Page 1 ROBOTICS Product manual IRB 360...
Page 2 Trace back information: Workspace 21A version a12 (not checked in) Published 2021-03-24 at 09:54:37 Skribenta version 5.4.005...
Page 3 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.
Page 4 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.
Page 5: Table Of Contents
Loads ....................Installation of options ..................2.5.1 Installation of safety lamp (option 213-1) ............2.5.2 Installation of (optional) customer connections IRB 360 ........2.5.3 Installation of vacuum system (option 218-9) ..........Electrical connections ..................2.6.1 Robot cabling and connection points ............
Page 6 Cable harness ....................4.5.1 Replacement of cable harness ..............4.5.2 Replacement of brake release button ............Calibration information When to calibrate ..................... Calibration method .................... Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 7 Standard toolkit ....................Special tools ....................Lifting accessories and lifting instructions .............. Grease specification ..................Spare part lists Spare part lists and illustrations ................Index Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
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Page 9: Overview Of This Manual
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.
Page 10 Overview of this manual Continued References All documents can be found via myABB Business Portal, www.abb.com/myABB. IRC5 Reference Document ID Product manual, spare parts - IRB 360 3HAC049101- Circuit diagram - IRB 360 3HAC028647- Product specification - IRB 360 3HAC029963-...
Page 11 This manual contains all safety instructions from the product manuals for the manipulators and the controllers. OmniCore Reference Document ID Product manual, spare parts - IRB 360 3HAC049101- Circuit diagram - IRB 360 3HAC028647- Product specification - IRB 360 3HAC029963-...
Page 12 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 • Added information about batteries. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 13 See Product manual, spare parts - IRB 360. • Mechanical interface of IRB 360 - 8/1130 and IRB 360 - 6/1600 updated. This revision includes the following updates: • Added information in calibration chapter, see...
Page 14 3HAC2091-1, see Different versions of bearing rings require different maintenance procedures on page 104. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 15 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. •...
Page 16: Product Documentation
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.
Page 17 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. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 18: How To Read The Product Manual
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. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 19: Safety
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.
Page 20: Requirements On Personnel
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. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 21: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 22 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 23: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 24 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 25 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 26 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 27 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 28 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 29: Robot Stopping Functions
• Product manual - OmniCore C30 • Product manual - IRC5 • Product manual - IRC5 Compact • Product manual - IRC5 Panel Mounted Controller Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 30: Installation And Commissioning
When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 31 The risk assessment should also consider other hazards arising from the application, such as, but not limited to: • Water • Compressed air • Hydraulics Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 32 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 33: Operation
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. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 35 Hazards related to batteries Under rated conditions, the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 36 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. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 37: Emergency Release Of The Robot Axes
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways. Make sure no personnel is near or beneath the robot. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 38: Brake Testing
Note For robots with the option SafeMove, the Cyclic Brake Check routine is recommended. See the manual for SafeMove in References on page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 39: Troubleshooting
The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.
Page 40: Decommissioning
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. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 41: Installation And Commissioning
Note If the IRB 360 is connected to power, always make sure that the robot is connected to protective earth and a residual current device (RCD) before starting any installation work. For more information see: •...
Page 42: Structure Manipulator
Upper arm axis 3 Axis-4 motor SMB unit Telescopic shaft axis 4 Parallel arm Movable plate Vacuum kit (optional) Medium house set (optional) Large house set (optional) Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 43: Unpacking
When these prerequisites have been met, For assemble of the robot, see section the robot may be taken to its installation site. Assembling the robot IRB 360 on page 49 Weight The following table shows the weight of the robot model.
Page 44 The following tables show the various forces and torques working on the robot during different kinds of operation. See figure below the tables. Robot version IRB 360 - 1/800, IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/1600 Force N Max. load in operation ±330 N...
Page 45 (with the robot mounted in the frame) higher than 17 Hz is used for robot versions IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600 and a frame with a lowest natural frequency higher than 40 Hz is used for robot version IRB 360 - 8/1130, IRB 360 - 6/1600.
Page 46 Wash-Down Stainless (WDS) IP69K Clean Room, Stainless Clean Room IP54 Note The stainless version is not available for the IRB 360 used with OmniCore controllers. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 47: Transport
When air transport is used, the robot must be located in a pressure-equalized area. WARNING The center of gravity for IRB 360 during transport is very high, 804-810 mm from the bottom. It might tilt and fall when carried on a forklift.
Page 48 2 Installation and commissioning 2.3.2 Transport Continued xx0700000434 Robot delivery box Securing point x3 Robot delivery note Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 49: Assembling The Robot Irb 360
2 Installation and commissioning 2.3.3 Assembling the robot IRB 360 2.3.3 Assembling the robot IRB 360 Overview Follow these steps to assemble the robot after unpacking. Assembling the robot Action Note Prepare the working site according to Amount of required space on page 57...
