ABB OmniCore C90XT Product Manual

ROBOTICS

Product manual

OmniCore C90XT

Trace back information:

Workspace 21A version a14

Checked in 2021-03-30

Skribenta version 5.4.005

Product manual

OmniCore C90XT

OmniCore

Document ID: 3HAC073706-001

Revision: D

© Copyright 2020-2021 ABB. All rights reserved.

Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.

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.

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.



Table of contents


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

Product documentation ....................................................................................................................

9

11

1 Safety

1.1

Safety information .............................................................................................

1.1.1

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

1.1.2

Safety data .............................................................................................

1.1.3

Requirements on personnel ......................................................................

1.2

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

1.2.1

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

1.2.2

Safety symbols on controller labels ............................................................

1.3

Robot stopping functions ....................................................................................

1.3.1

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

1.3.2

About emergency stops ............................................................................

1.3.3

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

1.4

Robot operating modes ......................................................................................

1.4.1

About the manual mode ...........................................................................

1.4.2

About the automatic mode ........................................................................

1.5

Installation and commissioning ............................................................................

1.6

Operation ........................................................................................................

1.7

Maintenance and repair ......................................................................................

1.8

Troubleshooting ................................................................................................

1.9

Decommissioning ..............................................................................................

13

27

29

30

33

22

24

25

27

17

17

19

22

13

13

14

16

34

35

36

2 Controller description

2.1

OmniCore C90XT ..............................................................................................

2.2

Technical data for OmniCore C90XT controller .......................................................

2.3

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

2.4

Handling of FlexPendant ....................................................................................

2.5

Network security ...............................................................................................

2.6

Open source and 3rd party components in RobotWare .............................................

2.7

ABB Ability .......................................................................................................

37

37

38

43

44

46

47

48

3 Installation and commissioning 51

3.1

Introduction to installation and commissioning .......................................................

3.2

Installation activities ..........................................................................................

3.3

Transporting and handling ..................................................................................

3.3.1

Lifting the controller cabinet ......................................................................

3.3.2

Unpacking .............................................................................................

3.3.3

Storing ..................................................................................................

3.4

On-site installation ............................................................................................

3.4.1

Required installation space .......................................................................

3.4.2

Mounting the FlexPendant holder ...............................................................

3.5

Electrical connections ........................................................................................

3.5.1

Connectors on the OmniCore C90XT controller .............................................

3.5.2

Connecting cables to the controller .............................................................

3.5.3

Connecting the manipulator to the controller ................................................

3.5.4

Fitting the connector ................................................................................

3.5.5

Connecting power supply to and grounding the controller ...............................

3.5.6

Connecting and detaching a FlexPendant ....................................................

3.5.7

Network connections on OmniCore ............................................................

3.5.8

Set up the network connection ...................................................................

3.5.9

Descriptions for connectors ......................................................................

3.5.10 Configuring safety stops ...........................................................................

3.5.11 Programmable stop functions ....................................................................

64

69

70

73

56

58

62

62

51

52

53

53

54

55

56

76

79

84

87

99

100

5 Product manual - OmniCore C90XT

3HAC073706-001 Revision: D



3.6

I/O system .......................................................................................................

3.6.1

Available fieldbuses .................................................................................

3.6.2

Scalable I/O, internal and external ..............................................................

3.7

Installing options ...............................................................................................

3.7.1

Installing the harness for double SMB .........................................................

3.7.2

Installing the scalable I/O devices ..............................................................

3.7.3

Installing the Ethernet extension switch .......................................................

3.7.4

Installing the power supply optional device ..................................................

3.7.5

Installing the fieldbus adapter slave devices .................................................

3.7.6

Installing the fieldbus master .....................................................................

3.7.7

Installing the conveyor tracking module .......................................................

3.7.8

Installing the cable grommet assembly ........................................................

3.7.9

Installing the filter ....................................................................................

3.8

Installing add-on devices ....................................................................................

3.8.1

Installing the extension box .......................................................................

3.8.2

Installing the conveyor tracking module to extension box ...............................

3.9

Installing external devices ...................................................................................

3.10 Initial test before commissioning ..........................................................................

116

120

122

134

137

143

145

145

103

103

105

106

106

110

113

150

153

154

4 Maintenance 155

4.1

Maintenance schedule, OmniCore ........................................................................

4.2

Inspection activities ...........................................................................................

4.2.1

Inspection of controller .............................................................................

4.3

Cleaning activities .............................................................................................

4.3.1

Cleaning air filter .....................................................................................

4.3.2

Cleaning of the controller cabinet ...............................................................

4.3.3

Cleaning the FlexPendant .........................................................................

4.4

Changing/replacing activities ...............................................................................

4.4.1

Replacement of air filter ............................................................................

4.5

Function tests ...................................................................................................

4.5.1

Function test of emergency stop ................................................................

4.5.2

Function test of manual, auto, and manual full speed mode with FlexPendant ....

4.5.3

Function test of three-position enabling device .............................................

4.5.4

Function test of contactors A1.Q1 and A1.Q2 inside the power unit ..................

4.5.5

Function test of auto stop .........................................................................

4.5.6

Function test of external emergency stop ....................................................

4.5.7

Function test of ESTOP_STATUS output .....................................................

4.5.8

Function test of reduced speed control ........................................................

162

165

165

166

167

168

169

170

171

172

155

156

156

157

157

159

160

162

5 Repair 173

5.1

Introduction to repair .........................................................................................

5.2

Replacement of controller parts ...........................................................................

5.2.1

Opening the robot controller ......................................................................

5.2.2

Replacing the axis computer .....................................................................

5.2.3

Replacing the fans ...................................................................................

5.2.3.1 Replacing the standard fans ..........................................................

5.2.3.2 Replacing the heat exchanger ........................................................

5.2.4

Replacing the robot signal exchange proxy ..................................................

5.2.5

Replacing the Ethernet switch ...................................................................

5.2.6

Replacing the Connected Services Gateway ................................................

5.2.7

Replacing the scalable I/O unit ...................................................................

5.2.8

Replacing the main computer ....................................................................

5.2.9

Replacing the power unit ..........................................................................

5.2.10 Replacing the power supply ......................................................................

5.2.11 Replacing the drive unit ............................................................................

5.2.12 Replacing the fieldbus master ....................................................................

5.2.13 Replacing the conveyor tracking module(CTM) .............................................

5.2.14 Replacing the air filter ..............................................................................

198

202

208

213

242

247

257

265

279

284

173

174

174

175

181

182

186

192

6


Product manual - OmniCore C90XT



5.3

Replacing parts on the panels .............................................................................

5.3.1

Replacing the manipulator signal connector (SMB) ........................................

5.3.2

Replacing the motor connector ..................................................................

5.3.2.1 Replacing the motor connector ......................................................

5.3.3

Replacing the fieldbus adapter slave ...........................................................

5.3.4

Replacing the power inlet .........................................................................

5.3.5

Replacing the HMI signal (FlexPendant) connector ........................................

5.3.6

Replacing the cable grommet assembly ......................................................

5.3.7

Replacing the cable grommet assembly ......................................................

5.3.8

Replacing the harness ETH outlet with cable ................................................

5.3.9

Replacing the LED indicator ......................................................................

5.4

Replacing parts on the FlexPendant .....................................................................

5.4.1

Replacing the power cable and power cable cover ........................................

5.4.2

Replacing the joystick protection ................................................................

5.4.3

Replacing the fasten strip .........................................................................

312

321

330

336

342

342

346

349

288

288

292

294

298

302

306

6 Decommissioning 351

6.1

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

6.2

Environmental information ..................................................................................

351

352

7 Troubleshooting 355

7.1

Introduction to troubleshooting ............................................................................

7.2

Troubleshooting fault symptoms ..........................................................................

7.2.1

No LEDs are lit on the controller .................................................................

7.2.2

Start-up failure ........................................................................................

7.2.3

System update failure ..............................................................................

7.2.4

Problem releasing the robot brakes ............................................................

7.2.5

Problem starting or connecting the FlexPendant ...........................................

7.2.6

Problem using the joystick ........................................................................

7.2.7

Controller fails to start ..............................................................................

7.2.8

Reflashing firmware failure ........................................................................

7.2.9

Inconsistent path accuracy .......................................................................

7.3

Troubleshooting units ........................................................................................

7.3.1

Troubleshooting LEDs in the controller ........................................................

7.3.2

Troubleshooting the FlexPendant ...............................................................

7.3.3

Troubleshooting the drive unit ...................................................................

7.3.4

Troubleshooting the power unit ..................................................................

7.3.5

Troubleshooting fieldbuses and I/O ............................................................

7.3.6

Troubleshooting the Connected Services Gateway ........................................

7.3.7

Troubleshooting the Ethernet switch ...........................................................

7.3.8

Troubleshooting the axis computer .............................................................

7.3.9

Troubleshooting the main computer ............................................................

7.3.10 Troubleshooting the power supply ..............................................................

7.3.11 Troubleshooting the fieldbus adapter slave ..................................................

7.3.12 Troubleshooting the robot signal exchange proxy .........................................

373

374

375

376

378

378

379

380

355

357

358

361

364

365

369

382

387

388

394

396

398

401

406

407

8 Reference information 413

8.1

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

8.2

Applicable standards .........................................................................................

8.3

Unit conversion .................................................................................................

8.4

Standard toolkit for controller ..............................................................................

8.5

Screw joints .....................................................................................................

8.6

Weight specifications .........................................................................................

8.7

Lifting accessories and lifting instructions ..............................................................

413

414

416

417

418

419

420

9 Spare parts 421

9.1

Controller parts .................................................................................................

9.2

FlexPendant parts .............................................................................................

422

440





9.3

Manipulator cables ............................................................................................

9.3.1

Manipulator cables ..................................................................................

9.3.2

Customer cables - CP/CS connectors (option) ..............................................

9.3.3

Customer cables - Ethernet floor cable ........................................................

441

441

442

443

Index 445

8




Overview of this manual


About this manual

This manual contains instructions for:

• mechanical and electrical installation of the controller

• maintenance of the controller

• mechanical and electrical repair of the controller

Usage

This manual should be used during:

• installation and commissioning, from lifting the product to its work site and securing it to the foundation, to making it ready for operation

• maintenance work

• repair work

• decommissioning work

Note

It is the responsibility of the integrator to conduct a hazard and risk analysis of the final application and to ensure its safety.

It is the responsibility of the integrator to provide safety and user guides for the robot system.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

A maintenance/repair/installation craftsman working with an ABB robot must:

• be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work.

• be trained to respond to emergencies or abnormal situations.

References

Document name

Product specification - OmniCore C line

Circuit diagram - OmniCore C90XT

Operating manual - RobotStudio

Operating manual - OmniCore

Operating manual - Integrator's guide OmniCore

Technical reference manual - System parameters

Document ID

3HAC065034-001

3HAC065464-009

3HAC032104-001

3HAC065036-001

3HAC065037-001

3HAC065041-001

Continues on next page





Continued

Revisions

Document name

Application manual - Connected Services

Application manual - Conveyor tracking

Application manual - Force Control

Application manual - SafeMove

Revision

A

B

C

D

Document ID

3HAC028879-001

3HAC066561-001

3HAC070206-001

3HAC066559-001

Description

First edition.

Published in release 20C. The following updates are made in this revision:

• Updated information about safety data.

• Updated information about robot signal exchange proxy.

Published in release 20D. The following updates are made in this revision:

• Section

Mounting the FlexPendant holder on page 58

has been updated with new installation method for the FlexPendant holder.

• Section

Network connections on OmniCore on page 79

has been updated with NOTE regarding correct usage of the MGMT port.

Published in release 21A. The following updates are made in this revision:

• Minor corrections in section

Connections on the main computer on page 80 .

• Added extension cable spare parts in section

FlexPendant parts on page 440

.

• Minor corrections in section

Descriptions for connectors on page 87

.

10




Product documentation


Categories for user documentation from ABB Robotics

The user documentation from ABB Robotics is divided into a number of categories.

This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.

Tip

All documents can be found via myABB Business Portal, www.abb.com/myABB .

Product manuals

Manipulators, controllers, DressPack/SpotPack, and most other hardware is delivered with a Product manual that generally contains:

• Safety information.

• Installation and commissioning (descriptions of mechanical installation or electrical connections).

• Maintenance (descriptions of all required preventive maintenance procedures including intervals and expected life time of parts).

• Repair (descriptions of all recommended repair procedures including spare parts).

• Calibration.

• Decommissioning.

• Reference information (safety standards, unit conversions, screw joints, lists of tools).

• Spare parts list with corresponding figures (or references to separate spare parts lists).

• References to circuit diagrams.

Technical reference manuals

The technical reference manuals describe reference information for robotics products, for example lubrication, the RAPID language, and system parameters.

Application manuals

Specific applications (for example software or hardware options) are described in

Application manuals . An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful).

• What is included (for example cables, I/O boards, RAPID instructions, system parameters, software).

• How to install included or required hardware.

• How to use the application.

• Examples of how to use the application.




11



Continued

Operating manuals

The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters.

12




1 Safety

1.1.1 Limitation of liability

1 Safety

1.1 Safety information

1.1.1 Limitation of liability

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.

In particular, liability cannot be accepted if injury or damage has been caused for any of the following reasons:

• Use of the robot in other ways than intended.

• Incorrect operation or maintenance.

• Operation of the robot when the safety devices are defective, not in their intended location or in any other way not working.

• When instructions for operation and maintenance are not followed.

• Non-authorized design modifications of the robot.

• Repairs on the robot and its spare parts carried out by in-experienced or non-qualified personnel.

• Foreign objects.

• Force majeure.

Spare parts and equipment

ABB supplies original spare parts and equipment which have been tested and approved. The installation and/or use of non-original spare parts and equipment can negatively affect the safety, function, performance, and structural properties of the robot. ABB is not liable for damages caused by the use of non-original spare parts and equipment.




13

1 Safety

1.1.2 Safety data

1.1.2 Safety data

Prevailing standards and directives

For the use of industrial robots, regulations must be fulfilled as described in the following standards and directives:

• EN ISO 10218-1:2011

• Machinery Directive 2006/42/EC

Performance level and category

EN ISO 10218-1 requires structure category 3 and performance level PL d on the robot, see EN ISO 13849-1.

Risk assessment

The results of a risk assessment performed on the robot and its intended application may determine that a safety-related control system performance other than that stated in ISO 10218 is warranted for the application.

The SISTEMA/ABB FSDT libraries contains details for the safety functions.

Note

The safety functions are divided into two types called Basic Safety Functions and Extended Safety Functions . The Extended Safety Functions is an option.

Performance level for OmniCore C90XT

The OmniCore C90XT controller safety system has a safety category 3 with performance level PL d according to EN ISO 13849-1 and thus fulfils the safety performance requirement of the robot safety standard EN ISO 10218-1. The following data is applicable for OmniCore C90XT together with all supported ABB manipulators.

Safety function DC [%] PFH

D

[1/hour]

Emergency Stop

External Emergency Stop

Automatic Stop

Three-position Enabling Device

ESTOP_STATUS Output

Calculated

MTTF

D

[years]

127

142

142

104

276

93

92

92

94

80

4.29E-08

4.29E-08

4.29E-08

4.29E-08

1.01E-07

Safety data for SafeMove function

SafeMove functions Calculated

MTTF

D

[years]

Detachable TPU (triggered through emergency stop button on FlexPendant or other trigger)

127

Manual Operation Supervision 104


14

DC avg

[%]

Calculated PFH

D

[1/hour]

93

94

4.29E-08

4.29E-08




1 Safety

1.1.2 Safety data

Continued

SafeMove functions

Contact Application Tolerance (CAP)

Safe Brake Ramp

Stand Still Supervision (SST)

Axis Speed Supervision (ASP) (category 0 stop/category 1 stop)

Tool Speed Supervision (TSP) (category 0 stop/category 1 stop)

Axis Position Supervision (APO) (category 0 stop/category 1 stop)

144

144

Tool Position Supervision (TPO) (category 0 stop/category 1 stop)

144

Tool Orientation Supervision (TOR) (category 0 stop/category 1 stop)

144

Control Error Supervision 144

Calculated

MTTF

D

[years]

370

144

144

144

90

90

90

90

73

90

90

90

90

DC avg

[%]

Calculated PFH

D

[1/hour]

1.01E-07

4.29E-08

4.29E-08

4.29E-08

4.29E-08

4.29E-08

4.29E-08

4.29E-08

4.29E-08




15

1 Safety

1.1.3 Requirements on personnel

1.1.3 Requirements on personnel

General

Only personnel with appropriate training are allowed to install, maintain, service, repair, and use the robot. This includes electrical, mechanical, hydraulics, pneumatics, and other hazards identified in the risk assessment.

Persons who are under the influence of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, service, repair, or use the robot.

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 product manual.

16




1 Safety

1.2.1 Safety signals in the manual

1.2 Safety signals and symbols

1.2.1 Safety signals in the manual

Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal consists of:

• A caption specifying the hazard level (DANGER, WARNING, or CAUTION) and the type of hazard.

• Instruction about how to reduce the hazard to an acceptable level.

• A brief description of remaining hazards, if not adequately reduced.

Hazard levels

The table below defines the captions specifying the hazard levels used throughout this manual.

For more information, see standard ISO 13849.

Symbol Designation

DANGER

Significance

Signal word used to indicate an imminently hazardous situation which, if not avoided, will result in serious injury.

WARNING Signal word used to indicate a potentially hazardous situation which, if not avoided, could result in serious injury.

ELECTRICAL

SHOCK

Signal word used to indicate a potentially hazardous situation related to electrical hazards which, if not avoided, could result in serious injury.

CAUTION Signal word used to indicate a potentially hazardous situation which, if not avoided, could result in slight injury.

ELECTROSTATIC

DISCHARGE (ESD)

Signal word used to indicate a potentially hazardous situation which, if not avoided, could result in severe damage to the product.

NOTE Signal word used to indicate important facts and conditions.





17

1 Safety

1.2.1 Safety signals in the manual

Continued

Symbol Designation

TIP

Significance

Signal word used to indicate where to find additional information or how to do an operation in an easier way.

18




1 Safety

1.2.2 Safety symbols on controller labels

1.2.2 Safety symbols on controller labels

Introduction to symbols

This section describes safety symbols used on labels (stickers) on the controller.

Symbols are used in combinations on the labels, describing each specific warning.

The descriptions in this section are generic, the labels can contain additional information such as values.

Note

The symbols on the labels on the product must be observed. Additional symbols added by the integrator must also be observed.

Types of symbols

Both the manipulator and the controller are marked with symbols, containing important information about the product. This is important for all personnel handling the robot, for example during installation, service, or operation.

The safety labels are language independent, they only use graphics. See

Symbols on safety labels on page 19

.

The information labels can contain information in text.

Symbols on safety labels

Label Description

Read the user manual before use.

xx1400001152

The robot is delivered to start in automatic mode xx2100000104





19

1 Safety


Continued


CE label xx1800000835

UL certified (robot with controller) xx1400002061

Safety UL label (for the Functional Safety solution together with UL mark).

xx1700000353

SafeMove label (for SafeMove Basic and SafeMove Pro software).

xx1700000355

Rating label (example) xx1900001805


20





Electrical shock

1 Safety


Continued xx1400001151

Risk of electrical shock.

