Page 1 ROBOTICS Product manual IRB 390...
Page 2 Trace back information: Workspace 21A version a11 Checked in 2021-03-19 Skribenta version 5.4.005...
Page 3 Product manual IRB 390 - 15/1300 IRB 390 - 10/1300 IRC5 Document ID: 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved. Specifications subject to change without notice.
Page 4 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
Expected component life ................. Inspection activities ................... 4.3.1 Inspecting the telescopic shafts ..............4.3.2 Inspecting the information labels ............... 4.3.3 Inspecting the lower arms ................ Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 6 Verifying the calibration ..................Checking the synchronization position ..............Troubleshooting Introduction to troubleshooting ................Oil and grease stains on motors and gearboxes ............Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 7 Introduction ...................... Applicable standards ..................Unit conversion ....................Weight specifications ..................Standard toolkit ....................Special tools ....................Lifting accessories and lifting instructions .............. Index Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
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Page 9: Overview Of This Manual
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.
Page 10 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. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 11: 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 12 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
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Page 15: 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 16: 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 17: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 18 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 19: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 20 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 21 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 22 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 23 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 24 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 25: Robot Stopping Functions
The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - IRC5 Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 26: 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 27 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 28 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 29: Operation
A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 31 Operating conditions, robot on page See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 32 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 33: 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 34: 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 35: Decommissioning
A robot may perform unexpected limited movement. WARNING Manipulator movements can cause serious injuries on users and may damage equipment. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
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Page 37: Technical Data
These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time! Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 38 The table shows the allowed storage conditions for the robot: Parameter Value Minimum ambient temperature -25°C Maximum ambient temperature 55°C Maximum ambient temperature (less than 24 hrs) 70°C Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 39 The table shows the available protection types of the robot, with the corresponding protection class. Protection type Protection class Manipulator, protection type Standard IP67 Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 40: Working Range
Measurement a Measurement b Measurement c Measurement d Measurement e 1,463 mm 1,274 mm 1,063 mm 475 mm 650 mm Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 41 +90° xx1900001422 Dimensions Measurement a Measurement b Measurement c Measurement d Measurement e 1,518 mm 1,329 mm 1,118 mm 380 mm 650 mm Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 42: 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 43: Robot Specific Labels (Rating Label, Calibration Label And Ul Label)
These labels can be installed on the robot or stored elsewhere. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
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Page 45: Installation And Commissioning
Note If the IRB 390 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 46: Unpacking
It also contains information useful during later re-installation of the robot. Prerequisites for installation personnel Installation personnel working with an ABB product must: • Be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work. • conform to all national and local codes.
Page 47: On-Site Installation
If the manipulator needs to be transported after it has been installed to the robot frame, it should be disassembled prior. Remove the delta unit, the lower arms and telescopic shaft from the base unit. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 48: Brief Installation Procedure
Introduction This procedure is a brief guide when installing the robot for the first time. Also see Pre-installation procedure on page First installation Use these procedures to install the IRB 390. Action Note Transport the manipulator to its intended location.
Page 49: Minimum Required Free Space Above The Robot
If a platform is not possible the service personnel need to be able to stand beside the robot according to the figure. xx2000000671 Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 50: Securing The Robot Frame
Illustration of leveling the ro- bot frame on page Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 51 See Requirements, foundation on page xx2000000601 Spirit level Fastening bolts that withstand requirements for current foundation Shim Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 52: Orienting, Assembling And Securing The Manipulator
3 Installation and commissioning 3.3.5 Orienting, assembling and securing the manipulator 3.3.5 Orienting, assembling and securing the manipulator Overview of the assembly order The IRB 390 is delivered in sub-assemblies which are assembled in the following order: Assembly order Illustration Install the base unit.
