical data 2 2 Working range Continued ...

Page 42: ... destroy sensitive electronics Safe handling Use one of the following alternatives Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly Use an ESD protective floor mat The mat must be grounded through a current limiting resistor Use a dissipative table mat The mat should provide a controlled discharge of static voltages and must b...

Page 43: ...l material is not FDA compliant Extra labels enclosed In addition to the labels attached to the robot according to previous figure an extra rating label and calibration label are also enclosed in the robot delivery These labels can be installed on the robot or stored elsewhere Product manual IRB 390 43 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 2 Technical data 2 4 Robot...

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

Page 45: ... extremely important that all safety information is observed 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 page15 before performing any installation work Note If the IRB 390 is connected to power always make sure that the robot is connected t...

Page 46: ...th if necessary 4 Make sure that the lifting accessory used if required is suitable to handle the weight of the robot as specified in Weight robot on page 37 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 38 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditio...

Page 47: ...rt the complete package to the installation site and assemble the robot to the robot frame See Orienting assembling and securing the manipulator on page 52 xx2000000860 Transportation after installation If the manipulator needs to be transported after it has been installed to the robot frame it should be disassembled prior Remove the delta unit the lower arms and telescopic shaft from the base uni...

Page 48: ...he valid platform or prepare the foundation for the manipulator 2 See Orienting assembling and se curing the manipulator on page52 Lift and secure the manipulator to the plat form foundation 3 See Product manual IRC5 Connect the manipulator to the controller 4 See Product manual IRC5 Configure the safety settings 5 See Product manual IRC5 How to start and run the robot is described in the product ...

Page 49: ...tery axis 4 and axis 5 motor cable harness Examples of access ways to the base components Service platform A service platform for access from above is recommended xx2000000672 Access way beside the robot If a platform is not possible the service personnel need to be able to stand beside the robot according to the figure xx2000000671 Product manual IRB 390 49 3HAC066566 001 Revision B Copyright 202...

Page 50: ... installation site for the robot con forms to the specifications in section Technical data on page 37 1 See Minimum required free space above the robot on page 49 Make sure that the space above the installation site is sufficient for repair and maintenance 2 Prepare the installation site 3 Use fastening bolts that withstand the requirements for current foundation Secure the robot frame to the floo...

Page 51: ...must achieve required values for the foundation requirements to run the robot safely See Requirements foundation on page 38 xx2000000601 Spirit level A Fastening bolts that withstand requirements for current foundation B Shim C Product manual IRB 390 51 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 4 Securing the robot frame Continued ...

Page 52: ...s 4 Attach the telescopic unit 5 Calibrate the robot 6 Detailed procedures for each step are given further on in this section Attachment screws The table below specifies the type of securing screws and washers to be used for securing the robot to the base foundation M16 stainless steel Minimum length of thread engagement 24 mm Suitable screws 3 pcs Quantity Minimum quality A4 80 Quality 17x15x3 st...

Page 53: ...0 robot is IRB 390 15 1300 133 kg IRB 390 10 1300 148 kg All lifting accessories used must be sized accordingly Roundsling 2 m Included in robot delivery xx1900002148 Used with an interchangeable head torque wrench not included in delivery Interface 14x18 mm 3HAC073854 001 Torque wrench head open end in sert Interchangeable head torque wrench Continues on next page Product manual IRB 390 53 3HAC06...

Page 54: ...rench head closed end Content is defined in section Standard toolkit on page 336 Standard toolkit Required consumables Note Article number Consumable Molykote P1900 3HAC070875 002 Anti seize paste Isopropanol Cleaning agent Continues on next page 54 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 5 Orienting assembli...

Page 55: ... mounting holes B Reference plane for each gearbox G1 G2 G3 The three support points of the manipulator base box shall be mounted against three flat surfaces with a flatness within the specification Use shims if necessary See specification in Requirements foundation on page 38 Assembling and installing The IRB 390 is delivered in sub assemblies Continues on next page Product manual IRB 390 55 3HAC...

Page 56: ...chment holes 3 Installing the base unit Use the procedure to install the base unit Note Action xx1900000210 Fasten three lifting eyes 1 CAUTION The weight of the complete base unit and upper arms is 136 kg All lifting accessories used must be sized accord ingly 2 Make sure the roundsling has free space and does not wear against any part of the robot Attach the roundslings to the lifting eyes Note ...

Page 57: ...tachment bolts and washers 6 Attachment bolts M16 stainless steel Minimum length of thread engagement 24 mm Minimum quality A4 80 3 pcs Washers 17x15x3 stainless steel 3HAC060866 005 Tightening torque 250 Nm xx2000000469 xx2000000470 Continues on next page Product manual IRB 390 57 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 5 Orientin...

Page 58: ...ntly Note Do not interchange the 24V and 0V pins If they are mixed up damage can be caused to internal electrical components 1 See Releasing the brakes on page 68 Release the brakes by pressing the brake release button and move the upper arms to synchroniza tion position 2 See Synchronization marks and synchronization position for axes on page 300 xx2000000676 Disconnect the 24V supply from the R1...

Page 59: ...r arm thread Note The surface under the thread head must be dry and not contain grease 2 Lower arm parallel bar 3HAC060138 001 xx1900001796 Fit the lower arm Make sure the sealing washer is in place Note The lower arm can be turned either way the ori entation has no significance 3 Continues on next page Product manual IRB 390 59 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved...

Page 60: ...unit Note Action Sealing washer 3HAC062123 001 xx2000000861 Fit sealing washers to the lower arms Replace the sealing washers if damaged 1 Anti seize paste 3HAC070875 002 Molykote P1900 xx2000000684 Lubricate the lower arm thread with grease Note The surface under the thread head must be dry and not contain grease 2 Continues on next page 60 Product manual IRB 390 3HAC066566 001 Revision B Copyrig...

Page 61: ...stable There is a risk of pinching or tipping the unit if holding or putting down the delta unit on its tilt arm Tip This operation is best performed by two persons working together Sealing washer 3HAC062123 001 xx2000001063 Fit all lower arms to the delta unit Make sure the sealing washers are in place 4 Continues on next page Product manual IRB 390 61 3HAC066566 001 Revision B Copyright 2020 202...

Page 62: ...se unit 1 Cleaning agent Isopropanol Clean the friction shim the sealing ring and the contact surfaces with isopropanol Inspect for damage 2 Friction shim 3HAC060200 001 Sealing ring 3HAC060263 001 Replace if damaged Telescopic shaft unit 3HAC059382 003 xx2000001109 Fit the upper end of the telescopic shaft by in stalling the friction shim sealing ring and the telescopic shaft at the base unit CAU...

Page 63: ...while loosen ing tightening the screws Requires two persons xx2000000346 2 Hold the motor shaft still by inserting a pin through the joints 5 axis robot or through the joint and against the casting Choose an appropriate material for the pin that does not damage the surface of the joints xx2000000688 Hexagon flange bolt 3HAC058625 001 Washer 3HAC058626 004 Tightening torque 35 Nm CAUTION There is a...

Page 64: ...spect the friction shim and sealing ring Replace if damaged Sealing ring 3HAC060263 001 xx1900001829 Fit the friction shim 3 xx2000001111 Install the sealing ring at the lower joint and guide the telescopic shaft into place CAUTION Hold the telescopic unit carefully the tube may slide and get damaged 4 Continues on next page 64 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 A...

Page 65: ...while loosen ing tightening the screws Requires two persons xx2000001103 2 Hold the motor shaft still by inserting a pin through the joints 5 axis robot or through the joint and against the casting Choose an appropriate material for the pin that does not damage the surface of the joints xx2000001104 Hexagon flange bolt 3HAC058625 001 Washer 3HAC058626 004 Tightening torque 35 Nm CAUTION There is a...

Page 66: ... counters on page 302 Update the revolution counters 1 66 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 5 Orienting assembling and securing the manipulator Continued ...

Page 67: ...owered 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 maintenance ...

Page 68: ... internal brake release unit is equipped with a button for controlling the axes brakes Note If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 MP on page 69 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpec ted ways Make sure no personnel is nea...

Page 69: ...n the robot in order to enable the brake release buttons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously and instantly 1 24 24V 11 0V 12 1 21 4 xx2000000686 Supply 0V on pin 12 24V on pin 11 Note Do not interchange the 24V and 0V pins If they are mixed up damage can be caused to internal electrical components 2 Co...

Page 70: ...ng button as described in Releasing the brakes on page 68 3 70 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 7 Manually releasing the brakes Continued ...

Page 71: ...ps or major damage to the robot Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot See Product specification Robot stopping distances according to ISO 10218 1 Product manual...

Page 72: ...talled by delivery No extra action is required Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the product manual for the controller 72 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 9 Signal lamp option ...

Page 73: ...hment holes for extra loads on the delta unit on page 79 IRB 390 15 1300 624 675 808 350 785 69 129 262 290 380 1463 425 975 A A xx2000001845 Continues on next page Product manual IRB 390 73 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 10 Fitting equipment on the robot robot dimensions ...

Page 74: ...view A A is shown in Attachment holes for extra loads on the delta unit on page 79 Continues on next page 74 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 10 Fitting equipment on the robot robot dimensions Continued ...

Page 75: ... 8 H8 14 100 h8 6x M8 12 56 H8 6 5 40 IRB 390 10 1300 IRB 390 15 1300 xx2000002064 Continues on next page Product manual IRB 390 75 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 10 Fitting equipment on the robot robot dimensions Continued ...

Page 76: ... gravity of arm load and robot payload Center of gravity for extra loads on upper and lower arms 70 40 120 40 136 A B xx2000002341 Allowed center of gravity for extra loads on upper arms A Allowed center of gravity for extra loads on lower arms B Continues on next page 76 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3...

Page 77: ...or attaching equipment Maximum extra load 0 5 kg upper arm 3x 12 0 24 5 D 30 204 6x M6 17 VIEW D xx2000001847 Continues on next page Product manual IRB 390 77 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 10 Fitting equipment on the robot robot dimensions Continued ...

Page 78: ...cks Plastic cable ties can be used but risk damaging of the paint Do not use metal directly on the lower arms Maximum extra load 0 15 kg lower arm 425 975 xx2000001849 Continues on next page 78 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 10 Fitting equipment on the robot robot dimensions Continued ...

Page 79: ...aximum extra load on the delta unit 0 5 kg 3x 120 3x M6 9 A A A A xx2000001848 Fastener quality Use suitable screws and tightening torque for your application Product manual IRB 390 79 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 10 Fitting equipment on the robot robot dimensions Continued ...

Page 80: ...ve ground Customer cables The customer cables also handle databus communication See the product manual for the controller see document number in References on page 9 Robot cables These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Connection point robot Connection point cabinet Description Cable sub category R1 MP XS1 Transfers drive power f...

Page 81: ...he cable diameter for static floor cables A B xx1600002016 Diameter A Diameter x10 B Grounding and bonding point on manipulator There is a grounding bonding point on the manipulator base The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx2000001106 Continues on next page Product manual IRB 390 81 3HAC066566 001 Revision B C...

Page 82: ...g installation Note Article number Equipment 54 5x3 3HAB3772 19 O ring nitrile rubber Used to seal between the main power cable and connector 82 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 4 1 Robot cabling and connection points Continued ...

Page 83: ...aintenance 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 IRB 390 is connected to power always...

Page 84: ...cified 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 Robots with the functionality Service Information System activated can show active counters in the device browser in RobotStudio or on the FlexPendant 84 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ...

