ABB MID 1000 Product Manual Download

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Table of contents

Overview of this manual ...................................................................................................................

Safety

1.1

General safety information ..................................................................................

1.1.1

Limitation of liability .................................................................................

1.1.2

Protective stop and emergency stop ...........................................................

1.2

Safety actions ...................................................................................................

1.2.1

Fire extinguishing ....................................................................................

1.2.2

Make sure that the main power has been switched off ....................................

1.3

Safety risks ......................................................................................................

1.3.1

Safety risks during installation and service work on robots ..............................

1.3.2

Moving robots are potentially lethal ............................................................

1.3.3

First test run may cause injury or damage ....................................................

1.3.4

Work inside the working range of the robot ..................................................

1.3.5

Enabling device and hold-to-run functionality ...............................................

1.3.6

Risks associated with live electric parts .......................................................

1.3.7

The unit is sensitive to ESD .......................................................................

1.3.8

Hot parts may cause burns .......................................................................

1.3.9

Brake testing ..........................................................................................

1.3.10 Safety risks during handling of batteries ......................................................

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

1.4

Safety signals and symbols .................................................................................

1.4.1

Safety signals in the manual ......................................................................

1.4.2

Safety symbols on product labels ...............................................................

Product overview

2.1

Introduction to motor units and gear units ..............................................................

2.2

Motor units .......................................................................................................

2.3

Gear units ........................................................................................................

2.4

Basic approach .................................................................................................

2.5

Scenarios ........................................................................................................

Installation

3.1

Installing motor units .........................................................................................

3.2

Installing gear units ...........................................................................................

3.3

Fastening cables ...............................................................................................

3.4

Handling of motors ............................................................................................

3.5

Testing the brake release buttons .........................................................................

3.6

Insulation in arc welding stations .........................................................................

3.7

Installing non ABB brake release buttons ...............................................................

3.8

Changing the cable harness in the controller ..........................................................

Configuration

4.1

Loading configuration files ..................................................................................

4.2

Dimensioning gear units .....................................................................................

4.3

Tuning ............................................................................................................

Calibration

Tuning the thermal supervision

Maintenance

7.1

Introduction ......................................................................................................

7.2

Maintenance schedule .......................................................................................

7.3

Inspecting cables ..............................................................................................

Product manual - Motor Units and Gear Units

3HAC040148-001 Revision: K

Table of contents

Summary of Contents for MID 1000

Page 1: ...ROBOTICS Product manual Motor Units and Gear Units ...

Page 2: ...Trace back information Workspace R18 2 version a15 Checked in 2018 10 30 Skribenta version 5 3 012 ...

Page 3: ...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 ...

Page 4: ... 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 ...

Page 5: ...during work with gearbox lubricants oil or grease 30 1 4 Safety signals and symbols 30 1 4 1 Safety signals in the manual 32 1 4 2 Safety symbols on product labels 39 2 Product overview 39 2 1 Introduction to motor units and gear units 40 2 2 Motor units 41 2 3 Gear units 42 2 4 Basic approach 43 2 5 Scenarios 47 3 Installation 47 3 1 Installing motor units 50 3 2 Installing gear units 53 3 3 Fast...

Page 6: ...lacing parts 88 8 2 Replacing SMB board 90 8 3 Repair in the motor connection box 91 9 Decommissioning 91 9 1 Environmental information 93 10 Reference information 93 10 1 Applicable standards 95 10 2 Unit conversion 96 10 3 Spare parts and exploded views 97 10 4 Circuit diagrams 99 Index 6 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reser...

Page 7: ...n 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 Document ID Reference 3HAC040278 001 Product manual spare parts Motor Units and Gear Units 3HAC039887 001 Circuit diagram Motor Units and Gear Un...

Page 8: ...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...

Page 9: ...lished 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 K Product manual Motor Units and Gear Units 9 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved Overview of this manual Continued ...

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Page 11: ...t 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 th...

Page 12: ... 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 r...

Page 13: ...protective stops and emergency stops are described in the product manual for the controller Product manual Motor Units and Gear Units 13 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 14: ...ote Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 14 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 15: ...urn 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 Product manual Motor Units and Gear Units 15 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 1 Safety 1 2 2 Make sure that the main power has been switched off ...

Page 16: ...k 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 c...