Page 53 Used with an interchangeable head torque wrench (not included in delivery). Interface: 14x18 mm. Interchangeable head torque wrench Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 54 Standard toolkit on page 336. Required consumables Consumable Article number Note Anti-seize paste 3HAC070875-002 Molykote P1900 Cleaning agent Isopropanol Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 55 Use shims if necessary. See specification in Requirements, foundation on page Assembling and installing The IRB 390 is delivered in sub-assemblies. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 56 Make sure the roundslings do not rub against any sharp edges. WARNING Personnel must not, under any circumstances, be present under the suspended load. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 57 Attachment bolts: M16 stainless steel. Minimum length of thread engagement: 24 mm, Minimum quality: A4-80 (3 pcs) Washers: 17x15x3 stainless steel (3HAC060866-005). Tightening torque: 250 Nm. xx2000000469 xx2000000470 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 58 Synchronization marks and synchronization position for axes on page 300. xx2000000676 Disconnect the 24V supply from the R1.MP con- nector. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 59 Make sure the sealing washer is in place. Note The lower arm can be turned either way, the ori- entation has no significance. xx1900001796 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 60 Anti-seize paste: 3HAC070875-002 (Molykote P1900) Note The surface under the thread head must be dry and not contain grease. xx2000000684 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 61 Fit all lower arms to the delta unit. Sealing washer: 3HAC062123-001. Make sure the sealing washers are in place. xx2000001063 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 62 The telescopic shaft must be oriented correctly, otherwise it is damaged. Always fit the narrow shaft part up against the base unit. xx2000001109 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 63 CAUTION There is a risk of damage to the joint if not handled with care. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 64 CAUTION Hold the telescopic unit carefully, the tube may slide and get damaged. xx2000001111 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 65 CAUTION There is a risk of damage to the joint if not handled with care. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 66 3 Installation and commissioning 3.3.5 Orienting, assembling and securing the manipulator Continued Calibration Action Note Update the revolution counters. Updating revolution counters on page 302. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 67: First Test Run May Cause Injury Or Damage
Collision risks CAUTION When programming the movements of the robot, always identify potential collision risks before the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 68: Manually Releasing The Brakes
Make sure no personnel is near or beneath the ro- bot. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 69 Do not interchange the 24V and 0V pins. If they are mixed up, damage can be caused to internal electrical components. (12) xx2000000686 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 70 3 Installation and commissioning 3.3.7 Manually releasing the brakes Continued Action Note Use the brake releasing button as described in Releasing the brakes on page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 71: Loads Fitted To The Robot, Stopping Time And Braking Distances
The performance of the motor brake depends on if there are any loads attached to the robot. See Product specification - Robot stopping distances according to ISO 10218-1. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 72: Signal Lamp (Option)
The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 73: Fitting Equipment On The Robot (Robot Dimensions)
The view A-A is shown in Attachment holes for extra loads on the delta unit on page IRB 390 - 15/1300 1463 xx2000001845 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 74 1615 xx2000001839 The view A-A is shown in Attachment holes for extra loads on the delta unit on page Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 75 8 H8 6 H8 6x M8 8x M8 40 H8 56 H8 100 h8 IRB 390-10/1300 IRB 390-15/1300 xx2000002064 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 76 Allowed center of gravity for extra loads on upper arms. Allowed center of gravity for extra loads on lower arms. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 77 There is a set of two M6 holes on top of each upper arm, that can be used for attaching equipment. Maximum extra load: 0.5 kg/upper arm. VIEW D xx2000001847 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 78 Do not use metal directly on the lower arms. Maximum extra load: 0.15 kg/lower arm. xx2000001849 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 79 Maximum extra load on the delta unit: 0.5 kg. 3x M6 xx2000001848 Fastener quality Use suitable screws and tightening torque for your application. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 80: Electrical Connections
Power cable 7 m 3HAC040503-001 Power cable 15 m 3HAC040503-002 Power cable 22 m 3HAC040503-003 Power cable 30 m 3HAC040503-004 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 81 There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices. xx2000001106 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 82 An extra O-ring is delivered together with the robot and must be fitted to the robot during installation. Equipment Article number Note O-ring, nitrile rubber 3HAB3772-19 54.5x3 Used to seal between the main power cable and connector. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 83: Maintenance
Note If the IRB 390 is connected to power, always make sure that the IRB 390 is connected to protective earth and a residual current device (RCD) before starting any maintenance work. For more information see: •...
Page 84: Maintenance Schedule And Expected Component Life
4.2.1 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 390: • Calendar time: specified in months regardless of whether the system is running or not.
Page 85: Maintenance Schedule
Inspecting the oil level in oil change or a maintenance gearboxes or repair activity where draining and filling oil is required. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 86 Operating hours counted by the DTC = Duty Time Counter The battery is to be replaced at given maintenance interval or at battery low alert. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 87: Expected Component Life
Expected component life Component Expected life Note Gearboxes 40,000 hours Universal joints 10,000 hours Telescopic shaft 10,000 hours Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 88: Inspection Activities
• hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 89 Check the universal joints for any damage or Replacing the universal joint cracks. on page 215. If damage or cracks are detected, replace the complete joint. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 90: Inspecting The Information Labels
Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. The figures show the location of the information labels to be inspected. The symbols...