Page 50: Working Range And Type Of Motion
2.3.4 Working range and type of motion 2.3.4 Working range and type of motion Motion pattern xx0700000448 Axis 1 Axis 2 Axis 3 Axis 4 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 51 50 mm IRB 360 - 6/1600 305 mm 1600 mm 1200 mm 155 mm IRB 360 - 8/1130 250 mm 1130 mm 750 mm 100 mm Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 52: The Unit Is Sensitive To Esd
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 be grounded. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 53: On-Site Installation
Never walk under a suspended load! Lifting position xx0700000434 Robot package top Robot package securing point x3 Delivery note Recommended equipment Equipment Art.no. Note Fork lift Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 54 Note CAUTION The delivery package weighs 200 kg! All lifting ac- cessories used must be sized accordingly. Lift the robot package to the installation site. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 55: Lifting The Robot With Roundslings
The lifting strap dimensions must comply with the applicable standards for lifting. Lifting position xx0700000433 L= 500 mm (20 inch) Recommended equipment Equipment Art.no. Note Roundslings Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 56 Attach the roundslings to the robot base box, see figure Lifting position on page CAUTION The IRB 360 weighs 120 kg (Std) and 145 kg (WDS). All lifting accessories used must be sized accordingly. xx0700000466 Product manual - IRB 360 3HAC030005-001 Revision: Z ©...
Page 57: Amount Of Required Space
389.5 28.50 R366 IRB 360 - 1/800 1160 R251 IRB 360 - 1/1600 1412 1112 R447 IRB 360 - 6/1600 1412.5 1107.5 478.9 148.3 R515 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 58: Orienting And Securing The Robot Frame
Make sure that the robot frame is secured before mounting the robot. Illustration xx0700000469 Spirit level Chemical or mechanical expander bolts Shim Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 59 Shim drawing on page 59 Secure the robot frame to the floor. Use chemical or mechanical ex- pander bolts. Shim drawing Example of shim. xx0700000623 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 60: Orienting And Securing The Robot
Spacer, metal Washer, EPDM-rubber compressed 50%. Required equipment Equipment, etc. Spare part no. Note Standard tools Standard toolkit on page 258 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 61 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. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 62 M12x (50) The length of the screws depend on the design of the robot frame Bonded seal washer, rubber/metal, 3 pcs. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 63 Lifting the robot with roundslings on page 55 Note If use of ABB’s vacuum system is inten- ded, make sure there is a space left for the bracket (F). Fit and tighten the bolts and washers The screw joint must be able to withstand the in the base attachment holes.
Page 64: Manually Releasing The Brakes
Press and hold the brake release button (keep it pressed in). The brake will func- tion again as soon as the button is re- leased. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 65 - cable harness. Press and hold the brake release button (keep it pressed in). The brake will function again as soon as the button is released. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 66: Fitting Equipment On Robot
2.4.7 Fitting equipment on robot 2.4.7 Fitting equipment on robot Overview This section describes how to fit equipment on the IRB 360. Note All equipment and cables used on the robot, must be designed and fitted not to damage the robot and/or its parts.
Page 67 2 Installation and commissioning 2.4.7 Fitting equipment on robot Continued Mechanical interface STD - IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600 xx0700000471 Free space, depth 6 mm R1/4” Ø14 H8 depth 4 mm Key grip = width 22 mm height 5.5 mm...
Page 68 2 Installation and commissioning 2.4.7 Fitting equipment on robot Continued 3D - IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600 xx0700000709 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z...
Page 69 2 Installation and commissioning 2.4.7 Fitting equipment on robot Continued IRB 360 - 8/1130, IRB 360 - 6/1600 3x 120° 57.5 +0.2 3x 6.6 4x M6 10 xx1300000170 Required equipment Equipment Article number Note Standard tools Standard toolkit on page 258...
Page 70 If a high frequent use of linear tool move- ment is intended, use a tool with mounting flange. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 71 2 Installation and commissioning 2.4.7 Fitting equipment on robot Continued Mounting equipment to flange on movable plate with swivel IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600 xx0700000523 4 pcs Screws M4 Action Note Attach the tool to the mounting flange.
Page 72: Loads
2.4.8 Loads 2.4.8 Loads General This section describes loads from external equipment. For information about general loads and diagrams see Product specification - IRB 360. Extra equipment attached to the manipulator arms xx0700000716 Limitation lines for center of gravity for M1...
Page 73 (35 g + 65 g = 100 g) gives the correct amount of 100 g located at the same position as TCP0. This point load needs to be added to the calculation of the users tool load and declared in used tooldata. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 74: Installation Of Options
Electrical safety on page 31 • Maintenance and repair on page 34 Location xx0700000546 Warning lamp. Screw M8 of suitable length. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 75 Lead-through in cover plate for the optional safety lamp. Cover gasket 3HAC028972-001 4pcs Screw M6x20 FB7 connector for resolver signals for axis 7 (Option 864-1) Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 76 Locate the connectors R3.H1 - R3.H2 and connect the safety lamp harness to it. Mount the safety lamp. Placement is optional. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 77: Installation Of (Optional) Customer Connections Irb 360
2 Installation and commissioning 2.5.2 Installation of (optional) customer connections IRB 360 2.5.2 Installation of (optional) customer connections IRB 360 General This section describes installation of customer connections. DANGER Turn off all electrical power, hydraulic and pneumatic pressure supplies before entering the workspace of the manipulator.