Page 85: ...d areas with a dry cloth x Cleaning the seals Cleaning the IRB 390 on page 116 x Cleaning the robot Changing oil axis 1 axis 2 and axis 3 gearbox on page 96 x Changing the oil in axis 1 axis 2 and axis 3 gearbox Changing oil axis 4 and axis 5 gear unit on page 101 x Changing the oil in axis 4 and axis 5 gear prestage Changing oil axis 4 and axis 5 gear unit on page 101 x Changing the oil in axis 4...

Page 86: ...age 114 x Lubricating the telescopic shafts x Overhaul of complete robot Changing the SMB battery on page 110 x ii Replacing the SMB battery pack i Operating hours counted by the DTC Duty Time Counter ii The battery is to be replaced at given maintenance interval or at battery low alert 86 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 ...

Page 87: ... vary greatly depending on how hard it is run Expected component life Note Expected life Component 40 000 hours Gearboxes 10 000 hours Universal joints 10 000 hours Telescopic shaft Product manual IRB 390 87 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 2 3 Expected component life ...

Page 88: ...al inspection no tools are required Note Article number Equipment Lint free cloth Inspecting the telescopic shafts Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 Continues on next page 88 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance...

Page 89: ...c shaft especially when new or after re greasing If excessive leakage is detected the seal might be damaged and the telescope then needs to be replaced See Replacing the universal joint on page 215 Check the universal joints for any damage or cracks If damage or cracks are detected replace the complete joint 4 Product manual IRB 390 89 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights r...

Page 90: ...on manipulator labels on page 19 A A 3x 3x Axis 1 Axis 2 Axis 3 SECTION A A Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 B C E D A J D F G H I G xx2000001850 Description Spare part number ABB logotype label 3HAC077213 001 A Waste Electrical Electronic Equipment WEEE label 3HAC067800 001 B Instruction label Brake release 3HAC075336 001 C Warning label Electrical flash 3HAC075337 001 D Continues on next page ...

Page 91: ...tools are required Inspecting labels Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate set is specified in Inspecting the information labels on page90 Replace any missing or damaged labels 3 Product manu...

Page 92: ...Interchangeable head torque wrench Included in robot delivery xx1900002148 Used with an interchangeable head torque wrench not included in delivery Interface 14x18 mm 3HAC073854 001 Torque wrench head open end in sert Continues on next page 92 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 3 3 Inspecting the lower arms ...

Page 93: ...fts 2 Interchangeable head torque wrench Use an interchangeable head torque wrench and the open end head insert Torque wrench head open end in sert 3HAC073854 001 xx1900002150 xx1900002152 See Replacing the lower arm on page 197 Check the lower arms for any damage or cracks If damage or cracks are detected replace the lower arm 3 Product manual IRB 390 93 3HAC066566 001 Revision B Copyright 2020 2...

Page 94: ...arboxes Information about the type of lubrication article number as well as the amount in the specific gearbox can be found in Technical reference manual Lubrication in gearboxes available for registered users on myABB Business Portal www abb com myABB Location of gearboxes The figure shows the location of the gearboxes xx1900000303 Axis 1 gear A Axis 2 gear B Continues on next page 94 Product man...

Page 95: ...r prestage D1 Axis 4 gear D2 Axis 5 gear prestage E1 Axis 5 gear E2 Product manual IRB 390 95 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 4 1 Type of lubrication in gearboxes Continued ...

Page 96: ...f the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubric ation in gearboxes on page 94 Oil dispenser Content is defined in section Standard toolkit on page 336 Standard toolkit Continues on next page 96 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Ma...

Page 97: ...ction Jog the axis for oil change to 0 calibration posi tion 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page30 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil...

Page 98: ...aining 7 Drain the oil 8 WARNING Used oil is hazardous material and must be dis posed of in a safe way See Decommissioning on page 327 for more information 9 Continues on next page 98 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 4 2 Changing oil axis 1 axis 2 and axis 3 gearbox Continued ...

Page 99: ...0 Nm xx1900000308 Tighten the oil plug 2 Fill oil until it reaches the lower edge of the upper oil plug hole 3 Tightening torque 10 Nm xx1900000309 Tighten the ventilation plug 4 xx2000001591 Refit the caps and sealing rings 5 Continues on next page Product manual IRB 390 99 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 4 2 Changing oil axis 1 axis 2 and axi...

Page 100: ...afety requirements are met when performing the first test run 6 100 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 4 2 Changing oil axis 1 axis 2 and axis 3 gearbox Continued ...

Page 101: ...pment The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubric ation in gearboxes on page 94 Oil dispenser Content is defined in section Standard toolkit on page 336 Standard toolkit Continues on next page Product manual IRB 390 101 3HAC066566 001 Revision B Copyright 2020 2021 ABB All...

Page 102: ...e gear Note Action Robot axis position has no significance 1 Choose a position convenient for service xx1900000315 Valid for IRB 390 10 1300 5 axis robot Turn the tilt arm to the opposite side of the oil plug 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 3 WARNING Handling gearbox oil involves several sa...

Page 103: ...01631 Remove the caps and sealing rings 6 IRB 390 10 1300 5 axis robot xx1900000313 IRB 390 15 1300 4 axis robot xx2000001632 Open the oil plugs on the gear unit 7 IRB 390 10 1300 5 axis robot xx2000001633 Continues on next page Product manual IRB 390 103 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 4 3 Changing oil axis 4 and axis 5 gear unit Continued ...

Page 104: ...il Note Action WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page30 1 Note Leave the oil plugs open to achieve a better flow 2 xx2000000268 Leave the oil plug holes on axis 4 and axis 5 open Fill with oil at the top oil plug hole until oil starts to drip out through the axis 4 and axis 5 holes 3 Continues on next page 104 Product manual IRB 390 ...

Page 105: ...back and forth to release oil bubbles 5 xx2000000269 Measure 25 mm from the oil surface to the upper oil plug surface to reach correct level 6 Tightening torque 10 Nm xx1900000314 Tighten the ventilation plug Make sure the gasket is undamaged 7 Continues on next page Product manual IRB 390 105 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 4 3 Changing oil ax...

Page 106: ...is undamaged 8 IRB 390 10 1300 5 axis robot xx1900000313 DANGER Make sure all safety requirements are met when performing the first test run 9 106 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 4 3 Changing oil axis 4 and axis 5 gear unit Continued ...

Page 107: ...This is a brief summary of the change procedure containing the major actions to be performed 1 Remove the axis 4 and axis 5 motor and gear units from the base unit 2 Remove the motor 3 Change the oil 4 Refit the motor 5 Refit the axis 4 and axis 5 motor and gear units to the base unit Continues on next page Product manual IRB 390 107 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights res...

Page 108: ...must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubric ation in gearboxes on page 94 Oil dispenser Content is defined in section Standard toolkit on page 336 Standard toolkit Required consumables Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricatin...

Page 109: ...e dis posed of in a safe way See Decommissioning on page 327 for more information 3 Information about the type of lubric ation article number as well as the amount in the specific gearbox can be found in Technical reference manual Lubrication in gearboxes available for registered users on myABB Business Portal www abb com myABB Fill new oil into the gear unit 4 Refitting the gear unit pre stage No...

Page 110: ...See Hazards related to batteries on page 31 Location of the SMB battery The SMB battery is located as shown in the figure xx1900000406 Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 390 via myABB Business Portal www abb com myABB Continues on next page 110 Product manual IRB 390 3HAC066566 001 Revision B Copyri...

Page 111: ...ounter Jog the robot to calibration position 1 DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 2 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 42 3 xx1900000407 Remove the SMB battery cover CAUTION Clean cover from metal residues...

Page 112: ...ABB ap proved equivalent 6 Refitting the battery Use this procedure to refit the SMB battery Refitting the SMB battery Note Action Connect the battery cables Battery cable connector R2 G 1 xx1900000408 Carefully push down the battery into the battery holder 2 Continues on next page 112 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 4 5 ...

Page 113: ...teel A4 80 Washer 3HAC058626 003 M6 hy gienic If the rubber is damaged replace the washer with new for hygienic purpose Anti seize paste 3HAC070875 002 Molykote P1900 xx1900000407 DANGER Make sure all safety requirements are met when performing the first test run 4 Product manual IRB 390 113 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 4 5 Changing the SMB ...

Page 114: ...red consumables Note Article number Consumable FM 222 3HAC029132 001 Grease Amount of re grease 2 5 ml Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 336 Standard toolkit Continues on next page 114 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 5 1 Lubricating the telesc...

Page 115: ...te the telescopic shaft with grease through the nipple 2 Amount of re grease 2 5 ml Nipple dimension DIN 3402 xx2000000003 Check that the telescope has not been lubricated with excessive amount of grease by jogging the telescope to fully compressed position 3 If there is too much grease there will be an over load error Product manual IRB 390 115 3HAC066566 001 Revision B Copyright 2020 2021 ABB Al...

Page 116: ...not use compressed air to clean the robot Do not use solvents that are not approved by ABB to clean the robot Do not spray from a distance closer than 0 4 m Do not remove any covers or other protective devices before cleaning the robot Cleaning methods This following table defines what cleaning methods are allowed for ABB manipulators depending on the protection type Cleaning method Protection typ...

Page 117: ...pax 990 Disinfectant Cables Movable cables need to be able to move freely Remove waste material such as sand dust and chips if it prevents cable movement Clean the cables if they have a crusty surface for example from dry release agents Product manual IRB 390 117 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 6 1 Cleaning the IRB 390 Continued ...

Page 118: ...This page is intentionally left blank ...

Page 119: ...r the article number and the revision of both the replaced unit and the replacement unit This is particularly important for safety equipment to maintain the safety integrity of the installation Safety information Make sure to read through the chapter Safety on page 15 before commencing any service work Note If the IRB 390 is connected to power always make sure that the IRB 390 is connected to prot...

Page 120: ...ement instructions given in the related product manuals must be strictly followed If there are any problems contact your local ABB for support L2 spare parts To replace the L2 parts require specialized training and might need special tools Only ABB field service personnel or qualified personnel trained by ABB can replace L2 parts 120 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 ...

Page 121: ...The pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that n...

Page 122: ...ote Action Check the sealing to ensure that The sealing is of the correct type There is no damage on the main lip 1 Inspect the shaft surface before mounting If scratches or damage are found the shaft must be replaced since it may result in future leakage Do not try to grind or polish the shaft surface to get rid of the defect 2 Article number is specified in Equipment on page 122 A B C xx20000000...

Page 123: ...ed because leakage could occur Clean the surfaces properly in accordance with the recommendations of ABB 2 Distribute the sealing compound evenly over the surface preferably with a brush 3 Tighten the screws evenly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including dama...

Page 124: ... the base cover it may slip out of its position in the cleaning process Lubricate the o ring with grease 4 Tighten the screws evenly while assembling 5 Check that the o ring is not squashed outside the o ring groove 6 124 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 2 Mounting instructions for sealings Continued ...

Page 125: ...or brittle materials Stainless steel screws Stainless steel screws should be secured by hand at least 2 turns before using an electric screwdriver Lubricate the thread of all stainless steel screws with Molykote P1900 3HAC070875 002 Use the torque specified in the repair maintenance or installation procedure Product manual IRB 390 125 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights re...

Page 126: ...r arms 4 Lift down the base unit to a workbench 5 Move the SMB unit the cable harness and the axis 4 and axis 5 motor and gear units from the old base to the new Also move the axis 1 axis 2 and axis 3 motors from the old base to the new if the base spare part is ordered without motors 6 Refit the new base unit to the robot frame 7 Refit the upper arms 8 Refit the lower arms and delta unit 9 Refit ...

Page 127: ... affected during the replacement procedure Replace if damaged or lost Note Article number Spare part Base unit top cover 3HAC058649 003 Sealing washer M8x40 stainless steel A4 80 3HAC060233 008 Hexagon flange bolt M8 hygienic If the rubber is damaged replace the washer with new for hygienic purpose 3HAC058626 004 Washer Between base unit and upper arm 3HAC062067 001 Sealing ring 3HAC043799 001 Was...