Page 91 Replace any missing or damaged labels. Article numbers for the labels and plate set is specified in Inspecting the information labels on page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 92: Inspecting The Lower Arms
Included in robot delivery. sert xx1900002148 Used with an interchangeable head torque wrench (not included in delivery). Interface: 14x18 mm. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 93 Check the lower arms for any damage or cracks. Replacing the lower arm on page 197. If damage or cracks are detected, replace the lower arm. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 94: Replacement/Changing Activities
Business Portal, www.abb.com/myABB. Location of gearboxes The figure shows the location of the gearboxes. xx1900000303 Axis-1 gear Axis-2 gear Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 95 4 Maintenance 4.4.1 Type of lubrication in gearboxes Continued Axis-3 gear Axis-4 gear prestage Axis-4 gear Axis-5 gear prestage Axis-5 gear Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 96: Changing Oil, Axis-1, Axis-2 And Axis-3 Gearbox
Type of lubric- ation in gearboxes on page Standard toolkit Content is defined in section Standard toolkit on page 336. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 97 The gearbox can contain an excess of pressure that can be hazardous. Open the oil plug carefully in order to let the excess pressure out. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 98 Used oil is hazardous material and must be dis- posed of in a safe way. See Decommissioning on page 327 for more information. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 99 Tighten the ventilation plug. Tightening torque: 10 Nm xx1900000309 Refit the caps and sealing rings. xx2000001591 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 100 4.4.2 Changing oil, axis-1, axis-2 and axis-3 gearbox Continued Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 101: Changing Oil, Axis-4 And Axis-5 Gear Unit
Type of lubric- ation in gearboxes on page Standard toolkit Content is defined in section Standard toolkit on page 336. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 102 Draining the gear Action Note Robot axis position has no significance. Choose a position convenient for service. Valid for IRB 390 - 10/1300 (5-axis robot): Turn the tilt arm to the opposite side of the oil plug. xx1900000315 DANGER Turn off all: •...
Page 103 Open the oil plugs on the gear unit. IRB 390 - 15/1300 (4-axis robot): xx2000001632 IRB 390 - 10/1300 (5-axis robot): xx2000001633 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 104 Fill with oil at the top oil plug hole until oil starts to drip out through the axis-4 and axis-5 holes. xx2000000268 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 105 Tighten the ventilation plug. Tightening torque: 10 Nm. Make sure the gasket is undamaged. xx1900000314 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 106 Make sure the gasket is undamaged. xx2000001631 IRB 390 - 10/1300 (5-axis robot): xx1900000313 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 107: Changing Oil, Axis-4 And Axis-5 Gear Unit Pre-Stage
3 Change the oil. 4 Refit the motor. 5 Refit the axis-4 and axis-5 motor and gear units to the base unit. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 108 Note Technical reference manual - Lub- 3HAC042927-001 Available for registered users on rication in gearboxes myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 109 Refit the gear unit pre-stage to the base unit ac- cording to: • Replacing the axis-4 gear unit pre-stage on page 265 • Replacing the axis-5 gear unit pre-stage on page 281 Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 110: Changing The Smb Battery
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B ©...
Page 111 Clean cover from metal residues before opening. Metal residues can cause shortage on the boards which can result in hazardous failures. xx1900000407 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 112 Battery cable connector R2.G. xx1900000408 Remove the SMB battery. Battery includes protection circuits. Only replace with a specified spare part or with an ABB-ap- proved equivalent. Refitting the battery Use this procedure to refit the SMB battery. Refitting the SMB battery...
Page 113 Anti-seize paste: 3HAC070875-002 (Molykote P1900) xx1900000407 DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 114: Lubrication Activities
Required tools and equipment Equipment Article number Note Standard toolkit Content is defined in section Standard toolkit on page 336. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 116: Cleaning Activities
4.6.1 Cleaning the IRB 390 General To secure high uptime it is important that the IRB 390 is cleaned regularly. The frequency of cleaning depends on the environment in which the manipulator works. Different cleaning methods are allowed depending on the type of protection of the IRB 390.
Page 117 Remove waste material, such as sand, dust and chips, if it prevents cable movement. • Clean the cables if they have a crusty surface, for example from dry release agents. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
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Page 119: 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 390, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 120: Definition Of Spare Part Levels
5.2 Definition of spare part levels 5.2 Definition of spare part levels Spare part level ABB spare parts are categorized into two levels, L1 and L2. Always check the part level before conducting a service work on a spare part. •...
