ROBOTICS

Product manual
Motor Units and Gear Units
Trace back information:
Workspace R18-2 version a15
Checked in 2018-10-30
Skribenta version 5.3.012
 Product manual
MU 80, MU 100, MU 200, MU 250, MU 300, MU 400
MTD 250, MTD 500, MTD 750, MTD 2000, MTD 5000
MID 500, MID 1000
IRC5

Document ID: 3HAC040148-001

Revision: K

© Copyright 2011 -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 2011 -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

Table of contents
Overview of this manual ................................................................................................................... 7

1 Safety 11
1.1 General safety information .................................................................................. 11
1.1.1 Limitation of liability ................................................................................. 11
1.1.2 Protective stop and emergency stop ........................................................... 13
1.2 Safety actions ................................................................................................... 14
1.2.1 Fire extinguishing .................................................................................... 14
1.2.2 Make sure that the main power has been switched off .................................... 15
1.3 Safety risks ...................................................................................................... 16
1.3.1 Safety risks during installation and service work on robots .............................. 16
1.3.2 Moving robots are potentially lethal ............................................................ 18
1.3.3 First test run may cause injury or damage .................................................... 19
1.3.4 Work inside the working range of the robot .................................................. 20
1.3.5 Enabling device and hold-to-run functionality ............................................... 21
1.3.6 Risks associated with live electric parts ....................................................... 22
1.3.7 The unit is sensitive to ESD ....................................................................... 24
1.3.8 Hot parts may cause burns ....................................................................... 25
1.3.9 Brake testing .......................................................................................... 26
1.3.10 Safety risks during handling of batteries ...................................................... 27
1.3.11 Safety risks during work with gearbox lubricants (oil or grease) ....................... 28
1.4 Safety signals and symbols ................................................................................. 30
1.4.1 Safety signals in the manual ...................................................................... 30
1.4.2 Safety symbols on product labels ............................................................... 32

2 Product overview 39
2.1 Introduction to motor units and gear units .............................................................. 39
2.2 Motor units ....................................................................................................... 40
2.3 Gear units ........................................................................................................ 41
2.4 Basic approach ................................................................................................. 42
2.5 Scenarios ........................................................................................................ 43

3 Installation 47
3.1 Installing motor units ......................................................................................... 47
3.2 Installing gear units ........................................................................................... 50
3.3 Fastening cables ............................................................................................... 53
3.4 Handling of motors ............................................................................................ 58
3.5 Testing the brake release buttons ......................................................................... 63
3.6 Insulation in arc welding stations ......................................................................... 64
3.7 Installing non ABB brake release buttons ............................................................... 66
3.8 Changing the cable harness in the controller .......................................................... 67

4 Configuration 69
4.1 Loading configuration files .................................................................................. 69
4.2 Dimensioning gear units ..................................................................................... 71
4.3 Tuning ............................................................................................................ 72

5 Calibration 73

6 Tuning the thermal supervision 75

7 Maintenance 77
7.1 Introduction ...................................................................................................... 77
7.2 Maintenance schedule ....................................................................................... 78
7.3 Inspecting cables .............................................................................................. 79

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Table of contents

7.4 Inspecting MU250 drain holes .............................................................................. 80

7.5 Replacing SMB battery ....................................................................................... 81
7.6 Cleaning the motor units and gear units ................................................................ 84
7.7 Lubricating the current collector ........................................................................... 85

8 Repair 87
8.1 Cut the paint or surface on the robot before replacing parts ...................................... 87
8.2 Replacing SMB board ........................................................................................ 88
8.3 Repair in the motor connection box ...................................................................... 90

9 Decommissioning 91
9.1 Environmental information .................................................................................. 91

10 Reference information 93
10.1 Applicable standards ......................................................................................... 93
10.2 Unit conversion ................................................................................................. 95
10.3 Spare parts and exploded views .......................................................................... 96
10.4 Circuit diagrams ................................................................................................ 97

Index 99

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 Overview of this manual

Overview of this manual

About this manual
This manual contains instructions for:
• Mechanical and electrical installation of the motor units and gear units.
• Maintenance of the motor units and gear units.
• Mechanical and electrical repair of the motor units and gear units.

Usage
This manual should be used during:
• Installation, from installation and connection, to making them 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 motor units and gear
units. Some variants and designs may have been removed from the business offer
and are no longer available for purchase.

References

Reference Document ID
Product manual, spare parts - Motor Units and Gear Units 3HAC040278-001
Circuit diagram - Motor Units and Gear Units 3HAC039887-001
Product specification - Motor Units and Gear Units 3HAC040147-001
Operating manual - General safety information i 3HAC031045-001
Product manual - IRC5 3HAC021313-001
IRC5 with main computer DSQC 639.
Product manual - IRC5 3HAC047136-001
IRC5 with main computer DSQC1000.
Product manual - IRC5 Panel Mounted Controller 3HAC027707-001
Product manual - IRC5 Compact 3HAC035738-001

Continues on next page

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Overview of this manual
Continued

Reference Document ID
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - RobotStudio 3HAC032104-001
Technical reference manual - System parameters 3HAC050948-001
Application manual - Additional axes and stand alone controller 3HAC051016-001
Application manual - TuneMaster 3HAC063590-001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.

Revisions

Revision Description
- First revision.
MU 100, MU 200, and MU 300 replaces MU10, MU20, and MU30.
A The following additions and corrections are made:
• Added information to use locking mechanism for MID units, see In-
stalling gear units on page 50.
• Added information about acceleration torque limit for motor units, see
Loading configuration files on page 69.
• Added descriptions of the abbreviations.
B The following additions and corrections are made:
• Added Tuning the thermal supervision on page 75.
• Added Safety risks during handling of batteries on page 27.
• Added Changing the cable harness in the controller on page 67.
C The following additions and corrections are made:
• The formula for acceleration and deceleration values is corrected, see
Dimensioning gear units on page 71.
• Corrected the quality of attachment screws for gear units, see Installing
gear units on page 50.
• Added Lubricating the current collector on page 85.
• Added Changing the cable harness in the controller on page 67.
• Added Make sure that the main power has been switched off on
page 15.
• A new SMB unit and battery is introduced, with longer battery lifetime.
D The following additions and corrections are made:
• The values for Tmaxgear is updated with physical units, see Dimension-
ing gear units on page 71.
E Minor corrections.
F • Updated the path to the template files, see Loading configuration files
on page 69.
G Published in release R17.1. The following updates are done in this revision:
• Added MU 250.
• Added information about Add-In in Installation Manager, see Loading
configuration files on page 69.
H Published in release R17.2. The following updates are made in this revision:
• Caution about removing metal residues added in sections about SMB
boards.
• Updated list of applicable standards.
• Added MU 80.

Continues on next page

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 Overview of this manual
Continued

Revision Description
J Published in release R18.1. The following updates are made in this revision:
• Added section, Cut the paint or surface on the robot before replacing
parts.
• Safety restructured.
K Published in release R18.2. The following updates are made in this revision:
• Changed cable routing for motor power cables on gear unit GU
MTD750.
• Updated description about assembling transmission elements, see
Assembly by pressing on the pinion on page 59.

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This page is intentionally left blank
 1 Safety
1.1.1 Limitation of liability

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.

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1 Safety
1.1.1 Limitation of liability
Continued

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
1.1.2 Protective stop and emergency stop

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
1.2.1 Fire extinguishing

1.2 Safety actions

1.2.1 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the

manipulator or controller.

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 1 Safety
1.2.2 Make sure that the main power has been switched off

1.2.2 Make sure that the main power has been switched off

Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
personal injuries, switch off the main power on the controller before proceeding
work.

Note

Switch off all main power switches in a MultiMove system.

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1 Safety
1.3.1 Safety risks during installation and service work on robots

1.3 Safety risks

1.3.1 Safety risks during installation and service work on robots

Requirements on personnel
Only persons who know the robot and are trained in the operation and handling
of the robot are allowed to maintain the robot. Persons who are under the influence
of alcohol, drugs or any other intoxicating substances are not allowed to install,
maintain, repair, or use the robot.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install or service/maintain the robot must have the appropriate
training for the equipment in question and in any safety matters associated
with it.
• Personnel should be trained on responding to emergency or abnormal
situations.