Page 78 2 Installation and commissioning 2.5.2 Installation of (optional) customer connections IRB 360 Continued Location en0700000642 Connections in customer cable Wire Spec. Connection point A Connection point B Note Desig- Term Type Desig- Term Type nation nation Power R1.CP R1.CP R1.CP...
Page 79 2 Installation and commissioning 2.5.2 Installation of (optional) customer connections IRB 360 Continued Wire Spec. Connection point A Connection point B Note Desig- Term Type Desig- Term Type nation nation R1.CP R1.CP R1.CP R1.CP R1.CP R1.CP R1.CP Conductor to cut off.
Page 80 2 Installation and commissioning 2.5.2 Installation of (optional) customer connections IRB 360 Continued Wire Spec. Connection point A Connection point B Note Desig- Term Type Desig- Term Type nation nation 12.1 12 BK R1.CS 12.2 12 OG Conductor to cut off.
Page 81: Installation Of Vacuum System (Option 218-9)
2.5.3 Installation of vacuum system (option 218-9) 2.5.3 Installation of vacuum system (option 218-9) General This section describes installation of (optional) vacuum system on an IRB 360. DANGER Turn off all electrical power, hydraulic and pneumatic pressure supplies before entering the workspace of the manipulator.
Page 82 Exhaust air Vacuum In Compressed air in (max. 6 bar) Vacuum switch Air filter (compressed air side) Air filter (vacuum side) Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 83 Hexagon bolt with flange, M6 x 20 (A2 DIN6921) Gasket Action Note Follow the refitting instructions in section Replace- ment of ejector unit on page 216 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 84 Assemble the customer cable 3HAC14860-X. X = Depending on length, see section Robot cabling and connec- tion points on page 86 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 85 Use connection R1.CS on the front of the ejector unit. Cut open the XP5 connector into several open ends. Assemble the open ends to the local I/O on the controller. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 86: Electrical Connections
The cable needs to be cut off and prepared to fit the controller's connection points, as described in the product manual for the controller. Cable Art. no. Robot control cable 7 m 3HAC029903-002 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 87 3HAC14860-7 Customer control cable 7 m 3HAC14860-1 Customer control cable 15 m 3HAC14860-2 Customer control cable 22 m 3HAC14860-3 Customer control cable 30 m 3HAC14860-4 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 88: Start Of Robot In Cold Environments
If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 89: Maintenance
Note If the IRB 360 is connected to power, always make sure that the IRB 360 is connected to protective earth and a residual current device (RCD) before starting any maintenance work. For more information see: •...
Page 90: Maintenance Schedule
3.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 360: • Calendar time: specified in months regardless of whether the system is running or not.
Page 91: Regular Maintenance
136. Lubricate sealings: Recommended lubrication, see • At regular intervals section: • Mounting instructions for • When needed. bearings on page 150 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 92: Maintenance Schedule Irb
2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See Operating manual - IRC5 with FlexPendant for instructions. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 93 See section Cleaning activities on page 136. • Cleaning instructions for wash down version, see section Cleaning activities on page 136. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 94: Inspection Activities
The wear on the bearings depends on the payload, cycle, environment, and lubrication. Telescopic shaft xx0700000556 Telescopic shaft (STD) Universal joint Set screw, dog point Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 96: Telescopic Shaft, Wash Down, Axis 4
The wear on the bearings depends on the payload, cycle, environment, and lubrication. Telescopic shaft xx0700000717 Required equipment and references References Replacement of telescopic shaft on page 182 Spare parts, telescopic shaft. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 98: Telescopic Shaft, Stainless, Axis 4
Note The wear on the bearings depends on the payload, cycle, environment, and lubrication. Note The stainless version is not available for the IRB 360 used with OmniCore controllers. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z...
Page 99 Spare parts, telescopic shaft Standard tools Standard toolkit on page 258. References Spare parts, telescopic shaft Replacement of telescopic shaft on page 182 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 101: Vacuum System (Optional)
Pneumatic or hydraulic related hazards on page 32 • Electrical safety on page 31 • Maintenance and repair on page 34 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 102 Pneumatic valve unit Spare parts, ejector unit. References Replacement of ejector unit on page 216 Draining of water separation filter on page 214 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 103 Interval 4,000 h or 2 Years Action Note Replace pneumatic valves. The service life of the valves is 4x10 cycles. Described in section Replacement of ejector unit on page 216 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 104: Bar System
Never use grease on the bar system. Different versions of bearing rings require different maintenance procedures Valid for robot versions: IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600. At delivery the robot is equipped with bearing rings 3HAC028087-001. These are maintenance free.