Page 128: ...ery xx1900002148 Used with an interchangeable head torque wrench not included in delivery Interface 14x18 mm 3HAC073854 001 Torque wrench head open end in sert Interchangeable head torque wrench Included in robot delivery xx2000000282 Used with a torque wrench not included in delivery to loosen and tighten the universal joint and telescopic shaft screws Hole interface 1 4 square 3HAC063379 001 Tor...

Page 129: ...ving the base unit Note Action Jog the robot to as close to synchronization posi tion as possible 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 2 Remove any loads or tools attached to the turning disk 3 Disconnect all cabling to the robot 4 Removing the telescopic shaft shafts including the universal joi...

Page 130: ...an open end wrench 47 mm at the joint while loosen ing tightening the screws Requires two persons xx2000000346 2 Hold the motor shaft still by inserting a pin through the joints 5 axis robot or through the joint and against the casting Choose an appropriate material for the pin that does not damage the surface of the joints xx2000000688 2 Continues on next page 130 Product manual IRB 390 3HAC06656...

Page 131: ... Note Keep the sealing ring and friction shim for refitting 3 xx2000001109 Removing the lower arms and the delta unit Note Action CAUTION Make sure that all supplies for electrical power are turned off 1 Continues on next page Product manual IRB 390 131 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 1 Replacing the base unit Continued ...

Page 132: ...1900002150 Use an interchangeable head torque wrench and the open end head insert xx1900001796 Remove the lower arms and the delta unit Note Save the sealing washer for refitting or replace it if damaged xx1900001801 4 Removing the upper arms Note Action xx1900001799 Remove the upper arm cover Note Keep the sealing for refitting 1 Continues on next page 132 Product manual IRB 390 3HAC066566 001 Re...

Page 133: ... CAUTION Make sure that all supplies for electrical power are turned off 1 CAUTION The weight of the base unit is 125 kg All lifting accessories used must be sized accord ingly 2 xx1900000210 Fasten three lifting eyes 3 Continues on next page Product manual IRB 390 133 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 1 Replacing the base unit Continued ...

Page 134: ...0 Lift away the robot and place it on a suitable working space for continuing the removal work 7 Moving equipment from the old base to the new spare part The base spare part has several possible configurations with included equipment Move equipment from the old base to the new spare part accordingly before refitting the base to the robot frame See detailed replacement procedures Replacing the SMB ...

Page 135: ...es 1 CAUTION The weight of the complete base unit and upper arms is 136 kg All lifting accessories used must be sized accord ingly 2 Make sure the roundsling has free space and does not wear against any part of the robot Attach the roundslings to the lifting eyes Note Make sure the roundslings do not rub against any sharp edges 3 WARNING Personnel must not under any circumstances be present under ...

Page 136: ...holes and secure with attachment bolts and washers 6 Attachment bolts M16 stainless steel Minimum length of thread engagement 24 mm Minimum quality A4 80 3 pcs Washers 17x15x3 stainless steel 3HAC060866 005 Tightening torque 250 Nm xx2000000469 xx2000000470 Continues on next page 136 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 1 Replaci...

Page 137: ... 12 9 Gle 603 Geo500 12 pcs Washers 12 pcs 3HAC043799 001 12 pcs Tightening torque 35 Nm xx1900001800 Gasket 3HAC058619 001 xx1900001822 Check the upper arm cover gasket Replace if damaged 3 Anti seize paste 3HAC070875 002 Molykote P1900 Lubricate the thread of the upper arm cover and the gasket with grease 4 Continues on next page Product manual IRB 390 137 3HAC066566 001 Revision B Copyright 202...

Page 138: ...2123 001 xx2000000861 Fit the sealing washer to the lower arm Replace the sealing washer if damaged 1 Anti seize paste 3HAC070875 002 Molykote P1900 xx2000000684 Lubricate the lower arm thread Note The surface under the thread head must be dry and not contain grease 2 Continues on next page 138 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 ...

Page 139: ...nd then use an interchangeable head torque wrench and the open end head insert to apply tightening torque Torque wrench head open end in sert 3HAC073854 001 xx1900002152 Refitting the delta unit Note Action Sealing washer 3HAC062123 001 xx2000000861 Fit sealing washers to the lower arms Replace the sealing washers if damaged 1 Continues on next page Product manual IRB 390 139 3HAC066566 001 Revisi...

Page 140: ...002 xx2000000687 Orientation of delta unit axis 4 universal joint side of delta unit directed towards axis 1 side of robot xx2000000685 CAUTION Axis 5 on the delta unit is not stable There is a risk of pinching or tipping the unit if holding or putting down the delta unit on its tilt arm Tip This operation is best performed by two persons working together Continues on next page 140 Product manual ...

Page 141: ... 001 xx1900002150 Refitting the upper end of the telescopic shaft Note Action CAUTION The telescopic shaft must be oriented correctly otherwise it is damaged Always fit the narrow shaft part up against the base unit 1 Cleaning agent Isopropanol Clean the friction shim the sealing ring and the contact surfaces with isopropanol Inspect for damage 2 Friction shim 3HAC060200 001 Sealing ring 3HAC06026...

Page 142: ... and the telescopic shaft at the base unit CAUTION The telescopic shaft must be oriented correctly otherwise it is damaged Always fit the narrow shaft part up against the base unit 3 Continues on next page 142 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 1 Replacing the base unit Continued ...

Page 143: ...ench 47 mm at the joint while loosen ing tightening the screws Requires two persons xx2000000346 2 Hold the motor shaft still by inserting a pin through the joints 5 axis robot or through the joint and against the casting Choose an appropriate material for the pin that does not damage the surface of the joints xx2000000688 Hexagon flange bolt 3HAC058625 001 Washer 3HAC058626 004 Tightening torque ...

Page 144: ...n shim 3HAC060200 001 Inspect the friction shim and sealing ring Replace if damaged Sealing ring 3HAC060263 001 xx1900001829 Fit the friction shim 3 xx2000001111 Install the sealing ring at the lower joint and guide the telescopic shaft into place CAUTION Hold the telescopic unit carefully the tube may slide and get damaged 4 Continues on next page 144 Product manual IRB 390 3HAC066566 001 Revisio...

Page 145: ...ench 47 mm at the joint while loosen ing tightening the screws Requires two persons xx2000001103 2 Hold the motor shaft still by inserting a pin through the joints 5 axis robot or through the joint and against the casting Choose an appropriate material for the pin that does not damage the surface of the joints xx2000001104 Hexagon flange bolt 3HAC058625 001 Washer 3HAC058626 004 Tightening torque ...

Page 146: ...alibration on page 297 Calibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 146 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 1 Replacing the base unit Continued ...

Page 147: ...arts of the IRB 390 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC043926 003 Cassette sealing Required consumables Note Article number Consumable P 80 THIX IFC 3HAC074427 001 Assembly lubricant Molykote P1900 3HAC070875 002 Anti seize paste Cable ties Continues on next page Product manual IRB 390 147 3HAC066566 001 Revision B Copyright 2020 2021 ABB All ri...

Page 148: ...with an interchangeable head torque wrench not included in delivery Interface 14x18 mm 3HAC073854 001 Torque wrench head open end in sert Interchangeable head torque wrench Used to press out the cassette sealing holder 4 pcs Screw M8 x minimum 25 mm Used to fit the cassette sealing 3HAC069723 010 Press tool cassette sealing Delivered as a set of calibration tools 3HAC055412 001 Calibration toolbox...

Page 149: ...parations before removing the cassette sealing Note Action xx2000000927 Jog the upper arms to an appropriate working position Move the robot so that the telescopic shaft is ex tended 230 mm as minimum to be able to secure the lower arms against the shaft further on in the procedure 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before enterin...

Page 150: ...osest to the telescopic shaft 2 Interchangeable head torque wrench Loosen the both lower arm shafts from the upper arm by loosening the bolts 3 Torque wrench head open end in sert 3HAC073854 001 xx1900002152 Use an interchangeable head torque wrench and the open end head insert xx1900001802 Disconnect the lower arms from the upper arm 4 Continues on next page 150 Product manual IRB 390 3HAC066566 ...

Page 151: ... arm Note Action xx1900001799 Remove the upper arm cover Note Keep the sealing for refitting 1 xx1900001800 Remove the screws and washers 2 xx1900001820 Remove the upper arm from the base unit Note Keep the sealing ring for refitting 3 Continues on next page Product manual IRB 390 151 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 2 Replacing the cassette sealin...

Page 152: ...chment screw holes A Insert two M8 screws with minimum length of 25 mm into opposite attachment screw holes A in the sealing holder just enough to get a grip of the holder Then rotate the sealing holder approximately 10 clockwise to the position where the press out holes B are accessible visible when looking through the attachment screw holes 2 Continues on next page 152 Product manual IRB 390 3HA...

Page 153: ... out the holder 3 xx2000000289 xx2000001112 Remove the cassette sealing from the holder by first pulling out the inner ring and then knocking out the outer ring with a striker CAUTION Be careful not to damage the outer and inner surface of the sealing holder highlighted in the figure xx2000000291 4 Continues on next page Product manual IRB 390 153 3HAC066566 001 Revision B Copyright 2020 2021 ABB ...

Page 154: ...older for scratches Replace the holder if there are damages on the surfaces highlighted in the figure 1 O ring 3HAB3772 110 Lubricate and fit the o ring to the cassette sealing holder 2 Anti seize paste 3HAC070875 002 Molykote P1900 xx2000000928 Replace if damaged Continues on next page 154 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 2 ...

Page 155: ...washer with new for hygienic purpose Anti seize paste 3HAC070875 002 Molykote P1900 xx2000000929 Sealing ring 3HAC067485 001 Lubricate and refit the sealing ring 4 Grease 3HAC042536 001 Shell Gadus S2 xx2000000930 Replace if damaged Tightening torque 10 Nm xx2000000112 Tighten the screws and washers 5 Continues on next page Product manual IRB 390 155 3HAC066566 001 Revision B Copyright 2020 2021 A...

Page 156: ...Fit the threaded shaft 7 Assembly lubricant 3HAC074427 001 P 80 THIX IFC xx2000001827 Lubricate the outer and inner diameter of the cassette sealing sparingly with assembly lubric ant 8 Continues on next page 156 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 2 Replacing the cassette sealing Continued ...

Page 157: ...older by screwing in the nut on the thread shaft until the press tool bottom Leave in place for at least 30 seconds before re moving the tool 11 Refitting the upper arm Note Action Sealing ring 3HAC062067 001 xx1900001821 Clean and fit the sealing ring Replace if damaged 1 Continues on next page Product manual IRB 390 157 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repa...

Page 158: ...Check the upper arm cover gasket Replace if damaged 3 Anti seize paste 3HAC070875 002 Molykote P1900 Lubricate the thread of the upper arm cover and the gasket with grease 4 Tightening torque approximately 45 Nm Refit the upper arm cover including the gasket 5 Tighten until the cover bottoms on the upper arm xx1900001799 Continues on next page 158 Product manual IRB 390 3HAC066566 001 Revision B C...

Page 159: ...er arm thread with grease Note The surface under the thread head must be dry and not contain grease 2 Lower arm parallel bar 3HAC060138 001 xx1900001802 Secure the lower arms including the sealing washers to the upper arm Make sure the sealing washers are in place 3 Continues on next page Product manual IRB 390 159 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 ...

Page 160: ...ening torque Torque wrench head open end in sert 3HAC073854 001 xx1900002152 Concluding procedure Note Action See Calibration on page 297 Calibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 160 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 2 Replacing the cassette sealing Continued ...