Page 121: General Procedures
Spray any suspected leak areas with the leak detec- tion spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 123 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 124 Tighten the screws evenly while assembling. Check that the o-ring is not squashed outside the o-ring groove. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 125: Screw Joints
5.3.3 Screw joints 5.3.3 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 126: Base
6 Refit the new base unit to the robot frame. 7 Refit the upper arms. 8 Refit the lower arms and delta unit. 9 Refit the telescopic shaft/shafts. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 127 5.4.1 Replacing the base unit Continued Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 128 Hole interface: 1/4" square. Overhead crane Lifting eye 3HAC16131-1 3 pcs Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 129 Removing the telescopic shaft/shafts including the universal joints Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 130 Choose an appropriate material for the pin, that does not damage the surface of the joints. xx2000000688 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 131 Removing the lower arms and the delta unit Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 132 Removing the upper arms Action Note Remove the upper arm cover. Note Keep the sealing for refitting. xx1900001799 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 133 The weight of the base unit is 125 kg All lifting accessories used must be sized accord- ingly. Fasten three lifting eyes. xx1900000210 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 134 See detailed replacement procedures: • Replacing the SMB unit on page 161. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 135 Make sure the roundslings do not rub against any sharp edges. WARNING Personnel must not, under any circumstances, be present under the suspended load. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 136 Attachment bolts: M16 stainless steel. Minimum length of thread engagement: 24 mm, Minimum quality: A4-80 (3 pcs) Washers: 17x15x3 stainless steel (3HAC060866-005). Tightening torque: 250 Nm. xx2000000469 xx2000000470 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 137 Lubricate the thread of the upper arm cover and Anti-seize paste: 3HAC070875-002 the gasket with grease. (Molykote P1900) Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 138 Anti-seize paste: 3HAC070875-002 (Molykote P1900) Note The surface under the thread head must be dry and not contain grease. xx2000000684 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 139 Action Note Fit sealing washers to the lower arms. Sealing washer: 3HAC062123-001. Replace the sealing washers if damaged. xx2000000861 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 141 Cleaning agent: Isopropanol. contact surfaces with isopropanol. Inspect for Friction shim: 3HAC060200-001. damage. Sealing ring: 3HAC060263-001 Replace if damaged. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 142 The telescopic shaft must be oriented correctly, otherwise it is damaged. Always fit the narrow shaft part up against the base unit. xx2000001109 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 143 CAUTION There is a risk of damage to the joint if not handled with care. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 144 CAUTION Hold the telescopic unit carefully, the tube may slide and get damaged. xx2000001111 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 145 CAUTION There is a risk of damage to the joint if not handled with care. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 146 Reconnect all cabling to the robot. Calibrate the robot. Calibration on page 297. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 147: Replacing The Cassette Sealing
The cassette sealing is located as shown in the figure. xx2000000110 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 148 Following parts are affected during the replacement procedure. Replace if damaged or lost. Spare part Article number Note O-ring 3HAB3772-110 Replace if damaged. Cassette sealing holder 3HAC067484-001 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 149 Loosening the lower arm shafts Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 150 Torque wrench head, open-end in- the open-end head insert. sert: 3HAC073854-001 xx1900002152 Disconnect the lower arms from the upper arm. xx1900001802 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 151 Remove the screws and washers. xx1900001800 Remove the upper arm from the base unit. Note Keep the sealing ring for refitting. xx1900001820 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 152 (B) are accessible (visible when looking through the attachment screw holes). xx2000000290 A Attachment screw holes B Press out holes xx2000000113 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 153 Be careful not to damage the outer and inner surface of the sealing holder, highlighted in the figure. xx2000001112 xx2000000291 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 154 Lubricate and fit the o-ring to the cassette sealing O-ring: 3HAB3772-110. holder. Anti-seize paste: 3HAC070875-002 Replace if damaged. (Molykote P1900) xx2000000928 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 155 Replace if damaged. Grease: 3HAC042536-001 (Shell Gadus S2) xx2000000930 Tighten the screws and washers. Tightening torque: 10 Nm. xx2000000112 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 156 Lubricate the outer and inner diameter of the Assembly lubricant: 3HAC074427- cassette sealing sparingly with assembly lubric- 001 (P-80 THIX IFC) ant. xx2000001827 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 157 Refitting the upper arm Action Note Clean and fit the sealing ring. Sealing ring: 3HAC062067-001. Replace if damaged. xx1900001821 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 158 Refit the upper arm cover including the gasket. Tightening torque: approximately 45 Nm. Tighten until the cover bottoms on the upper arm. xx1900001799 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 159 Lower arm / parallel bar: washers to the upper arm. 3HAC060138-001. Make sure the sealing washers are in place. xx1900001802 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 160 Action Note Calibrate the robot. Calibration on page 297. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 161: Replacing The Smb Unit
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 162 • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 163 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 164 R2.G connector to release the lock while pulling the connect- or upwards. xx1900000754 xx1700000993 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 165 Connect the connectors: • R2.FB1-4, R2.FB5 (IRB 390 - 10/1300) • Battery cable connector R2.G. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 166 15 pcs) Anti-seize paste: Molykote P1900 (3HAC070875-002) Tightening torque: 21 Nm. xx1900000469 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 167 Update the revolution counters. Updating revolution counters on page 302. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 168: Replacing The Cable Harness
4 Remove the axis-4 and axis-5 motor and gear units. 5 Replace the cable harness. 6 Refit the removed parts in reversed order. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 169 5.4.4 Replacing the cable harness Continued Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 170 • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 171 5 Repair 5.4.4 Replacing the cable harness Continued Loosening the telescopic shaft/shafts For IRB 390 - 10/1300 (5-axis robot): loosen both shafts. Action Note Remove the upper screws and washers of the Torque wrench head, closed end: telescopic shaft, using a special torque wrench 3HAC063379-001.