Page 105 Check the distance between the bearing holders. Distance between bearing holders on page 106. If needed, replace damaged parts as described in the repair chapter. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 106 Replace the bearing ring, if required, according to section Replacement of bearing rings on page 175. xx1000000018 IRB 360 WDS: xx2000002385 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 107 The bearing ring is worn out and requires immediate replacement. Operating the robot beyond this value will cause permanent damage to the arm system components. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 108: Joint Balls
Check surface of joint balls for cracks or burrs. If necessary replace the part as de- scribed in Replacement of joint balls on page 187 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 109: Upper Arms
Electrical safety on page 31 • Maintenance and repair on page 34 Check upper arm xx0700000501 Upper arm tube Joint balls Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 110 172 Check surface of joint balls for cracks or burrs. If necessary replace the part as described in Replacement of joint balls on page 187 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 111: Hoses
Maintenance and repair on page 34 Check hoses xx0700000499 Air filter inlet. Ejector unit Air filter inlet vacuum. Swivel cup Hose clamp Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 112 Check the entire hose and make sure there are no If necessary, exchange the part folds or surface damage. as described in Replacement of vacuum hoses on page 211 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 113: Spring Units
The spring units must be removed according to the description in section Replacement of parallel arms on page 167or they will be damaged. Check spring units IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600 xx0700000497 Hook Spring...
Page 114 3 Maintenance 3.3.9 Spring units Continued IRB 360 - 8/1130, IRB 360 - 6/1600 xx1300000162 Hook Spring Greasing points Required equipment and references Required equipment Spare part no. Note Grease Grease specification on page 261 Standard tools Standard toolkit on page 258...
Page 115: Movable Plate
Required equipment and references Required equipment Spare part no. Note Movable plate Spare parts, movable plate. Standard tools Standard toolkit on page 258. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 116 Check axis 4 so that the rotation is If necessary replace the movable plate as de- smooth. scribed in Replacement of movable plate on page 178 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 117: Inspecting Information Labels
Before dismantling see product manual Label, FlexPicker Axis marking Required equipment Equipment Spare part number Note Labels Spare part lists on page 267. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 118 Check all labels. See the figure in Location of information labels on page 117. Replace any missing or damaged labels. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 119: Replacement/Changing Activities
Always read the specific instructions for Clean Room robots before doing any repair work, see Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 120 3 Maintenance 3.4.1 Changing the battery in the measuring system Continued Location SMB DSQC 633A xx0700000506 SMB battery Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 121 Standard toolkit on page 258 Battery retainer (strap) References Updating revolution counters on page 241 Replacement of base cover gasket on page 160 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 122 Described in section Replacement of base M6 screws. cover gasket on page 160. Update the revolution counters. Described in section Updating revolution counters on page 241. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 123: Changing The Telescopic Shaft Including Universal Joints
The wear on the bearings depends on the payload, cycle, environment, and lubrication. Telescopic shaft xx0700000556 Telescopic shaft (STD) Universal joint Set screw, dog point Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 124 182. After a collision and/or if arms have fallen off After a collision and/or if arms have fallen off on page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 125: Lubrication Activities
Business Portal, www.abb.com/myABB. Location of gearboxes The figure shows the location of the gearboxes. xx1300000177 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 126 3 Maintenance 3.5.1 Type of lubrication in gearboxes Continued xx1300000178 Axis-1 gearbox Axis-2 gearbox Axis-3 gearbox Axis-4 gearbox Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 127: Gearboxes, Axes 1- 4
Always read the specific instructions for Clean Room robots before doing any repair work, see Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 128 Spare parts, gear units axis 1- 3 Spare parts, gear units axis 4 Spare parts, gear unit axis 4 Locking liquid Loctite 243 Sealing compound 3HAC073510-001 Trans7 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 129 Types and volumes of oil are specified in the Technical refer- plug holes, with spe- ence manual - Lubrication in gearboxes - 3HAC042927-001. cified volume. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 130 M6x20 (A) holding the 3 pcs flange (B) and the 3 pcs upper arm sealing rings. xx0700000509 A Screw M6x20 B Flange Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 131 Note Remove the cables to the brake release, described in section Replacement of brake release button on page 223. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 132 - Lubrication in gearboxes - 3HAC042927-001. specified volume, check oil level by re- moving the oil level plug (B). xx0700000729 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 133 Make sure that all old sealing compound is removed. xx1100000543 Apply a 5 mm string of sealing compound on the sealing upper sur- face. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 135 182 Refit base cover. CAUTION The base cover has sharp edges, use protective gloves. Described in section Replacement of base cover gasket on page 160 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 136: Cleaning Activities
Wash down: IP67 • Wash down stainless: IP69K according to ISO 20653:2001 • Clean Room: IP54 Note The stainless version is not available for the IRB 360 used with OmniCore controllers. Cleaning overview Protection type Cleaning method Vacuum Wipe with...
Page 137 Sensitive spots for direct flushing. Note This applies for IRB 360 WD and IRB 360 WDS versions. If standard version parts is used in a WD or WDS version robot the robot must be cleaned as a standard version robot.
Page 138 3.6.1 Introduction Continued Cleaning with water and steam Instructions for rinsing with water The IRB 360 with protection types Wash down and Wash down stainless can be cleaned by rinsing with water (water cleaner). The following list defines the prerequisites: •...
Page 139: Standard Cleaning
3.6.2 Standard cleaning 3.6.2 Standard cleaning Overview The standard version of IRB 360 is not manufactured for wash down applications, and must not be cleaned with water. Note If some part of a standard version robot is stainless the robot must still be cleaned as a standard version robot.