Keep controller cover closed when power is on.

Keep away from inside for 3 minutes after turning off power and disconnecting cable.

Read operation manual before installation.

Enclosure environmental type rating is type 1.

Inserting fingers or foreign objects into opening may cause personal injury.

xx1800000836

Warning & caution label

High voltage inside the module even if the main switch is in the OFF position.

xx1400001156

ESD sensitive components inside the controller.

xx1400001162




21

1 Safety

1.3.1 Protective stop and emergency stop

1.3 Robot stopping functions

1.3.1 Protective stop and emergency stop

Robot stopping functions

The robot has an emergency stop function and at least one protective stop function.

These functions have provision for the connection of external emergency stops and protective devices.

The emergency stop function is a complementary protective measure and shall not be applied as a substitute for safeguarding measures or safety functions.

The stop categories can be re-configured as defined by standards EN ISO

10218-1:2011 and IEC 60204-1:2016.

Emergency stop and protective stop functions are activated through dedicated safety inputs or safety protocols.

For example, an output from a safety rated presence sensing device output can be connected to a safety input on the robot controller. This is to initiate a protective stop of the robot.

Stop categories

Stop category 0

Stop category 1

Stop category 2

As defined in IEC 60204-1, stopping by immediate removal of power to the machine actuators.

As defined in IEC 60204-1, a controlled stop with power available to the machine actuators to achieve the stop and then removal of power when the stop is achieved.

As defined in IEC 60204-1, a controlled stop with power remaining available to the machine actuators.

Safety inputs to initiate a protective stop or an emergency stop

Protective stop and emergency stop inputs will initiate a stop, selectable of category

0 or category 1.

Safety inputs to initiate a stop

Description

Emergency stop (ES) The Emergency Stop is operational in both automatic and manual mode.

The default configuration is stop category 0. For deviations, see the product manual for the manipulator.

Protective Stop configured as Automatic stop (AS)

The safety input Automatic Stop is only operational in automatic mode.

The default configuration is stop category 1.

i

Protective Stop configured as General Stop (GS) i

The safety input General Stop is operational in both manual mode and automatic mode.

The default configuration is stop category 1.

Configuration to select General Stop, for example, protective stop in both manual mode and automatic mode, is not released.


22




1 Safety

1.3.1 Protective stop and emergency stop

Continued

Note

For OmniCore, a safety input that is initiated must remain active for at least 100 ms.

Stop category configuration for OmniCore

The stop category for the safety input can be configured, see Technical reference manual - System parameters .

i

Safety inputs

Automatic Stop

System parameter Function

Description

Category1AS Category1AS can be used to configure the protective stop in automatic mode either as stop category 0 or category 1. The default configuration is TRUE (stop category 1).

Emergency Stop Category1ES i

Category1ES is used to configure the emergency stop in automatic and manual mode. The default configuration is FALSE (stop category 0). The input is connected to the emergency stop on the FlexPendant and can also be connected to external devices.

In RobotWare 7.0 there are two values for the safety input Emergency Stop , named Category1EES

(for external emergency stop) and Category1LES (for emergency stop on FlexPendant). These are merged in RobotWare 7.1 into Category1ES .




23

1 Safety

1.3.2 About emergency stops

1.3.2 About emergency stops

The emergency stops

The purpose of the emergency stop function is to avert actual or impending emergency situations arising from the behavior of persons or from an unexpected hazardous event.

The emergency stop function is to be initiated by a single human action.

The emergency stop function is a complementary protective measure and shall not be applied as a substitute for safeguarding measures and other functions or safety functions.

The effect of an activated emergency stop device is sustained until the actuator of the emergency stop device has been disengaged. This disengagement is only possible by an intentional human action on the device where the command has been initiated. The disengagement of the device shall not restart the machinery but only permit restarting.

After actuation and before disengaging the emergency stop device, the machinery shall be inspected in order to detect the reason for actuation.

Recover from emergency stops

1 Make sure the hazardous situation that resulted in the emergency stop condition no longer exists.

2 Locate and reset the device or devices that initiated the emergency stop condition.

3 Press the Motors On button to recover from the emergency stop condition.

Use the FlexPendant or Robot Control Mate.

24




1 Safety

1.3.3 Enabling device and hold-to-run functionality

1.3.3 Enabling device and hold-to-run functionality

Three-position enabling device

CAUTION

The person using the three-position enabling device is responsible to observe the safeguarded area for hazards due to robot motion and any other hazards controlled by the robot.

The three-position enabling device is a manually operated, constant pressure push-button which, when in center-enabled position, allows potentially hazardous functions.

The three-position enabling device will when continuously held in center-enabled position permit robot motion and any hazards controlled by the robot. Release of or compression past the center-enabled position will stop the hazard, for example, robot motion.

CAUTION

For safe use of the three-position enabling device, the following must be implemented:

• The three-position enabling device must never be rendered inoperational in any way.

• If there is a need to enter safeguarded space, always bring the three-position enabling device. This is to enforce single point of control.

CAUTION

The single point of control cannot be guaranteed in automatic mode. External clients cannot be denied access.

CAUTION

On the IRB 14050, the three-position enabling device is not active unless a valid

SafeMove configuration is active in the controller.

CAUTION

A protective stop in manual mode does not exist.

Hold-to-run function in manual full speed mode

The hold-to-run function for manual full speed allows movement in conjunction with the three-position enabling device when the button connected to the function is actuated manually. This hold-to-run function can only be used in manual full speed mode. In case of hazard, release or compress the three-position enabling device.





1 Safety

1.3.3 Enabling device and hold-to-run functionality

Continued

How to use the hold-to-run function for manual full speed mode is described in the operating manual for the controller.

Note

The manual full speed mode is not available in all markets.

26




1 Safety

1.4.1 About the manual mode

1.4 Robot operating modes

1.4.1 About the manual mode

The manual mode

Manual mode is a control state that allows for the direct control by an operator.

The operator will through positioning the three-position enabling switch to the center-position allow for movement of the manipulator.

There are two manual modes:

• Manual reduced speed mode

• Manual high speed mode (optional)

Safeguard mechanisms

• Protective stops through

Three-position enabling switch

The manual reduced speed mode

In manual reduced speed mode the movement of the TCP is limited to 250 mm/s.

In addition, there is a limitation on the maximum allowed speed for each axis.

This mode is used for jogging, teaching, programming and program verification of the robot; it may be the mode selected when performing some maintenance tasks.

Manual control of the robot from inside the safeguarded space shall be performed at the reduced speed in conjunction with the TPU consisting of the three position enabling switch.

WARNING

Wherever possible, the manual mode of operation shall be performed with all persons outside the safeguarded space.

Tasks normally performed in manual reduced speed mode

The following tasks are normally performed in manual reduced speed mode.

• Set or reset I/O signals

• Creating and editing RAPID programs

• Modify system parameter values

• Starting, stepping, and stopping program execution

• Jog the manipulator.

• Teach or tune programmed manipulator positions

The manual high speed mode

In manual high speed, speeds up to programmed speeds can be achieved e.g. a speed greater than 250 mm/s. The initial speed limit is up to, but not exceeding,

250 mm/s. This is achieved by limiting the speed to 3% of the programmed speed.

Through manual control the speed can be increased up to 100% of the programmed speed.




27


1 Safety

1.4.1 About the manual mode

Continued

This mode is used for program verification only.

The three-position enabling switch must be pressed to the center-position and the hold-to-run button must be pressed to allow start of program execution.

WARNING

Wherever possible, the manual mode of operation shall be performed with all persons outside the safeguarded space.

Note

• When the three-position enabling switch is released or fully compressed, the speed is reset to 3% of programmed speed but not exceeding 250 mm/s.

• Editing RAPID programs and jogging the manipulator are disabled.

Tasks normally performed in manual high speed mode

The following tasks can be performed in the manual high speed mode.

• Starting and stopping program execution for program verification

• Stepping program execution

• Setting speed (0–100%)

• Setting program pointer (to Main, to routine, to cursor, to service routine, etc.

28




1 Safety

1.4.2 About the automatic mode

1.4.2 About the automatic mode

The automatic mode

Automatic mode is an operating mode in which the robot control system operates in accordance with the task program(s) and therefore not in direct control by an operator.

Tasks performed in automatic mode which might affect safety

The following tasks are typically performed in automatic mode:

• Remote clients can load, start, stop, and modify RAPID programs.

• Increase or decrease the speed in the interval zero to programmed speed of the manipulator.

• Restore backups. Only possible when robot is at stop.

• Return to operation after protective stops or emergency stop, including regain to path.

Limitations in automatic mode

See the integrator's documentation for the machinery/robot system for details on which tasks are to be performed in automatic mode.

Safeguard mechanisms

• Protective stop through

Automatic Stop, AS




29

1 Safety

1.5 Installation and commissioning

1.5 Installation and commissioning

National or regional regulations

The integrator of the robot system is responsible for the safety of the robot system.

The integrator is responsible that the robot system is designed and installed in accordance with the safety requirements set forth in the applicable national and regional standards and regulations.

The integrator of the robot system is required to perform an assessment of the hazards and risks.

Layout

The robot integrated to a robot system shall be designed to allow safe access to all areas during installation, operation, maintenance, and repair.

If robot movement can be initiated from an external control panel then an emergency stop must also be available.

If the manipulator is delivered with mechanical stops, these can be used for reducing the working area.

A perimeter safeguarding, for example a fence, shall be dimensioned to withstand the following:

• The force of the manipulator.

• The force of the load handled by the robot if dropped or released at maximum speed.

• The maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot.

The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator.

Consider exposure to hazards, such as slipping, tripping, and falling.

Hazards due to the working position and posture for a person working with or near the robot shall be considered.

Consider hazards from other equipment in the robot system, for example, that guards remain active until identified hazards are reduced to an acceptable level.

Allergenic material

See

Environmental information on page 352

for specification of allergenic materials in the product, if any.

Securing the robot to the foundation

The robot must be properly fixed to its foundation/support, as described in the product manual.

When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards.


30




1 Safety


Continued

Electrical safety

The mains power must be installed to fulfill national regulations.

The power supply wiring to the robot must be sufficiently fused and if necessary, it must be possible to disconnect it manually from the mains power.

The power to the robot must be turned off with the main switch and the mains power disconnected when performing work inside the controller cabinet. Lock and tag shall be considered.

Hazards due to stored electrical energy in the controller must be considered.

Harnesses between controller and manipulator shall be fixed and protected to avoid tripping and wear.

Wherever possible, power on/off or rebooting the robot controller shall be performed with all persons outside the safeguarded space.

Note

Use a CARBON DIOXIDE (CO

2

) extinguisher in the event of a fire in the robot.

Safety devices

The integrator is responsible for that the safety devices necessary to protect people working with the robot system are designed and installed correctly.

When integrating the robot with external devices to a robot system:

• The integrator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards.

• The integrator of the robot system must ensure that safety functions are interlocked in accordance with applicable standards.

Other hazards

WARNING

Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered.

A robot may perform unexpected limited movement.

WARNING

Manipulator movements can cause serious injuries on users and may damage equipment.

The risk assessment should also consider other hazards arising from the application, such as, but not limited to:

• Water

• Compressed air

• Hydraulics





1 Safety


Continued

Collaborative applications

If a robot is intended for a collaborative application, where occasional contact between the robot and the operator is expected, the safety aspects must still be addressed. See the product manual for the manipulator.

Verify the safety functions

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.

32




1 Safety

1.6 Operation

1.6 Operation

Lock and change of operating mode

To prevent hazard, it is the responsibility of the integrator to make sure that keys used to lock or change the operating mode are handled only by authorized personnel.

Safety actuators not in use

Devices with safety actuators that are not connected to the robot or robot system cannot initiate emergency stops or protective stops. These must be stored out of reach and sight so that they cannot be mistaken for being in use.




33

1 Safety

1.7 Maintenance and repair

1.7 Maintenance and repair

General

Corrective maintenance must only be carried out by personnel trained on the robot.

Maintenance or repair must be done with all electrical, pneumatic, and hydraulic power switched off, that is, no remaining hazards.

Never use the robot as a ladder, which means, do not climb on the controller, manipulator, including motors, or other parts. There are hazards of slipping and falling. The robot might be damaged.

Make sure that there are no loose screws, turnings, or other unexpected parts remaining after work on the robot has been performed.

When the work is completed, verify that the safety functions are working as intended.

Hot surfaces

Surfaces can be hot after running the robot. Touching the surfaces may result in burns.

Allow the parts to cool down before maintenance or repair.

Hazards related to batteries

Under rated conditions, the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside.

There is a hazard in case of abuse (mechanical, thermal, electrical) which leads to the activation of safety valves and/or the rupture of the battery container. As a result under certain circumstances, electrolyte leakage, electrode materials reaction with moisture/water or battery vent/explosion/fire may follow.

Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge or expose to temperatures above the declared operating temperature range of the product. Risk of fire or explosion.

Operating temperatures are listed in

Operating conditions on page 40 .

See safety instructions for the batteries in Material/product safety data sheet - Battery pack ( 3HAC043118-001 ).

Related information

See also the safety information related to installation and operation.

34




1 Safety

1.8 Troubleshooting

1.8 Troubleshooting

General

When troubleshooting requires work with power switched on, special considerations must be taken:

• Safety circuits might be muted or disconnected.

• Electrical parts must be considered as live .

• The manipulator can move unexpectedly at any time.

DANGER

Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers.

A risk assessment must be done to address both robot and robot system specific hazards.


See also the safety information related to installation, operation, maintenance, and repair.




35

1 Safety

1.9 Decommissioning

1.9 Decommissioning

General

See section

Decommissioning on page 351

.

36





2.1 OmniCore C90XT


2.1 OmniCore C90XT

About OmniCore C90XT

The OmniCore C90XT is one of OmniCore C line compact controllers. The OmniCore

C90XT controller offers a compact solution suitable for most applications with room for some additional equipment inside.

It is used to control an ABB manipulator used in industrial applications such as material handling and machine tending.




37


2.2 Technical data for OmniCore C90XT controller

2.2 Technical data for OmniCore C90XT controller

Overview of the controller

The OmniCore C90XT controller has all components in one cabinet.

xx1900001447

Basic box

Extension box

Drive

Power unit

SMB connector

Force control connector

HMI connector (TPU)

Motor connector

Scalable I/O

Additional I/O

IP20 DeviceNet

Conveyor tracker module

X17

B1

Motion Safety A2.K3

Connected Services Gateway (with antenna for 3G and

WiFi)

K7

Ethernet switch K4

T4

A1

X2

X3

X4

X1

K5.1

Baseline

Baseline

K5.2/K5.3

Option

OmniCore C90XT

Baseline

Option

Baseline

Baseline

Baseline

Option

Baseline

Option

Option

Baseline

Baseline

Option i


38






Continued

Standard fan

Heat exchanger

Axis computer

Main computer

Power supply

Power supply

ODVA power supply

Fieldbus adapter slave

Process Connector

Filter

Power inlet switch

Power inlet connector i

Robot signal exchange proxy

Baseline is 3G. Wired or WiFi available as option.

Q0

X0

K2

A2

T2

T5

G1

G2

K6

T5

X18

X81

OmniCore C90XT

Baseline

Baseline

Baseline

Baseline

Baseline

Option

Option

Option

Option

Option

Baseline

Baseline

Baseline

Dimensions

Parameter

Width

Depth

Height

Value

500 mm

355 mm

520 mm

Extension box

Parameter

Width

Depth

Height

Value

500 mm

355 mm

295 mm

Weight

The table shows the weight of the controller.

Controller

OmniCore C90XT

Extension Box

Weight

46 kg (not including the extension box)

25 kg

Note

The weight does not include any mounting kits fitted on the controller.

Transportation and storage conditions

Parameter

Minimum ambient temperature

Value

-25°C (-13°F)







Continued

Parameter

Maximum ambient humidity

Vibration

Bumps

Value

Maximum ambient temperature +55°C (+131°F)

Maximum ambient temperature (less than 24 hrs)

+70°C (+158°F)

Maximum 95% at constant temperature.

Max. Grms = 4 m/s

12.8 m/s 2 (Z axis)

2

(X & Y axis), Grms =

Max. 5 g = 50 m/s

2

(11 ms)

After storage, the operating conditions must be met for at least 4 hours before switching on the controller (see

Operating conditions on page 40

).

Operating conditions

The table shows the allowed operating conditions for the controller.

Parameter

Minimum ambient temperature

Maximum ambient temperature

Maximum ambient humidity

Maximum ambient altitude

Vibration

Bumps

Value

+5°C (+41°F)

+45°C (+113°F)

Maximum 95% at constant temperature.

2,000 m

Max. Grms = 2.86 m/s2 (X, Y, Z axis)

Max. 5 g = 50 m/s2 (11 ms)

Protection classes

Controller cabinet

Extension box cabinet

Controller electronics

FlexPendant

Protection class

IP54

IP54

IP54

IP54

The cabinet must be closed properly when the robot system is in production. If the cabinet is not properly closed, then it does not comply with the protection class

(IP54). The shield for electromagnetic compatibility (EMC) is also affected if the controller is not properly closed.

If the door is not closed, this can also affect parts inside cabinet due to dust or moisture, especially important in cases with high heat and humidity, or much pollution.

Note

To comply with IP54, all openings to the controller cabinet must be covered. This includes unconnected connectors which must be fitted with covers.


40






Continued

Power supply

Line fusing

Mains

Voltage for OmniCore C90XT

Voltage tolerance

Frequency

Frequency tolerance

Value

220/230 VAC, 1 phase

+10%, -15%

50/60 Hz

±3%

Note

The use of three phase power with delta connection (as sometimes used in North

Americas and some Asian countries) voids warranty. If the facility has a substation with any type of delta connection, a grounded Y-configured transformer must be installed before the robot controller.

There is no integrated fuse inside the OmniCore C90XT controller. Add an external fuse (time-delay) or circuit breaker (class K) according to full load current, as marked on the controller nameplate. The following table shows the recommended rating for an external fuse or circuit breaker.

Robot

IRB 1100

IRB 1300

IRB 910INV

Current (A)




Description

10 A

10 A

10 A





41



Continued

Wrist strap button

The location of the wrist strap button is shown in the following illustration.

xx1900001446

There is an additional wrist strap button on the main computer.

42





2.3 The unit is sensitive to ESD

2.3 The unit is sensitive to ESD

Description

ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges. This discharge may destroy sensitive electronics.

Safe handling

Use one of the following alternatives:

• Use a wrist strap. The wrist strap button is located inside the controller.

Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

• Use an ESD protective floor mat.

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.




43


2.4 Handling of FlexPendant

2.4 Handling of FlexPendant

Detached FlexPendant

A FlexPendant that is not connected to the robot or robot system cannot initiate emergency stops or protective stops. This must be stored out of reach and sight so that it cannot be mistaken for being in use.

Handling and cleaning

• The FlexPendant may only be used for the purposes mentioned in this manual.

• Always use the hand-strap while holding the FlexPendant.

• Handle with care. Do not drop, throw, or give the FlexPendant strong shock.

It can cause breakage or failure.

• If the FlexPendant is subjected to shock, always verify that the safety functions (three-position enabling device and emergency stop) work and are not damaged.