General risks during installation and service

The instructions in the product manual must always be followed.
Never turn the power on to the robot before it is properly fixed and bolted to its
foundation/support.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to remove the power cable to
the controller.
If the robot is installed at a height, hanging, or other than standing directly on the
floor, there may be additional risks than those for a robot standing directly on the
floor.
Energy stored in the robot for the purpose of counterbalancing certain axes may
be released if the robot, or parts thereof, are dismantled.
Never use the robot as a ladder, which means, do not climb on the controller,
motors, or other parts during service work. There is a risk of slipping because of
the high temperature of the motors and oil spills that can occur on the robot. There
is also a risk of the robot being damaged.
To avoid damaging the product, make sure that there are no loose screws, turnings,
or other parts inside the product after work has been performed.

Safety risks during operational disturbances

Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.

Continues on next page

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 1 Safety
1.3.1 Safety risks during installation and service work on robots
Continued

If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.

Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the robot and as a result of that affect
the active or passive safety operation. ABB is not liable for damages caused by
the use of non-original spare parts and special equipment. ABB is not liable for
damages or injuries caused by unauthorized modifications to the robot.

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface
for the connection of external safety devices. An external safety function can
interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.

Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment
for the installation.

Allergenic material
See Environmental information on page 91 for specification of allergenic materials
in the product, if any.

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1 Safety
1.3.2 Moving robots are potentially lethal

1.3.2 Moving robots are potentially lethal

Description
Any moving robot is a potentially lethal machine.
When running, the robot may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may
seriously injure any personnel and/or damage any piece of equipment located
within the working range of the robot.

Safe handling

Action Note
1 Before attempting to run the robot, make Emergency stop equipment such as gates,
sure all emergency stop equipment is cor- tread mats, light curtains, etc.
rectly installed and connected.
2 Usually the hold-to-run function is active How to use the hold-to-run function is de-
only in manual full speed mode. To in- scribed in section How to use the hold-to-
crease safety it is also possible to activate run function in the Operating manual - IRC5
hold-to-run for manual reduced speed with with FlexPendant.
a system parameter.
The hold-to-run function is used in manual
mode, not in automatic mode.
3 Make sure no personnel are present within
the working range of the robot before
pressing the start button.

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 1 Safety
1.3.3 First test run may cause injury or damage

1.3.3 First test run may cause injury or damage

Description
After installation and performing service activities, there are several safety risks
to take into consideration before the first test run.

Safe handling
Use this procedure when performing the first test run after installation, maintenance,
or repair.

DANGER

Running the robot without fulfilling the following aspects, may involve a risk of
injury and cause severe damage to the robot.

Action
1 Remove all tools and foreign objects from the robot and its working area.
2 Verify that the robot is properly secured to its position by all screws, before it is powered
up.
3 Verify that any safety equipment installed to secure the position or restrict the robot
motion during service activity is removed.
4 Verify that the fixture and work piece are well secured, if applicable.
5 Install all safety equipment properly.
6 Make sure all personnel are standing at a safe distance from the robot, and is out of
its reach behind safety fences, or similar.
7 If maintenance or repair has been done, pay special attention to the function of the
part that was serviced.

Collision risks

CAUTION

When programming the movements of the robot, always identify potential collision
risks before the first test run.

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1 Safety
1.3.4 Work inside the working range of the robot

1.3.4 Work inside the working range of the robot

WARNING

If work must be carried out within the work area of the robot, then the following
points must be observed:
• The operating mode selector on the controller must be in the manual mode
position to render the three-position enabling device operational and to block
operation from a computer link or remote control panel.
• The maximum speed of the robot is limited to 250 mm/s when the operating
mode selector is in the position Manual mode with reduced speed. This
should be the normal position when entering the working space.
The position Manual mode with full speed (100%) may only be used by
trained personnel who are aware of the risks that this entails. Manual mode
with full speed (100%) is not available in USA or Canada.
• Pay attention to the rotating axes of the robot. Keep away from axes to not
get entangled with hair or clothing. Also, be aware of any danger that may
be caused by rotating tools or other devices mounted on the robot or inside
the cell.
• Keep clear of moving parts so that limbs, hands, or fingers do not get trapped
or crushed by the robot.
• To prevent anyone else from taking control of the robot, always put a safety
lock on the cell door and bring the three-position enabling device with you
when entering the working space.

WARNING

NEVER, under any circumstances, stay beneath any of the robot's axes! There
is always a risk that the robot will move unexpectedly when robot axes are moved
using the three-position enabling device or during other work inside the working
range of the robot.

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 1 Safety
1.3.5 Enabling device and hold-to-run functionality

1.3.5 Enabling device and hold-to-run functionality

Three-position enabling device

The three-position enabling device is a manually operated, constant pressure
push-button which, when continuously activated in one position only, allows
potentially hazardous functions but does not initiate them. In any other position,
hazardous functions are stopped safely.
The three-position enabling device is of a specific type where you must press the
push-button only half-way to activate it. In the fully in and fully out positions,
operating the robot is impossible.

Note

The three-position enabling device is a push-button located on the teach pendant

which, when pressed halfway in, switches the system to MOTORS ON. When
the enabling device is released or pushed all the way in, the manipulator switches
to the MOTORS OFF state.
To ensure safe use of the teach pendant, the following must be implemented:
• The enabling device must never be rendered inoperational in any way.
• During programming and testing, the enabling device must be released as
soon as there is no need for the robot to move.
• Anyone entering the working space of the robot must always hold the teach
pendant. This is to prevent anyone else from taking control of the robot
without his/her knowledge.

Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. The
hold-to-run function can only be used in manual mode.
How to operate the hold-to-run function for IRC5 is described in Operating
manual - IRC5 with FlexPendant.

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1 Safety
1.3.6 Risks associated with live electric parts

1.3.6 Risks associated with live electric parts

Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified
electrician in accordance with electrical regulations.
Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the main switch to
OFF) when repairing faults, disconnecting electric leads, and disconnecting or
connecting units.
The main supply to the robot must be connected in such a way that it can be turned
off from outside the working space of the robot.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and robot during installation,
commissioning, and maintenance is guaranteed if the valid regulations are followed.

Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in
the controller.
• Units such as I/O modules, can be supplied with power from an external
source.
• The main supply/main switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)
• The drive unit (400/700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• The power supply unit for additional tools, or special power supply units for
the machining process.
• The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
• Additional connections.

Voltage related risks, manipulator

A danger of low voltage is associated with the manipulator in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max. 230
VAC).

Continues on next page

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 1 Safety
1.3.6 Risks associated with live electric parts
Continued

Voltage related risks, tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.

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1 Safety
1.3.7 The unit is sensitive to ESD

1.3.7 The unit is sensitive to ESD

Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.

Safe handling

Action Note
1 Use a wrist strap. The wrist strap Wrist straps must be tested frequently to ensure
button is located inside the control- that they are not damaged and are operating cor-
ler. rectly.
• Product manual - IRC5
2 Use an ESD protective floor mat. The mat must be grounded through a current-limit-
ing resistor.
3 Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.

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 1 Safety
1.3.8 Hot parts may cause burns

1.3.8 Hot parts may cause burns

Description
During normal operation, many parts become hot. Touching these may cause
burns.
There is also a risk of fire if flammable materials are put on hot surfaces.

Safe handling
Always use your hand, at some distance, to feel if heat is radiating from the
potentially hot component before actually touching it.
Wait until the potentially hot component has cooled if it is to be removed or handled
in any other way.
Do not put anything on hot metal surfaces, e.g. paper or plastic.

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1 Safety
1.3.9 Brake testing

1.3.9 Brake testing

When to test
During operation, the holding brake of each axis normally wears down. A test can
be performed to determine whether the brake can still perform its function.

How to test
The function of the holding brake of each axis motor may be verified as described
below:
1 Run each robot axis to a position where the combined weight of the robot
arm and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the robot does not change position as the motors are switched off, then
the brake function is adequate.

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 1 Safety
1.3.10 Safety risks during handling of batteries

1.3.10 Safety risks during handling of batteries

Description
Under normal conditions of use, the electrode materials and liquid electrolyte in
the batteries are not exposed to the outside, provided the battery integrity is
maintained and seals remain intact.
There is a risk of exposure only in case of abuse (mechanical, thermal, electrical)
which leads to the activation of safety valves and/or the rupture of the battery
container. Electrolyte leakage, electrode materials reaction with moisture/water or
battery vent/explosion/fire may follow, depending upon the circumstances.

Note

Appropriate disposal regulations must be observed.

Safe handling
Use safety glasses when handling the batteries.
In the event of leakage, wear rubber gloves and chemical apron.
In the event of fire, use self-contained breathing apparatus.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.

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1 Safety
1.3.11 Safety risks during work with gearbox lubricants (oil or grease)

1.3.11 Safety risks during work with gearbox lubricants (oil or grease)

Description
When handling gearbox lubricants, there is a risk of both personal injury and
product damage occurring. The following safety information must be regarded
before performing any work with lubricants in the gearboxes.