Page 140 3.6.2 Standard cleaning Continued Optional use of rubber belows - IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600 To simplify cleaning, it is possible to use the spring units without the rubber bellows.
Page 141: Wash Down Cleaning
Rinse thoroughly with water. After cleaning bearing races, swivel cup sealing and sealing ring (V-ring), lubricate them with provision classified grease. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 142 If the labels on the robot are Described in section Replacement of labels on damaged in the cleaning proced- page 206 ure, apply new labels. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 143: Wash Down Stainless Cleaning
3 Maintenance 3.6.4 Wash down stainless cleaning 3.6.4 Wash down stainless cleaning Note The stainless version is not available for the IRB 360 used with OmniCore controllers. Required equipment Equipment Note High pressure washer Usable detergents The stainless version is verified against the following detergents.
Page 144 If the labels on the robot are Described in section Replacement of labels on damaged in the cleaning proced- page 206 ure, apply new labels. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 145: Clean Room Cleaning
Use a vacuum cleaner to re- move loose particles. Use a cloth with cleaning deter- gent or Isopropyl alcohol to wipe off the dirt and dust. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 146: Measuring Activities
Apply torque 1 Nm, i.e. 10N on a distance of 100 mm from center of rotation. xx1700000046 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 147 Apply torque 1 Nm in the other direction, i.e. 10 N on a distance of 100 mm from center of rotation. xx1700000049 Decrease force to 0N. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 148 1 and 2 di- vided by 2πr. Note r is the distance from center of rotation to where the measurement is done. xx1700000051 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 149: Repair
Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRB 360, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 150: General Procedures
Make sure the bearing is properly aligned as this will directly affect the durab- ility of the bearing. Greasing of bearings Note This instruction is not valid for solid oil bearings. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 151 Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 152: Mounting Instructions For Sealings
Do not try to grind or polish the shaft surface to get rid of the defect. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 153 Never hammer directly on the sealing as this may result in leakage. xx2000000072 A Gap Make sure that no grease is left on the robot surface. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 154 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 155: Screw Joints
4.2.3 Screw joints 4.2.3 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
Page 156 A special torque specified in the repair, maintenance or installation procedure overrides the standard torque. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 157 4 Repair 4.2.3 Screw joints Continued Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 158: Cut The Paint Or Surface On The Robot Before Replacing Parts
Use ethanol on a lint free cloth. so that it is free from oil and grease. Place the tooling pin in hot water. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 159 Clean Room. Note After all repair work, wipe the robot free from particles with spirit on a lint free cloth. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 160: Complete Robot
Pneumatic or hydraulic related hazards on page 32 • Electrical safety on page 31 • Maintenance and repair on page 34 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 161 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 162 The base cover has sharp edges, use protective gloves. Remove and discard the hollow o-ring. See article number in Product manual, spare parts - IRB 360. Remove and discard the rubber gaskets. See article number in Product manual, spare parts - IRB 360.
Page 163: Replacement Of Serial Measurement Board
Pneumatic or hydraulic related hazards on page 32 • Electrical safety on page 31 • Maintenance and repair on page 34 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 164 Do not replace the battery contact! Equipment Spare part no. Note Standard tools Standard toolkit on page 258 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 165 Refit the bracket using the three(3) flange screws. Tightening torque 4 Nm Refit the base cover. Described in section Replacement of base cover gasket on page 160 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 166 4 Repair 4.3.2 Replacement of serial measurement board Continued Action Note Update the revolution counters. Described in section Updating re- volution counters on page 241 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 167: Replacement Of Parallel Arms
Pneumatic or hydraulic related hazards on page 32 • Electrical safety on page 31 • Maintenance and repair on page 34 Location IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600 xx0700000488 Upper arm Parallel arm Spring unit Bearing ring...
Page 168 4 Repair 4.3.3 Replacement of parallel arms Continued IRB 360 - 8/1130, IRB 360 - 6/1600 xx1300000163 Upper arm Parallel arm Spring unit Bearing ring Required equipment and references Equipment Spare part no. Note Standard tools Standard toolkit on page 258...
Page 169 Never use unnecessary force when removing the springs. Only work on one side or the spring will be overstressed. xx0700000525 xx0700000555 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 170 168. Note Always mount the movable plate with the axis 4 calibration mark in direction axis 1. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 171 4 Repair 4.3.3 Replacement of parallel arms Continued Action Note Recalibrate the robot. Calibration information on page 227. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 172: Replacement Of Upper Arm
VK- cover 6x hex socket head cap screw M6 x 40 (12.9 gleitmo) and 6x plain washer 6.4x12x1.6 steel A2-F Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 173 6x plain washer 6.4x12x1.6 Steel A2-F Remove the upper arm. Note Always check the condi- tion of the sealing ring and the flange gasket Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 174 Fit a new VK-cover. By hand. Refit the parallel arm. Described in section Replacement of parallel arms on page 167. Recalibrate the robot. Calibration information on page 227. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 175: Replacement Of Bearing Rings
258. Drifter Only required for robot ver- sions: IRB 360 - 1/800, IRB Dolly 360 - 1/1130, IRB 360 - 3/1130 and IRB 360 - 1/1600. Special tools on page 259 Pliers for parallel arms Special tools on page 259...
