ABB IRB 360-3/1130 User manual

Type
User manual
ROBOTICS
Product manual
IRB 360
Trace back information:
Workspace R18-2 version a18
Checked in 2018-11-20
Skribenta version 5.3.012
Product manual
IRB 360 - 1/800
IRB 360 - 1/1130
IRB 360 - 1/1600
IRB 360 - 3/1130
IRB 360 - 6/1600
IRB 360 - 8/1130
IRC5
Document ID: 3HAC030005-001
Revision: U
© Copyright 2008-2018 ABB. All rights reserved.
Specifications subject to change without notice.
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2008-2018 ABB. All rights reserved.
Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden
Table of contents
9Overview of this manual ...................................................................................................................
14Product documentation ....................................................................................................................
16How to read the product manual ......................................................................................................
171 Safety
171.1 General safety information ..................................................................................
171.1.1 Limitation of liability .................................................................................
191.1.2 Protective stop and emergency stop ...........................................................
201.2 Safety actions ...................................................................................................
201.2.1 Fire extinguishing ....................................................................................
211.2.2 Emergency release of the robot axes ..........................................................
221.2.3 Make sure that the main power has been switched off ....................................
231.3 Safety risks ......................................................................................................
231.3.1 Safety risks during installation and service work on robots ..............................
251.3.2 Moving robots are potentially lethal ............................................................
261.3.3 First test run may cause injury or damage ....................................................
271.3.4 Work inside the working range of the robot ..................................................
281.3.5 Enabling device and hold-to-run functionality ...............................................
291.3.6 Risks associated with live electric parts .......................................................
311.3.7 The unit is sensitive to ESD .......................................................................
321.3.8 Hot parts may cause burns .......................................................................
331.3.9 Safety risks related to pneumatic/hydraulic systems ......................................
341.3.10 Brake testing ..........................................................................................
351.3.11 Safety risks during handling of batteries ......................................................
361.3.12 Safety risks during work with gearbox lubricants (oil or grease) .......................
381.4 Safety signals and symbols .................................................................................
381.4.1 Safety signals in the manual ......................................................................
401.4.2 Safety symbols on product labels ...............................................................
472 Installation and commissioning
472.1 Introduction ......................................................................................................
482.2 Structure manipulator ........................................................................................
492.3 Unpacking .......................................................................................................
492.3.1 Pre-installation procedure .........................................................................
532.3.2 Transport ...............................................................................................
552.3.3 Assembling the robot IRB 360 ...................................................................
562.3.4 Working range and type of motion ..............................................................
582.4 On-site installation ............................................................................................
582.4.1 Lifting the robot with fork lift ......................................................................
602.4.2 Lifting the robot with roundslings ...............................................................
622.4.3 Amount of required space .........................................................................
632.4.4 Orienting and securing the robot frame .......................................................
652.4.5 Orienting and securing the robot ................................................................
692.4.6 Manually releasing the brakes ...................................................................
722.4.7 Fitting equipment on robot ........................................................................
782.4.8 Loads ....................................................................................................
802.5 Installation of options .........................................................................................
802.5.1 Installation of safety lamp (option 213-1) ......................................................
832.5.2 Installation of (optional) customer connections IRB 360 ..................................
872.5.3 Installation of vacuum system (option 218-9) ................................................
912.6 Electrical connections ........................................................................................
912.6.1 Connecting the controller to the manipulator ................................................
942.6.2 Manipulator cables IRB 360 .......................................................................
962.7 Start of robot in cold environments ......................................................................
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Table of contents
973 Maintenance
973.1 Introduction ......................................................................................................
