ABB IRB 360 User manual

ROBOTICS
Product manual
IRB 360

Trace back information:
Workspace 21A version a12 (not checked in)
Published 2021-03-24 at 09:54:37
Skribenta version 5.4.005

Product manual
IRB 360 - 1/800
IRB 360 - 1/1130
IRB 360 - 1/1600
IRB 360 - 3/1130
IRB 360 - 6/1600
IRB 360 - 8/1130
IRC5, OmniCore
Document ID: 3HAC030005-001
Revision: Z
© Copyright 2008-2021 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, 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 from ABB.
Original instructions.
© Copyright 2008-2021 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
16Product documentation ....................................................................................................................
18How to read the product manual ......................................................................................................
191 Safety
191.1 Safety information .............................................................................................
191.1.1 Limitation of liability .................................................................................
201.1.2 Requirements on personnel ......................................................................
211.2 Safety signals and symbols .................................................................................
211.2.1 Safety signals in the manual ......................................................................
231.2.2 Safety symbols on manipulator labels .........................................................
291.3 Robot stopping functions ....................................................................................
301.4 Installation and commissioning ............................................................................
331.5 Operation ........................................................................................................
331.5.1 Unexpected movement of robot arm ...........................................................
341.6 Maintenance and repair ......................................................................................
341.6.1 Maintenance and repair ............................................................................
371.6.2 Emergency release of the robot axes ..........................................................
381.6.3 Brake testing ..........................................................................................
391.7 Troubleshooting ................................................................................................
401.8 Decommissioning ..............................................................................................
412 Installation and commissioning
412.1 Introduction to installation and commissioning .......................................................
422.2 Structure manipulator ........................................................................................
432.3 Unpacking .......................................................................................................
432.3.1 Pre-installation procedure .........................................................................
472.3.2 Transport ...............................................................................................
492.3.3 Assembling the robot IRB 360 ...................................................................
502.3.4 Working range and type of motion ..............................................................
522.3.5 The unit is sensitive to ESD .......................................................................
532.4 On-site installation ............................................................................................
532.4.1 Lifting the robot with fork lift ......................................................................
552.4.2 Lifting the robot with roundslings ...............................................................
572.4.3 Amount of required space .........................................................................
582.4.4 Orienting and securing the robot frame .......................................................
602.4.5 Orienting and securing the robot ................................................................
642.4.6 Manually releasing the brakes ...................................................................
662.4.7 Fitting equipment on robot ........................................................................
722.4.8 Loads ....................................................................................................
742.5 Installation of options .........................................................................................
742.5.1 Installation of safety lamp (option 213-1) ......................................................
772.5.2 Installation of (optional) customer connections IRB 360 ..................................
812.5.3 Installation of vacuum system (option 218-9) ................................................
862.6 Electrical connections ........................................................................................
862.6.1 Robot cabling and connection points ..........................................................
882.7 Start of robot in cold environments ......................................................................
893 Maintenance
893.1 Introduction ......................................................................................................
903.2 Maintenance schedule .......................................................................................
903.2.1 Specification of maintenance intervals ........................................................
913.2.2 Regular maintenance ...............................................................................
923.2.3 Maintenance schedule IRB 360 ..................................................................
943.3 Inspection activities ...........................................................................................
943.3.1 Telescopic shaft, axis 4, standard ...............................................................
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Table of contents