• Always use and store the FlexPendant in such a way that the cable does not become a tripping hazard.

• When not using the device, place it so it does not accidentally fall.

• Never use sharp objects (such as screwdriver or pen) for operating the touch screen. This could damage the touch screen. Instead use your finger or a stylus.

• Never clean the FlexPendant with solvents, scouring agent, or scrubbing sponges.

See the product manual for the robot controller, section Cleaning the

FlexPendant .

• Always close the protective cap on the USB port when no USB device is connected. The port can break or malfunction if exposed to dirt or dust.

CAUTION

The FlexPendant touch screen is made of glass. If the device is dropped on a hard surface or receives a significant impact the glass could break. To reduce the risk of cuts if the glass chips or cracks, do not touch or attempt to remove the broken glass.

Cabling and power supply

• Make sure that nobody trips over the cable to prevent the device from falling to the ground.

• Do not squeeze and thus damage the cable.

• Do not lay the cable over sharp edges.

Custom connections for FlexPendant

Any means of connecting the FlexPendant with other than the supplied cable and its standard connector must not render the emergency stop button inoperative.


44





2.4 Handling of FlexPendant

Continued

Always test the emergency stop button to make sure it works if a custom connection cable is used.




45


2.5 Network security

2.5 Network security

Network security

This product is designed to be connected to and to communicate information and data via a network interface. It is your sole responsibility to provide, and continuously ensure, a secure connection between the product and to your network or any other network (as the case may be).

You shall establish and maintain any appropriate measures (such as, but not limited to, the installation of firewalls, application of authentication measures, encryption of data, installation of anti-virus programs, etc) to protect the product, the network, its system and the interface against any kind of security breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or information. ABB

Ltd and its entities are not liable for damage and/or loss related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

46





2.6 Open source and 3rd party components in RobotWare

2.6 Open source and 3rd party components in RobotWare

Open source and 3rd party components in RobotWare

ABB products use software provided by third parties, including open source software. The following copyright statements and licenses apply to various components that are distributed inside the ABB software. Each ABB product does not necessarily use all of the listed third party software components. Licensee must fully agree and comply with these license terms or the user is not entitled to use the product. Start using the ABB software means accepting also referred license terms. The third party license terms apply only to the respective software to which the license pertains, and the third party license terms do not apply to ABB products. With regard to programs provided under the GNU general public license and the GNU lesser general public license licensor will provide licensee on demand, a machine-readable copy of the corresponding source code. This offer is valid for a period of three years after delivery of the product.

ABB software is licensed under the ABB end user license agreement, which is provided separately.

For RobotWare, there is license information in the folder \licenses in the RobotWare distribution package.

For OleOS, the Linux based operating system used on the conveyor tracking module (CTM), a list of copyright statements and licenses is available in the file

/etc/licenses.txt

located on the CTM board and accessible via the console port or by downloading the file over SFTP.

For the CTM application, a list of copyright statements and licenses is available in the file /opt/ABB.com/ctm/licenses.txt

located on the CTM board and accessible via the console port or by downloading the file over SFTP.




47


2.7 ABB Ability

2.7 ABB Ability

Cellular data connection

If the ABB Ability™ OmniCore™ controller hardware is delivered together with a standard, free of charge (machine-to-machine or M2M) cellular data connection, it will automatically establish a connection to the ABB Ability™ digital platform once the power switch of the ABB Ability™ OmniCore™ controller hardware has been turned on and has been connected. After the establishment of the connection there will be a data flow from the OmniCore™ controller hardware to the ABB

Ability™ digital platform.

ABB does not warrant or guarantee an available, stable, uninterrupted, and interference free connection through the standard cellular data connection. This is dependent on the availability and quality of the cellular data signal as provided by the telecommunications carrier on the location where the ABB Ability™

OmniCore™ hardware is installed. The cellular data connection is to be used solely in connection with the ABB Ability™ OmniCore™ controller hardware and excludes, without limitation, voice services, web browsing, music downloading and other services that are not traditionally considered as machine to machine (M2M), but human-oriented telecommunication services.

ABB has established and maintains a formal information and cybersecurity procedures which includes commercially reasonable technical and organizational measures, in order to protect the data against security breaches, accidental or unlawful destruction, loss, alteration, and unauthorized disclosure of, or access to the data.

The cellular data connection is not required for the operation of the hardware and the connectivity settings can be adjusted and turned off at any given time. Detailed information on the mobile connection is further described in the service description that can be downloaded from the following web location: https://share.library.abb.com/api/v4?cid=9AAC910011&dk=Manual

Data

The OmniCore™ controller hardware is delivered with a standard mobile connection

(Cellular data connection), or WIFI modem and/or Ethernet connection.

ABB will not acquire any right, title and interest in the data other than the rights granted by Customer to ABB, but ABB will have the right to collect, store, aggregate, analyze or otherwise use the data for (i) providing and maintaining the hardware, services and/or the ABB software to Customer; (ii) prevent-ing, detecting and repairing problems related to the security and/or the operation of the hardware, the platform, software; (iii) improving and developing existing services, technologies, products and/or software and developing new services, technologies, products and/or software, and all improvements and developments (including all resulting intellectual property Rights) are exclusively owned by us. In addition, we have the right to use the data for benchmarking purposes if and to the extent it is anonymized or non-confidential.


48





2.7 ABB Ability

Continued

ABB Ability™ Connected Services

For as far as the robot installation includes ABB Ability™ Connected Services, this agreement is entered pursuant to and governed by the ABB Ability™ General

Terms and Conditions.

ABB Ability™ Terms and Conditions: https://ability.abb.com/terms

Special Terms and Conditions for ABB Ability™ Connected Services: https://new.abb.com/products/robotics/service/robot-registration




49

This page is intentionally left blank

3 Installation and commissioning

3.1 Introduction to installation and commissioning


3.1 Introduction to installation and commissioning

General

This chapter contains assembly instructions and information for installing the

OmniCore C90XT controller at the working site.

See also the product manual for the manipulator.

The installation must be done by qualified installation personnel in accordance with the safety requirements set forth in the applicable national and regional standards and regulations.

Safety information

Before any installation work is commenced, it is extremely important that all safety information is observed.

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 13

before performing any installation work.

Note

If the OmniCore C90XT is connected to power, always make sure that the robot is connected to protective earth and a residual current device (RCD) before starting any installation work.




51


3.2 Installation activities

3.2 Installation activities

Main steps for installing the controller

Use the following main steps to unload, transport, install, and connect the controller.

1

2

3

4

5

6

7

8

9

Action

Unpack the controller.

Install the controller.

Described in

Unpacking the controller on page 54 .

On-site installation on page 56 .

Connect the manipulator to the controller.

Connecting the manipulator to the controller on page 69

.

Connect power supply to the controller.

Connecting power supply to and grounding the controller on page 73 .

Connect input signals for presence sensing devices, etc.

Connect the FlexPendant to the controller.

Connecting and detaching a FlexPendant on page 76 .

Connect, for example, EtherNet, antenna,

PC, and other connections.

How to connect industrial networks, for example EtherNet, is described in the respective application manual.

How to connect to a network and a PC is described in section

Set up the network connection on page 84

. See also Operating manual - RobotStudio .

See also

Descriptions for connectors on page 87

.

Install options and add-ons (optional).

Installing options on page 106

.

Installing add-on devices on page 145

.

Initial test before commissioning.

Initial test before commissioning on page 154 .

52





3.3.1 Lifting the controller cabinet

3.3 Transporting and handling

3.3.1 Lifting the controller cabinet

Lifting device

Use the four lifting eyes (Torque: 11.3 Nm-12.6 Nm) or a fork lift when lifting the controller, as shown below.

The following figure shows the maximum angle between the lifting straps when lifting the controller. The weight of the controller module is detailed in section

Weight on page 39

.

6 0 ° xx1900001445

Note

After removing the lifting lock, tighten the plastic screws (Torque: 0.8 Nm-1 Nm) for the controller cabinet.




53


3.3.2 Unpacking

3.3.2 Unpacking

Unpacking the controller

1

2

3

4

5

6

7

8

Action

Make a visual inspection of the packaging and make sure that nothing is damaged.

Remove the packaging.

Check for any visible transport damage.

Note

Stop unpacking and contact ABB if transport damage is found.

Clean the unit with a lint-free cloth, if necessary.

Make sure that the lifting accessory used (if applicable) is suitable to handle the weight of the controller.

If the controller is not installed directly, it must be stored as described in

Transportation and storage conditions on page 39 .

Make sure that the expected operating environment of the controller conforms to the specifications as described in

Operating conditions on page 40

.

The controller can be taken to its installation site as described in section

On-site installation on page 56

.

54





3.3.3 Storing

3.3.3 Storing

Storing the controller

For storing, see

Transportation and storage conditions on page 39

.




55


3.4.1 Required installation space

3.4 On-site installation

3.4.1 Required installation space

Dimensions

The following illustration shows the required installation space for the OmniCore

C90XT controller.

500 500 520 xx1900001448

• A free space of 500 mm on the front of the controller is required if the controller is mounted on a desk (not rack-mounted).

• A free space of 200 mm on the back of the controller is required if the controller is mounted on a desk (not rack-mounted).

• A free space of 500 mm on the left side of the controller is required if the controller is mounted on a desk (not rack-mounted). Do not place any cables over the left cover as it leads to inefficient cooling.

• A free space of 520 mm on the right sides of the controller is required if the controller is mounted on a desk (not rack-mounted). Do not place any cables over the right covers as it leads to inefficient cooling.

The following illustration shows the dimensions between the feet of the OmniCore

C90XT controller, as seen from below.


56




41


3.4.1 Required installation space

Continued

418 11(4X) xx1900001449

The feet will be used for positioning and fastening.

Mounting requirements:

• Anchor bolts: M8 X 4

• Tightening torque: 11.3 Nm-12.6 Nm

• Maximum flatness deviation of the installation plane: 8 mm

Note

Fix the controller to a concrete foundation or steel platform with anchor bolts during stacking.

Note

According to IEC60204-1, the power-operated switch should be installed between

600 mm to 1,900 mm above the servicing level. The switch will be easily accessible.




57


3.4.2 Mounting the FlexPendant holder

3.4.2 Mounting the FlexPendant holder

Note

To avoid dropping the FlexPendant from height, the holder should be placed in a comfortable working height.

Always use and store the FlexPendant in such a way that the cable does not become a tripping hazard.

When not using the device, place it so it does not accidentally fall.

Required equipment

Equipment

Standard toolkit

Spare part number Note

See

Standard toolkit for controller on page 417 .

FlexPendant Holder w/t Estop cover

3HAC064927-001

Note

The FlexPendant should always be placed in the holder when it is not used and it is not allowed to use by unauthorized person.

Mounting the FlexPendant holder onto a flat surface (Horizontally)

Use this procedure to mount the FlexPendant holder onto a flat surface, like the top of the controller, desktop and so on.

1

2

Action

Clean the surface and make sure it is dry.

Note/illustration

Remove the protective liner from the tape.

xx2000002352


58






Continued

3

Action

Press the holder onto the desired place.

Note/illustration xx2000002353

Hanging the FlexPendant holder with the bracket

Use this procedure to hang the FlexPendant holder on any place where can hold the bracket, like the door of the controller.

Tip

The bracket is included when the FlexPendant is purchased.

1

Action

Hang the FlexPendant holder to the bracket according to the screws on the bracket.






59



Continued

2

Action

Hang the holder with the bracket to the desired place.


Hanging the front part of the FlexPendant holder with screws (Vertically)

Use this procedure to hang the front part of the FlexPendant holder to the desired place.

1

2

Action

Remove the four screws.

Separate the rear part from the FlexPendant holder.


3 Clean the surface and make sure it is dry.

xx2000002356


60






Continued

4

Action

Remove the protective liner from the tape.


5

6

Press the holder onto the desired place.

Use two M5 screws to secure the holder.

xx2000002357 xx2000002358




61


3.5.1 Connectors on the OmniCore C90XT controller

3.5 Electrical connections

3.5.1 Connectors on the OmniCore C90XT controller

General

The following section describes the connectors on the covers of the OmniCore

C90XT controller.

CAUTION

Always inspect the connector for dirt or damage before connecting it to the controller. Clean or replace any damaged parts.

Connectors

The following details the connection interface on the OmniCore C90XT controller.

A

B

C

D

E xx2000000338

Description

Manipulator signal connector

Cable grommet assembly (option)

Cable grommet assembly

Power inlet connector

Motor connector


62





3.5.1 Connectors on the OmniCore C90XT controller

Continued

F

G

H

J

K

Description

TPU cover

FlexPendant connection (TPU connector)

ETH outlet connector

Motors on lamp

Power inlet switch




63


3.5.2 Connecting cables to the controller

3.5.2 Connecting cables to the controller

General

A good and proper electrical installation of the robot system is necessary to ensure the best performance and prolong the lifetime of the whole robot system.

This section includes important information on how to connect cables and signals to the controller.

Signal classes

Different rules apply to the different classes when selecting and laying cables.

Signals from different classes must not be mixed.

Signal class

Power signals

Class 4 (noisy)

Description

Supplies external motors and brakes.

Applies to the cables associated with the power inputs and outputs of variable speed drives. Cables carrying strongly interfering signals such as motor cables, DC-link load sharing, unsuppressed inductive loads, DC motors, welding equipment, etc.

Control signals

Class 3 (slightly noisy)

Digital operating and data signals (digital I/O, protective stop, etc.).

Applies to cables carrying slightly interfering signals: AC power supply (<1 kV), DC power (24 V), power to equipment with RFI/EMI filters, control circuits with resistive or suppressed inductive loads

(such as contactors and solenoids), direct-on-line induction motors, etc.

Measurement signals

Class 2 (slightly sensitive)

Analog measurement and control signals (resolver and analog I/O).

This class covers ordinary analogue signals such as analogue signals (4-20 mA, 0-10V, or signals below 1 MHz), low-speed digital signals (RS232, RS485), digital (on/off) signals, limit switches, encoders, etc.

Data communication signals

Class 1 (sensitive)

Gateway (fieldbus) connection, computer link.

Applies to cables carrying very sensitive signals. Signals with a fullscale range less than 1 V or 1 mA, and/or a source impedance >1 kOhm, and/or a signal frequency >1 Mhz. For example high-speed digital communication (Ethernet), thermocouples, thermistors, strain gauges and flowmeters.

Selecting cables

All cables laid in the control cabinet must be capable of withstanding 70°C. In addition, the following rules apply to the cables of certain signal classes:

Signal class

Power signals

Control signals

Measurement signals


Cable type

Shielded cable with an area of at least 0.75 mm² or AWG 18.

Shielded cable.

Shielded cable with twisted pair conductors.

Shielded cable with twisted pair conductors. A specific cable should be used for field bus connections and Ethernet, according to the standard specification of the respective bus.


64






Continued

Note

Any local standards and regulations concerning insulation and area must always be complied with.

Route the cables

Routing of cables shall be done in a professional way.

• Cables of different classes, such as signal cables and power cables, must not be routed together as the power cables may introduce noise in the signal cables. The greater the separation distance, the lesser the risk for interference between the cables.

• Robot controller mains supply input cable and robot power cable should be separated even though they belong to the same class.

• If crossing cables from different classes, cables should cross at an angle close to 90 degrees.

• All external cables that are to be connected inside the controller must be shielded in the chassis before entering the cabinet.

Separation distances can be reduced if e.g. dividers are used between cables classes. Manufacturers of cable duct systems can provide information on how reduced separation distances can be achieved using their specific products.

Signal class

Power signals

Control signals

Measurement signals


Cable type

• These signals generate a lot of interference and must be laid separate from control, measurement, and communication signals.

• The shielding must be connected to a paint-free part of the panel chassis of the cabinet at both ends of the cable. Any unshielded cable must be as short as possible.

• The manipulator power cables are routed on the floor and along the left side of the controller cabinet.

• Cables should not be wound up like coils. This could cause an magnetic field disturbing the signals. There will also be a risk of overheating depending on the load.

• These signals are very sensitive to interference. To protect these signals they should not be laid along with the power signals.

• In the cable, each signal must be twisted with a neutral wire.

• The shielding must be connected directly to the chassis at both ends of the cable.

Shielding cables

When peripheral devices are connected to the robot system, a shielded cable is necessary to reduce coupling of the inner cable conductors to the environment they pass through.

Shielding cable requirements

• The best method for shielding is to ground the shield at both ends of the cable, provided the ends grounding are at the same potential.

• If the grounding points have different electric potentials - grounding both ends will create a ground loop allowing unwanted current to flow in the shield.







Continued

In such cases one end grounding may be used. The grounding point should then be at the robot controller side.

• Cables carrying analog low-level signals is another exception where the shield should be grounded at only one end.

• Most data network and field bus types have defined grounding topologies.

If such grounding schemes exist, they should be followed.

• In complex interference environments, two-layer shielding may be required.

The inner shield should be grounded at the controller side only end and the outer shield should be grounded at both ends. The optimum shielding is a combination of foil and braid screens.

• The best connection is one in which the shielding is extended up to and makes a solid 360° connection (shown below) with the ground plane or chassis.

Shielding example

The below example shows the shielding of a d-type connector: xx1700001320

A A dimpled connector body makes multiple bonds to the mating connector body all around its periphery, 360° bonding.

B Metal, or metallized, back shell makes 360° bond to the connector body.

C The cable shield is exposed and 360° clamped to the back shell. A tight fit is a must.

Many other 360° bonding methods and types of 360° shielded connectors are also acceptable.

Shield pigtail termination

Shield pigtail termination, as shown below, shall be avoided. If a pigtail connection cannot be avoided, make it as short as possible.

xx1700001321


66






Continued

Ground and screen connections

The task of the grounding system is twofold - protective and functional. The primary task is to serve as protective earth (PE) for personal and equipment safety. The secondary task is to serve as a return path for common mode current.

For further information refer to EN 60204-1 and UL 1740.

Grounding requirements

The controller cabinet ground must come from the mains power supply PE.

• The grounding cable color shall be green-yellow.

• The ground for the controller cabinet, robot manipulator and peripheral devices must be the same, preferably an equipotential ground grid (mesh).

• Ground connection points must have stable inter-metallic bonding, like screw fixation. Paint, dirt, rust, and other insulating material must be removed from the contacting surfaces.

For requirements on the marking of the supply ground connection inside the control cabinet refer to UL 508C. For further details on how grounding systems should be designed refer to IEC 61000-5-2. For details of cross-sectional area of PE refer to

IEC 60204-1.

Grounding installation

For information on how to install the ground for the manipulator, see the corresponding product manual.

Examples

The following figure shows 2 examples on how the ground and the signal cable screens can be connected:

Control cabinet External unit

Example 1

Example 2 xx1200000960





67



Continued

Example 1:

• Where a good ground is available on all units, the best shielding is obtained by grounding all screens at both ends on all units.

Example 2:

• If the cable is terminated where a good ground is not available a noise suppression capacitor can be used. The screens of the 2 cables must be connected as shown in the figure, but not connected to the chassis of the unit.

Interference elimination

Internal relay coils and other units that can generate interference inside the control cabinet are neutralized. External relay coils, solenoids and other units must be clamped in a similar way. The illustration below shows how this can be done.