Note

When handling oil, grease, or other chemical substances the safety information
of the manufacturer must be observed.

Note

When aggressive media is handled, an appropriate skin protection must be

provided. Gloves and goggles are recommended.

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Safe handling

Warning Description Elimination/Action

Changing and draining gearbox Make sure that protective gear
oil or grease may require hand- like goggles and gloves are al-
ling hot lubricant heated up to ways worn during this activity.
90 °C.
Hot oil or grease
When working with gearbox lub- Make sure that protective gear
ricant there is a risk of an allergic like goggles and gloves are al-
reaction. ways worn.

Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox

Continues on next page

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 1 Safety
1.3.11 Safety risks during work with gearbox lubricants (oil or grease)
Continued

Warning Description Elimination/Action

Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
The specified amount of oil or After filling, verify that the level
grease is based on the total is correct.
volume of the gearbox. When
changing the lubricant, the
amount refilled may differ from
the specified amount, depending
Specified amount de- on how much has previously
pends on drained been drained from the gearbox.
volume
When draining the oil make sure
that as much oil as possible is
drained from the gearbox. The
reason for this is to drain as
much oil sludge and metal chips
as possible from the gearbox.
The magnetic oil plugs will take
Contaminated oil in care of any remaining metal
gear boxes chips.

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1 Safety
1.4.1 Safety signals in the manual

1.4 Safety signals and symbols

1.4.1 Safety signals in the manual

Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the danger level (DANGER, WARNING, or CAUTION)
and the type of danger.
• A brief description of what will happen if the the danger is not eliminated.
• Instruction about how to eliminate danger to simplify doing the work.

Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol Designation Significance
DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height, and so on.
WARNING Warns that an accident may occur if the instructions
are not followed that can lead to serious injury, pos-
sibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height, etc.
ELECTRICAL Warns for electrical hazards which could result in
SHOCK severe personal injury or death.

CAUTION Warns that an accident may occur if the instructions

are not followed that can result in injury and/or
damage to the product. It also applies to warnings
of risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping, im-
pact, fall from height, etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.
ELECTROSTATIC Warns for electrostatic hazards which could result
DISCHARGE (ESD) in severe damage to the product.

Continues on next page

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 1 Safety
1.4.1 Safety signals in the manual
Continued

Symbol Designation Significance

NOTE Describes important facts and conditions.

TIP Describes where to find additional information or

how to do an operation in an easier way.

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1 Safety
1.4.2 Safety symbols on product labels

1.4.2 Safety symbols on product labels

Introduction to labels
This section describes safety symbols used on labels (stickers) on the product.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.

Note

The safety and health symbols on the labels on the product must be observed.
Additional safety information given by the system builder or integrator must also
be observed.

Types of labels
Both the manipulator and the controller are marked with several safety and
information labels, containing important information about the product. The
information is useful for all personnel handling the robot, for example during
installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 32.
The information labels can contain information in text (English, German, and
French).

Symbols on safety labels

Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.

xx0900000839

Continues on next page

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 1 Safety
1.4.2 Safety symbols on product labels
Continued

Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813

Before disassemble, see product manual

xx0900000816

Do not disassemble
Disassembling this part can cause injury.

xx0900000815

Extended rotation
This axis has extended rotation (working area) compared to
standard.

xx0900000814

Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808

Continues on next page

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1 Safety
1.4.2 Safety symbols on product labels
Continued

Symbol Description
Tip risk when loosening bolts
The robot can tip over if the bolts are not securely fastened.

xx0900000810

xx1500002402

Crush
Risk of crush injuries.

xx0900000817

Continues on next page

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 1 Safety
1.4.2 Safety symbols on product labels
Continued

Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)

xx0900000818

!
3HAC 4431-1/06

xx1300001087

Moving robot
4 6 The robot can move unexpectedly.
3 5

1
xx0900000819

xx1000001141

2 3

xx1500002616

Continues on next page

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1 Safety
1.4.2 Safety symbols on product labels
Continued

Symbol Description
Brake release buttons

xx0900000820

xx1000001140

Lifting bolt

xx0900000821

Chain sling with shortener

xx1000001242

Lifting of robot

xx0900000822

Oil
Can be used in combination with prohibition if oil is not allowed.

xx0900000823

Mechanical stop

xx0900000824

Continues on next page

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 1 Safety
1.4.2 Safety symbols on product labels
Continued

Symbol Description
No mechanical stop

xx1000001144

Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.

xx0900000825

Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.

xx0900000826

Shut off with handle

Use the power switch on the controller.

xx0900000827

Do not step
Warns that stepping on these parts can cause damage to the
parts.

xx1400002648

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This page is intentionally left blank
 2 Product overview
2.1 Introduction to motor units and gear units

2 Product overview
2.1 Introduction to motor units and gear units

Product overview
The motor units and gear units function as external axes in the IRC5 system. They
are controlled by drive units mounted in the IRC5 controller. The units are designed
for optimal performance, installation, and application.
The motor units and gear units use much of the same components and are therefore
described together.

SMB box
The SMB box (optional) contains a serial measurement board (with battery backup)
and brake release buttons (optional).
Note that if the motor unit is used in an arc welding station, the SMB box must
always be insulated from the weld circuit. See Insulation in arc welding stations
on page 64.

Axis selector
The axis selector (optional) is mounted inside the IRC5 controller and makes it
possible to cut the power for selected connected external units. The function is
controlled by instructions in the robot program.

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2 Product overview
2.2 Motor units

2.2 Motor units

Introduction
The motor units are specially designed for ABB's robots and can be used for
peripherals requiring servo steered motors that are synchronized with the robot
movements.

MU variants
The following motor unit variants are available:
• MU 80
• MU 100
• MU 200
• MU 250
• MU 300
• MU 400
MU stands for motor unit.

Product overview
The motor units consist of:
• Motor
• SMB box (optional)
• Axis selector (optional)
• Cables

Prerequisites
• IRC5 requires 3 phase power.
• Electronic Position Switches can be used with one motor.
• SafeMove can be used with up to three motors.

Technical data

Motor unit Weight [kg]

MU 80 1.37
MU 100 4.4
MU 200 9.3
MU 250 13.2
MU 300 15
MU 400 27

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 2 Product overview
2.3 Gear units

2.3 Gear units

Introduction
The gear units are divided in two categories, MTD and MID.
The number in the variant name describes the handling capacity.

MTD variants
The rotary unit MTD is a modular unit, developed specifically for robot applications
and is intended for positioning the workpiece.
• MTD 250
• MTD 500
• MTD 750
• MTD 2000
• MTD 5000
MTD stands for mechanical turning unit (D is a generation label).

MID variants
The station interchange unit MID is a modular unit specifically developed for robot
applications and is intended for indexed movement.
• MID 500
• MID 1000
MID stands for mechanical interchange unit (D is a generation label).

Product overview
The gear unit consists of:
• Gearbox
• Motor
• SMB box (optional)
• Axis selector (optional)
• Cables
• Drive Module with modified cable harness (optional)

Technical data

Gear unit Weight [kg]

MTD 250 70
MTD 500 180
MTD 750 180
MTD 2000 340
MTD 5000 770
MID 500 170
MID 1000 395

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2 Product overview
2.4 Basic approach

2.4 Basic approach

Introduction to basic approach

Depending on the application and system, the setting up procedure for the motor
unit or gear unit differs. This manual describes the basic approach and refers to
other manuals for more information.

Setting up motor units and gear units

Use this procedure to set up motor units or gear units.
1 Mount the motor unit or gear unit, and the SMB box. Connect cables.
For motor units, see Installing motor units on page 47.
For gear units, see Installing gear units on page 50.
2 Load the configuration files, see Loading configuration files on page 69.
3 Testrun with loads. If needed, tune the configuration data, see Tuning on
page 72.
4 Calibrate, see Calibration on page 73.
5 Tune the thermal supervision, see Tuning the thermal supervision on page 75.

Related information
Application manual - Additional axes and stand alone controller.
Operating manual - IRC5 with FlexPendant.
Operating manual - RobotStudio.

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 2 Product overview
2.5 Scenarios

2.5 Scenarios

Introduction
Below are different scenarios described for installation of the units. The axis
selector, available as an option inside the controller, allowing to cut the power to
the motor units and gear units, will not be shown in the scenarios below.

Motor units
Scenario A, Lean concept:
• One motor unit
• No SMB box
• Motor power connected to the IRC5 controller and resolver connected to FB7
at manipulator.