963.3.2 Telescopic shaft, wash down, axis 4 ...........................................................
983.3.3 Telescopic shaft, stainless, axis 4 ..............................................................
1013.3.4 Vacuum system (optional) .........................................................................
1043.3.5 Bar system .............................................................................................
1083.3.6 Joint balls ..............................................................................................
1093.3.7 Upper arms ............................................................................................
1113.3.8 Hoses ...................................................................................................
1133.3.9 Spring units ............................................................................................
1153.3.10 Movable plate .........................................................................................
1173.3.11 Inspecting information labels .....................................................................
1193.4 Replacement/changing activities ..........................................................................
1193.4.1 Changing the battery in the measuring system .............................................
1233.4.2 Changing the telescopic shaft including universal joints .................................
1253.5 Lubrication activities ..........................................................................................
1253.5.1 Type of lubrication in gearboxes ................................................................
1273.5.2 Gearboxes, axes 1- 4 ...............................................................................
1363.6 Cleaning activities .............................................................................................
1363.6.1 Introduction ............................................................................................
1393.6.2 Standard cleaning ...................................................................................
1413.6.3 Wash down cleaning ................................................................................
1433.6.4 Wash down stainless cleaning ...................................................................
1453.6.5 Clean room cleaning ................................................................................
1463.7 Measuring activities ...........................................................................................
1463.7.1 Measuring backlash axis 4 ........................................................................
1494 Repair
1494.1 Introduction ......................................................................................................
1504.2 General procedures ...........................................................................................
1504.2.1 Mounting instructions for bearings .............................................................
1524.2.2 Mounting instructions for sealings ..............................................................
1554.2.3 Screw joints ..........................................................................................
1584.2.4 Cut the paint or surface on the robot before replacing parts ............................
1604.3 Complete robot .................................................................................................
1604.3.1 Replacement of base cover gasket .............................................................
1634.3.2 Replacement of serial measurement board ..................................................
1674.3.3 Replacement of parallel arms ....................................................................
1724.3.4 Replacement of upper arm ........................................................................
1754.3.5 Replacement of bearing rings ....................................................................
1784.3.6 Replacement of movable plate ...................................................................
1824.3.7 Replacement of telescopic shaft ................................................................
1854.3.8 Replacement of universal joint ...................................................................
1874.3.9 Replacement of joint balls .........................................................................
1904.3.10 Replacement of gearbox unit 1- 3 ...............................................................
1944.3.11 Replacement of gearbox unit 4 ..................................................................
1974.3.12 Replacement of motor axis 1-3 ..................................................................
2024.3.13 Replacement of motor axis 4 .....................................................................
2064.3.14 Replacement of labels ..............................................................................
2094.3.15 Replacing of calibration marks ...................................................................
2114.4 Vacuum system ................................................................................................
2114.4.1 Replacement of vacuum hoses ..................................................................
2144.4.2 Draining of water separation filter ...............................................................
2164.4.3 Replacement of ejector unit .......................................................................
2204.5 Cable harness ..................................................................................................
2204.5.1 Replacement of cable harness ...................................................................
2234.5.2 Replacement of brake release button ..........................................................
2275 Calibration information
2275.1 When to calibrate .............................................................................................
2285.2 Calibration method ............................................................................................
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Table of contents

2305.3 Calibration movement directions for all axes ..........................................................
2315.4 Synchronization marks and synchronization position for axes ...................................
2325.5 Calibrating axis 1-3 ............................................................................................
2365.6 Calibrating axis 4 ..............................................................................................
2385.7 Fine calibration procedure on FlexPendant ............................................................
2415.8 Updating revolution counters ...............................................................................
2455.9 Checking the synchronization position ..................................................................
2496 Decommissioning
2496.1 Introduction ......................................................................................................
2506.2 Environmental information ..................................................................................
2526.3 Scrapping of robot .............................................................................................
2537 Reference information
2537.1 Introduction ......................................................................................................
2547.2 Applicable standards .........................................................................................
2567.3 Unit conversion .................................................................................................
2577.4 Weight specifications .........................................................................................
2587.5 Standard toolkit ................................................................................................
2597.6 Special tools ....................................................................................................
2607.7 Lifting accessories and lifting instructions ..............................................................
2617.8 Grease specification ..........................................................................................
2678 Spare part lists
2678.1 Spare part lists and illustrations ...........................................................................
269Index
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Table of contents

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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the IRB 360
• maintenance of the IRB 360
• mechanical and electrical repair of the IRB 360
The robot described in this manual has the following protection types:
•Standard
•Clean Room
•Wash
Usage
This manual should be used during:
• installation and commissioning, from lifting the product to its work site and
securing it to the foundation, to making it ready for operation
• maintenance work
• repair work
• decommissioning work
Note
It is the responsibility of the integrator to conduct a hazard and risk analysis of
the final application and to ensure its safety.
It is the responsibility of the integrator to provide safety and user guides for the
robot system.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.
Product manual scope
The manual covers all variants and designs of the IRB 360. Some variants and
designs may have been removed from the business offer and are no longer available
for purchase.
Continues on next page
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Overview of this manual

References
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
IRC5
Document IDReference
3HAC049101-
001
Product manual, spare parts - IRB 360
3HAC028647-
009
Circuit diagram - IRB 360
3HAC029963-
001
Product specification - IRB 360
3HAC031045-
001
Safety manual for robot - Manipulator and IRC5 or OmniCore controller i
3HAC021313-
001
Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-
001
Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC024480-
011
Circuit diagram - IRC5
3HAC035738-
001
Product manual - IRC5 Compact
IRC5 with main computer DSQC 639.
3HAC047138-
001
Product manual - IRC5 Compact
IRC5 with main computer DSQC1000.
3HAC049406-
003
Circuit diagram - IRC5 Compact
3HAC027707-
001
Product manual - IRC5 Panel Mounted Controller
IRC5 with main computer DSQC 639.
3HAC047137-
001
Product manual - IRC5 Panel Mounted Controller
IRC5 with main computer DSQC1000.
3HAC026871-
020
Circuit diagram - IRC5 Panel Mounted Controller
3HAC024120-
004
Circuit diagram - Euromap
3HAC050941-
001
Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC050944-
001
Operating manual - Service Information System
3HAC051016-
001
Application manual - Additional axes and stand alone controller
3HAC050798-
001
Application manual - Controller software IRC5
3HAC042927-
001
Technical reference manual - Lubrication in gearboxes
Continues on next page
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Overview of this manual
Continued