Note that the turn-off time for DC relays increases after neutralization, especially if a diode is connected across the coil. Varistors give shorter turn-off times.

Neutralizing the coils lengthens the life of the switches that control them.

+24 V DC 0 V

1)

68

+24 V AC/DC

2)

0 V

3) xx1200000961

1 The diode should be dimensioned for the same current as the relay coil, and a voltage of twice the supply voltage.

2 The varistor should be dimensioned for the same energy as the relay coil, and a voltage of twice the supply voltage.

3 When AC voltage is used, the components needs to be dimensioned for >500

V max voltage and 125 V nominal voltage.

The resistor should be 100 Ω, and the capacitor should be 1W 0.1 - 1 µF

(typically 0.47 µF).





3.5.3 Connecting the manipulator to the controller

3.5.3 Connecting the manipulator to the controller

General

Connect the manipulator and the controller to each other after installing them. The lists below specify which cables to be used in each application.

All connectors on the controller are shown in section

Connectors on the OmniCore

C90XT controller on page 62 .

Main cable categories

All cables between the manipulator and the controller are divided into the following categories:

Cable category

Manipulator cable

Position switch cables (option)

Customer cables (option)

Additional axes cables (option)

Description

Handles power supply to and control of the manipulator's motors as well as feedback from the serial measurement board.

Handles supply to and feedback from any position switches.

Handles communication with equipment fitted on the manipulator by the customer.

Handles power supply to and control of the external axes motors as well as feedback from the servo system.

These categories above are divided into sub-categories which are specified in spare part manual. See

Manipulator cables on page 441 .

Connecting the cables from the manipulator to the controller

1

2

3

Action

Connect the manipulator cable to the connector X1.

Lock the connector with the lever.

Secure the cables to avoid tripping or wear.




69


3.5.4 Fitting the connector

3.5.4 Fitting the connector

General

This section describes how to manufacture a cable for connecting the main power to the controller.

Detailed view xx1900001461

D A

B

C

A

B

C

D xx1900001457

Description

Female insert, quick lock

Angle hood M20

Cable gland M20

Sealing screw


70






Continued

Specifications

Included parts

Procedure

The following describes the cable requirements for the main power connection to the OmniCore C90XT controller.

Component

Cable type

Cable area

Description

Flexible oil resistant rubber

3C x 2.5 mm

2 or AWG14

The following parts are included in the delivery.

Part

Power connector

Order number

3HAC070308-001

1

2

Use the following procedure to fit the connectors.

Action

Cut the cable to desired length.

Connect the wires according to the illustration.


Quantity

1 xx1900001454

For single phase:

1 Live (L)

2 Neutral (N)

3 Not used

4 Not used

5 Not used

PE, Protective Earth, grounding





71



Continued

3

Action

Remove cable jacket and strip the fine stranded wires about 10 mm if needed.


4 Push fine stranded wires into the Han-

Quick Lock contact and push the slide with a screw driver until it comes to a stop.

xx1900001458 xx1900001459

72





3.5.5 Connecting power supply to and grounding the controller

3.5.5 Connecting power supply to and grounding the controller

Note

How to manufacture a cable with connector is described in section

Fitting the connector on page 70 .

DANGER

A residual current device (RCD) must be installed.

Location of power supply connection xx1900001479

Location of grounding point

Note

The whole cabinet ground is connected to the X0.PE point.





73



Continued

3

4

1

2

5

PE xx1900001455

Description

Live (L)

Neutral (N)

Not used

Not used

Not used

Protective Earth, grounding


Equipment

Main connection cable (single phase)

Note

L, N, PE

Details see

Fitting the connector on page 70

.

External earth fault protection (residual current device,

RCD)

30 mA

Standard toolkit See


Circuit diagram Circuit diagram - OmniCore

C90XT , 3HAC065464-009

Line fusing

There is no integrated fuse in side OmniCore C90XT controller. An external fuse or circuit breaker must be added by the integrator, according to the full load current rating. See

Line fusing on page 41 .

Connecting the power

The following procedure describes how to connect the main power to the controller.


74

CAUTION







Continued

1

Action

Connect the main power cable to the power inlet connector X0 and lock it by pressing the hook.

Tip

When you hear a clear clicking sound, it is locked.

xx1900001456




75


3.5.6 Connecting and detaching a FlexPendant

3.5.6 Connecting and detaching a FlexPendant

Introduction

When the controller is in automatic mode the FlexPendant can be detached from the controller without interrupting ongoing processes. This is possible only if the logged in user has the Safety Services grant.

CAUTION

Before detaching the FlexPendant, another emergency stop shall be available on the robot/robot system.

CAUTION

Without a connected FlexPendant, there is no visual identification of the operating mode.

CAUTION

A FlexPendant that is not connected to the robot or robot system cannot initiate emergency stops or protective stops. This must be stored out of reach and sight so that it cannot be mistaken for being in use.

CAUTION

The FlexPendant connector can only be used to connect a FlexPendant and

CANNOT be used to connect any other devices.

All external safety devices must be connected from the customer interface on robot signal exchange proxy.

Location of FlexPendant connector

The FlexPendant connector is located on the front panel on the controller.

Detaching the FlexPendant in automatic mode

Use the following procedure to detach the FlexPendant in automatic mode:

1 On the status bar, tap the QuickSet button.

2 Tap the Logout/Restart tab.

3 In the FlexPendant section, tap Detach FlexPendant .


76






Continued

The Detach FlexPendant window is displayed.

4 Tap Detach .

A popup window with 30 seconds countdown timer is displayed.

5 When the countdown is progressing, loosen the locking ring and detach the

FlexPendant from the controller.





77



Continued

The FlexPendant is shut down.

Note

If the FlexPendant cable is not detached within 30 seconds, the FlexPendant remains in the existing operating state.

WARNING

If the FlexPendant is detached after the 30 seconds countdown has passed, the controller will go to guard stop state.

Connecting the FlexPendant

The controller must be in manual mode when connecting the FlexPendant.

CAUTION


Plug in the connector on the controller and tighten the locking ring.

78 xx1900000975

CAUTION

Make sure that the emergency stop button is not pressed in when connecting the FlexPendant.





3.5.7 Network connections on OmniCore

3.5.7 Network connections on OmniCore

Connections on the OmniCore controller

The following figure illustrates the available Ethernet port connectors on the controller.

Note

For information regarding location of the Ethernet port connectors, see

Connectors on the OmniCore C90XT controller on page 62

.

1 xx1800003138

1 2 3 1 4

1

2

3

4


I/O + LAN + ETHERNET

SWITCH

Port to the robot's private network. Intended for connecting ABB Scalable I/O units and network based process equipment to the controller.

ABB Ability™ This port only exists if the wired variant of the Connected Services Gateway is used. Intended for connecting to the robot's Ability™ network.

WAN

MGMT (Management)

WAN port that can be used to host a public industrial network.

Port to the robot's private network. The MGMT port shall be used by service personnel in close proximity to the controller, with a single client connected to the controller.

Note

The management port shall never be used for more than one client at a time. ABB Robotics assumes no responsibility for any errors/hazards that may appear when more than one client is attached to the management port.

A factory wide I/O network should be connected to the Ethernet port WAN on the controller.





79



Continued

An I/O network that is local for a specific robot should be connected to the Ethernet port LAN, I/O or the ETHERNET SWITCH on the controller.

Note

It is not supported to connect multiple ports of the OmniCore controller to the same external switch unless static VLAN isolation is applied on the external switch.

Connections on the main computer

The Ethernet ports on the main computer belong to the following network segments:

Private Network Ability Network Public Network Drive Network

L

Service PC FlexPendant

Cameras, sensors, I/O

PLC Axis computer

Private Network xx1800003053

The ports X3 (MGMT), X6 (LAN 1), and X4 (LAN 2) and X2 (LAN 3) belong to the

Private Network segment.

Note

Private Network segments of multiple robot controllers cannot be connected to each other.

The MGMT port shall be used by service personnel in close proximity to the controller, with a single client connected to the controller.

Note

The management port shall never be used for more than one client at a time.

ABB Robotics assumes no responsibility for any errors/hazards that may appear when more than one client is attached to the management port.

The LAN1, LAN2 and LAN3 ports are intended for connecting robot controller internal computers or network based process equipment to the controller, for example cameras, and welding equipment.


80






Continued

Ability Network

Port X5 (LAN 4) belongs to the Ability Network segment. The LAN4 port is intended for connecting to the Connected Services Gateway module for a firewalled access to ABB Ability™ Cloud server.

The connectivity is done through an embedded Connected Services Gateway

(Wired, Wi-Fi, or 3G).

Public Network

The port X23 (WAN) belongs to the Public Network segment. The WAN port is the public network interface to the controller, typically connected to the industrial network with a public IP address provided by the network administrator.

The Public Network segment is used for:

• connecting a PC running RobotStudio

• mounting FTP or NFS disks from the controller

• running Industrial Ethernet.

Note

The Public Network can be configured in RobotStudio or on the FlexPendant.

Drive Network

The X9 (AXC) port is intended to be connected to the robot drive system.

The AXC port is always connected to the axis computer. If MultiMove is used, AXC is connected to a switch that connects to all the axis computers.

One EtherNet/IP network connected to the robot controller

EtherNet/IP Adapter is only available on the public network via WAN. Ethernet/IP

Scanner can be used on both the private and public network at the same time.

The following figure illustrates the network when connecting a scanner and an adapter to the WAN port of the main computer:

Cell I/O

PLC

I/O I/O

Factory Network & Industrial Network

EtherNet/IP

Robot Controller 1

Private

MGMT LAN1 LAN2 LAN3

Public

WAN

Private I/O xx1800003192


Private

MGMT LAN1 LAN2 LAN3

Public

WAN







Continued

Note

The Firewall Manager settings must be set to YES if the EtherNet/IP is to be used on the public network. Configuration is done in RobotStudio under Configuration

-> Communication -> Firewall Manager . See Operating manual - Integrator's guide OmniCore for more information.

Defining network settings

Network settings can be defined either in RobotStudio or from the FlexPendant for the controller:

• Defining network settings in RobotStudio:

1 In the Configuration browser, right-click the controller and select

Properties and then Network settings .

xx2000000488

2 In the Network settings window, set the values for:

IP address : The IP address for the OmniCore controller on the

EtherNet network.

Subnet mask : The subnet mask.

Default gateway : The default gateway.

xx2000000489


82






Continued

• Defining network settings on the FlexPendant:

1 On the start screen, tap Settings , and then select Network from the menu.

2 Define IP address for the controller and tap OK .

PROFINET on factory network

When the WAN port is used for connecting to an industrial network, the traffic shares the same media as the factory network and will share bandwith with other non industrial network traffic.

The following figure illustrates the network when connecting a controller and a device to the WAN port of the main computer:

Cell I/O

PLC

I/O I/O

Factory Network & Industrial Network

PROFINET


Private

MGMT LAN1 LAN2 LAN3

Public

WAN

Camera xx1900001102


Private

MGMT LAN1 LAN2 LAN3

Public

WAN




83


3.5.8 Set up the network connection

3.5.8 Set up the network connection

Management port

The management port is intended for service engineers and programmers connecting directly to the controller with a PC.

The management port is configured with the fixed IP address 192.168.125.1, which is the same for all controllers and cannot be changed, and has a DHCP server that automatically assigns an IP address to the connected PC.

Note

Do not connect another DHCP server to this port.

Note

For more information about connecting a PC to the management port, see section

Working online in Operating manual - RobotStudio .

WAN port

The WAN port is a public network interface to the controller, typically connected to the factory network with a public IP address provided by the network administrator.

The WAN port can be configured with fixed IP address, or DHCP, from RobotStudio or the FlexPendant. By default the IP address is blank.

Note

It is not recommended using leading zeros in dot-decimal notation of IP addresses. The numbers may wrongly be interpreted as octal numbers. Different behaviors on virtual and real controllers may be experienced.

Note

The WAN port cannot use any of the following IP addresses which are allocated for other functions on the controller:

• 192.168.125.0 - 255

• 192.168.126.0 - 255

• 192.168.127.0 - 255

The WAN port cannot be on a subnet which overlaps with any of the above reserved IP addresses. If a subnet mask in the class B range has to be used, then a private address of class B must be used to avoid any overlapping. Contact your local network administrator regarding network overlapping.

See the section Communication in Technical reference manual - System parameters .


84




LAN port

Ability port



Continued

Note

For more information about connecting a PC to the WAN port, see Operating manual - RobotStudio .

The LAN port on the front of the controller belongs to the controllers private network.

It is intended for connecting network based process equipment to the controller.

The LAN port is configured with the fixed IP address 192.168.125.1, which is the same for all controllers and cannot be changed, and has a DHCP server which can assign IP addresses to connected devices.

Note

Do not connect another DHCP server to this port.

The Ability port is a specific network interface to the controller, available on the

Connected Services Gateway wired (DSQC1041), connected to an Internet gateway with an IP address provided by the network administrator.

The Ability port must be configured with fixed IP address from RobotStudio or the

FlexPendant. By default the IP address is blank. An external gateway and DNS need to be provided.

For security reasons, only outbound access on port 53 DNS and 443 HTTP are allowed. The inbound access is blocked by an internal firewall and cannot be unblocked.

Note

The Ability port cannot use any of the following IP addresses which are allocated for other functions on the controller:

• 192.168.125.0 - 255

• 192.168.127.0 - 255

The Ability port cannot be on a subnet which overlaps with any of the above reserved IP addresses. If a subnet mask in the class B range has to be used, then a private address of class B must be used to avoid any overlapping. Contact your local network administrator regarding network overlapping.

See the section Communication in Technical reference manual - System parameters .

Note

For more information about connecting the Ability port to the internet, see

Application manual - Controller software OmniCore .







Continued

Firewall settings

The Firewall Management function is used to configure the network firewall on the controller. Configuration is done in RobotStudio under Configuration ->

Communication -> Firewall Manager where pre-configured Network Services can be enabled or disabled: xx1900000352

Note

Only pre-registered Network Services can be configured in the Firewall Manager settings. The user cannot add new Network Services in the Firewall Manager and can only change the parameters Enable on Public Network and Enable on

Private Network for pre-registered Network Services.

Note

Only users with UAS grant Modify network security properties can modify the firewall settings.

For more information, see Technical reference manual - System parameters .


See more information about network configuration in Operating manual - Integrator's guide OmniCore .

86





3.5.9 Descriptions for connectors

3.5.9 Descriptions for connectors

Internet connectors

The Connected Services Gateway unit has either an Ability port or an antenna connector on the front. See installation procedures in section

On-site installation on page 56 .

xx1900002450

Customer cable layout

The antenna should go through the cable grommet and fasten on the cabinet.

Note

The end user need to buy proper grommets according to the diameter of the cables which need to go through the grommet.

This will affect the protection level of the cabinet if it's not executed correctly.

It is recommended to use icotek KT grommet.





87



Continued

The cable layout is recommended as the following illustration.

xx2000000436

I/O connectors - Scalable I/O (option) xx1900002448

A

B

Scalable I/O output connectors

Scalable I/O input connectors

The connectors contain 16 digital input signals, 16 digital output signals, 24 V and

0 V for the outputs, and 0 V for the inputs.


88

CAUTION

The process power supply should be supplied separately. Connecting the process power supply through the logical power supply connector (X19) may damage the device.

If the process power supply is supplied by the logical power supply connector

(X19), a surge protector must be installed to protect the device.






Continued

For connection details, see Circuit diagram - OmniCore C90XT , 3HAC065464-009 and Application manual - Scalable I/O , 3HAC070208-001 .

Recommended surge protector

7 8

11 12

IN OUT

9 10

3 xx1800002551

The protect voltage for the surge protector should be 24 V DC.

4


It is recommended to use multicore cable for the customer connection.

The cables connected by customer to the I/O unit should go through the cable grommet and fasten on the cabinet.

Note





xx2000000434





89



Continued

Conveyor tracking module

For detail information on customer connections to conveyor tracking module, see

Application manual - Conveyor tracking , 3HAC066561-001 .

xx1800000941



The cables connected by customer to the conveyor tracking module should go through the cable grommet and fasten on the cabinet.

Note





90






Continued


xx2000000435

24V terminal block (option)

This connector is internally connected with the optional power supply. It is a 24 V power supply for the customer. The characteristics are shown in the following table.

Parameter

Voltage

Voltage tolerance

Max output current

Value

24V DC

-3% ~ +10%

4 A

Note

The 24 V terminal block power supply is isolated from the internal logical circuit of the controller.

For connection details, see Circuit diagram - OmniCore C90XT , 3HAC065464-009 .



The cables connected by customer to the 24V terminal block should go through the cable grommet and fasten on the cabinet.

Note










Continued


xx2000000433

Robot signal exchange proxy mating connectors

X14 xx1900002449

CAUTION

Safety functions must be verified before use. Safety functions must be tested regularly.

Connection

Type

Article number

Description

Customer safety interface: emergency stop and automatic stop

Weidmüller S2L 3.50 90F

S2L 3.50/16/90F 3.5SN BK BX 2*8 pins

1728680000 (or equivalent)


92






Continued

Note

External emergency stop switches are required in below cases in accordance with applicable standards:

• FlexPendant is hot swapped.

• FlexPendant is placed in its holder.

15 13

16 14

11 9

12 10

7

8

5

6

3

4

1

2 xx1800000553

9

7

5

3

1

Pin

15

13

11

Description

0V_CH1_CH2

AS1-

AS2-

0V_CH1_CH2

0V_CH1_CH2

ES1-

ES2-

0V_CH1_CH2

4

2

10

8

6

Pin

16

14

12

Description

24V_CH1

AS1+

AS2+

24V_CH2

24V_CH1

ES1+

ES2+

24V_CH2

The automatic stop and external emergency stop interfaces located in X14 are dual-channel safety inputs.

Each channel has 4 pins on the connectors, and the pin descriptions are shown in the following table.

Pin

24V_CH1/2

AS1+/ AS2+

AS1-/ AS2-

ES1+/ ES2+

ES1-/ ES2-

0V_CH1_CH2

Description

24 V power supplied by robot controller for stop switch use only. It must not be used for any other functions.

Safety loop high side of automatic stop input.

Safety loop low side of automatic stop input.

Safety loop high side of external emergency stop input.

Safety loop low side of external emergency stop input.

24V power reference ground.





93



Continued

The controller is shipped with a default configuration that the automatic stop circuit is opened and emergency stop circuit is bypassed (short-circuited). The controller

CANNOT work.

To enable the controller without any additional/external safety equipment, connect the safety circuit as shown in the following figure.

K2-X4

8

24V_CH1

K2-X4

16

24V_CH1

ES1+ AS1+

6

5 ES1-

14

13 AS1-

7

0V_CH1_CH2

15

0V_CH1_CH2

2

4

3

1

24V_CH2

ES2+

ES2-

0V_CH1_CH2

10

12

11

9

24V_CH2

AS2+

AS2-

0V_CH1_CH2 xx1900000060

In most applications it is required to connect automatic/external emergency stop switches. It is highly recommended to connect the stop switches as one of the following figures for the best safety performance. When the 24 V power is provided by customer instead of 24V_CH1/2, it shall be within the tolerance of 24 V -0%/+10%.