MU

xx1000001187

Scenario B:
• One motor unit connected to the IRC5 controller, according to Lean concept
above
• SMB box connected to the IRC5 controller
• Two motor units connected to SMB box

MU

1
2
MU
3

MU
xx1000001197

Continues on next page

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2 Product overview
2.5 Scenarios
Continued

Scenario C:
• SMB box connected to the IRC5 controller
• Three motor units connected to one SMB box

MU
1
2
MU
3

MU
xx1000001198

Gear units
Scenario A:
• SMB box connected to the IRC5 controller
• Three gear units connected to one SMB box

MTD

MTD
1

2
3

MID
xx1000001199

Continues on next page

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 2 Product overview
2.5 Scenarios
Continued

Scenario B:
• One motor unit connected to the IRC5 controller, according to Lean concept
• SMB box connected to the IRC5 controller
• Two gear units connected to one SMB box

MU

1 MTD

2
3
MTD

xx1000001200

Continues on next page

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2 Product overview
2.5 Scenarios
Continued

Scenario C:
• One SMB box connected to the IRC5 controller
• Two gear units connected to the IRC5 controller, through the SMB box
• One SMB box connected to IRC5 drive module
• Three motor units connected to the IRC5 drive module through the SMB box

MTD

MTD
1
2
3

MU
1

2
MU
3

MU
xx1000001201

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 3 Installation
3.1 Installing motor units

3 Installation
3.1 Installing motor units

Attachment screws
The table shows tightening torques for the attachment screws of the motor units.
The values are valid for non-lubricated screws. All screws should be of quality 8.8.
Motor unit Screw Tightening torque [Nm] ±10%
MU 80 M4 4
MU 100 M6 10
MU 200 M8 24
MU 250 M8 24
MU 300 M8 24
MU 400 M10 47

Use washers with minimum hardness 200HV (190HB).

Prerequisites

CAUTION

Never overheat the motor. The winding temperature must not exceed 140° C.
Check that the temperature on the motor frame is lower than 100°C.

WARNING

If the motor unit is used in an arc welding station, the SMB box must always be
insulated from the weld circuit. See Insulation in arc welding stations on page 64.

Motor connection
Positive electric rotation R ->S ->T -> (U, V, W) results in positive mechanical
rotation defined as clockwise direction, seen from the drive shaft side. See
illustration below.

xx0400001171

Continues on next page

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3 Installation
3.1 Installing motor units
Continued

Releasing the brakes during installation

To release the motor brake during installation, feed +24V to the connection
BRAKEA/B/L, and 0V to the connection BRAKE. See the circuit diagram.

CAUTION

Never shift polarity of the brake. If the polarity is shifted, the motor unit will be
damaged.

Installing motor units

Use this procedure to install motor units. For cable connections, see Fastening
cables on page 53.

Action Information
1 Fit the motor in position and secure it with
its attachments screws. CAUTION

CAUTION If using the motor unit in direct contact with

oil or grease, make sure that the running
When fitting the motor pinion, make sure conditions are suitable for the motor seal-
not to use high force or other methods that ing.
can damage the pinion, shaft, or resolver.
See Assembling motor axis and transmis-
sion element on page 58.

2 If using an SMB box, fit and secure the box. If there is a risk of return currents, then the
box must be isolated, see Insulation in arc
welding stations on page 64.
3 If using a separate drive module cabinet, Assembly instructions are included in the
connect the cable included with the cabin- kit.
et.
4 Connect the power cable from the control- If the controller is not prepared for motor
ler or SMB box to the motor. units, then the connector must be replaced,
see Changing the cable harness in the
Note controller on page 67.

Fasten the M23 connector fully. See

Fastening cables on page 53.

Note

Turn the connectors to avoid breaking the

cables. See Fastening cables on page 53.

5 Connect the resolver cable from the robot

or SMB box to the motor.
6 If using an SMB box, connect the SMB
cable from the controller to the SMB box.
7 Mark the cables.
8 Test the brake release buttons. See Testing the brake release buttons on
page 63.

Continues on next page

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 3 Installation
3.1 Installing motor units
Continued

CAUTION

Make sure that the thermal supervision is properly tuned, see Tuning the thermal
supervision on page 75.

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3 Installation
3.2 Installing gear units

3.2 Installing gear units

Attachment screws
The tables show the attachment screws and tightening torques for the gear units.
All screws should be of quality 12.9.

MTD

Gear unit Screw Tightening torque [Nm] Minimum thread length in

±10% gearbox [mm]
MTD 250 M12 120 29
MTD 500 M20 550 47
MTD 750 M20 550 47
MTD 2000 M20 550 50
MTD 5000 M24 950 37

MID
The maximum floor loads in relation to the base coordination system for the MID
units are described in Product specification - Motor Units and Gear Units.
Gear unit Screw
MID 500 M16
MID 1000 M20

Prerequisites

CAUTION

Never overheat the motor. The winding temperature must not exceed 140°C.
Check that the temperature on the motor frame is lower than 100°C.

WARNING

If the gear unit is used in an arc welding station, the SMB box must always be
insulated from the weld circuit. The gearbox is isolated from the motor. See
Insulation in arc welding stations on page 64.

Installing gear units

Use this procedure to install gear units. For cable connections, see Fastening
cables on page 53.

Action Information
1 Fit the gear unit in position and secure it
with its attachments screws. WARNING

The gear unit is heavy. Always use prop-

erly sized lifting accessories.

Continues on next page

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 3 Installation
3.2 Installing gear units
Continued

Action Information
2 If using an SMB box, fit and secure the box. If there is a risk of return currents, then the
box must be isolated, see Insulation in arc
welding stations on page 64.
3 If using a separate drive module cabinet, Assembly instructions are included in the
connect the cable included with the cabin- kit.
et.
4 Connect the power cable from the control-
ler or SMB box to the gear unit. Note

Fasten the M23 connectors fully. See

Fastening cables on page 53.

5 Connect the resolver cable from the robot

or SMB box to the gear unit.
6 If using an SMB box, connect the SMB
cable from the controller to the SMB box.
7 If using drive module cabinet:
• Assemble the cable kit
(3HAC040089-001) according to the
instructions delivered with the cable
kit.
• Connect cables to the controller
cabinet.
• Connect cables to the SMB box.
• Connect cables from the SMB box
to the motor units.
8 Mark the cables.
9 Install a current collector.
10 Test the brake release buttons. See Testing the brake release buttons on
page 63.
11 Fit and secure the flange to the equipment
to be controlled by the gear unit.

CAUTION

Make sure that the thermal supervision is properly tuned, see Tuning the thermal
supervision on page 75.

Continues on next page

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3 Installation
3.2 Installing gear units
Continued

Recommendations for MID units

The station interchange units have endless rotation and are delivered without a
locking mechanism. ABB recommends using a pneumatic, externally operated
locking pin for locking, to reduce the risk of collision with the end stop. This also
relieves the pressure on the station interchange unit.

Example

xx1100000478

A Locally made swing frame

B Pneumatic plunch

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 3 Installation
3.3 Fastening cables

3.3 Fastening cables

Protecting cables
Protect all flexible cables from weld spatter.
Place the cables so the risk of mechanical wear is minimized.

M23 connectors
Wobble the M23 connector body while tightening the connectors to make sure that
they are fully fastened.

Cable markings
Cable connections are marked with default names on delivery. Add suitable labels
or other markings during installation to simplify maintenance.
Cable connection Marking
Motor power cables MP
Feedback cables FB

SMB cable
The key pin in plug SMB bus cable (3HAC2493-1, 2530-1, 2566-1) must be removed
when connecting to XS41 or XS41.2 in the IRC5 controller.

Extended cables for MU 80

MU 80 provides extended power and signal cables.

xx1700001371

Continues on next page

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3 Installation
3.3 Fastening cables
Continued

Cable lengths are allowed to be shorted by cutting off the connector MP/FB by
customers. Always refer to the tables below to prepare new connectors.