Page 172 Remove the cover by removing the screws and washers. Also remove the sealing. xx1900000469 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 173 Disconnect the motor connectors. Loosen the bracket from the motor. xx2000002199 Pull out the bracket and cut the remaining cable ties. xx2000002200 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 174 Cut the cable tie located at the battery. Remove the screws that secure the SMB unit Screws (3 pcs) bracket. xx1900000753 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 175 Cut cable ties, snap loose all motor connectors and disconnect them. Remove the gear unit attachment screws and washers. xx1900001843 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 176 Snap loose the connectors from the connector bracket and disconnect the motor connectors. xx1900001845 Remove the gear unit attachment screws and washers. xx1900002171 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 177 Push through the connectors for axis-1, axis-2 and axis-3 motors into the base unit compartment, and remove the cable harness. xx2000001029 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 178 Reconnect the signal lamp connectors H1 and xx2000002211 Reconnect the brake release connector. xx2000001023 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 179 Lift the gear unit into the base. CAUTION Risk of pinching! Do not pinch the cabling routed next to the gear unit flange. xx1900002167 xx2000001025 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 180 Check that the motor is oriented according to the figure before securing the unit, for each axis re- spectively. xx2000001032 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 181 Hex socket head cap screw: M8x25 washers. 8.8-A3F (4 pcs). Plain washer: 8.4x16x1.6 steel-A2F (4 pcs). Tightening torque: 24 Nm. xx1900002171 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 182 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Secure the cables to connectors R2.FB1-4, R2.FB5 (IRB 390 - 10/1300) with a cable tie at the battery bracket. Connect the connectors: •...
Page 183 Cleaning agent: Isopropanol. contact surfaces with isopropanol. Inspect for Friction shim: 3HAC060200-001. damage. Sealing ring: 3HAC060263-001 Replace if damaged. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 184 The telescopic shaft must be oriented correctly, otherwise it is damaged. Always fit the narrow shaft part up against the base unit. xx1900001825 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 185 CAUTION There is a risk of damage to the joint if not handled with care. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 186 Note Anti-seize paste: 3HAC070875-002 Do not overtighten to avoid damaging the sealing. (Molykote P1900) xx1900000407 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 187 Refit the cable bracket with attachment screws, Torx pan head screw: M6x16 8.8- if removed. A2F (3 pcs). xx1900001837 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 188 Update the revolution counters. Updating revolution counters on page 302. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 189: Replacing The Brake Release Unit
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 190 • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 191 The unit is sensitive to ESD. Before handling the unit read the safety information in section unit is sensitive to ESD on page Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 192 R2.G connector to release the lock while pulling the connect- or upwards. xx1900000754 xx1700000993 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 193 Fit the brake release push button to the robot, Brake release unit: with the sealing (A) underneath the base. 1SFA616105R4006. Sealing: 3HAC059429-003. xx2000001060 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 194 R2.FB1-4, R2.FB5 (IRB 390 - 10/1300) • Battery cable connector R2.G. Secure the SMB bracket with the screws. M6x16 8.8-A2F (3 pcs) xx1900000753 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 195 Note Anti-seize paste: 3HAC070875-002 Do not overtighten to avoid damaging the sealing. (Molykote P1900) xx1900000407 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 196 Perform a function test of the brake release but- Manually releasing the brakes ton. on page DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 197: Upper And Lower Arms
The lower arms are located as shown in the figure. xx1900001427 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 198 Removing the lower arm Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 199 Remove the lower end of the arm from the delta unit. Save the sealing washer for refitting, or replace it if damaged. xx1900001801 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 200 Note Fit the sealing washer to the lower arm. Sealing washer: 3HAC062123-001. Replace the sealing washer if damaged. xx2000000861 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 202 Fit the lower arm. Lower arm / parallel bar: 3HAC060138-001. Make sure the sealing washer is in place. xx2000001063 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 203 Concluding procedure Action Note Remove the lashing strap, if used. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 204: Replacing The Upper Arm
The upper arms are located as shown in the figure. xx1900001426 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 205 230 mm as minimum, to be able to secure the lower arms against the shaft further on in the procedure. xx2000000927 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 207 CAUTION Put some soft material between the surfaces, to protect them from scratches etc. xx2000000921 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 208 Refitting the upper arm Action Note Clean and fit the sealing ring. Sealing ring: 3HAC062067-001. Replace if damaged. xx1900001821 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 209 Refit the upper arm cover including the gasket. Tightening torque: approximately 45 Nm. Tighten until the cover bottoms on the upper arm. xx1900001799 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 210 Lower arm / parallel bar: washers to the upper arm. 3HAC060138-001. Make sure the sealing washers are in place. xx1900001802 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 211 Action Note Calibrate the robot. Calibration on page 297. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 212: Replacing The Telescopic Shafts And Universal Joints
The figure shows an 5-axis IRB 390. xx1900000253 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 213 • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 214 Remove the upper screws and washers, using a Torque wrench head, closed end: special torque wrench head. 3HAC063379-001. xx1900001823 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 215 Cleaning agent: Cleaning agent. with isopropanol. Friction shim: 3HAC060200-001. Inspect the friction shim. Replace if damaged. Fit the friction shim. xx1900001829 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 216 Cleaning agent: Isopropanol. contact surfaces with isopropanol. Inspect for Friction shim: 3HAC060200-001. damage. Sealing ring: 3HAC060263-001 Replace if damaged. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 217 The telescopic shaft must be oriented correctly, otherwise it is damaged. Always fit the narrow shaft part up against the base unit. xx1900001825 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 218 CAUTION There is a risk of damage to the joint if not handled with care. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 219 CAUTION Hold the telescopic unit carefully, the tube may slide and get damaged. xx1900001826 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 220 CAUTION There is a risk of damage to the joint if not handled with care. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 221 5.5.3 Replacing the telescopic shafts and universal joints Continued Concluding procedure Action Note DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 222: Replacing The Delta Unit
The figure shows an 5-axis IRB 390. xx1900001428 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 223 Hole interface: 1/4" square. Calibration toolbox, Axis Calibra- 3HAC055412-001 Delivered as a set of calibration tion tools. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 224 Secure the telescopic shaft with a lashing strap Lashing strap through the universal joints closest to the telescop- ic shaft (shortest way). For IRB 390 - 10/1300 both shafts must be se- cured. CAUTION The telescopic shaft will extend if not secured with the lashing strap, when the delta unit is removed.