983.2 Maintenance schedule .......................................................................................
983.2.1 Specification of maintenance intervals ........................................................
993.2.2 Regular maintenance ...............................................................................
1003.2.3 Maintenance schedule IRB 360 ..................................................................
1023.3 Inspection activities ...........................................................................................
1023.3.1 Telescopic shaft, axis 4, standard ...............................................................
1043.3.2 Telescopic shaft, wash down, axis 4 ...........................................................
1063.3.3 Telescopic shaft, stainless, axis 4 ..............................................................
1093.3.4 Vacuum system (optional) .........................................................................
1123.3.5 Bar system .............................................................................................
1153.3.6 Joint balls ..............................................................................................
1163.3.7 Upper arms ............................................................................................
1183.3.8 Hoses ...................................................................................................
1203.3.9 Spring units ............................................................................................
1223.3.10 Movable plate .........................................................................................
1243.3.11 Inspecting information labels .....................................................................
1263.4 Replacement/changing activities ..........................................................................
1263.4.1 Changing the battery in the measuring system .............................................
1303.4.2 Changing the telescopic shaft including universal joints .................................
1323.5 Lubrication activities ..........................................................................................
1323.5.1 Type of lubrication in gearboxes ................................................................
1343.5.2 Gearboxes, axes 1- 4 ...............................................................................
1433.6 Cleaning activities .............................................................................................
1433.6.1 Introduction ............................................................................................
1463.6.2 Standard cleaning ...................................................................................
1483.6.3 Wash down cleaning ................................................................................
1503.6.4 Wash down stainless cleaning ...................................................................
1523.6.5 Clean room cleaning ................................................................................
1533.7 Measuring activities ...........................................................................................
1533.7.1 Measuring backlash axis 4 ........................................................................
1574 Repair
1574.1 Introduction ......................................................................................................
1584.2 General procedures ...........................................................................................
1584.2.1 Mounting instructions for bearings .............................................................
1604.2.2 Mounting instructions for seals ..................................................................
1624.2.3 Screw joints ..........................................................................................
1654.2.4 Cut the paint or surface on the robot before replacing parts ............................
1674.3 Complete robot .................................................................................................
1674.3.1 Replacement of base cover gasket .............................................................
1704.3.2 Replacement of serial measurement board ..................................................
1744.3.3 Replacement of parallel arms ....................................................................
1804.3.4 Replacement of upper arm ........................................................................
1834.3.5 Replacement of bearing rings ....................................................................
1864.3.6 Replacement of movable plate ...................................................................
1904.3.7 Replacement of telescopic shaft ................................................................
1934.3.8 Replacement of universal joint ...................................................................
1954.3.9 Replacement of joint balls .........................................................................
1984.3.10 Replacement of gearbox unit 1- 3 ...............................................................
2024.3.11 Replacement of gearbox unit 4 ..................................................................
2054.3.12 Replacement of motor axis 1-3 ..................................................................
2104.3.13 Replacement of motor axis 4 .....................................................................
2144.3.14 Replacement of labels ..............................................................................
2174.3.15 Replacing of calibration marks ...................................................................
2204.4 Vacuum system ................................................................................................
2204.4.1 Replacement of vacuum hoses ..................................................................
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Table of contents
2234.4.2 Draining of water separation filter ...............................................................
2254.4.3 Replacement of ejector unit .......................................................................
2294.5 Cable harness ..................................................................................................
2294.5.1 Replacement of cable harness ...................................................................
2324.5.2 Replacement of brake release button ..........................................................
2375 Calibration information
2375.1 When to calibrate .............................................................................................
2385.2 Calibration method ............................................................................................
2405.3 Calibration movement directions for all axes ..........................................................
2415.4 Synchronization marks and synchronization position for axes ...................................
2425.5 Calibrating axis 1-3 ............................................................................................
2455.6 Calibrating axis 4 ..............................................................................................
2475.7 Fine calibration procedure on FlexPendant ............................................................
2485.8 Updating revolution counters ...............................................................................
2515.9 Serial measurement board memory ......................................................................
2545.10 Checking the synchronization position ..................................................................
2596 Decommissioning
2596.1 Introduction ......................................................................................................
2606.2 Environmental information ..................................................................................
2626.3 Scrapping of robot .............................................................................................
2637 Reference information
2637.1 Introduction ......................................................................................................
2647.2 Applicable standards .........................................................................................
2667.3 Unit conversion .................................................................................................
2677.4 Weight specifications .........................................................................................
2687.5 Standard toolkit ................................................................................................
2697.6 Special tools ....................................................................................................
2707.7 Lifting accessories and lifting instructions ..............................................................
2717.8 Grease specification ..........................................................................................
2778 Spare part lists
2778.1 Spare part lists and illustrations ...........................................................................
2799 Circuit diagrams
2799.1 Circuit diagrams ................................................................................................
281Index
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Table of contents
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Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The manual also contains reference information for all procedures detailed in the
manual.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Product manual scope
The manual covers covers all variants and designs of the IRB 360. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
Organization of chapters
The manual is organized in the following chapters:
ContentsChapter
Safety information that must be read through before performing
any installation or service work on the robot. Contains general
safety aspects as well as more specific information on how to
avoid personal injuries and damage to the product.
