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ABB MU 80 Product Manual
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ABB MU 80 Product Manual

ABB MU 80 Product Manual

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ROBOTICS
Product manual
Motor Units and Gear Units

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Summary of Contents for ABB MU 80

  • Page 1 ROBOTICS Product manual Motor Units and Gear Units...
  • Page 2 Trace back information: Workspace 24B version a15 Checked in 2024-06-18 Skribenta version 5.5.019...

  • Page 3: Product Manual

    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 OmniCore Document ID: 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Inspecting MU250 drain holes ................Replacing the motor connection box battery ............Cleaning the motor units and gear units ..............Lubricating the current collector ................Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 6 Introduction to decommissioning ................. Environmental information .................. 10 Reference information 10.1 Applicable standards ..................10.2 Unit conversion ....................10.3 Standard toolkit ....................Index Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 7: Overview Of This Manual

    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.
  • Page 8 3HAC082287-001 Application manual - TuneMaster 3HAC063590-001 This manual contains all safety instructions from the product manuals for the manipulators and the controllers. All documents can be found via myABB Business Portal, www.abb.com/myABB. Revisions Revision Description First edition. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A ©...

  • Page 9: Safety

    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 robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.

  • Page 10: Requirements On Personnel

    The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 11: Safety Signals And Symbols

    NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 12 Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 13: Safety Symbols On Product Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 14 This axis has extended rotation (working area) compared to standard. xx0900000814 Crush Risk of crush injuries. xx0900000817 Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 15 Adjustable chain sling with shortener xx1000001242 Lifting xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 16 Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 17: Stopping Functions

    For more information see: • Product manual - OmniCore V250XT Type B • Product manual - OmniCore V400XT Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 18: Installation And Commissioning

    Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 19: Safety During Operation

    A mechanical unit may perform unexpected limited movement. WARNING Movements by mechanical units can cause serious injuries on users and may damage equipment. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 20: Safety During Maintenance And Repair

    Use appropriate protective gear such as heat-resistant gloves, goggles/protective visor, or a body suit if necessary. Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 21 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. Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 22 See the manual for SafeMove in References on page Related information See also the safety information related to installation and operation. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 23: Safety During Troubleshooting

    1.7 Safety during troubleshooting General DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. When troubleshooting requires work with power switched on, special considerations must be taken: •...

  • Page 24: Safety During Decommissioning

    A mechanical unit may perform unexpected limited movement. WARNING Mechanical unit movements can cause serious injuries on users and may damage equipment. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 25: Product Overview

    This manual provides the characteristics, installation, maintenance, and repair instructions for the Motor Units and Gear Units. The units are power-operated and function as external axes. They are powered from ABB drive units mounted in the robot controller. These drive units are controlled from robot control software.

  • Page 26: Motor Units

    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: •...

  • Page 27: Gear Units

    Connection Kit Mass Gear unit Weight [kg] MTD 250 MTD 500 MTD 750 MTD 2000 MTD 5000 Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 28 2 Product overview 2.3 Gear units Continued Gear unit Weight [kg] MID 500 MID 1000 Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 29: Cables

    Part of Motor connection kit 3069-x. Non-flexible cable. xx2300001889 OmniCore - MU Cable harness power Option 4114-1, 4114-2, 4114-3. (Flexible cable). xx2300001891 Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 30 Part of Motor connection kit 3069-x. Non-flexible cable. xx2300001892 MCB - MU/GU Signal Option 4118-1, 4119-1, 4120-1. (Flexible cable). xx2300001890 Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 31 2 Product overview 2.4 Cables Continued MCB - MU/GU Cable harness power Option 4115-1, 4116-1, 4117-1. (Flexible cable). xx2300001893 Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 32: Commissioning

    Tuning the thermal supervision on page Related information Application manual - Additional axes. Operating manual - OmniCore. Operating manual - RobotStudio. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 33: Scenarios

    No motor connection box (MCB) • Motor power connected to the robot controller and resolver connected to FB7 at manipulator. xx2300001886 Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 34 Up to three motor units or gear units motor units connected to one motor connection box (MCB) xx2300001489 Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 35 • Up to six motor units or gear units connected to the robot controller, through the motor connection box (MCB) xx2300001885 Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 36: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 37: Installation

    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 Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 38 If there is a risk of return currents, then the box. box must be isolated, see Insulation in arc welding stations on page Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 39 Testing the brake release buttons on page CAUTION Make sure that the thermal supervision is properly tuned, see Tuning the thermal supervision on page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 40: Installing Gear Units

    WARNING The gear unit is heavy. Always use prop- erly sized lifting accessories. Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 41 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.