Page 225 Loosen all lower arms from the delta unit and re- move the delta unit. Save the sealing washer for refitting, or replace it if damaged. xx1900001801 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 226 Anti-seize paste: 3HAC070875-002 (Molykote P1900) Note The surface under the thread head must be dry and not contain grease. xx2000000684 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 227 Fit all lower arms to the delta unit. Sealing washer: 3HAC062123-001. Make sure the sealing washers are in place. xx2000001063 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 228 Cleaning agent: Cleaning agent. with isopropanol. Friction shim: 3HAC060200-001. Inspect the friction shim. Replace if damaged. Fit the friction shim. xx1900001829 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 229 CAUTION There is a risk of damage to the joint if not handled with care. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 230 Remove the lashing strap. Calibrate the robot. Calibration on page 297. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 231: Replacing The Tilt Arm
The tilt arm is located as shown in the figure. xx2000000037 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 232 Removing the tilt arm Action Note CAUTION Make sure that all supplies for electrical power are turned off. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 233 Use these procedures to refit the tilt arm. Refitting the tilt arm Action Note Check the two sealing rings. Sealing ring: 3HAC061399-001 Replace if damage. xx2000000038 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 234 Spring washer, conical: 9ADA334- Note 9 (2 pcs) Do not reuse the screws. Tightening torque: 80 Nm +90° ± 10°. xx2000000042 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 235 Action Note Calibrate the robot. Calibration on page 297. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 236: Motors And Gears
Do not, under any circumstances, open the cover on the axis-1, axis-2 and axis-3 gears! It is strictly forbidden to do any repair work on the gears. xx2000001263 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 237 5.6.1 Replacing the axis-1, axis 2 and axis-3 motor Continued Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note Level Rotating AC motor M106.1...
Page 238 • hydraulic pressure supply • air pressure supply to the robot, before entering the safeguarded space. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 239 Cut all cable ties. Take pictures of the cable routing and placement of cable ties, before cutting the ties. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 240 Lubricate the guide pins with some grease to make the motor slide better. Remove the two remaining screws and washers. xx1900001835 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 241 CAUTION Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 242 Remove the guide pins and fit the remaining two screws and washers. Tighten by hand. Do not tighten with a torque yet. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 243 Tightening torque: 24 Nm. Fit sealing washers to the lower arms. Sealing washer: 3HAC062123-001. Replace the sealing washers if damaged. xx2000000861 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 244 Use an interchangeable head torque wrench and Interchangeable head torque the open-end head insert. wrench Torque wrench head, open-end in- sert: 3HAC073854-001 xx1900002150 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 245 Reconnect the motor cabling and snap the cable connectors to the cable bracket. xx2000001005 Secure the cabling to the cable bracket with cable Cable ties ties. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 246 Remove the lashing strap, if used. Calibrate the robot. Calibration on page 297. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 247: Replacing The Axis-4 Motor
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 248 Preparations before removing the axis-4 motor Action Note Jog the robot to calibration position. This is done to facilitate updating of the revolution counter. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 249 Remove the SMB battery cover. The battery cover is removed to see the battery position during refitting of the top cover. xx1900000407 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 250 • + = pin 2 • - = pin 5 Remove the motor attachment screws and wash- ers. xx2000001082 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 251 Use caution and lift the motor straight up to get the pinion parted from the gear. xx2000001083 Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 253 Refit the cable bracket to the motor with four Torx pan head screw: M6x12 Steel screws. 8.8-A2F (4 pcs) xx2000001031 Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 254 15 pcs) Anti-seize paste: Molykote P1900 (3HAC070875-002) Tightening torque: 21 Nm. xx1900000469 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 255 Action Note Calibrate the robot. Calibration on page 297. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 256: Replacing The Axis-5 Motor
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 257 Preparations before removing the axis-5 motor Action Note Jog the robot to calibration position. This is done to facilitate updating of the revolution counter. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 258 Remove the SMB battery cover. The battery cover is removed to see the battery position during refitting of the top cover. xx1900000407 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 259 • + = pin 2 • - = pin 5 Remove the motor attachment screws and wash- ers. xx2000001089 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 260 Use these procedures to refit the axis-5 motor. Refitting the axis-5 motor Action Note Check the o-ring. O-ring: 3HAB3772-163. Replace if damaged. xx2000001087 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 261 3HAC058581-003. Use the rotation tool to rotate the pinion when mating it into the gear. Rotation tool: 3HAB7887-1 xx2000001091 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 262 Disconnect the 24 VDC power supply. Connect the motor connectors and fasten the connectors to the connector bracket by snapping them into place. xx1900001845 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 263 Note Anti-seize paste: 3HAC070875-002 Do not overtighten to avoid damaging the sealing. (Molykote P1900) xx1900000407 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 264 Action Note Calibrate the robot. Calibration on page 297. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 265: Replacing The Axis-4 Gear Unit Pre-Stage