24V_CH1

AS1+ / ES1+

AS1- / ES1-

0V_CH1_CH2

24V_CH1

AS1+ / ES1+

AS1- / ES1-

0V_CH1_CH2

(A)

24V_CH2

AS2+ / ES2+

AS2- / ES2-

0V_CH1_CH2

(B)

24V_CH2

AS2+ / ES2+

AS2- / ES2-

0V_CH1_CH2

Customer provided power

Customer_24V_CH1

Customer provided power

24V_CH1

AS1+ / ES1+

AS1- / ES1-

0V_CH1_CH2

Customer_24V_CH1

24V_CH1

AS1+ / ES1+

AS1- / ES1-

0V_CH1_CH2

Customer_0V_CH1

Customer_0V_CH1

Customer_24V_CH2

Customer_24V_CH2

Customer_0V_CH2

(C)

24V_CH2

AS2+ / ES2+

AS2- / ES2-

0V_CH1_CH2 Customer_0V_CH2

(D)

24V_CH2

AS2+ / ES2+

AS2- / ES2-

0V_CH1_CH2 xx1900000600


94






Continued

Note

It is prohibited to connect the dual-channel switch as shown in the following figure, as this does not comply with the Cat.3 structure.

24V_CH1

AS1+ / ES1+

AS1- / ES1-

0V_CH1_CH2

24V_CH1

AS1+ / ES1+

AS1- / ES1-

0V_CH1_CH2

24V_CH2

AS2+ / ES2+

AS2- / ES2-

0V_CH1_CH2

24V_CH2

AS2+ / ES2+

AS2- / ES2-

0V_CH1_CH2

(A) (B) xx1900000599

For more connections other than those illustrated above, carefully assess the risk before use and contact your local ABB for support.

X15

Connection

Type

Article number

Description

Customer optional interface

Weidmüller S2L 3.50 90F

S2L 3.50/16/90F 3.5SN BK BX 2*9 pins


17 15 13 11 9

18 16 14 12 10 xx1800000555

5

3

1

11

9

7

Pin

17

15

13

Description

NC

NC

ESOUT1-

ESOUT2-

NC

NC

NC

MON_LAMP

MON_PB

7

8

6

4

2

12

10

8

Pin

18

16

14

5

6

3

4

1

2

Description

NC

NC

ESOUT1+

ESOUT2+

NC

NC

NC

24V_MON

24V_MON







Continued

Note

NC means those pins are reserved. They cannot be electrically connected to any external signal, ground, or voltage.

Pin

ESOUT1+

ESOUT1-

ESOUT2+

ESOUT2-

24V_MON

MON_LAMP

MON_PB

Description

High side terminal of Emergency stop output Channel 1.

Low side terminal of Emergency stop output Channel 1.

High side terminal of Emergency stop output Channel 2.

Low side terminal of Emergency stop output Output Channel 2.

24 V power supplied by robot controller for motors on lamp and motors on push button use only. It must not be used for any other functions.

Motors on lamp output interface. The max sink current is 50mA.

Motors on push button input interface.

Note

The device connected to the ESOUT pins shall fulfill the IEC 61131-2 type 1 Input.

Note

Logic low of Emergency stop output shall be recognized as Emergency stop triggered.

Note

The maximum length of the cable connected to the ESOUT pins shall be 10 m.

Note

The cable shall be protected from external EM disturbance, suggested to use separate multicore cables.

Note

The FlexPendant connector can only be used to connect a FlexPendant and

CANNOT be used to connect any other devices.

All external safety devices must be connected from the customer interface on robot signal exchange proxy.


96




X19



Continued

ESOUT1 +

Safety PLC

Or

Relay

Indicator

Relay Output for

Safety Input of

Next Stage

ESOUT 1-

ESOUT2 +

Indicator

Controller

Interface Isola!on

Safety PLC

Or

Relay

Relay Output for

Safety Input of

Next Stage

ESOUT 2-

Isola!on

xx2000001763

Although the Motors On function is available on the FlexPendant, an interface is provided in X15 for an optional Motors On push button and an indication lamp.

Both have 2 pins on the connectors.

Push Bu!on

24V_MON

MON_PB

Lamp

24V_MON

MON_LAMP xx1900000598

Connection

Type

Article number

Description

Customer IO power supply

Weidmüller SC 3.81 90F

SC 3.81/08/90F 3.2SN BK BX 8 Pins






97



Continued

X20

1 2 3 4 5 6 7 8 xx1800000556

6

7

4

5

8

Pin

1

2

3

Description

24V_IO_EXT

0V_IO_EXT

24V_IO_EXT

0V_IO_EXT

24V_IO_EXT

0V_IO_EXT

24V_IO_EXT

0V_IO_EXT

24V_IO_EXT is the 24 V power supply for the customer. The characteristics are shown in the following table.

Parameter

Voltage

Voltage tolerance

Max output current

Value

24V DC

-3% ~ +10%

3 A

Connection

Type

Article number

Description

Customer optional power input (Reserved)

Weidmüller SC 3.81 90F

SC 3.81/06/90F 3.2SN BK BX 6 Pins


98





3.5.10 Configuring safety stops

3.5.10 Configuring safety stops

Introduction

The automatic stop (AS) and the general stop (GS) are configured using the Visual

SafeMove functionality in RobotStudio.

Note

The automatic stop cannot be configured in RobotWare 7.0 and RobotWare 7.1.

In RobotWare 7.0 and 7.1, the stops are configured in the system parameters.

Configuration

The automatic stop is configurable to be either an automatic stop or a general stop, where the general stop will stop the robot in manual reduced speed mode.

After the configuration is done in the Visual SafeMove, the safety configuration must be written to the controller and then a restart of the controller is required.

WARNING

The new settings must be verified by test before the system is used.

• ProtectiveStop is the AS/GS input

• ExternalEmergencyStop is the ES input

• InternalEmergencyStop is the emergency stop button on the FlexPendant

Note

When upgrading RobotWare systems from 7.0 or 7.1, the stop configuration is done using system parameters.

See also the circuit diagram, Circuit diagram - OmniCore C90XT .




99


3.5.11 Programmable stop functions

3.5.11 Programmable stop functions

Stopping functions

There are different methods to stop the robot, in addition to manually initiated stops.

• Stop with system input signals

• Stop with RAPID instructions

• Other stops

Stop category configuration

The stop category can be configured, see Technical reference manual - System parameters .

Safety inputs

Automatic Stop

Emergency Stop

System parameter Function

Description

Category1AS

Category1LES

Category1AS can be used to configure the protective stop in automatic mode either as stop category 0 or category 1. The default configuration is TRUE (stop category 1).

Category1LES is used to configure the emergency stop on the FlexPendant in automatic and manual mode. The default configuration is FALSE (stop category 0).

Emergency Stop Category1EES Category1EES is used to configure an external emergency stop in automatic and manual mode. The default configuration is FALSE (stop category 0).

Stop with system input signals

In the control system, it is possible to define system input signals to be set/reset through different interactions, for example, through networks, I/O blocks, RobAPI, etc. See next release version .

Pre-defined system input Description

SoftStop

QuickStop

The manipulator is stopped on the path with no deviation.

Stop at End of Cycle

This is a faster stop of the manipulator than SoftStop . This stop is more stressing for the mechanics than SoftStop .

QuickStop ignores torque and acceleration limits.

Stops the RAPID program when the complete program is executed, that means when the last instruction in the main routine has been completed.

Stop at End of Instruction Stops program execution after the current instruction is completed.

All of these stops are performed without using the brakes, and the power is never disconnected. The program execution can be continued directly, for example by activating a start signal.

Note

Only safety rated input signals are allowed to be used for safety.


100






Continued

Stop with RAPID instructions

There are several RAPID instructions available that stops the robot.

Instruction

BREAK

EXIT

Description Arguments

SystemStopAction Stops all robots in all tasks immediately.

\Stop : similar to a normal program stop with stop button.

\StopBlock : as above, but to restart the PP has to be moved.

\Halt : this is like a category 0 stop, i.e. it will result in motors off state, stop of program execution and robot movements in all motion tasks. The Motors on button must be pressed before the program execution can be restarted.

Stop

StopMove

The current move instruction will be finished before the robot stops.

A restart will continue the program execution.

\NoRegain : the robot will not return to the stop point when restarted, e.g. after having been jogged away.

\AllMoveTasks : all robots will be stopped.

The current move instruction will be stopped immediately as a soft stop but the program execution will continue with the next instruction. This is often used in for example trap routines.

\AllMotionTasks : all robots will be stopped.

The current move instruction and the program execution will be stopped immediately as a normal program stop. A restart will continue the program execution.

The current move instruction and the program execution will be stopped immediately as a normal program stop. After stop the Program Pointer has to be reset to

Main.

EXITCYCLE

SearchX

The current move instruction and program execution will be stopped immediately. The Program Pointer will be reset to Main and if running mode is continuous, the program will be restarted.

Search instructions can be programmed with arguments to stop the robot movement close to the point where a search hit was noticed. The program execution will continue with the next instruction.

\Stop : Stiff stop - the robot will stop as fast as possible. This stop is performed by ramping down motion in each motor separate from each other, and as fast as possible. Since it will be without any coordination, the robot may slide off path fairly much.

\SStop : Soft stop - the robot will stop on path.

\Sup : the robot will continue to the

ToPoint . If more than one search hit is found, an error will be reported.







Continued

RAPID instructions are described in Technical reference manual - RAPID

Instructions, Functions and Data types .

Other unexpected stops

Type of stop

SysFail

Power fail

Stop at collision

Description

In the control system there is a surveillance and monitoring function that can detect abnormal situations. In such cases a stop will be initiated. The robot controller must be restarted.

In the control system there is a monitoring function that can detect power failure. In such cases a stop will be initiated.

In the control system there is a monitoring function that can detect collisions. In such cases a stop will be initiated.

WARNING

Special care must be taken when restarting a machine that is stopped due to a collision. The robot might make a limited movement when restarted.

WARNING

The revolution counters might need to be updated after a collision to ensure path accuracy.

Stopping time/distance

Stopping time/distance for emergency stop (category 0), program stop (category1) at max speed, max stretched out and max load, categories according to EN 60204-1.

All results are from tests on one moving axis. All stop distances are valid for floor mounted robot, without any tilting.

For detail stopping time/distance for each robot, see Product specification Robot stopping distances according to ISO 10218-1 .

102





3.6.1 Available fieldbuses

3.6 I/O system

3.6.1 Available fieldbuses

General

The controller can be fitted with a number of different fieldbus adapters, fieldbus boards, and software based fieldbuses. The software based fieldbuses do not require any hardware.

Fieldbus connections

There is one slot available for installing a fieldbus board (PCIe) on the main computer, with process connectors on the front panel, and one slot for installing a fieldbus adapter (slave).

The software based fieldbuses are connected directly to one of the Ethernet ports.

A xx1700000748

B C D

C

D

A

B

Fieldbus adapter (slave)

Slot for fieldbus adapters

Slot for fieldbus, PCI express card

Fieldbus board (master)

Available board

The following master board is available.

Description

DeviceNet Board

Article number

3HAC043383-001

Type designation

DSQC1006

Available software based fieldbuses

The following software based fieldbuses are available as RobotWare options.

• EtherNet/IP

• PROFINET






3.6.1 Available fieldbuses

Continued

Available adapter

The following fieldbus adapter slave is available.

Description

DeviceNet Slave Fieldbus Adapter

Article number

3HAC045973-001

Type designation

DSQC1004

References

For more information on how to install and configure the fieldbuses, see the respective manual.

Manual title

Application manual - DeviceNet Master/Slave

Article number

3HAC066562-001

104





3.6.2 Scalable I/O, internal and external

3.6.2 Scalable I/O, internal and external

General

The controller can be fitted with an internal I/O unit, DSQC1030, with 16 digital inputs and 16 digital outputs. The controller can also use external I/O units, with

DSQC1030 as base unit and add-on units as extension.

Scalable I/O units

The I/O unit DSQC1030 Digital Base belongs to the ABB Scalable I/O system, which is a modular, compact, and scalable I/O system that consists of a base device

(minimum configuration), and add-on devices.

The base device has a Plug & Produce interface and communicates over the default

EtherNet/IP communication protocol to the robot controller. When using the standard interface, no additional RobotWare options or hardware options are required to communicate with the robot controller. When using the RobotWare option

EtherNet/IP Scanner/Adapter , more configuration possibilities are available.

For more information about installing, configuring, and using the scalable I/O units, see Application manual - Scalable I/O .




105


3.7.1 Installing the harness for double SMB

3.7 Installing options

3.7.1 Installing the harness for double SMB

Location

The illustration shows the location of the harness double SMB in the controller.

xx2000000448

Required spare parts

Note

The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore C90XT via myABB Business Portal, www.abb.com/myABB .

Spare part

Harness Single SMB connection

Article number

3HAC069674-001

Harness Double SMB connection 3HAC069675-001

Note

Harness single SMB

Harness double SMB


106






Continued

Required tools and equipment

Equipment

Standard toolkit -

Article number Note

Content is defined in section

Standard toolkit for controller on page 417

.

ESD protective wrist band -

Required documents

Document Article number

Circuit diagram - OmniCore C90XT 3HAC065464-009

Note

Installing the harness double SMB

Preparations

Action

1

DANGER

Before doing any work inside the cabinet, disconnect the mains power. For more information, see

Electrical safety on page 31 .

Note/Illustration

2

3

Open the door.

Opening the door on page 174

.

ELECTROSTATIC DISCHARGE

(ESD)

Location of wrist strap button:

The unit is sensitive to ESD. Before handling the unit read the safety information in section

The unit is sensitive to

ESD on page 43 .

xx1900001446





107



Continued

Removing the harness for signal SMB

1

Action

Loosen the screw and disconnect:

• SMB - K6.X4


2 Remove the attachment screws on the cover.

xx1900001914 xx1900001915

3

4

Push the manipulator signal connector into the cabinet.

Take the manipulator signal connector out.

Refitting the harness for double SMB

Action

1

DANGER





108






Continued

Action

2


(ESD)



ESD on page 43 .


3

4

Insert the manipulator signal connector into the cover from inner side of the cabinet.

Secure it with the attachment screws.

Screws: Torx pan head screw M4x8 (4 pcs)

5 Reconnect and secure:

• K6.X4, K6.X5 - SMB.

xx2000000440 xx2000000439

Concluding procedure

1

2

Action

Close the door.

Perform the function tests to verify that the safety features work properly, see

Function tests on page 165

.


Closing the door on page 174

.




109


3.7.2 Installing the scalable I/O devices

3.7.2 Installing the scalable I/O devices

Location

The location of the base unit used as a scalable I/O internal unit is shown in the following illustration.

xx1900001467

The base unit can also be used as a scalable I/O external unit, with or without add-on devices.


Required parts

Part

Local I/O Digital base [3032-1]

Connectors digital base/add on

Digital add-on [3033-2]

Analog add-on [3034-2]

Connectors I/O Analog

Relay add-on [3035-2]

Connectors I/O Relay

Article number

3HAC058663-001

3HAC060919-001

3HAC058664-001

3HAC058665-001

3HAC060925-001

3HAC058666-001

3HAC060926-001

Note

DSQC1030

DSQC1031

DSQC1032

DSQC1033


Equipment

Standard toolkit -




.

ESD protective wrist band


110

-






Continued




Application manual - Scalable I/O 3HAC070208-001

Note

Installing the scalable I/O internal base device

Action

1

DANGER




2


(ESD)




ESD on page 43 .

3 Push the digital base into the bracket until you hear a clear clicking sound.

xx1900001446 xx1900002447





111



Continued

4

Action

Connect the adapter cable to the digital base.

• K5.1.X5 - A2.X4/K4.X7


Note

If the Ethernet extension switch is installed, connect and disconnect the connector K5.1.X5 to/from

K4.X7.

If the Ethernet extension switch is not installed, connect and disconnect the connector K5.1.X5 to/from

A2.X4.

• K5.1.X4 - K2.X3

• The harness connected to I/O unit by customer

Installing scalable I/O external devices


Action Note/Illustration

1

DANGER



2


(ESD)



ESD on page 43 .

3

4

5

6

7

8

Prepare the scalable I/O units for external mounting as described in Application manual - Scalable I/O .

Open the door.


.

Connect the external base device to the internal base device (X3) or the Ethernet switch, using an Ethernet cable.

Connect an external power supply to the external base units, connector X4.

Each base device requires its own power supply.

Close the door.


Function tests on page 165 .


.

112





3.7.3 Installing the Ethernet extension switch

3.7.3 Installing the Ethernet extension switch

Location

The illustration shows the location of the Ethernet extension switch in the controller.

xx1900001465


Note


Spare part

Ethernet Extension switch [3014-

1]

Article number

3HAC059187-001

Note

DSQC1035





113



Continued


Equipment

Standard toolkit -




.





Note

Installing the Ethernet extension switch

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Refitting the Ethernet extension switch (option)

Action

1

DANGER










Continued

2



(ESD)




ESD on page 43 .

3 Hook up the Ethernet extension switch to the bracket and then push the switch into position.

Note

During the installation, there should be no gap between the upper surface of the

Ethernet extension switch and the lower surface of highest bracket on the main computer.

xx1900001446 xx1900002330 xx1800000972


4 Reconnect:

• K2.X2 - K4.X8, A2.X1

• K4.X7 - K5.1.X5

• K4.X6 - A2.X4

1

2

Action

Close the door.





.




115


3.7.4 Installing the power supply optional device

3.7.4 Installing the power supply optional device

Location

The illustration shows the location of the power supply optional device in the controller.

xx2000000447


Note


Spare part

Power supply

DSQC 609 power supply


Article number

3HAC071301-001

3HAC14178-1

3HAC13398-2

Harness AC input of power supply 3HAC069617-001

End clamp 3HAB7983-1

Note

DSQC3035

DSQC 609

DSQC 634


Equipment

Standard toolkit -




.



116






Continued




Note

Installing the optional power supply

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Installing the 24V terminal block

1

Action

Hang the 24V terminal block to the bracket and push the lower part until you hear a clear clicking sound.






117



Continued

Fitting the optional power supply

1

Action

Fit the power supply to the bracket.

Note

For DSQC 609: Hang the power supply to the bracket and secure the power supply with the attached screw.

For DSQC 634: Hang the power supply to the bracket and push the lower part until you hear a clear clicking sound.


For DSQC 609:

Screws: Cross recessed cheese head screw

M4x8 (1 pcs) xx1900001908

For DSQC 634: xx1900001950


118






Continued

2

Action

Refit the end clamp besides the power supply.


For DSQC 609: xx1900001907

For DSQC 634: xx1900002443

3 Connect:

• T5.X1-AC Terminal block

• T5.X2-24V Terminal block

Note

The connector on the AC_in cable

(3HAC061099-001) is fastened to the cable clip in the illustration when the power supply optional is not selected.


1

2

Action

Close the door.





.




119


3.7.5 Installing the fieldbus adapter slave devices

3.7.5 Installing the fieldbus adapter slave devices

Location

The illustration shows the location of the fieldbus adapter slave devices in the controller.

xx1900001474


Note


Note Spare part

Fieldbus slot cover

Article number

3HAC062390-001

DeviceNet Slave Fieldbus adaptor

[3030-1]

3HAC045973-001

ProfiNet Board [3022-1]

Ethernet Unit [3025-1]

3HAC031670-001

3HAC027652-001

DSQC1004

DSQC 688

DSQC 669


Equipment

Standard toolkit -




.





