ABB MC91 HESG440588R4 HESG112714/B

Description

Detailed parameter table

ABB MC91 HESG440588R4 HESG112714/B

Product introduction

The ABB MC91 HESG440588R4 HESG112714/B is a high-performance motion control module engineered to deliver precise motor control in industrial automation systems, seamlessly integrating with ABB’s AC drives to enable advanced motion sequences. This module serves as a critical bridge between sensors, human-machine interfaces (HMIs), and drive systems, making it an essential component in applications requiring accurate position, speed, or torque regulation—from robotic arms to conveyor systems.

Featuring a versatile combination of analog and digital I/O, the ABB MC91 supports diverse sensor inputs (e.g., encoders, pressure transducers) and actuator outputs (e.g., servo valves, variable speed drives). Its dual communication interfaces (Profibus DP and RS485) facilitate real-time data exchange with PLCs and supervisory systems, ensuring synchronized operation in complex automation networks.

Built for industrial durability, the ABB MC91 operates reliably in temperatures ranging from -10°C to 60°C, resisting electromagnetic interference and vibration common in manufacturing environments. Its compact design (140mm × 100mm × 80mm) allows for space-efficient installation in control cabinets, while its modular architecture simplifies integration with existing ABB drive systems. Whether deployed in packaging machinery, material handling equipment, or precision assembly lines, this module delivers consistent performance for optimizing production efficiency.

Core advantages and technical highlights

Multi-mode control flexibility

The ABB MC91 supports position, speed, and torque control modes, enabling seamless adaptation to diverse motion requirements. For example, in a robotic welding application, it can switch from speed control (for arm movement) to torque control (for precise weld pressure) within 50 μs, ensuring process accuracy. This flexibility eliminates the need for specialized controllers, reducing system complexity and cost.

High-precision feedback integration

Equipped with a high-speed encoder interface (up to 1024 pulses/rev), the module achieves position resolution down to 0.0009 degrees for a 1024-pulse encoder, enabling micron-level positioning in applications like semiconductor wafer handling. The interface supports both HTL and TTL encoders, ensuring compatibility with legacy and modern feedback devices without additional adapters.

Fast processing and response

With a 50 μs control loop cycle, the ABB MC91 delivers rapid adjustments to motor output, critical for dynamic applications such as high-speed sorting systems. This speed minimizes overshoot during acceleration/deceleration phases, reducing product damage and improving throughput. For instance, in a bottle-filling line, the module can adjust conveyor speed within 50 μs of detecting a bottle position error, maintaining fill accuracy.

Versatile I/O configuration

The module’s 4 analog inputs (configurable for 0-10 V or 4-20 mA) and 2 analog outputs support a wide range of sensors and actuators. For example, an analog input can receive a 4-20 mA signal from a pressure sensor to adjust torque in a winding machine, while an analog output can send a 0-10 V signal to a proportional valve for tension control. The 8 digital inputs and 4 relay outputs handle discrete signals like limit switches and emergency stops, providing comprehensive control coverage.

Robust communication

Dual communication interfaces (Profibus DP at up to 12 Mbps and RS485) ensure reliable data exchange in distributed systems. Profibus DP enables real-time control commands from a central PLC, while RS485 supports local monitoring via HMI panels. This redundancy is critical in mission-critical applications like automotive assembly, where communication failures could halt production.

Typical application scenarios

Packaging machinery

In a carton folding machine, the ABB MC91 controls servo motors responsible for folding and sealing operations. Using position control mode, it ensures each carton is folded to within ±0.5mm tolerance, with encoder feedback verifying accuracy. Digital inputs detect carton presence via photoelectric sensors, triggering the module to adjust motor speed based on line throughput (communicated via Profibus DP from the main PLC). The result is consistent packaging quality at speeds up to 200 cartons per minute.

Material handling

In an automated storage and retrieval system (AS/RS), the module regulates the speed and position of stacker cranes. Torque control mode prevents overloading when lifting heavy pallets, while position feedback ensures precise alignment with storage racks (±2mm). Digital outputs activate brakes and clamps, synchronized with motion via the module’s fast processing loop. RS485 communication allows operators to monitor crane status via a local HMI, while Profibus DP integrates with the warehouse management system for centralized control.