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 266 Hole interface: 1/4" square. 24 VDC power supply Used to release the motor brakes. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 267 Clean cover from metal residues before opening. Metal residues can cause shortage on the boards which can result in hazardous failures. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 268 Remove the upper screws and washers of the Torque wrench head, closed end: telescopic shaft, using a special torque wrench 3HAC063379-001. head. xx1900001823 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 269 To release the brakes, connect the 24 VDC power 24 VDC power supply supply. Connect to R3.MP4-connector: • + = pin 2 • - = pin 5 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 270 Use caution and lift the motor straight up to get the pinion parted from the gear. xx2000001083 Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 271 See Decommissioning on page 327 for more information. Dispose the gear oil in a safe way. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 272 Cleaning agent: Isopropanol. contact surfaces with isopropanol. Inspect for Friction shim: 3HAC060200-001. damage. Sealing ring: 3HAC060263-001. Replace if damaged. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 273 Check the sealing ring in the base and make sure Sealing ring: 3HAC059017-002. it is properly seated on the tab. Replace if damaged. xx2000000049 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 274 Technical reference manual - Lubrication in gearboxes available for registered users on myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 276 Refit the cable bracket to the motor with four Torx pan head screw: M6x12 Steel screws. 8.8-A2F (4 pcs) xx2000001031 Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 277 The telescopic shaft must be oriented correctly, otherwise it is damaged. Always fit the narrow shaft part up against the base unit. xx1900001825 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 278 CAUTION There is a risk of damage to the joint if not handled with care. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 279 15 pcs) Anti-seize paste: Molykote P1900 (3HAC070875-002) Tightening torque: 21 Nm. xx1900000469 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 280 Action Note Calibrate the robot. Calibration on page 297. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 281: Replacing The Axis-5 Gear Unit Pre-Stage
Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the IRB 390 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
Page 282 Hole interface: 1/4" square. 24 VDC power supply Used to release the motor brakes. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 283 Clean cover from metal residues before opening. Metal residues can cause shortage on the boards which can result in hazardous failures. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 284 Remove the upper screws and washers of the Torque wrench head, closed end: telescopic shaft, using a special torque wrench 3HAC063379-001. head. xx1900001823 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 285 To release the brakes, connect the 24 VDC power 24 VDC power supply supply. Connect to R3.MP5-connector: • + = pin 2 • - = pin 5 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 286 Use caution and lift the motor straight up to get the pinion parted from the gear. xx2000001091 Disconnect the 24 VDC power supply. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 287 See Decommissioning on page 327 for more information. Dispose the gear oil in a safe way. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 288 Cleaning agent: Isopropanol. contact surfaces with isopropanol. Inspect for Friction shim: 3HAC060200-001. damage. Sealing ring: 3HAC060263-001. Replace if damaged. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 289 Check the sealing ring in the base and make sure Sealing ring: 3HAC059017-002. it is properly seated on the tab. Replace if damaged. xx2000000055 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 290 Technical reference manual - Lubrication in gearboxes available for registered users on myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 292 Cleaning agent: Isopropanol. contact surfaces with isopropanol. Inspect for Friction shim: 3HAC060200-001. damage. Sealing ring: 3HAC060263-001 Replace if damaged. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 293 The telescopic shaft must be oriented correctly, otherwise it is damaged. Always fit the narrow shaft part up against the base unit. xx1900001825 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 294 CAUTION There is a risk of damage to the joint if not handled with care. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 295 15 pcs) Anti-seize paste: Molykote P1900 (3HAC070875-002) Tightening torque: 21 Nm. xx1900000469 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 296 Action Note Calibrate the robot. Calibration on page 297. DANGER Make sure all safety requirements are met when performing the first test run. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 297: Calibration
A calibration routine to make a rough calibration of each manipulator axis. Synchronization mark Visual marks on the robot axes. When marks are aligned, the robot is in synchronization position. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 298: Calibration Methods
Brief description of calibration methods Axis Calibration method Axis Calibration is a standard calibration method for calibration of IRB 390 and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.