Page 161: ... space above the robot on page 49 Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 390 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 Complete unit with serial meas urement board and bracket 3HAC043904 001 Serial measurement unit DSQC 633C Continues on next page Product manual...

Page 162: ...ubber is damaged replace the washer with new for hygienic purpose 3HAC058626 004 Washer Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 336 Standard toolkit Removing the SMB unit Use these procedures to remove the SMB unit Preparations before removing the SMB unit Note Action This is done to facilitate updating of the revolution cou...

Page 163: ...ee the battery position during refitting of the top cover 3 xx1900000469 Remove the cover by removing the screws and washers Also remove the sealing 4 Removing the SMB unit Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 42 1 Continues on next page Product manual IRB 390 163 3H...

Page 164: ...om the SMB board R2 FB1 4 R2 FB5 IRB 390 10 1300 Battery cable connector R2 G Disconnect the battery cable by pressing down the upper lip of the R2 G connector to release the lock while pulling the connect or upwards 4 xx1700000993 Continues on next page 164 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 3 Replacing the SMB unit Continued ...

Page 165: ...MB unit Use these procedures to refit the SMB unit Refitting the SMB unit Note Action xx2000001051 Put the SMB unit into the SMB bracket and secure with the four screws 1 Connect the connectors R2 FB1 4 R2 FB5 IRB 390 10 1300 Battery cable connector R2 G 2 Continues on next page Product manual IRB 390 165 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 3 Replacin...

Page 166: ... squeezed under the cover 1 Hexagon flange bolt 3HAC060233 008 M8x40 stainless steel A4 80 15 pcs Washer 3HAC058626 004 M8 hy gienic If the rubber is damaged replace the washer with new for hygienic purpose 15 pcs Anti seize paste Molykote P1900 3HAC070875 002 Tightening torque 21 Nm xx1900000469 Continues on next page 166 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB Al...

Page 167: ...58626 003 M6 hy gienic If the rubber is damaged replace the washer with new for hygienic purpose Anti seize paste 3HAC070875 002 Molykote P1900 xx1900000407 xx2000001006 Reconnect connector R1 MP to the base 3 Concluding procedure Note Action See Updating revolution counters on page 302 Update the revolution counters 1 DANGER Make sure all safety requirements are met when performing the first test...

Page 168: ...mary of the replacement procedure This is a brief summary of the replacement procedure containing the major actions to be performed 1 Loosen upper ends of the telescopic shaft shafts 2 Disconnect the motor connectors at axis 1 axis 2 and axis 3 motors 3 Remove the SMB unit assembly 4 Remove the axis 4 and axis 5 motor and gear units 5 Replace the cable harness 6 Refit the removed parts in reversed...

Page 169: ...C060200 001 Friction shim Between universal joint and tele scopic shaft base unit delta unit 3HAC060263 001 Sealing ring M8x16 Bumax 109 3HAC058625 001 Hexagon flange bolt M8 hygienic If the rubber is damaged replace the washer with new for hygienic purpose 3HAC058626 004 Washer Base unit top cover 3HAC058649 003 Sealing washer M8x40 stainless steel A4 80 3HAC060233 008 Hexagon flange bolt M8 hygi...

Page 170: ... toolkit Removing the cable harness Use these procedures to remove the cable harness Preparations before removing the cable harness Note Action This is done to facilitate updating of the revolution counter Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 2 Continues on ...

Page 171: ... xx2000001022 Loosen the upper end of the telescopic shaft and secure the shaft against a part of the robot with a cable tie CAUTION Put some soft material between the surfaces to protect them from scratches etc Note Keep the sealing ring and friction shim for refitting xx1900001825 2 Continues on next page Product manual IRB 390 171 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights res...

Page 172: ...rdous failures 2 xx1900000407 Remove the SMB battery cover Tip The battery cover is removed to see the battery position during refitting of the top cover 3 xx1900000469 Remove the cover by removing the screws and washers Also remove the sealing 4 Continues on next page 172 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 4 Replacing the cabl...

Page 173: ...ets Tip Take pictures of the cable routing and placement of cable ties before cutting the ties 2 Disconnect the motor connectors 3 xx2000002199 Loosen the bracket from the motor 4 xx2000002200 Pull out the bracket and cut the remaining cable ties 5 Continues on next page Product manual IRB 390 173 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 4 Replacing the ca...

Page 174: ...efore handling the unit read the safety information in section The unit is sensitive to ESD on page 42 1 xx2000002210 Disconnect the connector from X1 on the SMB board 2 Cut the cable tie located at the battery 3 Screws 3 pcs xx1900000753 Remove the screws that secure the SMB unit bracket 4 Continues on next page 174 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All righ...

Page 175: ...ion xx1900001842 Loosen the holder for connector R1 MP1 and move it out of the way to get access to the gear unit attachment screws 1 Cut cable ties snap loose all motor connectors and disconnect them 2 xx1900001843 Remove the gear unit attachment screws and washers 3 Continues on next page Product manual IRB 390 175 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 ...

Page 176: ...900001845 Snap loose the connectors from the connector bracket and disconnect the motor connectors 1 xx1900002171 Remove the gear unit attachment screws and washers 2 Continues on next page 176 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 4 Replacing the cable harness Continued ...

Page 177: ...1 xx2000002211 Disconnect the signal lamp connectors H1 and H2 2 xx2000001029 Push through the connectors for axis 1 axis 2 and axis 3 motors into the base unit compartment and remove the cable harness 3 Continues on next page Product manual IRB 390 177 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 4 Replacing the cable harness Continued ...

Page 178: ...to the correct motor 2 Cable ties xx2000001025 Tie the cabling with cable ties inside the base unit CAUTION Be aware of the pinch points where the cabling passes next to the gear flanges Route and tie the cable to avoid pinching between the flange and the gear unit during refitting later on 3 xx2000002211 Reconnect the signal lamp connectors H1 and H2 4 xx2000001023 Reconnect the brake release con...

Page 179: ...t assemblies in regard to the cable outlet on top Check that the motor is oriented according to the figure before securing the unit for each axis re spectively 2 xx1900002167 Lift the gear unit into the base CAUTION Risk of pinching Do not pinch the cabling routed next to the gear unit flange xx2000001025 3 Continues on next page Product manual IRB 390 179 3HAC066566 001 Revision B Copyright 2020 ...

Page 180: ...ring in the base and make sure it is properly seated on the tab Replace if damaged 1 xx2000001032 The motors are oriented differently on the axis 4 and axis 5 gear unit assemblies in regard to the cable outlet on top Check that the motor is oriented according to the figure before securing the unit for each axis re spectively 2 Continues on next page 180 Product manual IRB 390 3HAC066566 001 Revisi...

Page 181: ...025 3 Hex socket head cap screw M8x25 8 8 A3F 4 pcs Secure the unit with attachment screws and washers 4 Plain washer 8 4x16x1 6 steel A2F 4 pcs Tightening torque 24 Nm xx1900002171 Continues on next page Product manual IRB 390 181 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 4 Replacing the cable harness Continued ...

Page 182: ...ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 42 1 Secure the cables to connectors R2 FB1 4 R2 FB5 IRB 390 10 1300 with a cable tie at the battery bracket 2 xx2000002201 Connect the connectors R2 FB1 4 R2 FB5 IRB 390 10 1300 3 Continues on next page 182 Product manual IRB 390 3HAC066566 ...

Page 183: ...nnected and routed correctly 1 Refitting the upper end of the telescopic shaft Note Action Cleaning agent Isopropanol Clean the friction shim the sealing ring and the contact surfaces with isopropanol Inspect for damage 1 Friction shim 3HAC060200 001 Sealing ring 3HAC060263 001 Replace if damaged Continues on next page Product manual IRB 390 183 3HAC066566 001 Revision B Copyright 2020 2021 ABB Al...

Page 184: ... and the telescopic shaft at the joint CAUTION The telescopic shaft must be oriented correctly otherwise it is damaged Always fit the narrow shaft part up against the base unit 2 Continues on next page 184 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 4 Replacing the cable harness Continued ...

Page 185: ...mm at the joint while loosen ing tightening the screws Requires two persons xx2000000346 2 Hold the motor shaft still by inserting a pin through the joints 5 axis robot or through the joint and against the casting Choose an appropriate material for the pin that does not damage the surface of the joints xx2000000688 Hexagon flange bolt 3HAC058625 001 Washer 3HAC058626 004 Tightening torque 35 Nm xx...

Page 186: ...0469 Tightening torque 4 Nm Check that the battery is located correctly in the battery compartment and not pinched under the top cover 2 Hexagon flange bolt 3HAC060233 006 M6x16 stainless steel A4 80 Then fasten the battery cover and sealing with lubricated screws and washers Note Do not overtighten to avoid damaging the sealing Washer 3HAC058626 003 M6 hy gienic If the rubber is damaged replace t...

Page 187: ...cabling to the cable bracket with cable ties if removed 1 Torx pan head screw M6x16 8 8 A2F 3 pcs xx1900001837 Refit the cable bracket with attachment screws if removed 2 Continues on next page Product manual IRB 390 187 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 4 Replacing the cable harness Continued ...

Page 188: ... 008 M8x40 stainless steel A4 80 4 pcs Replace if damaged Washer 3HAC058626 004 4 pcs Anti seize paste 3HAC070875 002 Molykote P1900 Tightening torque 22 Nm 10 xx1900000759 Concluding procedure Note Action See Updating revolution counters on page 302 Update the revolution counters 1 DANGER Make sure all safety requirements are met when performing the first test run 2 188 Product manual IRB 390 3HA...

Page 189: ...quired free space above the robot on page 49 Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 390 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 Push button heavy duty Includes new sealing 1SFA616105R4006 Brake release unit Continues on next page Product manual IRB 390 189 3HA...

Page 190: ...he washer with new for hygienic purpose 3HAC058626 003 Washer Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 336 Standard toolkit Removing the brake release button Use these procedures to remove the brake release button Preparations before removing the brake release button Note Action Jog the robot to an appropriate working positio...

Page 191: ...e battery position during refitting of the top cover 3 xx1900000469 Remove the cover by removing the screws and washers Also remove the sealing 4 Removing the SMB unit Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 42 1 Continues on next page Product manual IRB 390 191 3HAC066...

Page 192: ...e SMB board R2 FB1 4 R2 FB5 IRB 390 10 1300 Battery cable connector R2 G Disconnect the battery cable by pressing down the upper lip of the R2 G connector to release the lock while pulling the connect or upwards 4 xx1700000993 Continues on next page 192 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 5 Replacing the brake release unit Conti...

Page 193: ...art of the brake release push button and remove from the robot 2 Refitting the brake release button Use these procedures to refit the brake release button Refitting the brake release button Note Action Brake release unit 1SFA616105R4006 Fit the brake release push button to the robot with the sealing A underneath the base 1 Sealing 3HAC059429 003 xx2000001060 Continues on next page Product manual I...

Page 194: ...e with the four screws 1 Connect the connectors R2 FB1 4 R2 FB5 IRB 390 10 1300 Battery cable connector R2 G 2 M6x16 8 8 A2F 3 pcs xx1900000753 Secure the SMB bracket with the screws 3 Continues on next page 194 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 5 Replacing the brake release unit Continued ...

Page 195: ...9 Tightening torque 4 Nm Check that the battery is located correctly in the battery compartment and not pinched under the top cover 2 Hexagon flange bolt 3HAC060233 006 M6x16 stainless steel A4 80 Then fasten the battery cover and sealing with lubricated screws and washers Note Do not overtighten to avoid damaging the sealing Washer 3HAC058626 003 M6 hy gienic If the rubber is damaged replace the ...