Metal forming

In a press brake application, the ABB MC91 controls the ram position to achieve precise bending angles (±0.1 degrees). Analog inputs receive pressure feedback from load cells, adjusting ram speed during the bending phase to maintain consistent force. Digital inputs detect material thickness via laser sensors, automatically selecting the correct bending program stored in the module. The result is reduced setup time and improved part consistency in batch production.

Robotics

In a 6-axis robotic arm for electronics assembly, the module coordinates joint movements in position control mode. Encoder feedback from each joint ensures smooth motion trajectories, while torque control prevents damage to delicate components during insertion. Profibus DP communication with the robot controller enables complex sequences like pick-and-place with sub-millimeter accuracy, supported by the module’s 50 μs processing speed.

ABB MC91 HESG440588R4 HESG112714/B

Related model recommendations

ABB MC92 HESG440589R4: A higher-performance variant with 6 axes of control, suitable for multi-axis robots.

ABB ACS880-01-07A6-3: An AC drive paired with the ABB MC91 for 3-phase motor control up to 4 kW.

ABB EI803F 3BSE022369R1: An encoder interface module that extends the ABB MC91’s feedback capabilities to absolute encoders.

ABB CI854A 3BSE022469R1: A Profibus DP repeater that extends communication range for the ABB MC91 in large facilities.

ABB PP835 3BSE042236R1: An HMI panel that interfaces with the ABB MC91 for local motion parameter adjustment.

ABB 800xA Motion Control: Software that configures and monitors the ABB MC91, enabling advanced trajectory planning.

Installation, commissioning and maintenance instructions

Installation preparation

Mount the ABB MC91 on a 35mm DIN rail in a control cabinet, ensuring 100mm clearance above/below for ventilation. Avoid proximity to high-voltage cables or motors to minimize EMI.

Verify the 24 V DC power supply (±10%) and install a 2A fuse in the supply line. Use shielded twisted-pair cables for all I/O and communication connections, with shields grounded at both ends.

Prepare tools: torque screwdriver (0.5-0.8 Nm), wire strippers, and a multimeter. Label all connections (e.g., “Encoder A,” “Analog In 1”) to simplify troubleshooting.

Check compatibility with connected devices: ensure encoder signals match HTL/TTL settings, and analog sensors/outputs align with 0-10 V/4-20 mA ranges.

Commissioning steps

Power on the module and verify the green “POWER” LED illuminates. Check for fault LEDs (red) indicating wiring errors or communication issues.

Use ABB’s DriveCom software to configure control mode (position/speed/torque), I/O ranges, and encoder settings. Calibrate analog inputs using a precision signal generator to ensure ±0.1% accuracy.

Test motion sequences: send a position setpoint via Profibus DP and verify encoder feedback matches within ±1 pulse. Test digital inputs by activating limit switches and confirming the module triggers the correct output (e.g., motor stop).

Validate safety functions: simulate an emergency stop signal and confirm the module halts motor output within 50 ms. Check relay outputs for proper contact closure using a multimeter.

Perform a full system test under load, monitoring for overheating (module temperature <60°C) and communication latency (Profibus DP response <10 ms).

Maintenance suggestions

Inspect the ABB MC91 quarterly for dust accumulation; clean with compressed air (low pressure) to prevent overheating.

Check wiring connections semi-annually, retightening terminals to 0.6 Nm if loose—especially encoder and power connections, which are critical for feedback accuracy.

Calibrate analog inputs/outputs annually using a certified signal generator. Verify position accuracy with a laser interferometer for high-precision applications.

Monitor communication health monthly via DriveCom software, checking for Profibus DP errors (e.g., CRC faults). Replace communication cables if errors exceed 1 per hour.

Replace the module if fault LEDs persist after troubleshooting, or if motion accuracy degrades beyond acceptable limits (e.g., position error >5 pulses). Store spares in anti-static packaging at -25°C to 70°C.

Service and guarantee commitment

The ABB MC91 HESG440588R4 HESG112714/B comes with a 36-month warranty from installation, covering manufacturing defects and ensuring compliance with performance specifications. ABB guarantees replacement of faulty modules within 48 hours for critical applications, minimizing production downtime.

Technical support includes 24/7 access to ABB’s motion control specialists, who provide assistance with configuration, tuning, and system integration. Online resources include detailed wiring diagrams, tuning guides, and compatibility matrices with ABB drives. Extended service contracts offer annual preventive maintenance, calibration, and on-site support during system upgrades, ensuring the module maintains precision control throughout its 10-year design lifespan.