Extended power cable

A B

xx1700001372

A MP
B MP (M23)

The following table lists the materials used for making new connector MP. The
materials are delivered with the MU 80.
Item Component article number Qty.
1 3HAC026336-004 1
2 3HAC026345-002 2
3 3HAC026345-001 4

The following table shows the connection between connector MP and connector
MP(M23).
Wire type Description Pin on Connect- Pin on Connect-
or MP or MP(M23)
1.5 mm 2 wire U 1 3
1.5 mm 2 wire V 3 1
1.5 mm 2 wire W 5 4
1.5 mm 2 wire, GNYE PE 2 PE
0.5 mm 2 wire Brake + 4 A
0.5 mm 2 wire Brake 0V 6 B

Continues on next page

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 3 Installation
3.3 Fastening cables
Continued

Extended signal cable

A B

xx1700001373

A FB
B FB(M23)

The following table lists the materials used for making new connector FB. The
materials are delivered with the MU 80.
Item Component article number Qty.
1 3HAC6996-8 1
2 3HAC6962-3 6

The following table shows the connection between connector FB and connector
FB(M23).
Wire type Description Pin on Connect- Pin on Connect-
or FB or FB(M23)
Pair 1 BK, AWG24 X 5 1
Pair 1 WHBK, AWG24 X 0V 1 3
Pair 1 BN, AWG24 Y 6 4
Pair 1 WHBN, AWG24 Y 0V 2 2
Pair 1 RD, AWG24 EXC 0V 7 8
Pair 1 WHRD, AWG24 EXC 3 7

Continues on next page

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3 Installation
3.3 Fastening cables
Continued

Cable routing for motor power cable GU MTD750

The motor cables for GU MTD750 are possible to turn approximately 45 degrees
outwards, to avoid breaking the cables.

xx1800000601

Limitations
The following limitations apply when installing and fastening cables for the motor
units or gear units to get best performance and durability.

Bending
Make sure that cables are not bent too close to the fastening points or too sharply.

xx1000001397

A Fastening point or connector

B Minimum distance from fastening point to bend is 100mm
C Minimum bending radius is 100mm

Twisting
The minimum length between the fastening points is 900mm if the cable will be
twisted ±180°.

xx1000001398

A Fastening points or connectors

B Minimum length is 900mm

Continues on next page

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 3 Installation
3.3 Fastening cables
Continued

Fastening straps
Do not over-tighten cables when fastening them with straps.

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3 Installation
3.4 Handling of motors

3.4 Handling of motors

Assembling motor axis and transmission element

Couplings, pulley, and motor pinion (transmission elements) must be assembled
using adequate tools. Otherwise the motor shaft can be distorted which damages
the resolver. Never use a hammer, as this will damage the equipment.

CAUTION

When fitting the transmission element, make sure not to use high force or other
methods that can damage the transmission element, shaft, resolver, or connection
box.
The motor axis should be fitted using a press tool or a method with a dolly. Use
heating if required.
The maximum allowed press force depends on the assembly method. See the
following figures and tables.

Note

Grease the shaft after assembly to avoid oxidation.

Assembly with press tool

Assembly using a press tool with dolly is the best method. The tool can be fitted
on the motor shaft as shown in the following figure.

Note

This method is not applicable for MU 100 since it does not have a flange on the
motor shaft.

xx1300000317

Continues on next page

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 3 Installation
3.4 Handling of motors
Continued

Maximum allowed axial force (F)

MU 80 15 kN
MU 100 -
MU 200 40 kN
MU 250 40 kN
MU 300 40 kN
MU 400 60 kN

Assembly with nut and bolt

The motor and the transmission element can be assembled with a nut and bolt as
shown in the following figure. The transmission element is driven onto the motor
shaft by turning the nut. If needed, the transmission element can also be heated.

Screw M6
Nut M6
Press plate
Transmission element

Motor shaft adapter with key wedge

Motor shaft

xx1300000314

Assembly by pressing on the pinion

The motor and the transmission element can be assembled by pressing, with or
without heat.
Use the motor flange as a dolly, as shown in the following figure.

CAUTION

Make sure that the contact surfaces between the motor and the dolly distribute
the press force evenly.

Continues on next page

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3 Installation
3.4 Handling of motors
Continued

F F

xx1300000315

Maximum allowed axial force (F)

MU 80 650 N
MU 100 125 N
MU 200 1,963 N
MU 250 1,963 N
MU 300 1,963 N
MU 400 2,825 N

Assembly with open back cover

If no press tool with dolly is available, the back cover of the motor can be opened
so that some other flat and stable object can be used as dolly directly on the motor
shaft. Make sure not to press on the resolver.

Note

This method is not applicable for MU 80 since it does not have a connection box
and the back cover of the motor is not allowed to be opened.

Continues on next page

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 3 Installation
3.4 Handling of motors
Continued

xx1300000316

Maximum allowed axial force (F)

MU 100 10 kN
MU 200 20 kN
MU 250 20 kN
MU 300 20 kN
MU 400 30 kN

Continues on next page

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3 Installation
3.4 Handling of motors
Continued

Disassembling the transmission element from the motor

Use a puller tool to disassemble the the transmission element from the motor axis.

xx1300000318

Note

Place a shim or washer on the shaft end for protection, so that the puller tool
does not press directly on the shaft.

Lifting motors
Use lifting accessories that are accordingly sized for the motor.
When lifting the motor with roundslings, never place the sling around the motor
shaft.

xx1300000231

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 3 Installation
3.5 Testing the brake release buttons

3.5 Testing the brake release buttons

Introduction to testing brake release buttons

The brake release buttons should be tested before mounting loads or external
equipment.

Prerequisites
The motor unit or gear unit must be installed.
The brake release button must be installed correctly by referring to Circuit
diagram - Motor Units and Gear Units.
There must be power available to the controller.

Testing the brake release buttons

Use this procedure to test the brake release buttons.
Action Information
1 Turn on the power to the controller.
2
WARNING

When releasing the holding brakes, the axes can

move very quickly and sometimes in unexpected
ways! Make sure no personnel is near or beneath
an axis!

3 Press the brake release button. When the brake is released, the
axis should be possible to move.
4 Verify that the correct motor brake was released.

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3 Installation
3.6 Insulation in arc welding stations

3.6 Insulation in arc welding stations

Galvanic insulation from the weld circuit

If using the motor unit or gear unit in an arc welding cell, the return currents must
be properly taken care of. The SMB box must always be insulated from the weld
circuit.

Gear units
The rotary units (MTD) and the station interchange units (MID) have the motor
galvanically insulated from the weld circuit, that is, there is no connection between
the weld circuit and protective earth.

SMB box
The SMB box is connected to protective earth and must always be mounted
galvanically insulated from the weld circuit.

Motor units
The motor units are connected to protective earth. When using the motor units in
work piece positioners or other equipment connected to the weld circuit there will
be a connection between the weld circuit and protective earth.
To avoid malfunction:
• Verify that good contact is established between the welding power source
and work piece positioner.
• Never disconnect the weld return cable.
• Verify that the current collector, if used, is working properly and has a low
voltage drop.

Hazardous scenario
The following graphic shows a hazardous scenario with two faults causing the weld
current to flow in protective earth.
• The weld return cable is disconnected from the work piece positioner.
• The weld return cable has contact with protective earth, in this case a cable
channel made of metal.

Continues on next page

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 3 Installation
3.6 Insulation in arc welding stations
Continued

xx1100000103

A Weld return current in protective earth

B Current collector
C The weld return cable is disconnected from the work piece positioner
D The weld return cable has contact with protective earth
E Cable channel made of metal
F Power source
G SMB box galvanically insulated from the weld circuit
H Motor unit’s protective earth connected to the weld circuit

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3 Installation
3.7 Installing non ABB brake release buttons

3.7 Installing non ABB brake release buttons

Brake release buttons

The motor units are prepared for installing other brake release buttons than those
supplied in the SMB box.

Installing non ABB brake release buttons

Use connection BRAKE PB. See the connections in the circuit diagram, Circuit
diagram - Motor Units and Gear Units.

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 3 Installation
3.8 Changing the cable harness in the controller

3.8 Changing the cable harness in the controller

Cable harness
The cable harness for the seventh axis must be replaced if a motor unit is added
to a controller that is delivered without any of the motor unit options.

Note

The procedure depends on the motor variant, if an axis selector is used etc. Use
the action scenarios in the circuit diagram as reference during the installation of
the cable harness.

Changing the cable harness

Use this procedure to change the cable harness in the controller.
Action Note
1
DANGER

Before commencing any work inside the

cabinet, please observe the safety inform-
ation in section Make sure that the main
power has been switched off on page 15.