Document IDReference
3HAC050948-
001
Technical reference manual - System parameters
3HAC050996-
001
Application manual - Electronic Position Switches
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
OmniCore
Document IDReference
3HAC049101-
001
Product manual, spare parts - IRB 360
3HAC028647-
009
Circuit diagram - IRB 360
3HAC029963-
001
Product specification - IRB 360
3HAC031045-
001
Safety manual for robot - Manipulator and IRC5 or OmniCore controller i
3HAC060860-
001
Product manual - OmniCore C30
3HAC065036-
001
Operating manual - OmniCore
3HAC066554-
001
Application manual - Controller software OmniCore
3HAC042927-
001
Technical reference manual - Lubrication in gearboxes
3HAC065041-
001
Technical reference manual - System parameters
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition-
This revision includes the following additions and/or changes:
• Section What is an emergency stop? added to chapter Safety.
• Section Maintenance schedule: Interval for replacement of battery
pack changed.
A
This revision includes the following additions and/or changes:
• Implementation of IRB 360 1/1600.
B
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Continued

DescriptionRevision
This revision includes the following additions and/or changes:
• Chapter Maintenance sections Regular maintenance on page 91,
Telescopic shaft, axis 4, standard on page 94,Telescopic shaft, wash
down, axis 4 on page 96,Telescopic shaft, stainless, axis 4 on page 98
and Bar system on page 104 updated concerning collisions.
•Chapter Maintenance section Bar system on page 104 updated on how
to measure the distance between the bearing holders.
• Circuit diagrams are not included in this document but delivered as
separate files.
• List of standards updated, see Applicable standards on page 254.
• Spare parts chapter - art. no. updated for telescopic shaft and upper
arm.
Updates in the chapter Safety:
• Updated safety signal graphics for the levels Danger and Warning,
see Safety signals in the manual on page 21.
• New safety labels on the manipulators, see Safety symbols on manip-
ulator labels on page 23.
• Revised terminology: robot replaced with manipulator.
C
This revision includes the following additions and/or changes:
• Minor updates in the chapter Calibration.
D
This revision includes the following additions and/or changes:
• Added caution regarding swivel cup, see Fitting equipment on robot
on page 66.
•Updated instructions for cleaning, see Cleaning activities on page 136.
• Updated tightening sequence, see Replacement of base cover gasket
on page 160.
•Updated refitting instruction, see Replacement of brake release button
on page 223.
• Added information about when to update resolver values, see When
to calibrate on page 227.
• Updated information in Environmental information on page 250.
• Updated spare parts, see Spare parts in the base.
E
This revision includes the following updates:
• A new block, about general illustrations, added in section How to read
the product manual on page 18.
• New Option 864-1 connection FB7 on robot base.
F
This revision includes the following updates:
• Spare part number for the telescopic shaft (1600) is corrected, see
Spare parts - telescopic shaft.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 155.
• Maintenance interval regarding replacement of the telescopic shaft is
changed from 8,000 hours to 4,000 hours, see Maintenance schedule
IRB 360 on page 92.
• Added information about batteries.
G
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Overview of this manual
Continued