Safety
Required information about lifting and installation of the robot.Installation and commis-
sioning
Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used to plan periodical maintenance.
Maintenance
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Overview of this manual
ContentsChapter
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Repair
Procedures that do not require specific calibration equipment.
General information about calibration.
Calibration information
Environmental information about the robot and its components.Decommissioning
Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional doc-
uments, safety standards etc.
Reference information
Complete spare part list and complete list of robot components,
shown in exploded views.
Spare part / part list
Detailed illustrations of the robot with reference numbers to the
part list.
Exploded views
Reference to circuit diagram for the robot.Circuit diagram
References
Document IDReference
3HAC029963-001Product specification - IRB 360
3HAC031045-001Operating manual - General safety information
i
3HAC049101-001Product manual, spare parts - IRB 360
3HAC028647-009Circuit diagram - IRB 360
3HAC021313-001Product manual - IRC5
IRC5 with main computer DSQC 639.
3HAC047136-001Product manual - IRC5
IRC5 with main computer DSQC1000.
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC16578-1Operating manual - Calibration Pendulum
3HAC050944-001Operating manual - Service Information System
3HAC051016-001Application manual - Additional axes and stand alone controller
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC050948-001Technical reference manual - System parameters
3HAC050996-001Application manual - Electronic Position Switches
i
This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
DescriptionRevision
First edition-
This revision includes the following additions and/or changes:
• Section What is an emergency stop? added to chapter Safety.
• Section Maintenance schedule: Interval for replacement of battery
pack changed.
A
This revision includes the following additions and/or changes:
• Implementation of IRB360 1/1600.
B
Continues on next page
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Overview of this manual
Continued
DescriptionRevision
This revision includes the following additions and/or changes:
• Chapter Maintenance sections Regular maintenance on page 99,
Telescopic shaft, axis 4, standard on page 102, Telescopic shaft, wash
down, axis 4 on page 104, Telescopic shaft, stainless, axis 4 on page 106
and Bar system on page 112 updated concerning collisions.
• Chapter Maintenance section Bar system on page 112 updated on how
to measure the distance between the bearing holders.
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagrams on page 279.
• List of standards updated, see Applicable standards on page 264.
• Spare parts chapter - art. no. updated for telescopic shaft and upper
arm.
Updates in the chapter Safety:
• Updated safety signal graphics for the levels Danger and Warning,
see Safety signals in the manual on page 38.
• New safety labels on the manipulators, see Safety symbols on product
labels on page 40.
• Revised terminology: robot replaced with manipulator.
C
This revision includes the following additions and/or changes:
• Minor updates in the chapter Calibration.
D
This revision includes the following additions and/or changes:
• Added caution regarding swivel cup, see Fitting equipment on robot
on page 72.
• Updated instructions for cleaning, see Cleaning activities on page 143.
• Updated tightening sequence, see Replacement of base cover gasket
on page 167.
• Updated refitting instruction, see Replacement of brake release button
on page 232.
• Added information about when to update resolver values, see When
to calibrate on page 237.
• Updated information in Environmental information on page 260.
• Updated spare parts, see Spare parts in the base.
E
This revision includes the following updates:
• A new block, about general illustrations, added in section How to read
the product manual on page 16.
• New Option 864-1 connection FB7 on robot base.
F
This revision includes the following updates:
• Spare part number for the telescopic shaft (1600) is corrected, see
Spare parts - telescopic shaft.
• Some general tightening torques have been changed/added, see up-
dated values in Screw joints on page 162.
• 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 100.
• Added Safety risks during handling of batteries on page 35.
G
Continues on next page
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Overview of this manual
Continued
DescriptionRevision
This revision includes the following updates:
• Variant IRB 360 - 8/1130 is added to the manual.
• Information about type and volume of oil in gearboxes is removed
from the manual, and is instead now available in the Technical refer-
ence manual - Lubrication in gearboxes - 3HAC042927-001. More in-
formation in section Type of lubrication in gearboxes on page 132.
• Added Cut the paint or surface on the robot before replacing parts on
page 165.
• Added information about an alternative bearing ring, see Spare parts
and Bar system on page 112.
• A new SMB unit and battery is introduced, with longer battery lifetime.
• New article numbers for set screws, see Spare parts, telescopic shafts.
• Corrected directions in figure for calibration movement and jogging
directions, see Calibration movement directions for all axes on
page 240.
H
This revision includes the following updates:
• Variant IRB 360 - 6/1600 is added to the manual.