Page 176 Never use unnecessary force when refitting the springs. Only work on one side or the spring will be overstressed. Action Note Place a new bearing ring into the joint socket. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 177 Continued Action Note Valid for robot versions: IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600. 1 Place the parallel arm in the dolly. 2 Put the drifter into the bearing ring and knock it gently down to its resting position.
Page 178: Replacement Of Movable Plate
• Electrical safety on page 31 • Maintenance and repair on page 34 Location IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600 xx0700000532 Universal joint Set screw, dog point Sealing ring (V-ring)
Page 179 4 Repair 4.3.6 Replacement of movable plate Continued IRB 360 - 8/1130, IRB 360 - 6/1600 xx1300000165 Universal joint Set screw, dog point V-ring sealing (transparent in the figure) Required equipment and references Equipment Spare part number Note Spare parts, movable plate See Product manual, spare parts - IRB 360.
Page 180 Remove the movable plate from the tele- scopic shaft. Calibration mark, axis 4 IRB 360 - 1/1130, IRB 360 - 3/1130, IRB 360 - 1/800, IRB 360 - 1/1600 xx0700000629 Axis 4 calibration mark IRB 360 - 8/1130, IRB 360 - 6/1600...
Page 181 Never use unnecessary force when refitting the springs. Only work on one side or the spring will be overstressed. Action Note For robot versions IRB 360 - 8/1130, IRB 360 - 6/1600: Check the radial seal. xx1300000202 Refit the movable plate to the telescopic shaft and Use standard tools.
Page 182: Replacement Of Telescopic Shaft
Telescopic shaft Set screw Required equipment and references Equipment Spare part no. Note Standard tools Standard toolkit on page 258 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 183 Remove the upper set screw. xx0700000612 Use a 90° angled bit holder. Remove the telescopic shaft. Refitting Action Note Refit the telescopic shaft. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 184 Replacement of movable plate on use locking liquid (Loc- page 178. tite 243). Refit the parallel arms. Described in section Replacement of parallel arms on page 167. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 185: Replacement Of Universal Joint
Standard tools Standard toolkit on page 258. Locking liquid Loctite 243 Universal joint See Product manual, spare parts - IRB 360. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 186 9.5 Nm. Tightening torque for set screw 3HAC12846-4 (M16x6 A4): • 8.5 Nm. Refit the telescopic shaft. See section Replacement of telescopic shaft on page 182. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 187: Replacement Of Joint Balls
Standard toolkit on page 258 Joint ball See Product manual, spare parts - IRB 360. Pliers for parallel arms 3HAC6194-1 Locking liquid Loctite 243 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 188 A heat gun must be used if the movable plate is stainless, for other materials it is optional. Do not aim the heat on plastic parts. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 189 167. Run the robot for six (6) hours for the bearing rings to wear in. Wipe clean the joint balls and the bearing rings. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 190: Replacement Of Gearbox Unit 1- 3
Maintenance and repair on page 34 Note This action demands standard calibration of the robot. Described in section Calibration method on page 228. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 191 See Product manual, spare parts - IRB 360. References Gearboxes, axes 1- 4 on page 127 Circuit diagram 3HAC028647-009 Calibration method on page 228 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 192 Tightening torque 33 Nm. head cap screw M10 x 30 with washer 16.5x20x2 steel A3F. Note Gearbox unit weight 16 Kg. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 193 127, Method 2. Refit the arm system. Described in section Gearboxes, axes 1- 4 on page 127, Method 2. Recalibrate the robot. Calibration information on page 227. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 194: Replacement Of Gearbox Unit 4
Maintenance and repair on page 34 Note This action demands standard calibration of the robot. Described in section Calibration method on page 228. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 195 - IRB 360. Locking liquid Loctite 243 References Replacement of telescopic shaft on page 182 Replacement of base cover gasket on page 160 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 196 Use standard tools. Described in section Replacement of base cover gasket on page 160 Calibrate the robot. Described in section Calibration information on page 227. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 197: Replacement Of Motor Axis 1-3
Maintenance and repair on page 34 Note This action demands standard calibration of the robot. Described in section Calibration method on page 228. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 198 Washer 6,4x12x1,6 steel A2F Nitrile rubber O-ring 67,5x3,0 Oil plug Oil plug (upper oil level hole) Oil plug Gear Z1/1-3, 16 cog Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 199 Oil will be running out of the motor attachment hole when removing the motor! The oil can be hot. Take any necessary measures to collect the oil. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 200 Fit a new O-ring (E) onto Shown in figure Location on page 198. the motor flange, lubricate the o-ring with grease FM222. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 201 Refit the gearbox unit 1-3 Described in section Replacement of gearbox unit 1- 3 on page 190. Recalibrate the robot. Calibration information on page 227. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 202: Replacement Of Motor Axis 4
Pneumatic or hydraulic related hazards on page 32 • Electrical safety on page 31 • Maintenance and repair on page 34 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 203 Gearbox axis 4 Rotational ac motor O-ring, nitrile rubber Hex socket head cap screw M6x25 8.8 Washer 6,4x12x1,6 A2F Oil plug Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 204 Remove the gearbox with motor. Replacement of gearbox unit 4 on page 194. Remove the oil plug, and drain the oil. xx0700000728 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 205 Described in section Replacement of gearbox unit 4 on page 194. Refit the base cover. Described in section Replacement of base cover gasket on page 160. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 206: Replacement Of Labels
4 Repair 4.3.14 Replacement of labels 4.3.14 Replacement of labels General This section describes replacement and positioning of labels on the IRB 360. Label positioning Axis 2 Axis 1 Axis 3 SECTION A-A xx0700000691 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z ©...