Page 17: ...ons 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 ...

Page 18: ...uipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to run func...

Page 19: ...s powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If maintenan...

Page 20: ... 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 al...

Page 21: ...or 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 any...

Page 22: ...5 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 No...

Page 23: ...en if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged Product manual Motor Units and Gear Units 23 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 24: ... handling Note Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static voltages and must be grou...

Page 25: ...d 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 Product manual Motor Units and Gear Units 25 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 1 Safety...

Page 26: ...bed 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 26 Product manual Motor Units and Gear Units 3HAC040148 001 Revis...

Page 27: ...re 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 discharg...

Page 28: ...n Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic reaction Op...

Page 29: ... of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained 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...

Page 30: ...tions 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 WARNING Warns for electrical hazards which could result in severe personal injury or death ELECTRI...

Page 31: ...ons NOTE Describes where to find additional information or how to do an operation in an easier way TIP Product manual Motor Units and Gear Units 31 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 32: ...an and French Symbols on safety labels Description Symbol Warning xx0900000812 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 to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing i...

Page 33: ...isassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page Product manual Motor Units and Gear Units 33 3HAC040148 001 Revision K Copyright 2011 2018 ABB All ...

Page 34: ...f the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page 34 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 35: ...1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page Product manual Motor Units and Gear Units 35 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 36: ...ifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page 36 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 37: ...part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts Product manual Motor Units and Gear Units 37 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labe...

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Page 39: ...al 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 uni...

Page 40: ... 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 Weight kg Motor unit 1 37 MU 80 4 4 MU 100 9 3 MU 200 13 2 MU 250 15 MU 300 27 MU 400 40 Product manual Motor Units and Gear Unit...

Page 41: ...erchange 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 Weight kg Gear unit 70 MTD 2...

Page 42: ... 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 page75 Related information Application manual Additional axes and s...

Page 43: ...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 MU MU 3 2 1 xx1000001197 Continues on next page Product manual Motor Units and Gear Units 43 3HA...

Page 44: ...198 Gear units Scenario A SMB box connected to the IRC5 controller Three gear units connected to one SMB box MTD MTD MID 3 2 1 xx1000001199 Continues on next page 44 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 2 Product overview 2 5 Scenarios Continued ...

Page 45: ...B box connected to the IRC5 controller Two gear units connected to one SMB box 3 MTD MTD MU 2 1 xx1000001200 Continues on next page Product manual Motor Units and Gear Units 45 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 2 Product overview 2 5 Scenarios Continued ...

Page 46: ... box One SMB box connected to IRC5 drive module Three motor units connected to the IRC5 drive module through the SMB box MTD MTD MU MU MU 2 3 3 2 1 1 xx1000001201 46 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 2 Product overview 2 5 Scenarios Continued ...

Page 47: ...ng 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 page64 Motor connection Positive electric rotation R S T U V W results in positive mechanical rotation defined as clockwise direction se...

Page 48: ...then the box must be isolated see Insulation in arc welding stations on page 64 If using an SMB box fit and secure the box 2 Assembly instructions are included in the kit If using a separate drive module cabinet connect the cable included with the cabin et 3 If the controller is not prepared for motor units then the connector must be replaced see Changing the cable harness in the controller on pag...

Page 49: ...ervision is properly tuned see Tuning the thermal supervision on page 75 Product manual Motor Units and Gear Units 49 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 3 Installation 3 1 Installing motor units Continued ...

Page 50: ...he 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 connectio...

Page 51: ...ntroller to the SMB box 6 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 7 Mark the cables 8 Install a current collector 9 See Testing the brake release buttons on page 63 Test the brake release but...

Page 52: ...rated 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 Locally made swing frame A Pneumatic plunch B 52 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 3 Installation 3 2 Installing gear units Continued ...

Page 53: ...suitable labels or other markings during installation to simplify maintenance Marking Cable connection MP Motor power cables FB Feedback cables 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 Prod...

Page 54: ...1498 A B xx1700001372 MP A MP M23 B The following table lists the materials used for making new connector MP The materials are delivered with the MU 80 Qty Component article number Item 1 3HAC026336 004 1 2 3HAC026345 002 2 4 3HAC026345 001 3 The following table shows the connection between connector MP and connector MP M23 Pin on Connect or MP M23 Pin on Connect or MP Description Wire type 3 1 U ...