2 Remove the cable harness for the XS.7

contact.
3 Refit the new cable harness. Circuit diagram - Motor Units and Gear
Units

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This page is intentionally left blank
 4 Configuration
4.1 Loading configuration files

4 Configuration
4.1 Loading configuration files

Introduction to configuration files

Template configuration files are included in the delivery with the motor units and
gear units. The configurations for motor units and gear units can be tuned before
running in production to optimize performance.
The template files are located in the following directory in the RobotWare
installation:
• ...\RobotPackages\RobotWare_RPK_<version>\utility\MotorUnits\
• ...\RobotPackages\RobotWare_RPK_<version>\utility\GearUnits\

Note

Navigate to the RobotWare installation folder from the RobotStudio Add-Ins tab,
by right-clicking on the installed RobotWare version in the Add-Ins browser and
selecting Open Package Folder.

Tip

In RobotWare 6.05 (and later) the Add-In for motor units and gear units can be
selected directly in Installation Manager. The tuning is done after installation.

Limitations
The values for acceleration and deceleration used in the template files might need
to be verified. For gear units see Dimensioning gear units on page 71. For motor
units, see Application manual - Additional axes and stand alone controller.
For MID gear units, the working range must be carefully tested and if needed
redefined. If the defined value is wrong, there is a risk that the MID crashes into
the end stop.

Acceleration torque limit for motor units

The acceleration torque limit for the motor units is by default reduced to protect
connected equipment. The acceleration torque limit can be increased, see Product
specification - Motor Units and Gear Units.
Redefine the system parameter Torque Absolute Max in the type Stress Duty Cycle
(topic Motion) to increase the acceleration torque limit.

File name convention

The configuration files use a naming convention, based on the following data:
• Configuration topic
• Type of unit
• Drive unit and drive module (system parameters Drive Unit and Drive Module)

Continues on next page

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4 Configuration
4.1 Loading configuration files
Continued

• Measurement link, board position, and measurement node (system

parameters Measurement Link, Board Position, and Measurement Node)
For example, MOC_MU100_M7DM1_L1B1N7.cfg, defines:
• Topic Motion
• Motor unit MU 100
• Drive unit 7 and drive module 1
• Measurement link 1, board position 1, and measurement node 7

Loading configuration files

Use this procedure to load configuration files.
Action Information
1 In RobotStudio, load the configuration files for the All files are included in the folder
motor units and the gear units. Open the file ...\utility\... in the Robot-
readme.txt to verify which files to use. Ware installation.
2 If using an axis selector, load the configuration files
for the axis selector after the files for the motor units
and gear units are loaded. Use the add and replace
duplicates option to overwrite existing parameters.
3 Tune the motor. See Tuning on page 72.

Configuration files and standard system parameters are described in Technical

reference manual - System parameters.

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 4 Configuration
4.2 Dimensioning gear units

4.2 Dimensioning gear units

Acceleration and deceleration values

To secure that gear units will not run too hard and damage the gear box, the
acceleration and deceleration of the axis on the arm side must be calculated.
This calculation will give a maximum value for the system parameters Nominal
Acceleration and Nominal Deceleration. The value can be lowered if the acceleration
is too fast, see Application manual - Additional axes and stand alone controller.
Do not use values higher than the recommended maximum acceleration, see
Maximum gearbox torques on page 71.
(Tmaxgear - m * g * CoGRmax) / (m * CoGRmax 2 + J0z)

xx1100000104

J0z is the moment of inertia around the Z axis at the center of gravity (CoG).
CoGRmax is the radial distance in X and Y directions between the Z axis and the
center of gravity (CoG).
Define the system parameters Nominal Acceleration and Nominal Deceleration in
the type Acceleration Data in the topic Motion, based on the calculations.

Maximum gearbox torques

Use the Tmaxgear values from the table for the calculation.

Gear unit Tmaxgear (max torque on arm Recommended maximum acceleration and
side) (Nm) deceleration (rad/s 2 )
MTD 250 480 4
MTD 500 1,100 3
MTD 750 1,950 3
MTD 2000 5,000 0.8
MTD 5000 11,400 0.5
MID 500 1,950 2.4
MID 1000 5,000 1.1

Related information
Dimensioning of motors is described in Application manual - Additional axes and
stand alone controller.

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4 Configuration
4.3 Tuning

4.3 Tuning

Introduction to tuning
The template configuration files can be tuned to optimize the performance. The
configuration data is preferably tuned using TuneMaster, or as described for
additional axes, see Application manual - Additional axes and stand alone controller.

TuneMaster
TuneMaster is an easy to use PC tool to optimize the motion performance.
TuneMaster is included in the RobotWare distribution, in the folder Tools. How to
use TuneMaster is described in the help file included in the installation.

Basic approach for tuning

How to tune depends on the tools used. However, the following steps apply:
1 Testrun without loads to verify if tuning is needed.
2 Testrun with loads.
3 If needed, tune the configuration data and repeat steps 1-2.

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 5 Calibration

5 Calibration
When to calibrate
Mechanical units must be calibrated after installation, if parts of the transmission
are replaced, or if the resolver memory is lost.
Fine calibration defines the calibration zero position and updates the revolution
counters.
Robot calibration is described in Operating manual - IRC5 with FlexPendant, and
in the product manual for the robot.
Commutation of motors is described in Application manual - Additional axes and
stand alone controller.
Coordinated positioners and user frames are described in Application
manual - Additional axes and stand alone controller.

Calibration position
Any position can be defined as the calibration zero position but it must be possible
to move the axis to this position with good precision repeatedly. For example, this
can be a mechanical stop or another indicator that clearly shows the position.

Fine calibrating mechanical units

Use this procedure to fine calibrate the mechanical units.
Action Note
1 Move the mechanical unit to a suitable zero position Mark the zero position for future
for calibration. reference.
2 On the FlexPendant ABB menu, tap Calibration.
3 Tap to select the mechanical unit.
4 Tap Fine Calibration.
5 Tap to select the axis and then tap Calibrate.

Updating revolution counters

Use this procedure to update revolution counters.
Action Note
1 Move the mechanical unit to the zero position for
calibration.
2 On the FlexPendant ABB menu, tap Calibration.
3 Tap Rev. Counters and then tap Update Revolution
Counters.
4 Tap to select the axis and then tap Update.

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 6 Tuning the thermal supervision

6 Tuning the thermal supervision

Thermal supervision
The motor units (except MU 80 and MU 100) and the gear units are protected from
overload by a thermal supervision. If the motor temperature is close to the defined
maximum temperature then the system shows a warning. If the maximum
temperature is exceeded then the unit will stop.
For optimal efficiency, the thermal supervision should be tuned for the environment
in which the system is installed.

System parameters
The maximum temperature for the robot and the thermal supervision sensitivity
ratio are defined by the system parameters. The values can be changed using the
Control Panel on the FlexPendant.
System parameter Allowed val- Default value Note
ues
Maximum temperature +5°C to +45°C The value should be set to the
(Max Temperature Robot) +52°C maximum expected ambient
temperature for the MU, MTD,
MID, and manipulator.
Topic Motion, type Motion
System.
Thermal supervision 0.5 to 2 1.0 Topic Motion, type Supervi-
(Thermal Supervision Sensit- sion.
ivity Ratio)

Note

The system must be restarted after modifying the system parameters for the
changes to take effect.

CAUTION

Never let the motor body temperature exceed 105°C. It may cause motor
damages.

Tuning the thermal supervision

Use this procedure to tune the thermal supervision.
Action Information
1 Start the motor and run the toughest expected cycle.
2 Monitor the motor body temperature and the thermal Tstator_rise= Measured motor body
model temperature rise (test signal number 190), temperature + 35 – actual ambient
in TuneMaster. temperature
35 is the approximate difference
between the motor body temperat-
ure and the stator temperature.

Continues on next page

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6 Tuning the thermal supervision
Continued

Action Information
3 If Tstator_rise is larger than the thermal model temper-
ature rise, then increase the thermal supervision Tip
sensitivity ratio.
If Tstator_rise is smaller than the thermal model tem- You can use the ratio between
perature rise, then decrease the thermal supervision T
stator_rise and the thermal model
sensitivity ratio. temperature rise, when estimating
how much the Thermal supervi-
sion sensitivity ratio should be
changed.

4 If Tstator_rise + Max temperature robot > 130°C (max

allowed is 140°C, hot motor warnings will appear
at 130°C) consider actions to reduce the temperat-
ure, for example improving the cooling, reducing
the average torque, or choosing a larger motor unit
or gear unit.

Related information
Technical reference manual - System parameters
Application manual - TuneMaster

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 7 Maintenance
7.1 Introduction

7 Maintenance
7.1 Introduction

Structure of this chapter

This chapter describes all the maintenance activities recommended for the motor
units and gear units.
It is based on the maintenance schedule found at the beginning of the chapter.
The schedule contains information about required maintenance activities including
intervals, and refers to procedures for the activities.
Each procedure contains all the information required to perform the activity,
including required tools and materials.
The procedures are gathered in different sections and divided according to the
maintenance activity.

Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 11 before performing any service
work.

Note

If the motor units and gear units is connected to power, always make sure that
the motor units and gear units is connected to protective earth before starting
any maintenance work.
For more information see:
• Product manual - IRC5

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7 Maintenance
7.2 Maintenance schedule

7.2 Maintenance schedule

Introduction
The equipment must be maintained regularly to ensure proper function. The
maintenance activities and intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the equipment. Any
damages must be attended to immediately!
The inspection intervals do not specify the life of each component.

Activities and intervals

The table below specifies the required maintenance activities and intervals:
Maintenance activity Equipment Interval Detailed in section
Cleaning Motor units and gear - Cleaning the motor
units units and gear units
on page 84
Inspection Cables Running Inspecting cables on
page 79
Inspection MU250 drain holes Running Inspecting MU250
drain holes on
Note page 80

Only MU250 has drain

holes.

Lubrication Current collector 400 hours Lubricating the cur-

rent collector on
page 85
Replacement Battery pack, meas- 36 months or battery Replacing SMB bat-
urement system of low alert i tery on page 81
type RMU101 or
RMU102 (3-pole bat-
tery contact)
Replacement Battery pack, meas- Battery low alert ii Replacing SMB bat-
urement system with tery on page 81
2-pole battery contact,
e.g. DSQC633A
i The battery low alert (38213 Battery charge low) is displayed when the battery needs to be replaced.
The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned
on until the battery is to be replaced.
See the replacement instruction for more details.
ii The battery low alert (38213 Battery charge low) is displayed when remaining backup capacity
(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the
robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime
can be extended with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.

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 7 Maintenance
7.3 Inspecting cables

7.3 Inspecting cables

Inspecting cables
Use this procedure to inspect cables.
Action Information
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

2 Make an overall visual inspection of the cables to

detect wear or damage.
3 Check the connectors.
4 Check that all brackets and straps are properly at-
tached.
5 Replace the cables if wear, cracks, or damage is
detected.

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7 Maintenance
7.4 Inspecting MU250 drain holes

7.4 Inspecting MU250 drain holes

Inspecting MU250 drain holes

Use this procedure to inspect MU250 drain holes.
Action Information
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot work-
ing area.

2 Inspect the drain hole from the glass cover

in the middle.
3 Replace the MU250 if oil leakage is detected
in the middle drain hole. A
4 Check that the stop screws for the other two
drain holes are properly attached.
5 Secure or reassemble the stop screws if any
loose or missing.

C
xx1700000553

Parts:
• A: Drain hole with glass cover
• B: Drain hole with stop screw
• C: Drain hole with stop screw

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 7 Maintenance
7.5 Replacing SMB battery

7.5 Replacing SMB battery

Note

The battery low alert (38213 Battery charge low) is displayed when the battery
needs to be replaced. The recommendation to avoid an unsynchronized robot
is to keep the power to the controller turned on until the battery is to be replaced.
For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For an SMB board with 2-pole battery contact, the typical lifetime of a new battery
is 36 months if the robot is powered off 2 days/week or 18 months if the robot is
powered off 16 h/day. The lifetime can be extended for longer production breaks
with a battery shutdown service routine. See Operating manual - IRC5 with
FlexPendant for instructions.

WARNING

See instructions for batteries, Safety risks during handling of batteries on page 27.

Continues on next page

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7 Maintenance
7.5 Replacing SMB battery
Continued

Location of SMB battery

xx1000001415

A SMB battery

Note

There are two variants of SMB units and batteries. One with 2-pole battery contact
and one with 3-pole battery contact. The variant with the 3-pole battery contact
has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!

Continues on next page

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 7 Maintenance
7.5 Replacing SMB battery
Continued

Replacing SMB battery

Use this procedure to replace the SMB battery.
Action Information
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

2
ELECTROSTATIC DISCHARGE (ESD)

Before handling the unit, see The unit is sensitive

to ESD on page 24.

3 Open the cover on the SMB box.

CAUTION

Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.

4 Pull out the battery and disconnect the battery

cable.
5 Fit the new battery and connect the battery cable.
6 Close the SMB box.
7 Update the revolution counters. See Calibration on page 73.
8 Dispose of the old battery. See Environmental information on
page 91.

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7 Maintenance
7.6 Cleaning the motor units and gear units

7.6 Cleaning the motor units and gear units

WARNING

Turn off all electrical power supplies to the manipulator before entering its work
space.

General
To secure high uptime it is important that the motor units and gear units is cleaned
regularly. The frequency of cleaning depends on the environment in which the
product works.

Special cleaning considerations

This section specifies some special considerations when cleaning the robot.
• Always use cleaning equipment as specified. Any other cleaning equipment
may shorten the life of the robot.
• Always check that all protective covers are fitted to the robot before cleaning.
• Never point the water jet at connectors, joints, sealings, or gaskets.
• Do not use compressed air to clean the robot.
• Never use solvents that are not approved by ABB to clean the robot.
• Do not spray from a distance closer than 0.4 m.
• Do not remove any covers or other protective devices before cleaning the
robot.

Cleaning methods
The following table defines what cleaning methods are allowed.
Cleaning method Note
Vacuum cleaner Yes
Wipe with cloth Yes. With light cleaning detergent.
Rinse with water Yes. It is highly recommended that water contains a rust pre-
vention solution and that the robot is dried afterwards.
High pressure water or No
steam

Cables
Movable cables need to be able to move freely:
• 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.

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 7 Maintenance
7.7 Lubricating the current collector

7.7 Lubricating the current collector

DANGER

Turn off all electrical power, hydraulic and pneumatic pressure supplies before
entering the workspace of the manipulator.
Also read the safety sections:
• Risks associated with live electric parts on page 22
• Safety risks during installation and service work on robots on page 16

Current collector
The function of the current collector is to transfer the weld current through the
rotary unit. This takes place through a spring-loaded contact bar against the shaft.
The contact bar needs to be lubricated approximately after 400 hours of operation.
This should be done using a special grease, P34 from Nies, article number:
0501869-001.

Required equipment

Equipment Note
Grease Grease type: P34 from Nies. Article number:
0501869-001.
Standard tools
Grease gun

Lubricating the current collector

Action Information
1 Lubricate the current collector using a grease gun.
Note

Amount of grease: 12 ml.

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 8 Repair
8.1 Cut the paint or surface on the robot before replacing parts

8 Repair
8.1 Cut the paint or surface on the robot before replacing parts

General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.

Required equipment

Equipment Spare parts Note

Cleaning agent Ethanol
Knife
Lint free cloth
Touch up paint Standard/Foundry 3HAC037052-001
Plus, ABB Orange

Removing

Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.

xx0900000121

2 Carefully grind the paint edge that is left on

the structure to a smooth surface.

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8 Repair
8.2 Replacing SMB board

8.2 Replacing SMB board

WARNING

See safety instructions for batteries, Safety risks during handling of batteries on
page 27.

Required equipment

Note

There are different variants of SMB units and batteries. The variant with the
3-pole battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!

Equipment Note
SMB board See Spare parts and exploded views on
page 96.

Removing the SMB board

Use this procedure to remove the SMB board in the SMB box.
Action Information
1
DANGER

Turn off all:

• electric power supply
• hydraulic pressure supply
• air pressure supply
to the robot, before entering the robot working area.

2
ELECTROSTATIC DISCHARGE (ESD)

Before handling the unit, see The unit is sensitive

to ESD on page 24.

3 Open the cover on the SMB box.

CAUTION

Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards
which can result in hazardous failures.

4 Disconnect the cables.

5 Remove the screws holding the plate. Keep the toothed washers.
6 Pull out the plate.

Continues on next page

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 8 Repair
8.2 Replacing SMB board
Continued

Action Information
7 Loosen the four nuts holding the SMB board. The nuts do not have to be re-
moved, only loosened.
8 Pull out the SMB board.
9 Dispose of the old SMB board. See Environmental information on
page 91.

Refitting the SMB board

Use this procedure to refit the SMB board in the SMB box.
Action Information
1 Place the new SMB board on the mounting plate.
2 Check that the toothed washer is in place and fasten
the nuts fully.
3 Refit the plate and fasten the screws fully. Cross tighten the screws to make
sure the sealing is tight.
4 Connect the cables and close the cover.
5 Update the revolution counters. See Calibration on page 73.

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8 Repair
8.3 Repair in the motor connection box

8.3 Repair in the motor connection box

Motor connection box

The motor connection box can be opened to replace equipment.