Page 207 Transport protection label Required equipment and references Equipment Spare part no. Note Label-set See Product manual, spare parts - IRB 360. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 208 4 Repair 4.3.14 Replacement of labels Continued Assemble Action Note Make sure the surface is clean. Assemble the labels according to the illustrations. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 209: Replacing Of Calibration Marks
4.3.15 Replacing of calibration marks 4.3.15 Replacing of calibration marks Overview This section describes replacement of calibration marks on an IRB 360. Replace a calibration mark if it is damaged. DANGER Turn off all electrical power, hydraulic and pneumatic pressure supplies before entering the workspace of the manipulator.
Page 210 Remove the two M5 nuts. Use standard tools. Remove the calibration mark. Refitting Action Note Refit a new calibration mark. Refit the two M5 nuts. Tightening torque 4Nm. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 211: Vacuum System
Always read the specific instructions for Clean Room robots before doing any repair work, see Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 212 Pull the hose out from the swivel. Pull the hose out from the air filter. Refitting Action Note Fit a new hose on the swivel. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 213 Fit a new hose on the swivel. Fix the hose, do not tighten, against the three clamps on the parallel arm. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 214: Draining Of Water Separation Filter
Cut the paint or surface on the robot before replacing parts on page 158. Location xx0700000544 Air filter (comp) Air filter (Vac) Water separation bottom nipple Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 215 4 Repair 4.4.2 Draining of water separation filter Continued Removal water Action Drain the water separation filter, opening the bottom nipple (C). Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 216: Replacement Of Ejector Unit
Always read the specific instructions for Clean Room robots before doing any repair work, see Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 217 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 218 Remove all the nuts for the air nozzles, pressure guard cap and the pressure guard nut. Remove the ejector unit inwards direction. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 219 Reconnect the air supply, vacuum hoses and signal cable from the ejector unit. Refit the base cover. Replacement of base cover gas- ket on page 160 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 220: Cable Harness
Always read the specific instructions for Clean Room robots before doing any repair work, see Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 221 R3.FB4 X1(SMB) X2(SMB) - R3.FB1-4 Required equipment and references Equipment Spare part no. Note Standard tools Standard toolkit on page 258. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 222 - IRB 360, 3HAC028647-009. Strap all cable connections to there connector brackets. Refit the base cover. Described in section Replacement of base cover gasket on page 160. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 223: Replacement Of Brake Release Button
4.5.2 Replacement of brake release button 4.5.2 Replacement of brake release button Introduction This section describes replacement of brake release button on the IRB 360. DANGER Turn off all electrical power, hydraulic and pneumatic pressure supplies before entering the workspace of the manipulator.
Page 224 Always cut the paint with a knife and grind the paint edge when disassembling parts. See Cut the paint or surface on the robot before replacing parts on page 158. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 225 Remove the contact from the push button, pushing in the locking device. Use a screw driver to push in the locking device. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 226 Refit the cables to the contact before this step. Refit the base cover. Replacement of base cover gasket on page 160 CAUTION The base cover has sharp edges, use protective gloves. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 227: Calibration Information
The resolver values are changed If resolver values are changed, the robot must be re-calibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual. The resolver values will change when parts affecting the calibration position are replaced on the robot, for example motors or parts of the transmission.
Page 228: Calibration Method
Arm in Technical reference manu- al - System parameters. Calibration methods The calibration method for the IRB 360 is different from other robots, and normal calibration methods are not applicable. Calibration by hand Standard calibration is detailed in section Calibrating axis 1-3 on page 232.
Page 229 Ring calibration A factory reset using ring calibration requires specific calibration equipment and is performed by ABB. Please contact ABB. Ring calibration is measuring each contact point for axis 1-3 and modifies cal_position. The Ring calibration method gives a better nominal kinematics and the modified cal_positions will help to get back to the same points when calibrating with Standard calibration.
Page 230: Calibration Movement Directions For All Axes
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. xx0700000448 Axis 1 Axis 2 Axis 3 Axis 4 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 231: Synchronization Marks And Synchronization Position For Axes
This section shows the position of the synchronization marks and the synchronization position for each axis. Synchronization marks, IRB 360 xx0700000569 Calibration mark axis 4 Calibration marks axis 1-3 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 232: Calibrating Axis 1-3
5.5 Calibrating axis 1-3 General This section is valid for IRB 360 all models. It describes how to perform the actual fine calibration of axis 1-3. If the robot needs to have a factory reset instead, please contact ABB. See Calibration method on page 228.