Page 196: ...ng the brakes on page 68 Perform a function test of the brake release but ton 1 DANGER Make sure all safety requirements are met when performing the first test run 2 196 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 5 Replacing the brake release unit Continued ...

Page 197: ...yABB Level Note Article number Spare part L1 3HAC060138 001 Lower arm parallel bar Required consumables Note Article number Consumable Molykote P1900 3HAC070875 002 Anti seize paste Other spare parts Following parts are affected during the replacement procedure Replace if damaged or lost Note Article number Spare part To the lower arm 3HAC062123 001 Sealing washer Continues on next page Product ma...

Page 198: ...fore removing the lower arm Note Action The robot does not need to be jogged into any specific position due to repair activity 1 Do not move the position of the robot arms during lower arm replacement DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 2 Remove any loads or tools attached to the turning disk 3 R...

Page 199: ...aft 2 Interchangeable head torque wrench Loosen the lower shaft from the delta unit by loosening the nut 3 Torque wrench head open end in sert 3HAC073854 001 xx1900002150 Use an interchangeable head torque wrench and the open end head insert xx1900001801 Remove the lower end of the arm from the delta unit Save the sealing washer for refitting or replace it if damaged 4 Continues on next page Produ...

Page 200: ...ove the lower arm Save the sealing washer for refitting or replace it if damaged 6 Refitting the lower arm Use these procedures to refit the lower arm Refitting the lower arm to the upper arm Note Action Sealing washer 3HAC062123 001 xx2000000861 Fit the sealing washer to the lower arm Replace the sealing washer if damaged 1 Continues on next page 200 Product manual IRB 390 3HAC066566 001 Revision...

Page 201: ...wer arm can be turned either way the ori entation has no significance 3 Tightening torque 100 Nm Tighten the shaft 4 Interchangeable head torque wrench Start by hand then use an interchangeable head torque wrench and the open end head insert to apply tightening torque Torque wrench head open end in sert 3HAC073854 001 xx1900002152 Continues on next page Product manual IRB 390 201 3HAC066566 001 Re...

Page 202: ...lykote P1900 xx2000000684 Lubricate the lower arm thread Note The surface under the thread head must be dry and not contain grease 2 Lower arm parallel bar 3HAC060138 001 xx2000001063 Fit the lower arm Make sure the sealing washer is in place 3 Continues on next page 202 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower ...

Page 203: ...apply tightening torque Torque wrench head open end in sert 3HAC073854 001 xx1900002150 Concluding procedure Note Action Remove the lashing strap if used 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 390 203 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 5 1 Replacing the lower arm Continued ...

Page 204: ...ote Article number Spare part L1 3HAC060604 003 Upper arm Required consumables Note Article number Consumable Molykote P1900 3HAC070875 002 Anti seize paste Cable ties Other spare parts Following parts are affected during the replacement procedure Replace if damaged or lost Note Article number Spare part To the lower arm 3HAC062123 001 Sealing washer Continues on next page 204 Product manual IRB 3...

Page 205: ...elivered as a set of calibration tools 3HAC055412 001 Calibration toolbox Axis Calibra tion Content is defined in section Standard toolkit on page 336 Standard toolkit Removing the upper arm Use these procedures to remove the upper arm Preparations before removing the upper arm Note Action xx2000000927 Jog the upper arms to an appropriate working position Move the robot so that the telescopic shaf...

Page 206: ... turned off 1 Lashing strap xx2000000334 CAUTION The delta unit will become unstable when a lower arm is removed Support the weight of the delta unit before remov ing the arm to minimize the movement Either support the weight from underneath or secure the weight with a lashing strap through the universal joints closest to the telescopic shaft 2 Continues on next page 206 Product manual IRB 390 3HA...

Page 207: ... the open end head insert xx1900001802 Disconnect the lower arms from the upper arm 4 Cable ties xx2000000921 Secure the lower arms against the telescope shaft with a cable tie CAUTION Put some soft material between the surfaces to protect them from scratches etc 5 Continues on next page Product manual IRB 390 207 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 5 2...

Page 208: ...t Note Keep the sealing ring for refitting 3 Refitting the upper arm Use these procedures to refit the upper arm Refitting the upper arm Note Action Sealing ring 3HAC062067 001 xx1900001821 Clean and fit the sealing ring Replace if damaged 1 Continues on next page 208 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 5 2 Replacing the upper arm...

Page 209: ...822 Check the upper arm cover gasket Replace if damaged 3 Anti seize paste 3HAC070875 002 Molykote P1900 Lubricate the thread of the upper arm cover and the gasket with grease 4 Tightening torque approximately 45 Nm Refit the upper arm cover including the gasket 5 Tighten until the cover bottoms on the upper arm xx1900001799 Continues on next page Product manual IRB 390 209 3HAC066566 001 Revision...

Page 210: ... lower arm thread with grease Note The surface under the thread head must be dry and not contain grease 2 Lower arm parallel bar 3HAC060138 001 xx1900001802 Secure the lower arms including the sealing washers to the upper arm Make sure the sealing washers are in place 3 Continues on next page 210 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair ...

Page 211: ...ightening torque Torque wrench head open end in sert 3HAC073854 001 xx1900002152 Concluding procedure Note Action See Calibration on page 297 Calibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 390 211 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 5 2 Replacing the upper arm Continued ...

Page 212: ... parts of the IRB 390 via myABB Business Portal www abb com myABB Level Note Article number Spare part L1 Nipple dimension DIN 3402 3HAC059382 003 Telescopic shaft unit L1 3HAC059503 001 Universal joint Required consumables Note Article number Consumable Isopropanol Cleaning agent Molykote P1900 3HAC070875 002 Anti seize paste Continues on next page 212 Product manual IRB 390 3HAC066566 001 Revisi...

Page 213: ...d with a torque wrench not included in delivery to loosen and tighten the universal joint and telescopic shaft screws Hole interface 1 4 square 3HAC063379 001 Torque wrench head closed end Content is defined in section Standard toolkit on page 336 Standard toolkit Removing the telescopic shaft Use these procedures to remove the telescopic shaft Preparations before removing the telescopic shaft Not...

Page 214: ...ing a special torque wrench head 2 xx1900001831 Loosen the lower end of the telescopic shaft Note Keep the sealing ring and friction shim for refitting 3 Torque wrench head closed end 3HAC063379 001 xx1900001823 Remove the upper screws and washers using a special torque wrench head 4 Continues on next page 214 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights rese...

Page 215: ...crews and washers using a special torque wrench head Note Keep the sealing ring and friction shim for refitting 1 Cleaning agent Cleaning agent Clean the friction shim and the contact surfaces with isopropanol 2 Friction shim 3HAC060200 001 Inspect the friction shim Replace if damaged xx1900001829 Fit the friction shim 3 Continues on next page Product manual IRB 390 215 3HAC066566 001 Revision B C...

Page 216: ... hygienic pur pose if the rubber is damaged Washer M8 hygienic 3HAC058626 004 Anti seize paste Molykote P1900 3HAC070875 002 Tightening torque 35 Nm xx1900001827 xx2000001061 Refitting the telescopic shaft Use these procedures to refit the telescopic shaft Refitting the upper end of the telescopic shaft Note Action Cleaning agent Isopropanol Clean the friction shim the sealing ring and the contact...

Page 217: ...scopic shaft at the joint CAUTION The telescopic shaft must be oriented correctly otherwise it is damaged Always fit the narrow shaft part up against the base unit 2 Continues on next page Product manual IRB 390 217 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 5 3 Replacing the telescopic shafts and universal joints Continued ...

Page 218: ...nt while loosen ing tightening the screws Requires two persons xx2000000346 2 Hold the motor shaft still by inserting a pin through the joints 5 axis robot or through the joint and against the casting Choose an appropriate material for the pin that does not damage the surface of the joints xx2000000688 Hexagon flange bolt 3HAC058625 001 Washer 3HAC058626 004 Tightening torque 35 Nm xx1900001823 CA...

Page 219: ...e friction shim and sealing ring Replace if damaged Sealing ring 3HAC060263 001 xx1900001830 Fit the friction shim to the telescopic shaft lower joint 3 xx1900001826 Install the sealing ring at the lower joint and guide the telescopic shaft into place CAUTION Hold the telescopic unit carefully the tube may slide and get damaged 4 Continues on next page Product manual IRB 390 219 3HAC066566 001 Rev...

Page 220: ...nt while loosen ing tightening the screws Requires two persons xx2000001103 2 Hold the motor shaft still by inserting a pin through the joints 5 axis robot or through the joint and against the casting Choose an appropriate material for the pin that does not damage the surface of the joints xx2000001104 Hexagon flange bolt 3HAC058625 001 Washer 3HAC058626 004 Tightening torque 35 Nm xx1900001824 CA...

Page 221: ...ure all safety requirements are met when performing the first test run 1 Product manual IRB 390 221 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 5 3 Replacing the telescopic shafts and universal joints Continued ...

Page 222: ... spare parts of the IRB 390 via myABB Business Portal www abb com myABB Level Note Article number Spare part L1 3HAC058371 003 Delta unit axis 4 L1 3HAC058372 002 Delta unit axis 4 5 Required consumables Note Article number Consumable Isopropanol Cleaning agent Molykote P1900 3HAC070875 002 Anti seize paste Continues on next page 222 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 ...

Page 223: ...gth 2 5 m Lashing strap Included in robot delivery xx1900002148 Used with an interchangeable head torque wrench not included in delivery Interface 14x18 mm 3HAC073854 001 Torque wrench head open end in sert Interchangeable head torque wrench Included in robot delivery xx2000000282 Used with a torque wrench not included in delivery to loosen and tighten the universal joint and telescopic shaft scre...

Page 224: ...s or tools attached to the turning disk 3 Lashing strap xx2000000334 Secure the telescopic shaft with a lashing strap through the universal joints closest to the telescop ic shaft shortest way For IRB 390 10 1300 both shafts must be se cured CAUTION The telescopic shaft will extend if not secured with the lashing strap when the delta unit is removed 4 Removing the delta unit Note Action CAUTION Ma...

Page 225: ...ings and frictions shims for re fitting 3 Interchangeable head torque wrench Loosen the lower arm shafts from the delta unit by loosening the nuts 4 Torque wrench head open end in sert 3HAC073854 001 xx1900002150 Use an interchangeable head torque wrench and the open end head insert xx1900001801 Loosen all lower arms from the delta unit and re move the delta unit Save the sealing washer for refitt...

Page 226: ...Replace the sealing washers if damaged 1 Anti seize paste 3HAC070875 002 Molykote P1900 xx2000000684 Lubricate the lower arm thread with grease Note The surface under the thread head must be dry and not contain grease 2 Continues on next page 226 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 5 4 Replacing the delta unit Continued ...

Page 227: ...n the delta unit is not stable There is a risk of pinching or tipping the unit if holding or putting down the delta unit on its tilt arm Tip This operation is best performed by two persons working together Sealing washer 3HAC062123 001 xx2000001063 Fit all lower arms to the delta unit Make sure the sealing washers are in place 4 Continues on next page Product manual IRB 390 227 3HAC066566 001 Revi...

Page 228: ... 3HAC073854 001 xx1900002150 Refitting the telescopic shaft shafts Note Action Cleaning agent Cleaning agent Clean the friction shim and the contact surfaces with isopropanol 1 Friction shim 3HAC060200 001 Inspect the friction shim Replace if damaged xx1900001829 Fit the friction shim 2 Continues on next page 228 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights r...

Page 229: ... mm at the joint while loosen ing tightening the screws Requires two persons xx2000001103 2 Hold the motor shaft still by inserting a pin through the joints 5 axis robot or through the joint and against the casting Choose an appropriate material for the pin that does not damage the surface of the joints xx2000001104 Washer M8 hygienic 3HAC058626 004 Anti seize paste Molykote P1900 3HAC070875 002 T...