DescriptionRevision
This revision includes the following updates:
• Variant IRB 360 - 8/1130 is added to the manual.
• Information about type and volume of oil in gearboxes is removed
from the manual, and is instead now available in the Technical refer-
ence manual - Lubrication in gearboxes -3HAC042927-001. More in-
formation in section Type of lubrication in gearboxes on page 125.
• Added Cut the paint or surface on the robot before replacing parts on
page 158.
• Added information about an alternative bearing ring, see Spare parts
and Bar system on page 104.
• A new SMB unit and battery is introduced, with longer battery lifetime.
•New article numbers for set screws, see Spare parts, telescopic shafts.
• Corrected directions in figure for calibration movement and jogging
directions, see Calibration movement directions for all axes on
page 230.
H
This revision includes the following updates:
• Variant IRB 360 - 6/1600 is added to the manual.
•Corrected the protection class for protection typ Standard, see Protec-
tion classes on page 46.
• Changed the tightening torque, see Replacement of motor axis 4 on
page 202.
• Added information about visual difference between bearing ring ver-
sions, see Different versions of bearing rings require different main-
tenance procedures on page 104.
• Universal joint 3HAC028132-001 is replaced with 3HAC046664-001,
see Spare parts - telescopic shafts.
J
This revision includes the following updates:
• Illustrations of placement of labels updated.
• Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 252.
•Spare parts and exploded views are not included in this document
but delivered as a separate document. See Product manual, spare
parts - IRB 360.
•Mechanical interface of IRB 360 - 8/1130 and IRB 360 - 6/1600 updated.
K
This revision includes the following updates:
•Added information in calibration chapter, see Using the jogging window
on the FlexPendant on page 245.
• Clarification made about when to choose standard calibration vs. ring
calibration, see Types of calibration on page 228.
•Clarification made about measured distance between bearing holders,
regarding wear on bearing rings, see Distance between bearing
holders on page 106.
• Minor corrections
L
This revision includes the following updates:
•Updated instructions for cleaning, see Cleaning activities on page 136.
• Minor corrections
M
This revision includes the following updates:
• Minor corrections
N
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Continued

DescriptionRevision
Published in release R16.2. The following updates are done in this revision:
• Corrections due to updates in terminology.
• Warning about high center of gravity during transport added.
• Updates about parameter Calibration Position (cal_position) in Calib-
ration information on page 227.
• Added information about tightening torque in section Replacement of
movable plate on page 178.
P
Published in release R17.1. The following updates are done in this revision:
• Major updates in cleaning section.
• Updates regarding checking the calibration position.
• Measurement method in Maintenance added.
Q
Published in release R17.2. The following updates are done in this revision:
• Caution about removing metal residues added in sections about SMB
boards.
• Updated list of applicable standards.
• Changed torque on oil plug (Gear-motor unit axis 4).
• Section Start of robot in cold environments on page 88 added.
• Updated figure on motor axis 4.
• Added a note in the instruction Removal on page 188.
• Updated maintenance schedule with sealing ring (v-ring) and the af-
fected cleaning instructions.
• Updated information regarding extra load mass.
R
Published in release R18.1. The following updates are done in this revision:
• Safety restructured.
• Updated information regarding extra load mass.
• Added sections in General procedures on page 150.
• Minor update of graphics in the calibration chapter.
• Information about myABB Business Portal added.
S
Published in release R18.2. The following updates are done in this revision:
• Added section for inspection of labels in maintenance chapter.
• Grease article number updated (is 3HAC042560-001, was
3HAC029132-001)
T
Published in release R18.2. The following updates are done in this revision:
• Reference updated.
U
Published in release 19B. The following updates are made in this revision:
• New touch up color Graphite White available. See Cut the paint or
surface on the robot before replacing parts on page 158.
V
Published in release 19D. The following updates are made in this revision:
• Sealing compound Sikaflex 521 FC replaced by Trans7 from Trans
Clear.
• Requirement to paint touch up color on refitted joints sealed with
Trans7 is removed.
W
Published in release 20A. The following updates are made in this revision:
• Changed the repair procedure for replacing parallel arms.
• Clarified and added information in mounting instructions for rotating
sealings, see Mounting instructions for sealings on page 152.
X
Published in release 20C. The following updates are made in this revision:
• Updated information regarding the fact that installation instructions
no longer are enclosed with bearing rings 3HAC2091-1, see Different
versions of bearing rings require different maintenance procedures
on page 104.
Y
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Continued

DescriptionRevision
Published in release 21A. The following updates are made in this revision:
• Added information on supporting OmniCore controller.
• Added image showing distance between bearing holders on IRB 360
WDS, see Distance between bearing holders on page 106.
• Corrected image of calibration marks location, see Replacing of calib-
ration marks on page 209.
• Updated the instruction Manually releasing the brakes on page 64.
• Size of grease nipple on telescopic shaft clarified, see Telescopic
shaft, stainless, axis 4 on page 98.
Z
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Continued

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

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

How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 19.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
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How to read the product manual

1 Safety
1.1 Safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications 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 supplies original spare parts and equipment which have been tested and
approved. The installation and/or use of non-original spare parts and equipment
can negatively affect the safety, function, performance, and structural properties
of the robot. ABB is not liable for damages caused by the use of non-original spare
parts and equipment.
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1 Safety
1.1.1 Limitation of liability

1.1.2 Requirements on personnel
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence 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.
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1 Safety
1.1.2 Requirements on personnel