Page 233 Press the brake release button to re- lease the brakes. xx0700000435 A Brake release button Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 234 On the FlexPendant, press Manual to switch to manual mode. On the FlexPendant, press Motor Off to set the robot as motor off status. xx2000002535 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 235 Release the brakes and gently pull the calibrated upper arm in to a horizontal position. Return to step 4, and proceed with axis 2 and 3. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 236: Calibrating Axis 4
5.6 Calibrating axis 4 5.6 Calibrating axis 4 General This section is valid for IRB 360 all models. It describes how to perform the actual fine calibration of axis 4. The calibration positions are shown in Checking the synchronization position on...
Page 237 5 Calibration information 5.6 Calibrating axis 4 Continued IRB 360 - 8/1130, IRB 360 - 6/1600 Calibrating axis 4 Action Note In manual mode, tap Jogging/Jog in the ABB menu. Tap Motion mode to choose group of axes to jog.
Page 238: Fine Calibration Procedure On Flexpendant
Tapping Calibrate results in briefly displaying a dialog box, announcing that the calib- ration process has started. The axis is calibrated and the system returns to the list of available mechanical units. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 239 • Tap Yes to proceed. • Tap No to cancel. Select the check-box for the current axis/axes to be calibrated. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 240 The axis is calibrated and the system returns to the list of available mechanical units. Tap OK. The fine calibration process is complete. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 241: Updating Revolution Counters
When connecting to IRC5 controller Use this procedure to update the revolution counter with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 242 All mechanical units connected to the system are shown with their calibration status. Tap the mechanical unit in question. xx1500000943 A screen is displayed, tap Rev. Counters. en0400000771 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 243 The calibration options are displayed. Tap Revolution Counters. In the Selection column select the axes for which revolution counters need to be up- dated. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 244 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 245. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 245: Checking The Synchronization Position
In manual mode, tap Jog- Manual mode described in the section Calibrating axis 1-3 ging/Jog in the ABB on page 232. menu. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 246 Tap to select the axis to jog, axis 1, 2, or 3. Press the brake release button to release the brakes. xx0700000435 A Brake release button Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 247 Note Always check one axis at a time, starting with axis xx0700000626 A Calibration device Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 248 Calibration Position. xx0700000628 xx2000002536 The parameter Calibration Position (cal_position) is set at the ABB factory, and is a robot specific parameter. For more information about parameter Calibration Position, see topic Motion, type Arm in Technical reference manual - System parameters.
Page 249: Decommissioning
These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 250: Environmental Information
Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 251 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. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 252: Scrapping Of Robot
• 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 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 253: Reference Information
7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 254: Applicable Standards
– Immunity standard for industrial environments IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards – Emission standard for industrial environments (option 129-1) Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 255 Degrees of protection provided by enclosures (IP code) Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots. Only robots with protection Clean Room. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 256: Unit Conversion
1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 257: Weight Specifications
All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.
Page 258: Standard Toolkit
Socket head cap 3, 5, 8 mm Torque wrench 4-33 Nm Small screwdriver Plastic mallet Ratchet head for torque wrench 1/2 Cut-off pliers 90° angled bit holder Spirit level Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 259: Special Tools
(Required if the moveable plate is stainless, see Removal on page 188.) Note The stainless version is not available for the IRB 360 used with OmniCore controllers. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 260: Lifting Accessories And Lifting Instructions
This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 261: Grease Specification
Pos. For: Type Spare part number Amount Telescopic shaft Food accepted FM 222 3HAC042560-001 Spring units Food accepted FM 222 3HAC042560-001 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 262 Continued Grease on sealings xx0700000706 Pos. For: Type Spare part num- Amount O-rings in gear units Food accepted FM 222 3HAC042560-001 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 263 7 Reference information 7.8 Grease specification Continued xx0800000003 Pos. For: Type Spare part num- Amount Grease in swivel Food accepted FM 222 3HAC042560-001 Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 264 Only lubricate bearing rings 3HAC2091-1. Bearing rings 3HAC028087-001 must not be lubricated! Read about the difference in Different versions of bearing rings require different maintenance procedures on page 104. Continues on next page Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 265 • FM 222 (was Mobilgrease FM 102 or Optimol Obeen UF 2) Different versions of bearing rings require different mainten- ance procedures on page 104. Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
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Page 267: Spare Part Lists
Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.abb.com/myABB. All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manual - IRB 360 3HAC030005-001 Revision: Z...
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Page 269 30 Fitting equipment, 66 personnel FlexPendant requirements, 20 updating revolution counters, 241 plastic disposal, 250 positive directions, axes, 230 gearboxes PPE, 20 location of, 125 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 270 231 screw joints, 155 washing, 136 secured robot frame, 58 Secure the robot, 60 signals zero position safety, 21 checking, 245 SMB, 119 Product manual - IRB 360 3HAC030005-001 Revision: Z © Copyright 2008-2021 ABB. All rights reserved.
Page 272 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2008-2021 ABB. All rights reserved. Specifications subject to change without notice.

ABB IRB 360 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration Information

6 Decommissioning

7 Reference Information

8 Spare Part Lists

Quick Links

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Summary of Contents for ABB IRB 360

Table of Contents