• Corrected the protection class for protection typ Standard, see Protec-
tion classes on page 52.
• Changed the tightening torque, see Replacement of motor axis 4 on
page 210.
• Added information about visual difference between bearing ring ver-
sions, see Different versions of bearing rings require different main-
tenance procedures on page 112.
• Universal joint 3HAC028132-001 is replaced with 3HAC046664-001,
see Spare parts - telescopic shafts.
J
This revision includes the following updates:
• Illustrations of placement of labels updated.
• Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 262.
• Spare parts and exploded views are not included in this document
but delivered as a separate document. See Product manual, spare
parts - IRB 360.
• Mechanical interface of IRB 360 - 8/1130 and IRB 360 - 6/1600 updated.
K
This revision includes the following updates:
• Added information in calibration chapter, see Using the jogging window
on the FlexPendant on page 254.
• Clarification made about when to choose standard calibration vs. ring
calibration, see Types of calibration on page 238.
• Clarification made about measured distance between bearing holders,
regarding wear on bearing rings, see Distance between bearing
holders on page 114.
• Minor corrections
L
This revision includes the following updates:
• Updated instructions for cleaning, see Cleaning activities on page 143.
• Minor corrections
M
This revision includes the following updates:
• Minor corrections
N
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Overview of this manual
Continued
DescriptionRevision
Published in release R16.2. The following updates are done in this revision:
• Corrections due to updates in terminology.
• Warning about high center of gravity during transport added.
• Updates about parameter Calibration Position (cal_position) in Calib-
ration information on page 237.
• Added information about tightening torque in section Replacement of
movable plate on page 186.
P
Published in release R17.1. The following updates are done in this revision:
• Major updates in cleaning section.
• Updates regarding checking the calibration position.
• Measurement method in Maintenance added.
Q
Published in release R17.2. The following updates are done in this revision:
• Caution about removing metal residues added in sections about SMB
boards.
• Updated list of applicable standards.
• Changed torque on oil plug (Gear-motor unit axis 4).
• Section Start of robot in cold environments on page 96 added.
• Updated figure on motor axis 4.
• Added a note in the instruction Removal on page 196.
• Updated maintenance schedule with sealing ring (v-ring) and the af-
fected cleaning instructions.
• Updated information regarding extra load mass.
R
Published in release R18.1. The following updates are done in this revision:
• Safety restructured.
• Updated information regarding extra load mass.
• Added sections in General procedures on page 158.
• Minor update of graphics in the calibration chapter.
• Information about myABB Business Portal added.
S
Published in release R18.2. The following updates are done in this revision:
• Added section for inspection of labels in maintenance chapter.
• Grease article number updated (is 3HAC042560-001, was
3HAC029132-001)
T
Published in release R18.2. The following updates are done in this revision:
• Reference updated.
U
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Overview of this manual
Continued
Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Continues on next page
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Product documentation
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation
Continued
How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, and so on. The
references are read as described below.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Note/IllustrationAction
Shown in the figure Location of
gearbox on page xx.
Remove the rear attachment screws, gearbox.8.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.)
required for the different actions in the procedure. The equipment is marked with
italic text in the procedures and completed with a reference to the section where
the equipment is listed with further information, that is article number and
dimensions.
The designation in the procedure for the component or attachment point
corresponds to the designation in the referenced list.
The table below shows an example of a reference to a list of required equipment
from a step in a procedure.
Note/IllustrationAction
Art. no. is specified in Required
equipment on page xx.
Fit a new sealing, axis 2 to the gearbox.3.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 17.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
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How to read the product manual
1 Safety
1.1 General safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the robot.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Nation/region specific regulations
To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.
To be observed by the supplier of the complete system
The integrator is responsible that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Continues on next page
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1 Safety
1.1.1 Limitation of liability
The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the section
Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the robot can be stopped quickly. If any of the buttons do not stop all the robot
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they do not drop work pieces/tools
in the event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered robot are prohibited. Without
the consent of ABB, it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength of the robot could
be affected.
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1 Safety
1.1.1 Limitation of liability
Continued
1.1.2 Protective stop and emergency stop
Overview
The protective stops and emergency stops are described in the product manual
for the controller.
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1 Safety
1.1.2 Protective stop and emergency stop
1.2 Safety actions
1.2.1 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO
2
) extinguisher in the event of a fire in the
manipulator or controller.
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1 Safety
1.2.1 Fire extinguishing
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ABB IRB 360-3/1130 User manual

Type
User manual

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