ABB IRB 390 User manual

ROBOTICS
Product manual
IRB 390

Trace back information:
Workspace 21A version a11
Checked in 2021-03-19
Skribenta version 5.4.005

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.

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 2020 - 2021 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
11Product documentation ....................................................................................................................
13How to read the product manual ......................................................................................................
151 Safety
151.1 Safety information .............................................................................................
151.1.1 Limitation of liability .................................................................................
161.1.2 Requirements on personnel ......................................................................
171.2 Safety signals and symbols .................................................................................
171.2.1 Safety signals in the manual ......................................................................
191.2.2 Safety symbols on manipulator labels .........................................................
251.3 Robot stopping functions ....................................................................................
261.4 Installation and commissioning ............................................................................
291.5 Operation ........................................................................................................
291.5.1 Unexpected movement of robot arm ...........................................................
301.6 Maintenance and repair ......................................................................................
301.6.1 Maintenance and repair ............................................................................
331.6.2 Brake testing ..........................................................................................
341.7 Troubleshooting ................................................................................................
351.8 Decommissioning ..............................................................................................
372 Technical data
372.1 Technical data ..................................................................................................
402.2 Working range .................................................................................................
422.3 The unit is sensitive to ESD .................................................................................
432.4 Robot specific labels (rating label, calibration label and UL label) ...............................
453 Installation and commissioning
453.1 Introduction to installation and commissioning .......................................................
463.2 Unpacking .......................................................................................................
463.2.1 Pre-installation procedure .........................................................................
473.3 On-site installation ............................................................................................
473.3.1 Transport ...............................................................................................
483.3.2 Brief installation procedure .......................................................................
493.3.3 Minimum required free space above the robot ..............................................
503.3.4 Securing the robot frame .........................................................................
523.3.5 Orienting, assembling and securing the manipulator ......................................
673.3.6 First test run may cause injury or damage ....................................................
683.3.7 Manually releasing the brakes ...................................................................
713.3.8 Loads fitted to the robot, stopping time and braking distances .........................
723.3.9 Signal lamp (option) .................................................................................
733.3.10 Fitting equipment on the robot (robot dimensions) .........................................
803.4 Electrical connections ........................................................................................
803.4.1 Robot cabling and connection points ..........................................................
834 Maintenance
834.1 Introduction ......................................................................................................
844.2 Maintenance schedule and expected component life ...............................................
844.2.1 Specification of maintenance intervals ........................................................
854.2.2 Maintenance schedule .............................................................................
874.2.3 Expected component life .........................................................................
884.3 Inspection activities ...........................................................................................
884.3.1 Inspecting the telescopic shafts .................................................................
904.3.2 Inspecting the information labels ...............................................................
924.3.3 Inspecting the lower arms ........................................................................
Product manual - IRB 390 5
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© Copyright 2020 - 2021 ABB. All rights reserved.
Table of contents