Note

Installing the fieldbus adapter slave variants

Action

1

DANGER









3.7.5 Installing the fieldbus adapter slave devices

Continued

2



(ESD)




ESD on page 43 .

xx1900001446

3

4

5

Open the door.

Remove the fieldbus slot cover with a screwdriver.

Insert the fieldbus adapter slave and secure the screws.


.

xx1900001917

6

7

Close the door.




.




121


3.7.6 Installing the fieldbus master

3.7.6 Installing the fieldbus master

Location

The illustration shows the location of the fieldbus master in the main computer.

Required spare parts xx1800003420

Harness DeviceNet is an option of process connector.

Note


Spare part

DeviceNet Board

Article number

3HAC043383-001

Note

DSQC1006


Equipment

Standard toolkit -




.





Note


122






Continued

Installing the DeviceNet board

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Removing the main computer assembly

1

Action

Disconnect all the connectors on the assembly group of the robot signal exchange proxy, Ethernet switch (option),

Connected Services Gateway, and main computer.


For the robot signal exchange proxy:

• K2.X8 - A2.X6

• (option): K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K2.X10 - A1.X13

• K2.X21 - TempSensor

• K2.X4 - A1.X9

• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,

K7.X1

• K2.X1 - T2.X2

• K2.X17 - G2.X1, G1.X2

• K2.X6, K2.X11 - A1.X2

• K2.X7, K2.X22 - Harn. LV robot power

• K2.X9 & X13 - FlexPendant







Continued

Action

For the Ethernet extension switch (option):

• K2.X2 - K4.X8, A2.X1

• K4.X7 - K5.1.X5

• K4.X6 - A2.X4

For the Connected Services Gateway:

• K7.X1 - K2.X3

i

• K7.X2 - A2.X5


Note

The connector K7.X2 is locked; grab the connector, push it in to release it and then remove the connector.

For the main computer:

• K2.X8 - A2.X6

• K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K6.X2 - A2.X9

• A2.X5 - K7.X2

• A2.X4 - K4.X6/K5.1.X5

Note

If the Ethernet extension switch is installed, connect and disconnect the connector A2.X4 to/from

K4.X6.

If the Ethernet extension switch is not installed, connect and disconnect the connector A2.X4 to/from

K5.1.X5.

2 Remove the screws holding the main computer.

xx1900001877


124






Continued

3

Action

Remove the assembly from the mounting plate.


Note

Avoid colliding with the frame when removing the unit.


(ESD)

When handling the computer outside of the controller, use the wrist strap button located on the side of the computer.

xx1900001878 xx1900001885 i

For Connected Services Gateway wired, there is no power cable.

Removing the robot signal exchange proxy

1



(ESD)



xx2000000419





125



Continued

2

Action

Pull the cable ties out from the locking holes.


3 Remove the screws and lift out the robot signal exchange proxy.

xx1900001879 xx1900001880

Installing the DeviceNet board

1



(ESD)



xx2000000419


126






Continued

2

Action

Remove the screws on top of the main computer and take the cover off.


3 Remove the attachment screw on the cover of the fieldbus master and take out the cover.

xx1800003415

Note

The Connected Services Gateway and Ethernet extension switch are omitted on the illustration to make it more clear.

xx1800003414

Note






127



Continued

4

Action

Insert the DeviceNet board into the card slots along the guide rail in the main computer.


B

A

5 Secure the DeviceNet board with the screw.

xx1800003417

A

B

Card slots

Guide rail

Note


Screw: Screw with flange M3x6 (1 pcs) xx1800003416

Note



128






Continued

6


Refit the cover on the main computer and secure the screws.

Screws: Hexalobular socket pan head screw

M3x6 (4 pcs) xx1800003418

Note


Refitting the robot signal exchange proxy

Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx2000000419





129



Continued

3


Fit the robot signal exchange proxy and secure the screws.


4 Insert the cable ties into the locking holes.

xx1900001880 xx1900001879

Refitting the main computer assembly to the cabinet

Action

1

DANGER





130






Continued

2



(ESD)



3 Refit the assembly onto the mounting plate.

xx1900001446 xx1900001885 xx1900001878





131



Continued

4

Action

Fasten the assembly with the screws.


5 Reconnect all the connectors on assembly of the robot signal exchange proxy, ethernet extension-seven port switch (option), ABB ability™ connected services, and main computer.


• K2.X8 - A2.X6

• (option): K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K2.X10 - A1.X13

• K2.X21 - TempSensor (G3.TEMP)

• K2.X4 - A1.X9

• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,

K7.X1

• K2.X1 - T2.X2

• K2.X17 - G3.X1, G1.X2

• K2.X6, K2.X11 - A1.X2

• K2.X7, K2.X22 - Harn. LV robot power (X1)

• K2.X9 & X13 - FlexPendant (X4)


• K2.X2 - K4.X8, A2.X1

• K4.X7 - K5.1.X5

• K4.X6 - A2.X4


• K7.X1 - K2.X3

i

• K7.X2 - A2.X5

Note


xx1900001877


132






Continued

Action


• A2.X3 - X24

• K2.X8 - A2.X6

• K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K6.X2 - A2.X9

• A2.X5 - K7.X2

• A2.X4 - K4.X6/K5.1.X5


Note


K4.X6.


K5.1.X5.

Concluding procedure i


1

2

Action

Close the door.





.




133


3.7.7 Installing the conveyor tracking module

3.7.7 Installing the conveyor tracking module

Overview

The conveyor tracking module uses network communication to share conveyor speed and position data with one or more robot controllers. It contains a WAN port, which is used to connect to the robot controllers and two LAN ports that can be used for installation and service purposes.

xx1800000941

Required parts

Note


Spare part Article number

Conveyor tracking module [3103-

1]

CONNECTOR KIT - DSQC2000

3HNA027579-001

3HNA029345-001

Note

DSQC2000


Equipment

Standard toolkit -




.



134






Continued





3HAC066561-001

Note

Installing the conveyor tracking module

Action

1

DANGER




2


(ESD)




ESD on page 43 .

3 Open the door.

xx1900001446


.





135



Continued

4

Action

Fit the conveyor tracking module and push the lower part until you hear a clear clicking sound.

Note/Illustration xx1900001913

136 xx1900001912

7

8

5

6

Connect:

• B1.X1 - K2.X19.1, K2.X19.2(Power cable)

• B1.X7 - K4.X1-5 (Ethernet cable)

Connect wires to the input and output connectors as required.

Close the door.

See Application manual - Conveyor tracking .


.



For more information about the option Conveyor Tracking , see Application manual - Conveyor tracking .





3.7.8 Installing the cable grommet assembly

3.7.8 Installing the cable grommet assembly

Location

The illustration shows the location of the cable grommet assembly on the controller.

xx1900001480

Note





Note


Spare part

Cable grommet asm

Article number

3HAC066396-001

Note







Continued


Equipment

Standard toolkit -




.





Note

Installing cables with the cable grommet assembly

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446


138






Continued

Removing the slot cover (baseline)

1

Action

Remove the attachment screws.


2 Take out the cover from the inside of the controller.

xx1900002444

Refitting the cable grommet assembly

Refitting the cables to the cable grommet assembly

1

Action

Insert and equip the cable to the corresponding KT grommet.






139



Continued

2

Action

Slide the grommets into the frame halves.


Note

It must be ensured that the flat side of the grommets in the lower row are pointing to the open side of the frame half (flat sides pointing upwards).

Note

The fl at side of the grommets in the upper row have to point downwards so that all flat sides rest on each other. When using single row frames the fl at side has to point towards the cover strip.

xx1900002336

3 Refit the cover strip onto the frame.

xx1900002335

4 Secure the frame and cover strip with the screws.

Screws: Hex socket head cap screw M5x50

12.9 Gleitmo 603+Geomet 500 (3 pcs)

Tightening torque: 2 Nm - 3 Nm.


140 xx1900002334






Continued

5

Action

Route the cables through the cut-out.


6 Refit the cable entry frame to the enclosure wall and secure with the screws.


Tightening torque: 1.5 Nm.

xx1900002332

Refitting the cable grommet assembly

Action

1

DANGER








141



Continued

2



(ESD)




ESD on page 43 .

xx1900001446

3 Insert the cable grommet assembly into the cover of the cabinet.

Secure it with the screws.

Screws: Torx pan head screw M4x8 (4 pcs) xx1900002340


1

2

Action

Close the door.





.

142





3.7.9 Installing the filter

3.7.9 Installing the filter

Location

The illustration shows the location of the air filter on the controller.

xx1900001473


Note


Note Spare part

Air filter-coarse filter

Air filter-Fine filter

Air filter (Polymeric)

Article number

3HAC068415-001

3HAC068416-001

3HAC068543-001 Filter element of fine filter


Equipment

Standard toolkit -




.






143


3.7.9 Installing the filter

Continued




Note

Installing the air filter

Action

1

DANGER



2 Fit the air filter to the cabinet.



3 Perform the function tests to verify that the safety features work properly, see


xx1900001492

144





3.8.1 Installing the extension box

3.8 Installing add-on devices

3.8.1 Installing the extension box

General

As an option an empty extension box can be purchased, to use for custom equipment. The extension box can be installed on the basic box or anywhere else as a standalone equipment.

xx1900001453

Note

Connect PE19 as grounding for the extension box in any use case.


Equipment

Standard toolkit

Information

See






145



Continued

Specifications


The following describes the cable requirements for the X106 connection in the extension box.

Component

Cable type

Cable area

Description

Flexible oil resistant rubber

4C x 0.5 mm

2 or AWG20

Included parts

The following parts are included in the delivery when the extension box is selected.

Part

Connector for X106

Order number

3HAC074661-001

Quantity

1

Procedure

1

2

Use this procedure to stack an extension box to a basic box.

3

Action

Place the controller in desired place.

Fix the basic box to a concrete foundation or steel platform with anchor bolts.

Info/illustration

Anchor bolts: M8 X 4

Tighten torque: 11.3 Nm-12.6 Nm

Remove the four plastic screw.

xx1900001450


146






Continued

4

Action

Assemble the hexalobular socket pan head screws onto the cabinet.


5 Place the extension box upright the basic box with lifting accessory. Lock them with screws.

xx1900001451

6 Open the door of the extension box.

xx1900001452

Opening the door on page 174 .





147



Continued

7

Action

Fit the connector (3HAC074661-001) for

X106.


8 Connect through the cable grommet:

• PE19

• X106 xx2000000690

1 24 V

2 0 V

3 24 V

4 0 V

How to insert cable through cable grommet, see

Releasing the cables from the cable grommet assembly on page 314

and

Refitting the cables to the cable grommet assembly on page 317 .

xx2000000446 xx2000000689


148






Continued

9

Action

Install the equipment to the extension box according to your requirements.


WARNING

ABB only offers the extension box as an encapsulation for customer installing external devices.

It is the system builder's responsibly to ensure the complacence with electrical safety, for example the Low Voltage Directive.




149


3.8.2 Installing the conveyor tracking module to extension box

3.8.2 Installing the conveyor tracking module to extension box

Overview

The conveyor tracking module uses network communication to share conveyor speed and position data with one or more robot controllers. It contains a WAN port, which is used to connect to the robot controllers and two LAN ports that can be used for installation and service purposes.

xx1800000941

Required parts

Note




1]


3HNA027579-001

3HNA029345-001

Note

DSQC2000


Equipment

Standard toolkit -




.



150






Continued





3HAC066561-001

Note

Installing the conveyor tracking module

Action

1

DANGER




2


(ESD)




ESD on page 43 .

3

4

Open the door of the extension box.

Fit the conveyor tracking module by snapping it onto the mounting rail .

xx1900001446


.

xx1900001913





151



Continued

8

9

5

6

7


Connect the 24V power supply to the conveyor tracking module from the basic box or other power supply.

How to insert cable through cable grommet, see

Releasing the cables from the cable grommet assembly on page 314

and

Refitting the cables to the cable grommet assembly on page 317

.

Connected to Ethernet through the cable grommet:

• B1.X7 - K4.X1-5

Connect wires to the input and output connectors as required.

For details on connecting wires to the conveyor tracking module, see Application manual - Conveyor tracking .

Close the door.




.

For more information about the option Conveyor Tracking , see Application manual - Conveyor tracking .

152





3.9 Installing external devices

3.9 Installing external devices

General

WARNING

Only LVD

1 equipments can be installed on the door of the controller.

WARNING

ABB only offers the extension box as an encapsulation for customer installing external devices.

It is the system builder's responsibly to ensure the complacence with electrical safety, for example the Low Voltage Directive.

1

Low Voltage Directive




153


3.10 Initial test before commissioning

3.10 Initial test before commissioning

Function tests

When the installation is complete, perform the function tests in section


to verify that the safety features work properly.

154




4 Maintenance

4.1 Maintenance schedule, OmniCore

4 Maintenance

4.1 Maintenance schedule, OmniCore

General

The controller must be maintained at regular intervals to ensure its function. The activities and intervals are described in this section.

Activities and intervals

Equipment

Complete controller

Air filter

Air filter

System fans

Maintenance activity

Inspection

Cleaning

Replacement

Inspection

Interval

12 months

24 months *

6 months

i

i

Detailed in section:

Inspecting the OmniCore C90XT controller on page 156

Cleaning air filter on page 157

Replacement of air filter on page 162

Inspecting the OmniCore C90XT controller on page 156

Control cabinet

FlexPendant

Cleaning

Cleaning

Emergency stop

(FlexPendant)

Function test

Manual, auto and manual full speed mode with FlexPendant

Function test

Enable device Function test

When needed

12 months

12 months

Cleaning of the controller cabinet on page 159

Cleaning the FlexPendant on page 160

Function test of emergency stop on page 165

Function test of manual, auto, and manual full speed mode with Flex-

Pendant on page 166

Contactors A1.Q1

and A1.Q2

Function test

12 months

12 months

Function test of three-position enabling device on page 167

Function test of contactors A1.Q1

and A1.Q2 inside the power unit on page 168

Function test of auto stop on page 169

Auto stop (tested if used)

Function test 12 months

External emergency stop (tested if used)

Function test

ESTOP_STATUS output (tested if used)

Function test

12 months

12 months

Function test of external emergency stop on page 170

Function test of ESTOP_STATUS output on page 171

i

Reduced speed control

Function test During commissioning

Function test of reduced speed control on page 172

.

The interval depends on the working environment of the equipment: a cleaner environment may extend the maintenance interval and vice versa.

Function test after replacement of component

After replacing a component in the controller, the function tests should be performed. See





155

4 Maintenance

4.2.1 Inspection of controller

4.2 Inspection activities

4.2.1 Inspection of controller

Inspecting the OmniCore C90XT controller

Action

1

DANGER




2


(ESD)




ESD on page 43 .

3

4

5

Inspect connectors and cabling to make sure they are securely fastened and cabling not damaged.

Inspect the fans and ventilation holes to make sure they are clean.

After inspection: Temporarily turn the power supply on. Inspect the fans to make sure they function correctly. Switch the power off.

xx1900001446

156




4.3 Cleaning activities

4.3.1 Cleaning air filter

Location

The air filter is located as shown in the illustration below.

4 Maintenance

4.3.1 Cleaning air filter xx1900001473


Equipment

Cleaning agent

Compressed air

Note

Water 30-40°C with cleansing liquid or detergent.

Cleaning

3

4

The procedure below details how to clean the moist dust filter.

1

2

Action

Remove the air filter.


How to remove the air filter is detailed in section

Replacing the air filter on page 284 .

If a fine filter is used, remove the polymeric filter element first.

Clean the filter three or four times.

Allow the filter to dry in one of these ways:

• Lying flat on a flat surface

• Blow with compressed air in opposite direction of filter airflow.

Note

Do not wring the filter to press out water.

5 If a fine filter us used, refit a new polymeric filter element to the filter.




157


4 Maintenance

4.3.1 Cleaning air filter

Continued

6

Action

Refit the air filter.


158




4 Maintenance

4.3.2 Cleaning of the controller cabinet

4.3.2 Cleaning of the controller cabinet


Equipment, etc.

Vacuum cleaner

Note

ESD protected

Cleaning considerations

This section specifies some special considerations when cleaning the controller.

• Always use ESD protection.

• Always use cleaning equipment as specified above. Any other cleaning equipment may shorten the life of paint work, rust inhibitors, signs, or labels.

• Always make sure that all protective covers are fitted to the controller before cleaning.

• Never remove any covers or other protective devices when cleaning the outside of the controller.

• Never use compressed air or spray with a high pressure cleaner.

• Never leave the door open when cleaning the exterior.




159

4 Maintenance

4.3.3 Cleaning the FlexPendant

4.3.3 Cleaning the FlexPendant

Location

The surfaces to clean are shown in the illustration below.

A B xx1800000128

A

B

Touch screen

Hard buttons


Equipment, etc.

Soft cloth

Water/Mild cleaning agent

Note

ESD protected

Clean the touch screen

This section describes how to clean the touch screen.

1

2

3

4

Action

Lock the screen.

It is safe to clean the FlexPendant when the Lock screen appears.

Clean the touch screen and hardware buttons using a soft cloth and water or a mild cleaning agent.

Unlock the screen, by tapping the buttons.

Info/Illustration

Cleaning considerations

The section below specifies some special considerations when cleaning the

FlexPendant:

• Use ESD Protection

• Use cleaning equipment as specified above. Any other cleaning equipment may shorten the life time of the touch screen.

• Check that all protective covers are fitted to the device before cleaning.

• Make sure that no foreign objects or liquids can penetrate into the device.





4 Maintenance

4.3.3 Cleaning the FlexPendant

Continued

• Do not remove any covers before cleaning the FlexPendant.

• Do not spray with a high pressure cleaner.

• Do not clean the device, operating panel and operating elements with compressed air, solvents, scouring agent or scrubbing sponges.




161

4 Maintenance

4.4.1 Replacement of air filter

4.4 Changing/replacing activities

4.4.1 Replacement of air filter

Location

The air filter is located as shown in the illustration below.

xx1900001473


Equipment

Air filter

Note

Other tools and procedures may be required.

See references to these procedures in the stepby-step instructions below.

These procedures include references to the tools required.

Removing the air filter

Preparations

Action

1

DANGER





162




4 Maintenance


Continued

Removing the air filter

1

Action

Loosen the attachment screws on the air filter.


2 Remove the air filter.

xx1900001491 xx1900001492

Removing the polymeric filter element

1

Action

Take out the polymeric filter element from the filter.






163

4 Maintenance


Continued

Refitting the air filter

Refitting the polymeric filter element

1

Action

Insert the polymeric filter element to the filter and secure with the metallic line.


Refitting the air filter

Action

1

DANGER



2 Refit the air filter to the cabinet.




1

Action




164




4 Maintenance

4.5.1 Function test of emergency stop

4.5 Function tests

4.5.1 Function test of emergency stop

Overview

Perform this test on the FlexPendant emergency stop button.

Performing the function test

1

2

3

4

Action Note

Make a visual inspection of the emergency stop button to make sure it is not physically damaged.

If any damage is found on the emergency stop button, it must be replaced.

Pull and rotate the emergency stop button clockwise to verify that it is not pressed in.

