Table of contents7Overview of this manual ...................................................................................................................111 Safety111.1 General safety information ..................................................................................111.1.1 Limitation of liability .................................................................................131.1.2 Protective stop and emergency stop ...........................................................141.2 Safety actions ...................................................................................................141.2.1 Fire extinguishing ....................................................................................151.2.2 Make sure that the main power has been switched off ....................................161.3 Safety risks ......................................................................................................161.3.1 Safety risks during installation and service work on robots ..............................181.3.2 Moving robots are potentially lethal ............................................................191.3.3 First test run may cause injury or damage ....................................................201.3.4 Work inside the working range of the robot ..................................................211.3.5 Enabling device and hold-to-run functionality ...............................................221.3.6 Risks associated with live electric parts .......................................................241.3.7 The unit is sensitive to ESD .......................................................................251.3.8 Hot parts may cause burns .......................................................................261.3.9 Brake testing ..........................................................................................271.3.10 Safety risks during handling of batteries ......................................................281.3.11 Safety risks during work with gearbox lubricants (oil or grease) .......................301.4 Safety signals and symbols .................................................................................301.4.1 Safety signals in the manual ......................................................................321.4.2 Safety symbols on product labels ...............................................................392 Product overview392.1 Introduction to motor units and gear units ..............................................................402.2 Motor units .......................................................................................................412.3 Gear units ........................................................................................................422.4 Basic approach .................................................................................................432.5 Scenarios ........................................................................................................473 Installation473.1 Installing motor units .........................................................................................503.2 Installing gear units ...........................................................................................533.3 Fastening cables ...............................................................................................583.4 Handling of motors ............................................................................................633.5 Testing the brake release buttons .........................................................................643.6 Insulation in arc welding stations .........................................................................663.7 Installing non ABB brake release buttons ...............................................................673.8 Changing the cable harness in the controller ..........................................................694 Configuration694.1 Loading configuration files ..................................................................................714.2 Dimensioning gear units .....................................................................................724.3 Tuning ............................................................................................................735 Calibration756 Tuning the thermal supervision777 Maintenance777.1 Introduction ......................................................................................................787.2 Maintenance schedule .......................................................................................797.3 Inspecting cables ..............................................................................................Product manual - Motor Units and Gear Units 53HAC040148-001 Revision: K© Copyright 2011 -2018 ABB. All rights reserved.Table of contents