Page 230: ...ation on page 297 Calibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 230 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 5 4 Replacing the delta unit Continued ...

Page 231: ...f the IRB 390 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 3HAC059345 001 Tilt arm L2 2 pcs Always use new friction shims 3HAC061398 001 Friction shim L2 M12x50 12 9 Gleitmo 603 2 pcs Always use new screws 3HAB3409 69 Hex socket head cap screw Continues on next page Product manual IRB 390 231 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserv...

Page 232: ...s defined in section Standard toolkit on page 336 Standard toolkit Removing the tilt arm Use these procedures to remove the tilt arm Preparations before removing the tilt arm Note Action Jog the robot to an appropriate working position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 2 Removing the tilt arm...

Page 233: ...ilt arm Discard the friction shims 4 Refitting the tilt arm Use these procedures to refit the tilt arm Refitting the tilt arm Note Action Sealing ring 3HAC061399 001 xx2000000038 Check the two sealing rings Replace if damage 1 Continues on next page Product manual IRB 390 233 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 5 5 Replacing the tilt arm Continued ...

Page 234: ...im between the sealing ring and tilt arm on the other side and then push the sleeve in 4 Sleeve 3HAC061440 001 xx2000000041 Hex socket head cap screw 3HAB3409 69 M12x50 12 9 Gleitmo 603 2 pcs Secure with two washers and two new screws Tighten Note Do not reuse the screws 5 Spring washer conical 9ADA334 9 2 pcs Tightening torque 80 Nm 90 10 xx2000000042 Continues on next page 234 Product manual IRB...

Page 235: ...damaged Concluding procedure Note Action See Calibration on page 297 Calibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 390 235 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 5 5 Replacing the tilt arm Continued ...

Page 236: ... cover on the axis 1 axis 2 and axis 3 gears Note Do not under any circumstances open the cover on the axis 1 axis 2 and axis 3 gears It is strictly forbidden to do any repair work on the gears xx2000001263 Continues on next page 236 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 1 Replacing the axis 1 axis 2 and axis 3 motor ...

Page 237: ...on flange bolt M8 hygienic If the rubber is damaged replace the washer with new for hygienic purpose 3HAC058626 004 Washer To the lower arm 3HAC062123 001 Sealing washer Required tools and equipment Note Article number Equipment The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubric ...

Page 238: ...ndard toolkit on page 336 Standard toolkit Removing the motor Use these procedures to remove the axis 1 axis 2 or axis 3 motor Preparations before removing the axis 1 axis 2 or axis 3 motor Note Action Jog the robot to synchronization position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 2 Continues on ...

Page 239: ...ke sure that all supplies for electrical power are turned off 1 xx1900000759 Remove the motor cover and the sealing 2 Cut all cable ties Tip Take pictures of the cable routing and placement of cable ties before cutting the ties 3 Continues on next page Product manual IRB 390 239 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 1 Replacing the axis 1 axis 2 and axi...

Page 240: ...3 MP3 connector pin 2 pin 5 xx1900000760 Remove two of the screws and washers securing the motor 7 Guide pin M8x150 3HAC15520 2 xx1900001835 Fasten two guide pins Tip Lubricate the guide pins with some grease to make the motor slide better 8 Remove the two remaining screws and washers 9 Continues on next page 240 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights r...

Page 241: ...th grease and fit it to the motor flange 1 Anti seize paste 3HAC070875 002 Molykote P1900 xx1900001962 Guide pin M8x150 3HAC15520 2 If not already fitted fasten two guide pins to op posite screw holes Tip Lubricate the guide pins with some grease to make the motor slide better 2 CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 3 Continues on nex...

Page 242: ... when mating it into the gear 6 Leave the rotation tool and 24 VDC power supply connected for play adjustment Hex socket head cap screw M8x25 8 8 A3F Fit the attachment screws and washers Tighten by hand 7 Plain washer 8 4x16x1 6 steel A2F Remove the guide pins and fit the remaining two screws and washers Tighten by hand Do not tighten with a torque yet 8 Continues on next page 242 Product manual ...

Page 243: ...001801 Adjust the play on the motor by starting with a big play and then gradually finding the smallest play 2 Turn the motor shaft seven turns and find the smallest play within this range Push or tap the motor in radial direction so that the play becomes minimal within one motor turn without the gear chewing Tightening torque 24 Nm Tighten the motor attachment screws 3 Sealing washer 3HAC062123 0...

Page 244: ...Make sure the sealing washers are in place 6 Tightening torque 100 Nm Tighten the lower arm shafts 7 Interchangeable head torque wrench Use an interchangeable head torque wrench and the open end head insert Torque wrench head open end in sert 3HAC073854 001 xx1900002150 Continues on next page 244 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair ...

Page 245: ...ble bracket with attachment screws if removed 2 xx2000001005 Reconnect the motor cabling and snap the cable connectors to the cable bracket 3 Cable ties Secure the cabling to the cable bracket with cable ties 4 Continues on next page Product manual IRB 390 245 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 1 Replacing the axis 1 axis 2 and axis 3 motor Continued...

Page 246: ...ze paste 3HAC070875 002 Molykote P1900 Tightening torque 22 Nm 10 xx1900000759 Concluding procedure Note Action Remove the lashing strap if used 1 See Calibration on page 297 Calibrate the robot 2 DANGER Make sure all safety requirements are met when performing the first test run 3 246 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 1 Repla...

Page 247: ...ree space above the robot on page 49 Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 390 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 Includes o ring 3HAB3772 163 and pinion 3HAC058581 003 Rotating AC motor M104 with pinion Continues on next page Product manual IRB 390 247 ...

Page 248: ...hygienic purpose 3HAC058626 003 Washer Required tools and equipment Note Article number Equipment Used to release the motor brakes 24 VDC power supply Always use guide pins in pairs Guide pin M6x150 Used to rotate the motor pinion 3HAB7887 1 Rotation tool Delivered as a set of calibration tools 3HAC055412 001 Calibration toolbox Axis Calibra tion Content is defined in section Standard toolkit on p...

Page 249: ...ION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 2 xx1900000407 Remove the SMB battery cover Tip The battery cover is removed to see the battery position during refitting of the top cover 3 Continues on next page Product manual IRB 390 249 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5...

Page 250: ...ose the connectors from the connector bracket and disconnect the motor connectors 2 24 VDC power supply To release the brakes connect the 24 VDC power supply 3 Connect to R3 MP4 connector pin 2 pin 5 xx2000001082 Remove the motor attachment screws and wash ers 4 Continues on next page 250 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 2 Re...

Page 251: ...the gears may be damaged if excessive force is used 6 xx2000001083 Use caution and lift the motor straight up to get the pinion parted from the gear 7 Disconnect the 24 VDC power supply 8 Continues on next page Product manual IRB 390 251 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 2 Replacing the axis 4 motor Continued ...

Page 252: ...elease the brakes connect the 24 VDC power supply 3 Connect to R3 MP4 connector pin 2 pin 5 xx2000001032 4 Axis 4 motor 5 Axis 5 motor The motors are oriented differently on the axis 4 and axis 5 gear unit assemblies in regard to the cable outlet on top Check that the motor is oriented according to the figure before securing the unit for each axis re spectively 4 Continues on next page 252 Product...

Page 253: ...s Secure the unit with attachment screws and washers 6 Plain washer 6 4x12x1 6 steel A2F 4 pcs Tightening torque 10 Nm xx2000001082 Torx pan head screw M6x12 Steel 8 8 A2F 4 pcs xx2000001031 Refit the cable bracket to the motor with four screws 7 Disconnect the 24 VDC power supply 8 Continues on next page Product manual IRB 390 253 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reser...

Page 254: ...B battery does not get squeezed under the cover 1 Hexagon flange bolt 3HAC060233 008 M8x40 stainless steel A4 80 15 pcs Washer 3HAC058626 004 M8 hy gienic If the rubber is damaged replace the washer with new for hygienic purpose 15 pcs Anti seize paste Molykote P1900 3HAC070875 002 Tightening torque 21 Nm xx1900000469 Continues on next page 254 Product manual IRB 390 3HAC066566 001 Revision B Copy...

Page 255: ...Washer 3HAC058626 003 M6 hy gienic If the rubber is damaged replace the washer with new for hygienic purpose Anti seize paste 3HAC070875 002 Molykote P1900 xx1900000407 xx2000001006 Reconnect connector R1 MP to the base 3 Concluding procedure Note Action See Calibration on page 297 Calibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product m...

Page 256: ...ree space above the robot on page 49 Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 390 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 Includes o ring 3HAB3772 163 and pinion 3HAC058581 003 Rotating AC motor M104 with pinion Continues on next page 256 Product manual IRB 390 ...

Page 257: ...hygienic purpose 3HAC058626 003 Washer Required tools and equipment Note Article number Equipment Used to release the motor brakes 24 VDC power supply Always use guide pins in pairs Guide pin M6x150 Used to rotate the motor pinion 3HAB7887 1 Rotation tool Delivered as a set of calibration tools 3HAC055412 001 Calibration toolbox Axis Calibra tion Content is defined in section Standard toolkit on p...

Page 258: ...ION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 2 xx1900000407 Remove the SMB battery cover Tip The battery cover is removed to see the battery position during refitting of the top cover 3 Continues on next page 258 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5...

Page 259: ...r bracket and disconnect the motor connectors 1 24 VDC power supply To release the brakes connect the 24 VDC power supply 2 Connect to R3 MP5 connector pin 2 pin 5 xx2000001089 Remove the motor attachment screws and wash ers 3 Continues on next page Product manual IRB 390 259 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 3 Replacing the axis 5 motor Continued ...

Page 260: ...the motor straight up to get the pinion parted from the gear 6 Disconnect the 24 VDC power supply 7 Refitting the motor Use these procedures to refit the axis 5 motor Refitting the axis 5 motor Note Action O ring 3HAB3772 163 xx2000001087 Check the o ring Replace if damaged 1 Continues on next page 260 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 R...

Page 261: ...xis 4 and axis 5 gear unit assemblies in regard to the cable outlet on top Check that the motor is oriented according to the figure before securing the unit for each axis re spectively 4 Rotating AC motor M104 with pin ion 3HAC058581 003 Lift the motor into the base Use the rotation tool to rotate the pinion when mating it into the gear 5 Rotation tool 3HAB7887 1 xx2000001091 Continues on next pag...

Page 262: ...ening torque 10 Nm xx2000001089 Disconnect the 24 VDC power supply 7 xx1900001845 Connect the motor connectors and fasten the connectors to the connector bracket by snapping them into place 8 Continues on next page 262 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 3 Replacing the axis 5 motor Continued ...

Page 263: ...0469 Tightening torque 4 Nm Check that the battery is located correctly in the battery compartment and not pinched under the top cover 2 Hexagon flange bolt 3HAC060233 006 M6x16 stainless steel A4 80 Then fasten the battery cover and sealing with lubricated screws and washers Note Do not overtighten to avoid damaging the sealing Washer 3HAC058626 003 M6 hy gienic If the rubber is damaged replace t...

Page 264: ... Action See Calibration on page 297 Calibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 264 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 3 Replacing the axis 5 motor Continued ...

Page 265: ...e above the robot on page 49 Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 390 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 Does not include motor 3HAC060588 003 Gear unit pre stage Required consumables Note Article number Consumable Cable ties Continues on next page Prod...

Page 266: ...it top cover 3HAC058649 003 Sealing washer M8x40 stainless steel A4 80 3HAC060233 008 Hexagon flange bolt M8 hygienic If the rubber is damaged replace the washer with new for hygienic purpose 3HAC058626 004 Washer M6x16 stainless steel A4 80 3HAC060233 006 Hexagon flange bolt M6 hygienic If the rubber is damaged replace the washer with new for hygienic purpose 3HAC058626 003 Washer Required tools ...