Page 55: ... 500000091498 A xx1700001373 FB A FB M23 B The following table lists the materials used for making new connector FB The materials are delivered with the MU 80 Qty Component article number Item 1 3HAC6996 8 1 6 3HAC6962 3 2 The following table shows the connection between connector FB and connector FB M23 Pin on Connect or FB M23 Pin on Connect or FB Description Wire type 1 5 X Pair 1 BK AWG24 3 1 ...

Page 56: ...les are not bent too close to the fastening points or too sharply xx1000001397 Fastening point or connector A Minimum distance from fastening point to bend is 100mm B Minimum bending radius is 100mm C Twisting The minimum length between the fastening points is 900mm if the cable will be twisted 180 xx1000001398 Fastening points or connectors A Minimum length is 900mm B Continues on next page 56 Pr...

Page 57: ...Do not over tighten cables when fastening them with straps Product manual Motor Units and Gear Units 57 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 3 Installation 3 3 Fastening cables Continued ...

Page 58: ... 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 Th...

Page 59: ...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 Conti...

Page 60: ... 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 60 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights res...

Page 61: ... kN MU 100 20 kN MU 200 20 kN MU 250 20 kN MU 300 30 kN MU 400 Continues on next page Product manual Motor Units and Gear Units 61 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 3 Installation 3 4 Handling of motors Continued ...

Page 62: ...tion 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 62 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 3 Installation 3 4 Handling of motors Con...

Page 63: ...brake release buttons Use this procedure to test the brake release buttons Information Action Turn on the power to the controller 1 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 2 When the brake is released the axis should be possible to move Press the brake release button 3 Verify that th...

Page 64: ...iece 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 sce...

Page 65: ... contact with protective earth D Cable channel made of metal E Power source F SMB box galvanically insulated from the weld circuit G Motor unit s protective earth connected to the weld circuit H Product manual Motor Units and Gear Units 65 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 3 Installation 3 6 Insulation in arc welding stations Continued ...

Page 66: ... 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 66 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 3 Installation 3 7 Installing non ABB brake release buttons ...

Page 67: ...e cable harness Changing the cable harness Use this procedure to change the cable harness in the controller Note Action 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 1 Remove the cable harness for the XS 7 contact 2 Circuit diagram Motor Units and Gear Units Refit the new cable h...

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Page 69: ... 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 accel...

Page 70: ...tStudio load the configuration files for the motor units and the gear units Open the file readme txt to verify which files to use 1 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 2 See Tuning on page 72 Tune the motor 3 Configuration...

Page 71: ...he 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 Recommended maximum acceleration and de...

Page 72: ... 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...

Page 73: ...ith 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 Note Action Mark the zero position for future reference Move the mechanical unit to a suitable zero position for calibration 1 On the FlexPendant ABB menu tap Calibration 2 Tap to sel...

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Page 75: ...ipulator 45 C 5 C to 52 C Maximum temperature Max Temperature Robot Topic Motion type Motion System Topic Motion type Supervi sion 1 0 0 5 to 2 Thermal supervision Thermal Supervision Sensit 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 th...

Page 76: ...re rise then decrease the thermal supervision sensitivity ratio 3 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 4 Related information Technical reference manual System parameters Application...

Page 77: ...ded 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 an...

Page 78: ...ths or battery low alert i Battery pack meas urement system of type RMU101 or RMU102 3 pole bat tery contact Replacement Replacing SMB bat tery on page 81 Battery low alert ii Battery pack meas urement system with 2 pole battery contact e g DSQC633A Replacement i The battery low alert 38213 Battery charge low is displayed when the battery needs to be replaced The recommendation to avoid an unsynch...

Page 79: ...re entering the robot working area 1 Make an overall visual inspection of the cables to detect wear or damage 2 Check the connectors 3 Check that all brackets and straps are properly at tached 4 Replace the cables if wear cracks or damage is detected 5 Product manual Motor Units and Gear Units 79 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 7 Maintenance 7 3 Inspecting cab...

Page 80: ...ole from the glass cover in the middle 2 Replace the MU250 if oil leakage is detected in the middle drain hole 3 Check that the stop screws for the other two drain holes are properly attached 4 Secure or reassemble the stop screws if any loose or missing 5 Parts A Drain hole with glass cover B Drain hole with stop screw C Drain hole with stop screw 80 Product manual Motor Units and Gear Units 3HAC...