  • Page 42: Fastening Cables

    Cable connection Marking Motor power cables Resolver feedback cables Extended cables for MU 80 MU 80 provides extended power and resolver feedback cables. xx1700001371 Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 43 Always refer to the tables below to prepare new connectors. Extended power cable xx1700001372 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. 3HAC026336-004...
  • Page 44 3 Installation 3.3 Fastening cables Continued Extended resolver feedback cable xx1700001373 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. 3HAC6996-8 3HAC6962-3 Prepared...
  • Page 45 The minimum length between the fastening points is 900mm if the cable will be twisted ±180°. xx1000001398 Fastening points or connectors Minimum length is 900mm Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 46 3 Installation 3.3 Fastening cables Continued Fastening straps Do not over-tighten cables when fastening them with straps. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 47: Handling Of Motors

    This method is not applicable for MU 100 since it does not have a flange on the motor shaft. xx1300000317 Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 48 Make sure that the contact surfaces between the motor and the dolly distribute the press force evenly. Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 49 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...
  • Page 50 10 kN MU 200 20 kN MU 250 20 kN MU 300 20 kN MU 400 30 kN Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 51 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 Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 52: Testing The Brake Release Buttons

    The brake release buttons shall be tested before mounting loads or external equipment. Note The brake release buttons are part of MCB (optional). Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 53 Press the brake release button. When the brake is released, the axis should be possible to move. Verify that the correct motor brake was released. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 54: Insulation In Arc Welding Stations

    The motor units are connected to protective earth when using cables supplied by ABB. 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.
  • Page 55 Cable channel made of metal Power source MCB box galvanically insulated from the weld circuit Motor unit’s protective earth connected to the weld circuit Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 56: Installing Non Abb Brake Release Buttons

    Installing non ABB brake release buttons Use connection BRAKE PB. See the connections in the circuit diagram, Circuit diagram - Motor Units and Gear Units. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 57: Configuration

    Open the file ...\utility\... in the Robot- readme.txt to verify which files to use. Ware installation. Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 58 Tune the motor. Tuning on page Configuration files and standard system parameters are described in Technical reference manual - System parameters. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 59: Creating And Downloading The Robotware System

    Additional axes should be configured to use Safe Disable of Drive Unit in Visual SafeMove, see limitations for SafeMove in Application manual - Functional safety and SafeMove. Continues on next page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 60 4.2 Creating and downloading the RobotWare system Continued The interchange positions can be configured using Axis Position Supervision in Visual SafeMove. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 61: Dimensioning Gear Units

    MTD 5000 11400 MID 500 1950 MID 1000 5000 Related information Dimensioning of motors is described in Application manual - Additional axes. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 62: Tuning

    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. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 63: Safe Disable Of Drive Unit

    More information about the safety function Safe Disable of Drive Unit is available in Application manual - Functional safety and SafeMove. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
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  • Page 65: Calibration

    Commutation of motors is described in Application manual - Additional axes. Coordinated positioners and user frames are described in Application manual - Additional axes. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
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  • Page 67: Tuning The Thermal Supervision

    6 Tuning the thermal supervision Thermal supervision For protection against overheating of motor units (except MU 100 and MU 80) and gear units, there is a thermal supervision model that shall be configured and tuned. When properly tuned, there will be a warning close to maximum temperature and complete stop when maximum temperature is exceeded.
  • Page 68 Related information Technical reference manual - System parameters Application manual - TuneMaster Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 69: Maintenance

    For more information see: • Product manual - OmniCore V250XT Type B • Product manual - OmniCore V400XT • Fastening cables on page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 70: Maintenance Schedule

    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 - OmniCore for instructions. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 71: Inspecting Cables

    Check the connectors. Check that all brackets and straps are properly at- tached. Replace the cables if wear, cracks, or damage is detected. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 72: Inspecting Mu250 Drain Holes

    • A: Drain hole with glass cover • B: Drain hole with stop screw • C: Drain hole with stop screw Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 73: Replacing The Motor Connection Box Battery

    For replacement, see Product manual for V250XT or V400XT section Replacing the motor connection box battery. WARNING Hazards related to batteries on page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 74: Cleaning The Motor Units And Gear Units

    Never point the water jet at connectors, joints, sealings, or gaskets. • Do not use compressed air to clean the equipment. • Never use solvents that are not approved by ABB to clean the equipment. • Do not spray from a distance closer than 0.4 m. •...

  • Page 75: Lubricating The Current Collector

    Grease gun Lubricating the current collector Action Information Lubricate the current collector using a grease gun. Note Amount of grease: 12 ml. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 76 This page is intentionally left blank...

  • Page 77: Repair

    Carefully grind the paint edge that is left on the structure to a smooth surface. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 78: Replacing The Measurement Unit

    For replacement, see Product manual for V250XT or V400XT section Replacing the motor connection box battery. WARNING Hazards related to batteries on page Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 79: 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.
  • Page 80 This page is intentionally left blank...

  • Page 81: Decommissioning

    See also Environmental information on page Transportation Prepare the parts according to the risk assessment before transport, this to avoid hazards. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 82: Environmental Information

    9.2 Environmental information 9.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
  • Page 83 Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 84 This page is intentionally left blank...

  • Page 85: Reference Information

    – Immunity standard for industrial environments IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards – Emission standard for industrial environments Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 86: Unit Conversion

    0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.

  • Page 87: Standard Toolkit

    Socket head cap no: 6, socket 40 mm bit L 145 mm Socket head cap no: 6, socket 40 mm bit L 220 mm Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 88 This page is intentionally left blank...
  • Page 89 47 fine calibrating, 65 protective equipment, 10 fire extinguishing, 18 protective wear, 10 floor loads puller too, 51 MID, 40 Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 90 26 symbols weld current, 37, 40 safety, 11 system integrator requirements, 18 system parameters zero position, 65 loading, 57 Product manual - Motor Units and Gear Units 3HAC090254-001 Revision: A © Copyright 2011 -2024 ABB. All rights reserved.
  • Page 92 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2011 -2024 ABB. All rights reserved. Specifications subject to change without notice.

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