Page 267: ...tion This is done to facilitate updating of the revolution counter Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 2 Removing the top cover Note Action xx2000001006 Disconnect connector R1 MP from the base 1 CAUTION Clean cover from metal residues before opening Metal ...

Page 268: ...ers Also remove the sealing 4 Loosening the telescopic shaft Note Action Torque wrench head closed end 3HAC063379 001 xx1900001823 Remove the upper screws and washers of the telescopic shaft using a special torque wrench head 1 Continues on next page 268 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 4 Replacing the axis 4 gear unit pre st...

Page 269: ... the axis 4 motor Note Action xx2000001031 Remove the cable bracket from the motor by re moving the four screws 1 Snap loose the connectors from the connector bracket and disconnect the motor connectors 2 24 VDC power supply To release the brakes connect the 24 VDC power supply 3 Connect to R3 MP4 connector pin 2 pin 5 Continues on next page Product manual IRB 390 269 3HAC066566 001 Revision B Cop...

Page 270: ...mating motor and gearbox the gears may be damaged if excessive force is used 6 xx2000001083 Use caution and lift the motor straight up to get the pinion parted from the gear 7 Disconnect the 24 VDC power supply 8 Continues on next page 270 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 4 Replacing the axis 4 gear unit pre stage Continued ...

Page 271: ...out from the base 3 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page30 4 WARNING Used oil is hazardous material and must be dis posed of in a safe way See Decommissioning on page 327 for more information Dispose the gear oil in a safe way 5 Continues on next page Product manual IRB 390 271 3HAC066566 001 Revision B Copyright 2020 2021 ABB All ...

Page 272: ...ar unit Use these procedures to refit the axis 4 motor and gear unit Refitting the universal joint Note Action Cleaning agent Isopropanol Clean the friction shim the sealing ring and the contact surfaces with isopropanol Inspect for damage 1 Friction shim 3HAC060200 001 Sealing ring 3HAC060263 001 Replace if damaged Continues on next page 272 Product manual IRB 390 3HAC066566 001 Revision B Copyri...

Page 273: ...the joint while tightening the screws Requires two persons Note Replace the washers with new for hygienic pur pose if the rubber is damaged Hexagon flange bolt 3HAC058625 001 Washer 3HAC058626 004 Tightening torque 35 Nm xx2000000335 Refitting the axis 4 gear unit pre stage Note Action Sealing ring 3HAC059017 002 xx2000000049 Check the sealing ring in the base and make sure it is properly seated o...

Page 274: ...ndling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page30 4 Information about the type of lubric ation article number as well as the amount in the specific gearbox can be found in Technical reference manual Lubrication in gearboxes available for registered users on myABB Business Portal www abb com myABB Fill oil into the gear unit pre stage 5 Continues on nex...

Page 275: ...r supply 3 Connect to R3 MP4 connector pin 2 pin 5 xx2000001032 4 Axis 4 motor 5 Axis 5 motor The motors are oriented differently on the axis 4 and axis 5 gear unit assemblies in regard to the cable outlet on top Check that the motor is oriented according to the figure before securing the unit for each axis re spectively 4 Continues on next page Product manual IRB 390 275 3HAC066566 001 Revision B...

Page 276: ...e the unit with attachment screws and washers 6 Plain washer 6 4x12x1 6 steel A2F 4 pcs Tightening torque 10 Nm xx2000001082 Torx pan head screw M6x12 Steel 8 8 A2F 4 pcs xx2000001031 Refit the cable bracket to the motor with four screws 7 Disconnect the 24 VDC power supply 8 Continues on next page 276 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 R...

Page 277: ...001 Sealing ring 3HAC060263 001 Replace if damaged Telescopic shaft unit 3HAC059382 003 xx1900001825 Fit the upper end of the telescopic shaft by in stalling the friction shim sealing ring and the telescopic shaft at the joint CAUTION The telescopic shaft must be oriented correctly otherwise it is damaged Always fit the narrow shaft part up against the base unit 2 Continues on next page Product ma...

Page 278: ...he joint while loosen ing tightening the screws Requires two persons xx2000000346 2 Hold the motor shaft still by inserting a pin through the joints 5 axis robot or through the joint and against the casting Choose an appropriate material for the pin that does not damage the surface of the joints xx2000000688 Hexagon flange bolt 3HAC058625 001 Washer 3HAC058626 004 Tightening torque 35 Nm xx1900001...

Page 279: ...he cover with lubric ated screws CAUTION Check that the SMB battery does not get squeezed under the cover 1 Hexagon flange bolt 3HAC060233 008 M8x40 stainless steel A4 80 15 pcs Washer 3HAC058626 004 M8 hy gienic If the rubber is damaged replace the washer with new for hygienic purpose 15 pcs Anti seize paste Molykote P1900 3HAC070875 002 Tightening torque 21 Nm xx1900000469 Continues on next page...

Page 280: ...3HAC058626 003 M6 hy gienic If the rubber is damaged replace the washer with new for hygienic purpose Anti seize paste 3HAC070875 002 Molykote P1900 xx1900000407 xx2000001006 Reconnect connector R1 MP to the base 3 Concluding procedure Note Action See Calibration on page 297 Calibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 280 Product manu...

Page 281: ...ve the robot on page 49 Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 390 via myABB Business Portal www abb com myABB Level Note Article number Spare part L2 Does not include motor 3HAC060588 003 Gear unit pre stage Required consumables Note Article number Consumable Cable ties Continues on next page Product m...

Page 282: ...it top cover 3HAC058649 003 Sealing washer M8x40 stainless steel A4 80 3HAC060233 008 Hexagon flange bolt M8 hygienic If the rubber is damaged replace the washer with new for hygienic purpose 3HAC058626 004 Washer M6x16 stainless steel A4 80 3HAC060233 006 Hexagon flange bolt M6 hygienic If the rubber is damaged replace the washer with new for hygienic purpose 3HAC058626 003 Washer Required tools ...

Page 283: ...tion This is done to facilitate updating of the revolution counter Jog the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 2 Removing the top cover Note Action xx2000001006 Disconnect connector R1 MP from the base 1 CAUTION Clean cover from metal residues before opening Metal ...

Page 284: ...ers Also remove the sealing 4 Loosening the telescopic shaft Note Action Torque wrench head closed end 3HAC063379 001 xx1900001823 Remove the upper screws and washers of the telescopic shaft using a special torque wrench head 1 Continues on next page 284 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 5 Replacing the axis 5 gear unit pre st...

Page 285: ...or refitting xx1900001825 2 Removing the axis 5 motor Note Action xx1900001845 Snap loose the connectors from the connector bracket and disconnect the motor connectors 1 24 VDC power supply To release the brakes connect the 24 VDC power supply 2 Connect to R3 MP5 connector pin 2 pin 5 Continues on next page Product manual IRB 390 285 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights res...

Page 286: ...mating motor and gearbox the gears may be damaged if excessive force is used 5 xx2000001091 Use caution and lift the motor straight up to get the pinion parted from the gear 6 Disconnect the 24 VDC power supply 7 Continues on next page 286 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 5 Replacing the axis 5 gear unit pre stage Continued ...

Page 287: ... safety risks see Gearbox lubricants oil or grease on page30 3 WARNING Used oil is hazardous material and must be dis posed of in a safe way See Decommissioning on page 327 for more information Dispose the gear oil in a safe way 4 Continues on next page Product manual IRB 390 287 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 5 Replacing the axis 5 gear unit pre...

Page 288: ...ar unit Use these procedures to refit the axis 5 motor and gear unit Refitting the universal joint Note Action Cleaning agent Isopropanol Clean the friction shim the sealing ring and the contact surfaces with isopropanol Inspect for damage 1 Friction shim 3HAC060200 001 Sealing ring 3HAC060263 001 Replace if damaged Continues on next page 288 Product manual IRB 390 3HAC066566 001 Revision B Copyri...

Page 289: ...the joint while tightening the screws Requires two persons Note Replace the washers with new for hygienic pur pose if the rubber is damaged Hexagon flange bolt 3HAC058625 001 Washer 3HAC058626 004 Tightening torque 35 Nm xx2000000335 Refitting the axis 5 gear unit pre stage Note Action Sealing ring 3HAC059017 002 xx2000000055 Check the sealing ring in the base and make sure it is properly seated o...

Page 290: ...ndling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page30 4 Information about the type of lubric ation article number as well as the amount in the specific gearbox can be found in Technical reference manual Lubrication in gearboxes available for registered users on myABB Business Portal www abb com myABB Fill oil into the gear unit pre stage 5 Continues on nex...

Page 291: ...r supply 3 Connect to R3 MP5 connector pin 2 pin 5 xx2000001032 4 Axis 4 motor 5 Axis 5 motor The motors are oriented differently on the axis 4 and axis 5 gear unit assemblies in regard to the cable outlet on top Check that the motor is oriented according to the figure before securing the unit for each axis re spectively 4 Continues on next page Product manual IRB 390 291 3HAC066566 001 Revision B...

Page 292: ...he 24 VDC power supply 7 xx1900001845 Connect the motor connectors and fasten the connectors to the connector bracket by snapping them into place 8 Refitting the upper end of the telescopic shaft Note Action Cleaning agent Isopropanol Clean the friction shim the sealing ring and the contact surfaces with isopropanol Inspect for damage 1 Friction shim 3HAC060200 001 Sealing ring 3HAC060263 001 Repl...

Page 293: ...e telescopic shaft at the joint CAUTION The telescopic shaft must be oriented correctly otherwise it is damaged Always fit the narrow shaft part up against the base unit 2 Continues on next page Product manual IRB 390 293 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 5 Repair 5 6 5 Replacing the axis 5 gear unit pre stage Continued ...

Page 294: ...he joint while loosen ing tightening the screws Requires two persons xx2000000346 2 Hold the motor shaft still by inserting a pin through the joints 5 axis robot or through the joint and against the casting Choose an appropriate material for the pin that does not damage the surface of the joints xx2000000688 Hexagon flange bolt 3HAC058625 001 Washer 3HAC058626 004 Tightening torque 35 Nm xx1900001...

Page 295: ...the SMB battery does not get squeezed under the cover 1 Hexagon flange bolt 3HAC060233 008 M8x40 stainless steel A4 80 15 pcs Washer 3HAC058626 004 M8 hy gienic If the rubber is damaged replace the washer with new for hygienic purpose 15 pcs Anti seize paste Molykote P1900 3HAC070875 002 Tightening torque 21 Nm xx1900000469 Continues on next page Product manual IRB 390 295 3HAC066566 001 Revision ...

Page 296: ...3HAC058626 003 M6 hy gienic If the rubber is damaged replace the washer with new for hygienic purpose Anti seize paste 3HAC070875 002 Molykote P1900 xx1900000407 xx2000001006 Reconnect connector R1 MP to the base 3 Concluding procedure Note Action See Calibration on page 297 Calibrate the robot 1 DANGER Make sure all safety requirements are met when performing the first test run 2 296 Product manu...

Page 297: ...eneric term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine can later on be used to re calibrate the robot back to the same po...

Page 298: ...ibration method for calibration of IRB 390 and is the most accurate method for the standard calibration It is the recommended method in order to achieve proper performance The following routines are available for the Axis Calibration method Fine calibration Update revolution counters Reference calibration The calibration equipment for Axis Calibration is delivered as a toolkit An introduction to t...

Page 299: ...ost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 302 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and controller are conn...

Page 300: ...ion This section shows the position of the synchronization marks and the synchronization position for each axis Synchronization marks IRB 390 xx2000000004 300 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 6 Calibration 6 2 1 Synchronization marks and synchronization position for axes ...