Note

MU 80 does not have a connection box.

Note

When assembling the connection box to the motor or the top cover to the
connection box, make sure that the o-ring is in the groove.

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 9 Decommissioning
9.1 Environmental information

9 Decommissioning
9.1 Environmental information

Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).

xx1800000058

Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Batteries, NiCad or Lithium Serial measurement board
Copper Cables, motors
Cast iron/nodular iron Gear housings
Steel Gears, screws, shafts, brackets, and so on.
Neodymium Brakes, motors
Plastic/rubber Cables, connectors, and so on.
Oil, grease Gearboxes
Aluminium Motor housings

Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an
authorized person/contractor in accordance with local regulations. Do not dispose
of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration
must be carried out under controlled conditions in accordance with local regulations.

Continues on next page

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9 Decommissioning
9.1 Environmental information
Continued

Also note that:

• 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.

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 10 Reference information
10.1 Applicable standards

10 Reference information
10.1 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.

Standards, EN ISO
The product is designed in accordance with the requirements of:
Standard Description
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850:2015 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-1:2011 Robots for industrial environments - Safety requirements -Part
1 Robot
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
ISO 9283:1998 Manipulating industrial robots, performance criteria, and related
test methods
EN ISO 14644-1:2015 i Classification of air cleanliness
EN ISO 13732-1:2008 Ergonomics of the thermal environment - Part 1
EN 61000-6-4:2007 + EMC, Generic emission
A1:2011
IEC 61000-6-4:2006 +
A1:2010
(option 129-1)
EN 61000-6-2:2005 EMC, Generic immunity
IEC 61000-6-2:2005
EN IEC 60974-1:2012 ii Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-10:2014 ii Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part
1 General requirements
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only robots with protection Clean Room.
ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard Description
EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles

Continues on next page

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10 Reference information
10.1 Applicable standards
Continued

Standard Description
EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design

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 10 Reference information
10.2 Unit conversion

10.2 Unit conversion

Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

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10 Reference information
10.3 Spare parts and exploded views

10.3 Spare parts and exploded views

Introduction
Spare parts and exploded views are not included in the manual but delivered as
a separate document on the documentation DVD. Article number for Product
manual, spare parts - Motor Units and Gear Units is 3HAC040278-001.

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 10 Reference information
10.4 Circuit diagrams

10.4 Circuit diagrams

Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.myportal.abb.com.
See the article numbers in the tables below.

Controllers

Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Compact 3HAC049406-003
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 3HAC024120-004
Circuit diagram - Spot welding cabinet 3HAC057185-001

Robots

Product Article numbers for circuit diagrams

Circuit diagram - IRB 120 3HAC031408-003
Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 260 3HAC025611-001
Circuit diagram - IRB 360 3HAC028647-009
Circuit diagram - IRB 460 3HAC036446-005
Circuit diagram - IRB 660 3HAC025691-001
Circuit diagram - IRB 760 3HAC025691-001
Circuit diagram - IRB 1200 3HAC046307-003
Circuit diagram - IRB 1410 3HAC2800-3
Circuit diagram - IRB 1600/1660 3HAC021351-003
Circuit diagram - IRB 1520 3HAC039498-007
Circuit diagram - IRB 2400 3HAC6670-3
Circuit diagram - IRB 2600 3HAC029570-007
Circuit diagram - IRB 4400/4450S 3HAC9821-1
Circuit diagram - IRB 4600 3HAC029038-003
Circuit diagram - IRB 6400RF 3HAC8935-1
Circuit diagram - IRB 6600 type A 3HAC13347-1
3HAC025744-001
Circuit diagram - IRB 6600 type B 3HAC13347-1
3HAC025744-001
Circuit diagram - IRB 6620 3HAC025090-001
Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001

Continues on next page

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10 Reference information
10.4 Circuit diagrams
Continued

Product Article numbers for circuit diagrams

Circuit diagram - IRB 6640 3HAC025744-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001
Circuit diagram - IRB 6660 3HAC025744-001
3HAC029940-001
Circuit diagram - IRB 6700 3HAC043446-005
Circuit diagram - IRB 7600 3HAC13347-1
3HAC025744-001
Circuit diagram - Product.ProductName 3HAC050778-003
Circuit diagram - IRB 910SC 3HAC056159-002

Other hardware

Product Article numbers for circuit diagrams

Circuit diagram - Motor Units and Gear Units 3HAC039887-001

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 Index

Index ESD
damage elimination, 24
sensitive equipment, 24
A external safety devices, 17
abbreviations
MID, 41 F
MTD, 41 files
MU, 40 template configurations, 69
SMB, 39 fine calibrating, 73
acceleration, 71 fire extinguishing, 14
acceleration torque limit, 69 floor loads
aluminum MID, 50
disposal, 91
arc welding, 47, 50 G
assessment of hazards and risks, 12 gear units
axis selector installing, 50
description, 39 grease
disposal, 91
B
batteries H
disposal, 91 hanging
handling, 27 installed hanging, 16
battery pack hazardous material, 91
replacing, interval, 78 height
bending installed at a height, 16
cables, 56 hold-to-run, 21
brake release button HRA, 12
non ABB, 66
testing, 63 I
brakes installing
testing function, 26 gear units, 50
motors, 47
C SMB box, 47, 50
cabinet lock, 16, 22 insulation, 50
cables SMB box, 64
bending, 56 integrator responsibility, 11
fastening, 53 intervals, 78
limitations, 53 isolation, 47
markings, 53
twisting, 56 L
calibrating, 73 labels
calibration position, 73 robot, 32
carbon dioxide extinguisher, 14 lifting
cast iron motors, 62
disposal, 91 limitation of liability, 11
cleaning, 84 Lithium
climbing on robot, 16 disposal, 91
configuration files loading files, 69
loading, 69 locking mechanism, 50
names, 69
connection M
external safety devices, 17 M23 connectors, 53
connection box, 90 maintenance schedule, 78
connectors motors
M23, 53 gear units, 41
copper handling, 58
disposal, 91 installing, 47
current collector, 85 lifting, 62
motor units, 40
D
danger levels, 30 N
deceleration, 71 naming convention, 69
disassembling motor, 62 nation specific regulations, 11
neodymium
E disposal, 91
enabling device, 21 NiCad
environmental information, 91 disposal, 91

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Index

nodular iron gear units, 50

disposal, 91 motor units, 47
signals
O safety, 30
oil SMB battery
disposal, 91 replacing, 81
oil change SMB board, 88
safety risks, 28 SMB box
description, 39
P installing, 47, 50
pedestal insulation, 50, 64
installed on pedestal, 16 isolation, 47
plastic standards, 93
disposal, 91 EN, 93
press tool, 58 EN IEC, 93
product standards, 93 EN ISO, 93
protective equipment, 17 steel
protective wear, 17 disposal, 91
puller too, 62 straps, 57
symbols
R safety, 30
recommendations system integrator requirements, 11
cables, 53 system parameters
SMB box, 64 loading, 69
region specific regulations, 11
replacing, 88 T
SMB battery, 81 template files, 69
SMB board, 88 names, 69
responsibility and validity, 11 testing
return current, 47, 50, 64 brakes, 26
revolution counters three-position enabling device, 21
updating, 73 tools, 72, 76
robot Torque Absolute Max, 69
labels, 32 torques
symbols, 32 acceleration, deceleration, 71
RobotStudio gear units, 50
configurations, 69 motor units, 47, 69
rubber TuneMaster, 72, 76
disposal, 91 tuning, 72
twisting
S cables, 56
safety
brake testing, 26 U
ESD, 24 updating
fire extinguishing, 14 calibration, 73
moving robots, 18 revolution counters, 73
signals, 30 Utility, 69
signals in manual, 30
symbols, 30 V
symbols on robot, 32 validity and responsibility, 11
test run, 19 variants
working range, 20 MID, 41
safety fence, 12 MTD, 41
safety risk MU, 40
electric parts, 22
hot parts, 25 W
installation, 16 washers
oil change, 28 motor units, 47
operational disturbance, 16 weight
service work, 16 gear units, 41
voltage, 22 motor units, 40
safety signals weld current, 47, 50
in manual, 30
safety standards, 93 Z
safety zones, 12 zero position, 73
screws

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ABB AB, Robotics
Robotics and Motion
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400

ABB AS, Robotics

Robotics and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion
No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

ABB Inc.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000

abb.com/robotics
3HAC040148-001, Rev K, en

© Copyright 2011 -2018 ABB. All rights reserved.

Specifications subject to change without notice.