944.4 Replacement/changing activities ..........................................................................
944.4.1 Type of lubrication in gearboxes ................................................................
964.4.2 Changing oil, axis-1, axis-2 and axis-3 gearbox .............................................
1014.4.3 Changing oil, axis-4 and axis-5 gear unit ......................................................
1074.4.4 Changing oil, axis-4 and axis-5 gear unit pre-stage ........................................
1104.4.5 Changing the SMB battery ........................................................................
1144.5 Lubrication activities ..........................................................................................
1144.5.1 Lubricating the telescopic shafts ................................................................
1164.6 Cleaning activities .............................................................................................
1164.6.1 Cleaning the IRB 390 ...............................................................................
1195 Repair
1195.1 Introduction ......................................................................................................
1205.2 Definition of spare part levels ..............................................................................
1215.3 General procedures ...........................................................................................
1215.3.1 Performing a leak-down test ......................................................................
1225.3.2 Mounting instructions for sealings ..............................................................
1255.3.3 Screw joints ..........................................................................................
1265.4 Base ...............................................................................................................
1265.4.1 Replacing the base unit ............................................................................
1475.4.2 Replacing the cassette sealing ..................................................................
1615.4.3 Replacing the SMB unit ............................................................................
1685.4.4 Replacing the cable harness .....................................................................
1895.4.5 Replacing the brake release unit ................................................................
1975.5 Upper and lower arms ........................................................................................
1975.5.1 Replacing the lower arm ...........................................................................
2045.5.2 Replacing the upper arm ..........................................................................
2125.5.3 Replacing the telescopic shafts and universal joints ......................................
2225.5.4 Replacing the delta unit ............................................................................
2315.5.5 Replacing the tilt arm ...............................................................................
2365.6 Motors and gears ..............................................................................................
2365.6.1 Replacing the axis-1, axis 2 and axis-3 motor ...............................................
2475.6.2 Replacing the axis-4 motor ........................................................................
2565.6.3 Replacing the axis-5 motor ........................................................................
2655.6.4 Replacing the axis-4 gear unit pre-stage ......................................................
2815.6.5 Replacing the axis-5 gear unit pre-stage ......................................................
2976 Calibration
2976.1 Introduction to calibration ...................................................................................
2976.1.1 Introduction and calibration terminology ......................................................
2986.1.2 Calibration methods .................................................................................
2996.1.3 When to calibrate ...................................................................................
3006.2 Synchronization marks and axis movement directions .............................................
3006.2.1 Synchronization marks and synchronization position for axes .........................
3016.2.2 Calibration movement directions for all axes ................................................
3026.3 Updating revolution counters ...............................................................................
3056.4 Calibrating with Axis Calibration method ...............................................................
3056.4.1 Description of Axis Calibration ..................................................................
3086.4.2 Calibration tools for Axis Calibration ...........................................................
3106.4.3 Installation locations for the calibration tools ...............................................
3126.4.4 Axis Calibration - Running the calibration procedure ......................................
3176.4.5 Reference calibration ...............................................................................
3196.5 Verifying the calibration ......................................................................................
3206.6 Checking the synchronization position ..................................................................
3217 Troubleshooting
3217.1 Introduction to troubleshooting ............................................................................
3237.2 Oil and grease stains on motors and gearboxes ......................................................
6 Product manual - IRB 390
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© Copyright 2020 - 2021 ABB. All rights reserved.
Table of contents

3247.3 Mechanical noise or dissonance ..........................................................................
3267.4 Manipulator collapses on power down ...................................................................
3278 Decommissioning
3278.1 Environmental information ..................................................................................
3298.2 Scrapping of robot .............................................................................................
3319 Reference information
3319.1 Introduction ......................................................................................................
3329.2 Applicable standards .........................................................................................
3349.3 Unit conversion .................................................................................................
3359.4 Weight specifications .........................................................................................
3369.5 Standard toolkit ................................................................................................
3379.6 Special tools ....................................................................................................
3409.7 Lifting accessories and lifting instructions ..............................................................
341Index
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© Copyright 2020 - 2021 ABB. All rights reserved.
Table of contents

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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope
The manual covers covers all variants and designs of the 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 IDDocument name
3HAC066567-001Product manual, spare parts - IRB 390
3HAC066568-001Product specification - IRB 390
3HAC047136-001Product manual - IRC5
3HAC050948-001Technical reference manual - System parameters
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC060545-009Circuit diagram - IRB 390
3HAC043118-001Material/product safety data sheet - Battery pack
3HAC048645-001Product specification - Robot stopping distances according to ISO
10218-1
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Product manual - IRB 390 9
3HAC066566-001 Revision: B
© Copyright 2020 - 2021 ABB. All rights reserved.
Overview of this manual

Revisions
DescriptionRevision
First edition.A
Published in release 21A. The following updates are made in this revision:
• Updated article number on press tool, cassette sealing.
• Updated article 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