Page 299: When To Calibrate
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 300: Synchronization Marks And Axis Movement Directions
6.2.1 Synchronization marks and synchronization position for axes Introduction This section shows the position of the synchronization marks and the synchronization position for each axis. Synchronization marks, IRB 390 xx2000000004 Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 301: 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. xx2000000006 Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 302: Updating Revolution Counters
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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 303 Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration. Tap Manual Method (Advanced). xx1500000944 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 304 Check the synchronization position very carefully after each update. See Checking the synchronization position on page 320. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 305: Calibrating With Axis Calibration Method
FlexPendant. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. WARNING The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.
Page 306 A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.
Page 307 Unrestricted. Axis is allowed to be jogged to other position than 0 degrees. Axis must be put in position 0 degrees. Special requirement Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 308: Calibration Tools For Axis Calibration
There is no risk for bad calibrations as long as the calibration tool is in one piece. WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel. Equipment, etc. Article number...
Page 309 It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below. Note The tool identifier is NOT delivered from ABB, it is a customized solution. Action Note It is possible to use any RFID solution, with the correct dimensions.
Page 310: Installation Locations For The Calibration Tools
This is shown in the figure. xx2000000025 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 311 Replace damaged parts with new. Spare part Article number Note Protection cover and plug set 3HAC056806-001 Contains replacement calibration pin covers and protective plugs for the bushing. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 312: Axis Calibration - Running The Calibration Procedure
WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel. Equipment, etc.
Page 313 Use this procedure to start the Axis Calibration routine on the FlexPendant. Action Note On the ABB menu, tap Calibration. xx1500000942 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 314 The three-position enabling device on the Press and hold the three-position enabling FlexPendant has been released during robot device and press Play. movement. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 315 Replace the cover with new spare part, if missing or damaged. xx1600002102 Protection cover and plug set: 3HAC056806-001. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 316 Ensure that the sealing is not damaged. Replace the plug and the sealing with new spare part, if missing or damaged. xx1500000952 Protection cover and plug set: 3HAC056806-001. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 317: Reference Calibration
(step 5, see Brief introduction to Reference Calibration on page 317). Example "Adjust axis 4": 1 Create a backup. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 318 11 Repeat the manual tuning if needed. 12 Create a new reference if the intention is to use the reference in the future. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 319: Verifying The Calibration
Write down the values on a new label and stick it on top of the calibration label. The label is located on the xx. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 320: Checking The Synchronization Position
If they do not, up- ization position for axes on page 300 date the revolution counters. Updating revolution counters on page 302. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 321: Troubleshooting
• the configuration files • connectors • options and their configuration • changes in the robot working area/movements. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 322 The robot has recently Check: been moved from one site • connections to another (an already • software versions working robot) Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 323: Oil And Grease Stains On Motors And Gearboxes
"cooling periods" into the your local ABB representative. application. • Overpressure created inside gearbox. Inspect all sealings and gaskets between motor and gearbox. Replace broken parts. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 324 Make sure the bearings are fitted correctly. Tighten the screws if a heat sink, fan, or metal sheet is loose. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 325 Investigate whether it chased from your local ABB representat- is possible to program small "cooling ive. periods" into the application. • Overpressure created inside gearbox. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 326 Remove the motor from the gearbox to in- If found faulty, the motor must be replaced spect it from the drive side. as a complete unit. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 327 Sealings, cable harness Stainless steel Flange bolts, covers, washers, cassette sealings Steel Gears, pinions, bearings, shafts, brackets, motors, screws, washers Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 328 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 329 • When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 330 This page is intentionally left blank...
Page 331 9 Reference information 9.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 332 – 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 333 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 334 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 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 335 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 336 Useful for retrieving dropped screws or wash- ers during spare part re- placements inside the base. Striker Used for knocking out the cassette sealing. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 337 If the replacing procedure is not listed in the table below, only standard tools are needed for the procedure. Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 338 Roundsling, 2 m Press tools Press tool, cassette 3HAC069723-010 sealing Other tools 24 VDC power supply Calibration toolbox, 3HAC055412-001 Axis Calibration Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 339 Blind hole bearing puller Lashing strap xx2000001117 Leak-down tester Oil collecting vessel Oil dispenser Overhead crane Rotation tool 3HAB7887-1 Continues on next page Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 340 This implies that the instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 341 302 foundation requirements, 38 cabinet lock, 27 free space above robot, 49 cable harness replacing, 168 cabling between robot and controller, 80 gearboxes Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 342 15 replacing, 236 revolution counters motor axis-1 storing on FlexPendant, 302 replacing, 236 updating, 302 mounting, equipment, 73 risk of burns, 30 Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 343 332 working range ANSI, 332 robot, 40 CAN, 332 EN IEC, 332 EN ISO, 332 zero position steel checking, 320 disposal, 327 Product manual - IRB 390 3HAC066566-001 Revision: B © Copyright 2020 - 2021 ABB. All rights reserved.
Page 346 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 2020 - 2021 ABB. All rights reserved. Specifications subject to change without notice.

ABB IRB 390 Product Manual

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