Page 301: ...e routines will handle the calibration movements automatically and these might be different from the positive directions shown below Calibration movement and jogging directions The following graphic shows the positive and negative directions for each axis and the linear directions when jogging the robot in the base coordinate system xx2000000006 Product manual IRB 390 301 3HAC066566 001 Revision B...

Page 302: ...ation marks and synchron ization position for axes on page 300 Jog the manipulator to align the synchron ization marks 2 Step 2 Updating the revolution counter with the FlexPendant on page 302 When all axes are positioned update the revolution counter 3 Step 2 Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant IRC5 Action O...

Page 303: ... RobotWare 6 02 and later 3 Calibration method used at factory for each axis is shown as well as calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 Continues on next page Product manual IRB 390 303 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 6 Calibration 6 3 Updating revolution counters Continued ...

Page 304: ...is displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn m...

Page 305: ...able calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the FlexPendant WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB Using other pins in the calibration bushings may cause severe damage to the robot and or personnel WARNING The calibration tool must be fully inser...

Page 306: ...BB factory The reference value will be named according to tool name date etc Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values When reference calibration is performed the robot is restored to the status given by the reference values Update revolution counters Choose this routine to make a rough calibration of each manipulator axis by u...

Page 307: ...quirements for axis positioning during calibration Axis to calibrate Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1 Required position of axis X X Axis 1 X X Axis 2 X X Axis 3 0 Axis 4 Axis 5 Axis to be calibrated Unrestricted Axis is allowed to be jogged to other position than 0 degrees Axis must be put in position 0 degrees 0 Special requirement X Product manual IRB 390 307 3HAC066566 001 Revision B C...

Page 308: ...ng other pins in the calibration bushings may cause severe damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools 3HAC055412 001 Calibration toolbox Ax is Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube insert the plastic protection and the steel spring ring are present...

Page 309: ...solution Note Action It is possible to use any RFID solution with the correct dimensions ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices 13 56 Mhz according to ISO 14443 or ISO 15693 Note The maximum dimensions on the RFID chip must not exceed Ø7 9 mm x 8 0 mm Ø5 9 mm x 8 0 mm or Ø3 9 mm x 8 0 mm depending on calibra tion tool size 1 There is a cavi...

Page 310: ...n and a bushing for the movable calibration tool are located on each axis as follows If there is not enough space on an axis to install a fixed calibration pin the axis is equipped with two bushings instead for installation of two calibration tools when calibration is carried out This is shown in the figure xx2000000025 Continues on next page 310 Product manual IRB 390 3HAC066566 001 Revision B Co...

Page 311: ...aling in the bushing Replace damaged parts with new Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC056806 001 Protection cover and plug set Product manual IRB 390 311 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 6 Calibration 6 4 3 Installation locations for the calibration tools Continued ...

Page 312: ...on procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step Use the following list to learn about the calibration procedure before running the RobotWare program on the FlexPendant It gives you a brief overview of the calibration procedure sequence After the calibration method has been called for on the FlexPendant the follo...

Page 313: ...GER While conducting the calibration the robot needs to be connected to power Make sure that the robot s working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 Starting the calibration procedure Use this procedure to start the Axis Cali...

Page 314: ...n the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 312 Follow the instructions given on the FlexPendant 4 Restarting an interrupted calibration procedure If the Axis Calibration procedure is interrupted before the calibration is finished the RobotWare program needs to be started again Use this procedure to take required action Action Situation Press and...

Page 315: ... and will force SafeMove to unsynchronize automatically However SafeMove may generate other warning messages anytime during the Axis Calibration routine When a warning message is displayed tap Acknowledge to confirm the unsynchronized state and continue Axis Calibration procedure CAUTION SafeMove must be synchronized after the calibration is completed After calibration Note Action xx1600002102 Che...

Page 316: ... Ensure that the sealing is not damaged Replace the plug and the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC056806 001 316 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 6 Calibration 6 4 4 Axis Calibration Running the calibration procedure Continued ...

Page 317: ...to save reference values for all axes that is to be replaced Make sure that the values are saved in RobotStudio or FTP program The files are located in Active system folder name HOME RefCalibFiles 7 Perform the repair 8 Make sure that the tooling and process equipment are the same as when creating the reference Use Reference calibration to update the system with new calibration offset value for th...

Page 318: ... ie 96 3 94 2 2 1 degrees 8 Manually jog axis 4 the calculated angle difference 2 1 NOTE The direction shall be the same direction as the direction used when axis 4 was manually jogged to coincide with the verification process In the example 2 1 degrees 9 Make a new manual fine calibration of axis 4 with axis in 2 1 degrees position 10 Check again against the verification position 11 Repeat the ma...

Page 319: ...osition program twice Do not change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 300 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the xx Product manua...

Page 320: ... page 300 and Updating revolution counters on page 302 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis...

Page 321: ...ctly fitted 2 Replace one thing at a time 3 Do not replace units randomly 4 Make sure that there are no loose screws turnings or other unexpected parts remaining after work has been performed 5 When the work is completed verify that the safety functions are working as intended Keep a track of history Make a historical fault log to keep track of problems over time Consult those working with the rob...

Page 322: ...ilities between hardware and software options and their configuration The robot recently had a software upgrade Check connections software versions The robot has recently been moved from one site to another an already working robot 322 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 1 Introduction to troubleshooting Continued ...

Page 323: ... the oil spill is small this step is sufficient Wipe off the oil or grease see Cleaning the IRB 390 on page 116 2 Monitor the robot over time to see if new oil or grease occurs Check the gearbox oil level 3 Robots performing certain ex tremely heavy duty work cycles may be fitted with vented oil plugs These are not fitted to normal duty robots but can be purchased from your local ABB representativ...

Page 324: ...noise is emitted from a gearbox the following can also apply Overheating Recommended actions The following actions are recommended Information Action CAUTION Allow hot parts to cool down 1 Verify that the service is done according to the maintenance schedule 2 If a bearing is emitting the noise determine which one and make sure that it has suffi cient lubrication 3 If possible disassemble the join...

Page 325: ...t ive Too hot gearbox oil may be caused by Incorrect oil quality or level The robot work cycle runs a specific axis too hard Investigate whether it is possible to program small cooling periods into the application Overpressure created inside gearbox 8 Product manual IRB 390 325 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 Mechanical noise or dissonanc...

Page 326: ...nding equipment Possible causes The symptom can be caused by Faulty brake Faulty power supply to the brake Recommended actions The following actions are recommended Information Action Determine which motor s causes the robot to collapse 1 See the circuit diagram Check the brake power supply to the col lapsing motor during the Motors OFF state 2 If found faulty the motor must be replaced as a compl...

Page 327: ...ns to prevent health or environmental hazards Example application Material Base unit upper arm covers tilt arm gear housing motors Aluminium Serial measurement board Batteries Lithium Lower arms Carbon fiber Cables motors Copper Motors Neodymium Coating Nickel Gearboxes telescopic shaft Oil grease Sealings cable harness Plastic rubber Flange bolts covers washers cassette sealings Stainless steel G...

Page 328: ...ncineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills can form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 328 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 8 Decommissionin...

Page 329: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 390 329 3HAC066566 001 Revision B Copyright 2020 2021 ABB All ri...

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Page 331: ...apter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 390 331 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 9 Reference information 9 1 Introduction ...

Page 332: ...or design ISO 13849 1 2006 Safety of machinery Emergency stop Principles for design ISO 13850 Safety of machinery Electrical equipment of machines Part 1 General requirements IEC 60204 1 2005 Safety of machinery Functional safety of safety related elec trical electronic and programmable electronic control systems IEC 62061 2005 Region specific standards and regulations Description Standard Safety ...

Page 333: ...2014i Classification of air cleanliness ISO 14644 1 2015ii Degrees of protection provided by enclosures IP code IEC 60529 1989 A2 2013 i Only valid for arc welding robots Replaces IEC 61000 6 4 for arc welding robots ii Only robots with protection Clean Room Product manual IRB 390 333 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 9 Reference information 9 2 Applicable stand...

Page 334: ...39 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 334 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 9 Reference information 9 3 Unit conversion ...

Page 335: ...essory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The arm weighs 25 kg All lifting accessories used must be sized accord ingly Product manual IRB 390 335 3HAC066566 001 Revision B Copyright 2020 2021 ABB Al...

Page 336: ...ench 4 190 Nm 1 Interchangeable head torque wrench 1 To be used as an anvil during fitting of universal joint to axis 4 and axis 5 motor shaft Open end wrench 47 mm 1 Torx bit size T30 1 Ratchet head for torque wrench 1 2 1 Hex socket wrench insert size 10 mm 1 Hex socket wrench insert size 13 mm 1 Hexagon bit socket head cap size 6 mm 1 To be used to press out the cassette sealing holder from the...

Page 337: ...oolkit on page 336 and of special tools listed directly in the instructions and also gathered in this section Special tools Note If the replacing procedure is not listed in the table below only standard tools are needed for the procedure Continues on next page Product manual IRB 390 337 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 9 Reference information 9 6 Special tools ...

Page 338: ...1 1 1 1 1 1 1 xx2000000282 3HAC063379 001 Torque wrench head closed end Included in robot delivery 1 1 1 1 1 1 1 xx1900002148 3HAC073854 001 Torque wrench head open end insert Included in robot delivery Lifting tools 3 3 xx2000000261 3HAC16131 1 Lifting eye 3 3 Roundsling 2 m Press tools 1 3HAC069723 010 Press tool cassette sealing Other tools 1 1 1 24 VDC power supply 1 1 1 1 1 1 1 1 3HAC055412 0...

Page 339: ...llation Tools and equipment with spare part number These tools can be ordered from ABB 1 Blind hole bearing puller 1 1 1 2 1 1 xx2000001117 Lashing strap 1 Leak down tester 1 Oil collecting vessel 1 Oil dispenser 1 1 Overhead crane 1 1 1 3HAB7887 1 Rotation tool Continues on next page Product manual IRB 390 339 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 9 Reference infor...

Page 340: ...ting 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 340 Product manual IRB 390 3HAC066566 001 Revision B Copyright 2020 2021 ABB All rights reserved 9 Reference information 9 7 Lifting accessories and lifting i...

Page 341: ...ling between robot and controller 80 calibrating robot 305 roughly 302 calibrating robot 305 calibration rough 302 standard type 298 verification 319 when to calibrate 299 calibration manuals 298 calibration marks 300 calibration position jogging to 320 scales 300 calibration scales 300 carbon dioxide extinguisher 27 carbon fiber disposal 327 cassette sealing replacing 147 changing axis 5 gear uni...

Page 342: ...national regulations 26 negative directions axes 301 neodymium disposal 327 noise 324 O oil 30 amount in gearboxes 94 disposal 327 type of oil 94 oil leaks 323 operating conditions 39 original spare parts 15 overfilled gearbox 323 P pedestal installed on pedestal 26 personnel requirements 16 plastic disposal 327 positive directions axes 301 PPE 16 product standards 332 protection classes 39 protec...

Page 343: ...y 17 stainless steel disposal 327 standards 332 ANSI 332 CAN 332 EN IEC 332 EN ISO 332 steel disposal 327 storage conditions 38 symbols safety 17 synchronization position 302 sync marks 300 system integrator requirements 26 T technical data robot 37 telescopic shaft inspecting 88 replacing 212 temperatures operation 39 storage 38 testing brakes 33 tilt arm replacing 231 torques on foundation 37 tr...

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Page 346: ... 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics Discrete Automation No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics Discrete Automation 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC066566 001 Rev B en Copyright 2020 2021 ABB All rights reserved Specifications subject to change without notice ...

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