Start the robot system.

Press the emergency stop button.

Note

The test is passed if the event message

10013 Emergency stop state appears in the event log.

If the event message 20223 Emergency stop conflict appears in the event log, or the event message 10013 Emergency stop state (and 90518 Safety controller Emergency stop triggered for collaborative robots) does not appear, then the test has failed and the root cause of the failure must be found.

Note

For collaborative robots, the event message 90518 Safety controller Emergency stop triggered appears by default. The message 10013 Emergency stop state is also available in the event log.

5 Release the emergency stop button to reset the emergency stop state.




165

4 Maintenance

4.5.2 Function test of manual, auto, and manual full speed mode with FlexPendant

4.5.2 Function test of manual, auto, and manual full speed mode with FlexPendant

Overview

Perform this function test to change the mode on the FlexPendant using the following operation:

• Status bar > Common Settings > Operating Mode (Auto/Manual/Man FS) .

For more detailed information, see Operating manual - OmniCore , 3HAC065036-001 .


1

2

3

4

Action Note


Change to Automatic operating mode and

Motors ON state, and then run the robot in auto mode.

This test is passed if it is possible to run the robot program in auto mode.

If it is not possible to run the robot program, this test is failed and the root cause of the failure must be found.

Change to Manual operating mode and

Motors ON state, and then run the robot in manual mode.

This test is passed if it is possible to run the robot program in manual mode.


Change to Manual Full Speed mode and

Motors ON state, and then run the robot in manual full speed mode.

Note

This test is passed if it is possible to run the robot program in manual full speed mode.


Manual full speed mode is not available in

USA or Canada.

166




4 Maintenance

4.5.3 Function test of three-position enabling device

4.5.3 Function test of three-position enabling device


1

2

3

Action Note

Start the robot system and turn the mode switch to manual mode.

Press the three-position enabling device to the middle position and then hold the enabling device in this position.

This test is passed if the event message

10011 Motors ON state appears in the event log.

If the event message 10011 Motors ON state does not appear, or if the event message 20224 Enabling device conflict appears in the event log, then the test has failed and the root cause of the failure must be found.

While still holding the three-position enabling device pressed, press the enabling device harder to the enable the device's third position.


10012 safety guard stop state appears in the event log.

If the event message 10012 Safety guard stop state does not appear, or if the event message 20224 Enabling device conflict appears in the event log, then the test has failed and the root cause of the failure must be found.




167

4 Maintenance

4.5.4 Function test of contactors A1.Q1 and A1.Q2 inside the power unit

4.5.4 Function test of contactors A1.Q1 and A1.Q2 inside the power unit

Performing the motor function test

1

2

3

Action Note

Start the robot system and change the operating mode to manual.



10011 Motors ON state appears in the event log.

If the event message 37001 Motor on activation error appears in the event log, then the test has failed and the root cause of the failure must be found.

Release the three-position enabling device.


10012 Safety guard stop state appears in the event log.

If the event message 20227 Motor contactor conflict appears in the event log, then the test has failed and the root cause of the failure must be found.

Performing the brake function test

1

2

3

Action


Note


While having eye contact with the manipulator, move the joystick slightly in any direction to disengage the brakes.

This test is passed if the brakes are disengaged and the manipulator can be moved.

If the event message 50056 Joint collision appears in the event log, then the test has failed and the root cause of the failure must be found.

Release the three-position enabling device to engage the brakes.


10012 Safety guard stop state appears in the event log.

If the event message 37101 Brake failure appears in the event log, then the test has failed and the root cause of the failure must be found.

168




4 Maintenance

4.5.5 Function test of auto stop

4.5.5 Function test of auto stop


1

2

Action Note

Start the robot system and change the operating mode to auto mode.

Activate the auto stop, for example by opening the connected robot cell door, which has interlock connection with auto stop.


20205 Auto stop open appears in the event log.

If the event message 20205 Auto stop open does not appear or if the event message 20225 Auto stop conflict appears in the event log, then the test has failed and the root cause of the failure must be found.




169

4 Maintenance

4.5.6 Function test of external emergency stop

4.5.6 Function test of external emergency stop

Overview

Perform this test on the external emergency stop device.


1

2

Action Note

Make a visual inspection of the external emergency stop device and the connection harness to make sure they are not physically damaged.

If any damage is found on the external emergency stop device or the connection harness, it must be replaced.

Pull and rotate the button on the external emergency stop device clockwise to verify that it is not pressed in.

Note

If the external emergency stop device is not controlled by a push-button, make sure to verify that it is not activated.

3

4





Note


Note


5 Release the external emergency stop device to reset the external emergency stop state.

170




4 Maintenance

4.5.7 Function test of ESTOP_STATUS output

4.5.7 Function test of ESTOP_STATUS output

Overview

Perform this test on the FlexPendant emergency stop button or the external emergency stop device, with the accessory device.


1

2

Action Note

Make a visual inspection of the emergency stop button, external emergency stop device, accessory device and the connection harness to make sure they are not physically damaged.

If any damage is found, it must be replaced.

Pull and rotate the emergency stop button clockwise to verify that it is not pressed in.

Note

If the external emergency stop device is not controlled by a push-button, make sure to verify that it is not activated.

3

4





Note


Note


5

6

7

Make sure that the accessory device is in emergence stop status.

Release the emergency stop button or the external emergency stop device to reset the emergency stop state.

Make sure that the accessory device is not in emergence stop status any more and can be reset.




171

4 Maintenance

4.5.8 Function test of reduced speed control

4.5.8 Function test of reduced speed control


1

2

3

Action

Start the program in manual mode and measure the time it takes for the robot to travel the distance.

Note


Create a test program where the robot moves along a known distance with a programmed speed higher than 250 mm/s.

The distance and speed must be adapted to the current installation and robot model.

This test is passed if the speed of the robot does not exceed 250 mm/s, otherwise the test is failed and the root cause of the failure must be found.

Tip

To get accurate results, use sensors or I/O signals to measure the time.

172




5 Repair

5.1 Introduction to repair

5 Repair

5.1 Introduction to repair

Structure of this chapter

This chapter describes all repair activities recommended for the OmniCore C90XT and any external unit.

It is made up of separate procedures, each describing a specific repair activity.

Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials.

All procedures assume that the controller is easy to access from all sides and that no additional covers or equipment are fitted.

WARNING

Repair activities not described in this chapter must only be carried out by ABB.

Otherwise damage to the mechanics and electronics may occur.


The details of the equipment required to perform a specific repair activity are listed in the respective procedures.

Safety information

There are general safety information and specific safety information. The specific safety information describes the danger and safety risks while performing specific steps in a procedure. Make sure to read through the chapter

Safety on page 13

before commencing any service work.

WARNING

Wait at least three minutes after powering off the controller before opening it and at least fifteen minutes until all LED indicators are off before replacing modules.

Note

When replacing a part on the OmniCore C90XT, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.

This is particularly important for safety equipment to maintain the safety integrity of the installation.




173

5 Repair

5.2.1 Opening the robot controller

5.2 Replacement of controller parts

5.2.1 Opening the robot controller


Equipment

Standard toolkit -




.





Note

Opening the door

Preparations

Action

1

DANGER




Opening the door

1

2

3

Action

Insert the key to the door and turn it anticlockwise.


Pull out the handle and turn it anti-clockwise.

Pull out the door with the handle.

Closing the door

Closing the door

1

2

3

Action

Push the door back.

Turn the handle clockwise and push it back into the lock.

Turn the key back and take it out.


174




5 Repair

5.2.2 Replacing the axis computer

5.2.2 Replacing the axis computer

Location

The illustration shows the location of the axis computer in the controller.

xx1900001462


Note


Spare part

Axis Computer

Article number

3HAC029157-001

Note

DSQC 668


Equipment

Standard toolkit -




.





Note





5 Repair


Continued

Removing the axis computer

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Removing the axis computer from the cabinet

1

2

Action

Disconnect:

• K6.X11 - A1.X3

• K6.X2 - A2.X9

• K6.X1 - K2.X3.


• K6.X4, K6.X5 - SMB.



176




5 Repair


Continued

3

Action

Remove the screws on the bracket.


4 Take out the axis computer with the bracket from the cabinet.

Tip

Be careful with the locking hole on the cabinet when doing assembling or disassembling work.

xx1900001484 xx1900001485 xx1900001486





177

5 Repair


Continued

Removing the axis computer

1

Action

Remove the bracket screws.


2 Remove the axis computer.

Refitting the axis computer

Refitting the axis computer

1

Action

Refit the axis computer to the bracket and secure the screws.



Refitting the axis computer to the frame

Action

1

DANGER





178




5 Repair


Continued

2



(ESD)




ESD on page 43 .

xx1900001446

3 Fit the axis computer bracket and secure the screws.

Screws: Torx pan head screw M4x8 (4 pcs) xx1900001486 xx1900001484

4 Reconnect:

• K6.X11 - A1.X3

• K6.X2 - A2.X9

• K6.X1 - K2.X3





179

5 Repair


Continued


5

Action

Reconnect and secure the screw:

• K6.X4, K6.X5 - SMB.

1

2


Action

Close the door.





.

180




5 Repair

5.2.3 Replacing the fans

5.2.3 Replacing the fans

Location

The illustration shows the location of the fans in the controller.

xx1900001463


Note


Note Spare part

Standard fan

Heat exchanger

Article number

3HAC059214-001

3HAC065526-001


Equipment

Standard toolkit -




.





Note





5 Repair

5.2.3.1.1 Replacing the standard fan

5.2.3.1 Replacing the standard fans

5.2.3.1.1 Replacing the standard fan

Removing the standard fan

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Removing the standard fan

1

2

Action

Disconnect standard fan:

• G1.X2-K2.X17

Remove the fan bracket screws.



182 xx1900001488




5 Repair


Continued

3

Action

Take out the fan with the bracket.

Removing the standard fan from the bracket

1

2

Action

Remove the screws on the fan to the bracket.

Remove the fan from the bracket.



Tip


xx1900001498 xx1900001489





183

5 Repair


Continued

Refitting the standard fan

Refitting the standard fan to the bracket

1

Action

Refit the standard fan to the bracket.

Tip




2 Secure the screws.

xx1900001489

Refitting the standard fan


1

DANGER



2


(ESD)




ESD on page 43 .


184 xx1900001446




5 Repair


Continued

3

4

Action

Refit the standard fan with the bracket into position according to the location pin.

Secure the screws.



5 Reconnect:

• G1.X2-K2.X17


1

2

Action

Close the door.





.




185

5 Repair

5.2.3.2 Replacing the heat exchanger

5.2.3.2 Replacing the heat exchanger

Removing the heat exchanger

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446


1

Action




186




2

Action

Remove the air filter.

5 Repair


Continued


Removing the heat exchanger

1

2

Action

Disconnect heat exchanger:

• G3.X1-K2.X17

Remove the screws locking the sensor and pull out the sensor.






187

5 Repair


Continued

3

Action

Remove the heat exchanger attachment screws.


4 Take out the heat exchanger.

Refitting the heat exchanger

Refitting the heat exchanger

Action

1

DANGER





188




5 Repair


Continued

2



(ESD)




ESD on page 43 .

3 Refit the heat exchanger into position according to the location pin.

xx1900001446 xx1900001494





189

5 Repair


Continued

4

Action

Secure the attachment screws.


Screws: Torx, countersunk screw M4x10 (10 pcs) xx1900001493

5

6

Reconnect:

• G3.X1-K2.X17

Refit the sensor cable and secure with screws.



190




5 Repair


Continued


Action

1

DANGER



2 Refit the air filter to the cabinet.




1

2

Action

Close the door.





.




191

5 Repair

5.2.4 Replacing the robot signal exchange proxy

5.2.4 Replacing the robot signal exchange proxy

Location

The illustration shows the location of the robot signal exchange proxy in the controller.

xx1900001464


Note


Spare part

Signal exchange

Harness Short-circuit connector

Article number

3HAC064662-001

3HAC065107-001

Harness 24_PC

Harness dual channel safety

3HAC064091-001

3HAC059273-001

Note

DSQC3037

Mating connector for robot signal exchange proxy.

Harness K2.X2 - K4.X8, A2.X1

Harness K2.X12 - K3.X6, K3.X7


192




5 Repair


Continued

WARNING

NEVER open the robot signal exchange proxy.

There is residual voltage in the robot signal exchange proxy even the controller is power off in a short time.


Equipment

Standard toolkit -




.





Note

Removing the robot signal exchange proxy

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446





193

5 Repair


Continued


1

2

Action

Disconnect:

• K2.X8 - A2.X6

• (option): K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K2.X10 - A1.X13


• K2.X4 - A1.X9

• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,

K7.X1

• K2.X1 - T2.X2

• K2.X17 - G3.X1, G1.X2

• K2.X6, K2.X11 - A1.X2



Remove the mating connectors by loosening their attachment screws.


3 Pull the cable ties out from the locking holes.

xx1900002339 xx1900001495


194




5 Repair


Continued

4

Action

Remove the screws and lift out the robot signal exchange proxy.


Refitting the robot signal exchange proxy


Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx1900001446





195

5 Repair


Continued

3


Fit the robot signal exchange proxy and secure the screws.



xx1900001496

5 Refit the mating connectors and secure their attachment screws.

xx1900001495 xx1900002339


196




5 Repair


Continued


6

Action

Reconnect:

• K2.X8 - A2.X6

• (option): K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K2.X10 - A1.X13


• K2.X4 - A1.X9

• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,

K7.X1

• K2.X1 - T2.X2

• K2.X17 - G3.X1, G1.X2

• K2.X6, K2.X11 - A1.X2




1

2

Action

Close the door.





.




197

5 Repair

5.2.5 Replacing the Ethernet switch

5.2.5 Replacing the Ethernet switch

Location

The illustration shows the location of the Ethernet switch in the controller.

xx1900001465


Note


Spare part

Ethernet Extension switch [3014-

1]

Article number

3HAC059187-001

Note

DSQC1035


198




5 Repair


Continued


Equipment

Standard toolkit -




.





Note

Removing the Ethernet extension switch (option)

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

Removing the Ethernet extension switch (option)

1

Action

Disconnect:

• K2.X2 - K4.X8, A2.X1

• K4.X7 - K5.1.X5

• K4.X6 - A2.X4

xx1900001446






199

5 Repair


Continued

2

Action

Carefully pull the side of the Ethernet extension switch and rotate it tightly to take it out from the bracket.

Note/Illustration xx1900001499 xx1900002328

Refitting the Ethernet extension switch (option)


Action

1

DANGER





200




5 Repair


Continued

2



(ESD)




ESD on page 43 .

3 Hook up the Ethernet extension switch to the bracket and then push the switch into position.

Note



xx1900001446 xx1900002330 xx1800000972


4 Reconnect:

• K2.X2 - K4.X8, A2.X1

• K4.X7 - K5.1.X5

• K4.X6 - A2.X4

1

2

Action

Close the door.





.




201

5 Repair

5.2.6 Replacing the Connected Services Gateway

5.2.6 Replacing the Connected Services Gateway

Location

The illustration shows the location of the Connected Services Gateway in the controller. For the 3G variant, there is a sim card is located inside the unit.

xx1900001466


Note


Spare part

Connected Services-3G [3013-3]

Article number

3HAC060960-001

Magnetic roof antenna, 3G

Magnetic roof antenna, WiFi

3HAC028459-001

Connected Services-WiFi [3013-2] 3HAC060962-001

3HAC059424-001

Connected Services-Wired [3013-

1]

3HAC061701-001

Harness Ethernet with Mini-IO 3HAC061136-001

Note

DSQC1039

DSQC1040

DSQC1041

Harness A2.X5 - K7.X2


202




5 Repair


Continued


Equipment

Standard toolkit -




.





Note

Removing the Connected Services Gateway

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446





203

5 Repair


Continued

Disconnecting the antenna

1

Action

Disconnect the antenna cable from the

Connected Services Gateway by rotating the connector.


2

3

4

Record the cable routine when you remove the cable from the cabinet.

Take the cable out from the cable grommet.

Removing the cable grommet assembly on page 313 .

Remove the magnet part of the antenna from the top the cabinet.

xx1900001949

Removing the Connected Services Gateway

1

Action

Disconnect:

• K7.X1 - K2.X3

i

• K7.X2 - A2.X5

Note




204




5 Repair


Continued

2

Action

Carefully pull the side of the Connected

Services Gateway and rotate it tightly to take it out from the bracket.

Note/Illustration xx1900001500 xx1900002329 i


Refitting the Connected Services Gateway

Refitting the Connected Services Gateway

Action

1

DANGER








205

5 Repair


Continued

Action

2


(ESD)



ESD on page 43 .


3 Hook up the Connected Services Gateway to the bracket and push carefully into position.

Note

During the installation, the gap between the lower surface of the Connected Services Gateway and the upper surface of the main computer should be zero.

xx1900002331 i

4 Reconnect:

• K7.X1 - K2.X3

i

• K7.X2 - A2.X5


Reconnecting the antenna

1

2


Insert the cable from the cable grommet.

Refitting the cable grommet assembly on page 317 .

Refit the cable in the cabinet according to the record during the disassembly.


206




5 Repair


Continued

3

Action

Connect the antenna cable to the Connected Services Gateway by rotating.


4 Put the magnet part of the antenna on the top the cabinet.

xx1900001948 xx1900001949


1

2

Action

Close the door.





.




207

5 Repair

5.2.7 Replacing the scalable I/O unit

5.2.7 Replacing the scalable I/O unit

Location

The illustration shows the location of the scalable I/O in the controller.

xx1900001467


Note


Spare part

Local I/O Digital base [3032-1]

Connectors digital base/add on

Digital add-on [3033-2]

Analog add-on [3034-2]

Connectors I/O Analog

Relay add-on [3035-2]

Connectors I/O Relay

Article number

3HAC058663-001

3HAC060919-001

3HAC058664-001

3HAC058665-001

3HAC060925-001

3HAC058666-001

3HAC060926-001

Note

DSQC1030

DSQC1031

DSQC1032

DSQC1033


Equipment

Standard toolkit -




.



208

-




5 Repair


Continued




Application manual - Scalable I/O 3HAC070208-001

Note

Removing the digital base (option)

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446





209

5 Repair


Continued

Removing the digital base (option)

1

Action

Disconnect:

• K5.1.X5 - A2.X4/K4.X7

2

Note


K4.X7.


A2.X4.

• K5.1.X4 - K2.X3


Push the buckle of the digital base slightly and take out the digital base.



210




5 Repair


Continued

Refitting the digital base (option)

Refitting the digital base (option)

Action

1

DANGER




2


(ESD)




ESD on page 43 .

3 Push the digital base into the bracket until you hear a clear clicking sound.

xx1900001446 xx1900002447





211

5 Repair


Continued

4

Action

Connect the adapter cable to the digital base.

• K5.1.X5 - A2.X4/K4.X7


Note


K4.X7.


A2.X4.

• K5.1.X4 - K2.X3



1

2

Action

Close the door.





.

212




5 Repair

5.2.8 Replacing the main computer

5.2.8 Replacing the main computer

Location

The illustration shows the location of the main computer in the controller.

xx1900001468


Note



Main computer module assembly 3HAC063061-001

Note


Note

For robots with the controller delivered to start in automatic mode, a FlexPendant is required after the replacement to be able to change to automatic mode.

