ABB robots are trusted worldwide for their precision, efficiency, and reliability in industrial automation. But like any high-performance machine, they require regular maintenance to keep running at their best. One task that often gets overlooked—but is critical—is replacing the track power cable.

This cable delivers power to the robot’s moving parts. When it wears out or gets damaged, you risk reduced performance, unexpected downtime, or even system failure. In this guide, we’ll walk you through the step-by-step process of replacing the track power cable on an ABB robot, from preparation to final testing.

1. Preparation: Safety First

Before touching any tools, power down the robot completely. Disconnect it from the power source and place a clear warning sign—“Under Maintenance, Do Not Switch On”—on the switch to prevent accidents.

Wear the right protective gear:

• Safety helmet

• Insulating gloves

• Protective goggles

You’ll also need the right tools:

• Wrenches and screwdrivers

• Wire cutters and strippers

• Crimping pliers

• Multimeter

Finally, have your replacement track power cable ready. Make sure it’s the same model and specification as the original to avoid compatibility problems. You can find the exact details in your ABB robot technical manual—this will also help you understand the cable’s location and routing before you start.

2. Removing the Old Track Power Cable

The first step involves locating and removing the old track power cable. Begin by opening the robot's access panels or housing. This will grant you visibility and access to the connection points where the track power cable interfaces with various robot components, such as motors and control cabinets. Using the appropriate tools, carefully unscrew or unplug these connections.

Start by unpacking the new track power cable. Route it through the trunking or conduit, following the exact path taken by the old cable. Ensure that the new cable does not interfere with any other components within the robot. Connect one end of the new cable to the robot's motor or other power equipment. Securely tighten the screws or firmly plug it in to establish a stable connection.

After the new cable is connected, it's essential to tidy up the cables within the trunking or conduit. Organize them neatly to avoid tangling, which could lead to future problems. Once the cables are in order, close the robot's access panels or housing, making sure they are securely fastened. Now, restore power to the robot.

By following these replacement steps meticulously, you can successfully replace the track power cable of an ABB robot, ensuring its continued efficient and reliable operation.

• Position the Robot – Manually move the robot into a safe, accessible position.

• Remove Covers – Open the access panels or housing to locate the track power cable connection points.

• Locate the Seventh-Axis Cable – If replacing the seventh-axis motor cable, remove the seventh-axis cover plate to access it.

• Disconnect the Cable – Remove the fixed cover plates at both ends of the drag chain, unplug the cable from the motor, and cut any zip ties securing it.

3. Installing the New Track Power Cable

Manually move the robot to a suitable position and then disconnect its power.

Remove the seventh-axis cover plate to locate the seventh-axis motor power cable. Confirm the worn -out cable model (orange).

Remove the fixed cover plates at both ends of the drag chain. Unplug the short cable connected to the robot motor and pull out the cable (note the zip ties securing the wiring).

Obtain a seventh-axis motor cable of the same model (Motor Movement Track M2008-15m3HAW050008608-01 5) and replace the worn-out cable on the robot's seventh-axis motor. Route the new cable through the drag chain, paying attention to the wiring installation.

After replacing the seventh-axis motor cable, manually move the robot to check for any interference or rubbing of the wiring. Verify that there are no issues before restoring the line.

• Prepare the New Cable – Use a cable of the same model, such as Motor Movement Track M2008-15m3HAW050008608-01 5.

• Route the Cable – Pass the cable through the drag chain, following the exact path of the old one.

• Reconnect – Attach one end to the seventh-axis motor or relevant component, making sure the connection is tight and secure.

• Organize the Wiring – Use zip ties or clamps to keep everything neat and prevent interference.

• Close Panels – Reinstall all covers and panels securely.

4. Testing the Installation

Before fully restoring power:

• Manually move the robot to check for any rubbing or interference.

• Ensure all connections are secure.

• Once confirmed, power up the robot and run a brief test cycle.

Conclusion

Replacing the track power cable on an ABB robot isn’t just routine maintenance—it’s essential for preventing downtime and keeping your automation system running at peak performance. With proper preparation, careful handling, and thorough testing, you can complete the replacement efficiently and safely.

For industrial robot spare parts, including ABB cables and accessories, visit inrobots.shop to find compatible, high-quality replacements.