Page 81: ...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 duri...

Page 82: ...th 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 82 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 7 Maintenance 7 5 Replacing SMB battery Continued ...

Page 83: ...TION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 3 Pull out the battery and disconnect the battery cable 4 Fit the new battery and connect the battery cable 5 Close the SMB box 6 See Calibration on page 73 Update the revolution counters 7 See Environmental information on page 91 Dispose of the old battery 8 P...

Page 84: ...e 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 Note Cleaning method Yes Vacuum cleaner Yes With light cleaning detergent Wipe with cloth Yes It is highly recommended t...

Page 85: ...lace 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 Note Equipment Grease type P34 from Nies Article number 0501869 001 Grease Standard tools Grease gun Lubricating the current collector Information Action No...

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Page 87: ...01 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 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 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Product manual Motor Units and Gear Units 87 3HAC040148 001 Revision K Copyright 2011 2018 ABB ...

Page 88: ...e the SMB board in the SMB box Information Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 ELECTROSTATIC DISCHARGE ESD Before handling the unit see The unit is sensitive to ESD on page 24 2 Open the cover on the SMB box CAUTION Clean cover from metal residues before opening Metal residues can cause...

Page 89: ...ormation Action Place the new SMB board on the mounting plate 1 Check that the toothed washer is in place and fasten the nuts fully 2 Cross tighten the screws to make sure the sealing is tight Refit the plate and fasten the screws fully 3 Connect the cables and close the cover 4 See Calibration on page 73 Update the revolution counters 5 Product manual Motor Units and Gear Units 89 3HAC040148 001 ...

Page 90: ...0 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 90 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 8 Repair 8 3 Repair in the motor connection box ...

Page 91: ...or Lithium Cables motors Copper Gear housings Cast iron nodular iron Gears screws shafts brackets and so on Steel Brakes motors Neodymium Cables connectors and so on Plastic rubber Gearboxes Oil grease Motor housings Aluminium 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...

Page 92: ...sms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 92 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 9 Decommissioning 9 1 Environmental information Continued ...

Page 93: ... 1998 Classification of air cleanliness EN ISO 14644 1 2015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60...

Page 94: ...control devices Functional aspects Principles for design EN 574 1996 A1 2008 94 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 10 Reference information 10 1 Applicable standards Continued ...

Page 95: ...3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume Product manual Motor Units and Gear Units 95 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 10 Reference information 10 2 Unit conversion ...

Page 96: ...vered as a separate document on the documentation DVD Article number for Product manual spare parts Motor Units and Gear Units is 3HAC040278 001 96 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 10 Reference information 10 3 Spare parts and exploded views ...

Page 97: ...Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB 2400 3HAC029570 007 Circuit diagram IRB 2600 3HAC9821 1 Circuit dia...

Page 98: ... 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram Product ProductName 3HAC056159 002 Circuit diagram IRB 910SC Other hardware Article numbers for circuit diagrams Product 3HAC039887 001 Circuit diagram Motor Units and Gear Units 98 Product manual Motor Units and Gear Units 3HAC040148 001 Revision K Copyright 2011 2018 ABB All rights reserved 10 Reference informati...

Page 99: ...ling motor 62 E enabling device 21 environmental information 91 ESD damage elimination 24 sensitive equipment 24 external safety devices 17 F files template configurations 69 fine calibrating 73 fire extinguishing 14 floor loads MID 50 G gear units installing 50 grease disposal 91 H hanging installed hanging 16 hazardous material 91 height installed at a height 16 hold to run 21 HRA 12 I installin...

Page 100: ...service work 16 voltage 22 safety signals in manual 30 safety standards 93 safety zones 12 screws gear units 50 motor units 47 signals safety 30 SMB battery replacing 81 SMB board 88 SMB box description 39 installing 47 50 insulation 50 64 isolation 47 standards 93 EN 93 EN IEC 93 EN ISO 93 steel disposal 91 straps 57 symbols safety 30 system integrator requirements 11 system parameters loading 69...

Page 101: ......

Page 102: ...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 ...

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ABB MID 1000, Product Manual

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