Equipment

Standard toolkit -




.





5 Repair


Continued

Equipment






Note

Note

The main computer is part of an assembly group, secured on a process plate.

To remove the computer, either lift out the assembly group and then remove the computer, or take out the parts on top of the computer and then the computer itself.

To remove the assembly group, see

Removing the main computer by assembly group on page 214

.

To remove the modules on the top of the computer, see

Removing the main computer by parts on page 227

.

Removing the main computer by assembly group

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446


214




5 Repair


Continued


1

Action





• K2.X8 - A2.X6

• (option): K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K2.X10 - A1.X13


• K2.X4 - A1.X9

• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,

K7.X1

• K2.X1 - T2.X2

• K2.X17 - G2.X1, G1.X2

• K2.X6, K2.X11 - A1.X2




• K2.X2 - K4.X8, A2.X1

• K4.X7 - K5.1.X5

• K4.X6 - A2.X4


• K7.X1 - K2.X3

i

• K7.X2 - A2.X5

Note



• K2.X8 - A2.X6

• K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K6.X2 - A2.X9

• A2.X5 - K7.X2

• A2.X4 - K4.X6/K5.1.X5

Note


K4.X6.


K5.1.X5.





5 Repair


Continued

2

Action

Remove the screws holding the main computer.


3 Remove the assembly from the mounting plate.

Note



(ESD)


xx1900001878 xx1900001885 i



216




5 Repair


Continued


1



(ESD)




xx2000000419


xx1900001879 xx1900001880





217

5 Repair


Continued


1

Action




218




5 Repair


Continued


1

Action




TOP VIEW

Refitting the main computer by assembly group


Action

1

DANGER








219

5 Repair


Continued

2



(ESD)




ESD on page 43 .


Note


xx2000000419 xx1800000497

TOP VIEW xx1900001884


220




5 Repair


Continued


Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx2000000419





221

5 Repair


Continued

3

Action

Hook up the Ethernet extension switch to the bracket and then push the switch into position.


Note



xx1800000493 xx1800000972 xx1900001882


Action

1

DANGER





222




5 Repair


Continued

2



(ESD)




ESD on page 43 .

xx2000000419

3 Fit the robot signal exchange proxy and secure the screws.



xx1900001880 xx1900001879





223

5 Repair


Continued


Action

1

DANGER




2


(ESD)



xx1900001446


224




5 Repair


Continued

3

Action

Refit the assembly onto the mounting plate.


4 Fasten the assembly with the screws.

xx1900001878


xx1900001877





225

5 Repair


Continued

Action


• K2.X8 - A2.X6

• (option): K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K2.X10 - A1.X13


• K2.X4 - A1.X9

• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,

K7.X1

• K2.X1 - T2.X2

• K2.X17 - G3.X1, G1.X2

• K2.X6, K2.X11 - A1.X2




• K2.X2 - K4.X8, A2.X1

• K4.X7 - K5.1.X5

• K4.X6 - A2.X4


• K7.X1 - K2.X3

i

• K7.X2 - A2.X5


Note



• A2.X3 - X24

• K2.X8 - A2.X6

• K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K6.X2 - A2.X9

• A2.X5 - K7.X2

• A2.X4 - K4.X6/K5.1.X5

Note


K4.X6.


K5.1.X5.

i



226




5 Repair


Continued


1

2

3

Action

Close the door.



.

Restore the hardware settings.



Restoring the hardware settings on page 241 .

Removing the main computer by parts

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Disconnecting the connectors to the main computer assembly

1

Action


Connected Services Gateway, scalable

I/O (option), and main computer.






227

5 Repair


Continued

Action


• K2.X8 - A2.X6

• (option): K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K2.X10 - A1.X13


• K2.X4 - A1.X9

• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,

K7.X1

• K2.X1 - T2.X2

• K2.X17 - G3.X1, G1.X2

• K2.X6, K2.X11 - A1.X2



For the Ethernet extension switch:

• K2.X2 - K4.X8, A2.X1

• K4.X7 - K5.1.X5

• K4.X6 - A2.X4



• K7.X1 - K2.X3

i

• K7.X2 - A2.X5

Note



• A2.X3 - X24

• K2.X8 - A2.X6

• K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K6.X2 - A2.X9

• A2.X5 - K7.X2

• A2.X4 - K4.X6/K5.1.X5

Note


K4.X6.


K5.1.X5.

i



228




5 Repair


Continued


1

Action

Pull the cable ties out from the locking holes.



xx1900001886 xx1900001887





229

5 Repair


Continued


1

Action




230




5 Repair


Continued


1

Action




TOP VIEW





231

5 Repair


Continued

Removing the main computer

1

Action



2 Remove the main computer.


(ESD)


xx1900001892 xx1900001893 xx1900001894


232




5 Repair


Continued

Refitting the main computer by parts

Refitting the main computer

Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx1900001446





233

5 Repair


Continued

3

Action

Fit the main computer to the mounting plate.


4 Fasten the main computer with the screws.

xx1900001893



234




5 Repair


Continued


Action

1

DANGER




2


(ESD)



ESD on page 43 .


Note


xx1900001890 xx1800000495

TOP VIEW





235

5 Repair


Continued


Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx1900001446


236




5 Repair


Continued

3

Action

Hook up the Ethernet extension switch to the bracket and then push the switch into position.


Note



xx1900001888 xx1800000972 xx1800000491


Action

1

DANGER








237

5 Repair


Continued

2



(ESD)




ESD on page 43 .

xx1900001446




xx1900001887 xx1900001886


238




5 Repair


Continued

Reconnecting the connectors to the main computer assembly


1

DANGER



2


(ESD)



3 Reconnect all the connectors on assembly of the robot signal exchange proxy, ethernet extension-seven port switch (option), ABB ability™ connected services, scalable I/O digital base (option), and main computer.


• K2.X8 - A2.X6

• (option): K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K2.X10 - A1.X13


• K2.X4 - A1.X9

• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,

K7.X1

• K2.X1 - T2.X2

• K2.X17 - G3.X1, G1.X2

• K2.X6, K2.X11 - A1.X2



For the Ethernet extension switch:

• K2.X2 - K4.X8, A2.X1

• K4.X7 - K5.1.X5

• K4.X6 - A2.X4

xx1900001446





239

5 Repair


Continued

Action


• K7.X1 - K2.X3

i

• K7.X2 - A2.X5


Note



• A2.X3 - X24

• K2.X8 - A2.X6

• K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K6.X2 - A2.X9

• A2.X5 - K7.X2

• A2.X4 - K4.X6/K5.1.X5

1

2

3

Note


K4.X6.


K5.1.X5.

Concluding procedure i


Action

Close the door.



.

Restore the hardware settings.



Restoring the hardware settings on page 241 .


240




5 Repair


Continued

Restoring the hardware settings

The controller hardware settings include information such as controller type and serial number. When the main computer has been replaced, the serial number must be restored before any software can be installed, or any licences can be imported.

Note

When replacing the main computer, both the serial number and licences are lost.

The serial number must be restored as described below. Licences however, can either be restored automatically when the RobotWare system is installed, or manually through Manage Licences in RobotWare Installation Utilities.

1

2

Action

Download the hardware information file

(hwsettings.rsf) from MyABB, or from a previous system backup.

Access the RobotWare Installation Utilities.


3

4

5

6

Tap Advanced , and then Restore Hardware Settings .

The Restore Hardware Settings window is displayed.

Follow the instructions and tap Next to proceed.

Carefully read the information and then check all boxes to confirm that you agree with the ABB conditions. Tap Next to proceed.

Read the serial number on the front of the controller and type it in field Serial

Number . Tap Next .

xx1900000110 xx2000000007

7 Tap Browse to open the hardware information file from its location. The restoration of the serial number is completed.

The system compares the downloaded file and the manually entered serial number to ensure that there is a match.




241

5 Repair

5.2.9 Replacing the power unit

5.2.9 Replacing the power unit

Location

The illustration shows the location of the power unit in the controller.

xx1900001469


Note


Spare part

Power unit

Article number

3HAC059152-001

Note

DSQC3044


Equipment

Standard toolkit -




.





Note


242




5 Repair


Continued

Removing the power unit

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Removing the power unit

1

Action

Disconnect:

• A1.X13 - K2.X10

• A1.X9 - K2.X4

• A1.X4 - T4.X5

• A1.X5 - T4.X1

• A1.X12 - T4.X3

• A1.X1 - Power inlet (X0)

• A1.X6 A1.X7-T2.X1 and AC Terminal block






243

5 Repair


Continued

2

Action

Remove the screws and pull the power unit out from the two snaps on the mounting plate.


CAUTION

Only the sheet metal on the power unit can be used for holding.

Do not touch the connectors or the filter on the power unit.

xx1900001895 xx1900001896

Refitting the power unit

Refitting the power unit

Action

1

DANGER





244




5 Repair


Continued

2



(ESD)




ESD on page 43 .

xx1900001446

3 Push the power unit until it snaps on the mounting plate and secure the screws.






245

5 Repair


Continued


4

Action

Reconnect:

• A1.X13 - K2.X10

• A1.X9 - K2.X4

• A1.X4 - T4.X5

• A1.X5 - T4.X1

• A1.X12 - T4.X3

• A1.X1 - Power inlet (X0)

• A1.X6 A1.X7-T2.X1 and AC Terminal block


1

2

Action

Close the door.





.

246




5 Repair

5.2.10 Replacing the power supply

5.2.10 Replacing the power supply

Location

The illustration shows the location of the power supply in the controller.

xx1900001470


Note


Spare part

Power supply


Article number

3HAC071301-001

3HAC14178-1


End clamp

3HAC13398-2

Harness AC input of power supply 3HAC069617-001

3HAB7983-1

Note

DSQC3035

DSQC 609

DSQC 634

WARNING

Do not touch the power supply when the DC OK Led is on.

There is residual voltage in the power supply even the controller is power off in a short time.





247

5 Repair


Continued


Equipment

Standard toolkit -




.





Note

Removing the power supply baseline

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

Removing the power supply baseline

1

Action

Disconnect:

• T2.X1 - A1.X6

• T2.X2 - K2.X1

xx1900001446



248




5 Repair


Continued

2

Action

Remove the screws and the power supply.


Refitting the power supply baseline

Refitting the power supply

Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx1900001446





249

5 Repair


Continued

3

Action

Fit the power supply and fasten it with screws.





• T2.X1 - A1.X6

• T2.X2 - K2.X1.

1

2

Action

Close the door.





.

Removing the DSQC 609 power supply

Preparations

Action

1

DANGER




2 Open the door.


.


250




5 Repair


Continued

3



(ESD)




ESD on page 43 .

xx1900001446

Removing the power supply

1

Action

Remove the end clamp besides the power supply with a screwdriver.






251

5 Repair


Continued

2

3

Action

Disconnect:



Remove the screw and the power supply.


Refitting the DSQC 609 power supply


Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx1900001446


252




5 Repair


Continued

3

4


Fit the power supply to the bracket and fasten it with screw.

Screws: Cross recessed cheese head screw

M4x8 (1 pcs)

Reconnect:



5 Refit the end clamp besides the power supply.

xx1900001908 xx1900001907


1

2

Action

Close the door.





.





253

5 Repair


Continued

Removing the DSQC 634 power supply

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Removing the power supply

1

Action

Remove the end clamp besides the power supply with a screwdriver.



254




5 Repair


Continued

2

3

Action

Disconnect:



Press the lower buckle to release and remove the power supply.


Refitting the DSQC 634 power supply


Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx1900001446





255

5 Repair


Continued

3

4

Action

Hang the power supply into the bracket and push the lower of it until you hear a clear clicking sound.

Reconnect:




5 Refit the end clamp besides the power supply.

xx1900001950 xx1900002443


1

2

Action

Close the door.





.

256




5 Repair

5.2.11 Replacing the drive unit

5.2.11 Replacing the drive unit

Location

The illustration shows the location of the drive unit in the controller.

xx1900001471


Note


Spare part

Drive

Harness DC-BUS

Harness 24_SYS_DRV

Harness EtherCAT

Article number

3HAC063913-001

3HAC063344-001

3HAC064389-001

3HAC059894-001

Note

DSQC3041

Harness A1.X4 - T4.X5

Harness A1.X5 - T4.X1

Harness T4.X3 - A1.X12


Equipment

Standard toolkit -




.






5 Repair


Continued




Note

Removing the drive unit

Preparations


1

DANGER



2

3

Open the door.


.


(ESD)




ESD on page 43 .

Removing the power supply baseline

1

Action

Disconnect:

• T2.X1 - A1.X6

• T2.X2 - K2.X1

xx1900001446



258




5 Repair


Continued

2

Action

Remove the screws and the power supply.


Removing the drive unit

1

2

Action

Disconnect:

• T4.X7, T4.X8, T4.X9

• T4.X5 - A1.X4

• T4.X3 - A1.X12

• T4.X1 - A1.X5

Cut the cable tie for the DC-bus cable and move it to the other side.


3 Cut the cable tie for the EtherCAT cable.

xx1900001900 xx1900002338





259

5 Repair


Continued

4


Remove the attachment screws and pull the drive unit out from the two snaps.

Lengthened screwdriver xx1900001898 xx1900001899


260




5 Repair


Continued

Refitting the drive unit

Refitting the drive unit


1

DANGER



2


(ESD)




ESD on page 43 .

xx1900001446





261

5 Repair


Continued

3


Push the drive unit into the snaps on the mounting plate and secure the screws.



262




5 Repair


Continued

4

Action

Fasten the DC-bus cable with a new cable tie to the drive unit.


5 Fasten the EtherCAT cable with a new cable tie to the drive unit.

xx1900001900 xx1900002338

6 Reconnect:

• T4.X7, T4.X8, T4.X9

• T4.X5 - A1.X4

• T4.X3 - A1.X12

• T4.X1 - A1.X5


Action

1

DANGER








263

5 Repair


Continued

2



(ESD)




ESD on page 43 .

xx1900001446

3 Fit the power supply and fasten it with screws.



4 Reconnect:

• T2.X1 - A1.X6

• T2.X2 - K2.X1.

1

2

Action

Close the door.





.

264




5 Repair

5.2.12 Replacing the fieldbus master

5.2.12 Replacing the fieldbus master

Location

The illustration shows the location of the fieldbus master in the controller.

xx1800003420


Note


Spare part

DeviceNet Board

Article number

3HAC043383-001

Note

DSQC1006


Equipment

Standard toolkit -




.





Note





5 Repair


Continued

Removing the fieldbus master

Note

The fieldbus master is part of an assembly group, secured on a process plate.

To remove the fieldbus master, either lift out the assembly group and then remove the fieldbus master, or take out the parts on top of the main computer and then remove the fieldbus master.

Preparations


1

DANGER



2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446


1

Action





266




5 Repair


Continued

Action


• K2.X8 - A2.X6

• (option): K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K2.X10 - A1.X13


• K2.X4 - A1.X9

• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,

K7.X1

• K2.X1 - T2.X2

• K2.X17 - G2.X1, G1.X2

• K2.X6, K2.X11 - A1.X2




• K2.X2 - K4.X8, A2.X1

• K4.X7 - K5.1.X5

• K4.X6 - A2.X4


• K7.X1 - K2.X3

i

• K7.X2 - A2.X5


Note



• K2.X8 - A2.X6

• K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K6.X2 - A2.X9

• A2.X5 - K7.X2

• A2.X4 - K4.X6/K5.1.X5

Note


K4.X6.


K5.1.X5.





267

5 Repair


Continued

2

Action



3 Remove the assembly from the mounting plate.

Note



(ESD)


xx1900001878 xx1900001885 i



268




5 Repair


Continued


1



(ESD)




xx2000000419


xx1900001879 xx1900001880





269

5 Repair


Continued

Removing the fieldbus master

1



(ESD)



2 Remove the attachment screws and take the cover off.

xx2000000419 xx1900001909

Note



270




5 Repair


Continued

3

Action

Remove the attachment screw on the fieldbus master and take out the fieldbus master.


Note

Be careful when you pull it out from the card slot.

xx1900001910

Note


Refitting the fieldbus master

Preparations

Action

1

DANGER




2


(ESD)



ESD on page 43 .

xx1900001446





271

5 Repair


Continued

Refitting the fieldbus master

1



(ESD)



2 Insert the fieldbus master straight into the card slots along the guide rail.

xx2000000419 xx1900001911

Note



272




5 Repair


Continued

3

Action

Secure the fieldbus adapter with the screw.


Screws: Screw with flange M3x6 (1 pcs) xx1900001910

Note


4 Refit the cover of the main computer and secure the screws.

Screws: Hexalobular socket pan head screw

M3x6 (4 pcs) xx1900001909

Note






273

5 Repair


Continued


Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx2000000419




274




5 Repair


Continued

4

Action

Insert the cable ties into the locking holes.



Action

1

DANGER




2


(ESD)



xx1900001446





275

5 Repair


Continued

3

Action

Refit the assembly onto the mounting plate.


4 Fasten the assembly with the screws.

xx1900001878


xx1900001877


276




5 Repair


Continued

Action


• K2.X8 - A2.X6

• (option): K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K2.X10 - A1.X13


• K2.X4 - A1.X9

• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,

K7.X1

• K2.X1 - T2.X2

• K2.X17 - G3.X1, G1.X2

• K2.X6, K2.X11 - A1.X2




• K2.X2 - K4.X8, A2.X1

• K4.X7 - K5.1.X5

• K4.X6 - A2.X4


• K7.X1 - K2.X3

i

• K7.X2 - A2.X5


Note



• A2.X3 - X24

• K2.X8 - A2.X6

• K2.X2 - K4.X8, A2.X1

• K2.X12 - A2.K3.X6, A2.K3.X7

• K6.X2 - A2.X9

• A2.X5 - K7.X2

• A2.X4 - K4.X6/K5.1.X5

Note


K4.X6.


K5.1.X5.

i






277

5 Repair


Continued


1

2

Action

Close the door.





.

278




5 Repair

5.2.13 Replacing the conveyor tracking module(CTM)

5.2.13 Replacing the conveyor tracking module(CTM)

Location

The illustration shows the location of the conveyor tracking module in the controller.

xx1900001472


Note


Spare part

Harness 24V_CTM

Article number


1]


3HNA027579-001

3HNA029345-001

3HAC069618-001

Note

DSQC2000

Power cable of CTM


Equipment

Standard toolkit -




.






279

5 Repair


Continued





3HAC066561-001

Note

Removing the conveyor tracking module (option)

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Removing the conveyor tracking module (option)

1

Action

Disconnect:

• B1.X1 - K2.X19.1 & K2.X19.2

• B1.X7 - K4.X1-5



280




5 Repair


Continued

2

Action

Pull on the lower side of the conveyor tracking module slightly and take out the conveyor tracking module.


Note

The conveyor tracking module is secured by the buckles.

Be careful with the direction of the buckles when doing assembling/disassembling work.

xx1900001912 xx1900001913

Refitting the conveyor tracking module (option)

Refitting the conveyor tracking module (option)

Action

1

DANGER








281

5 Repair


Continued

2



(ESD)




ESD on page 43 .

3 Hang the conveyor tracking module into the bracket and push the lower of it until you hear a clear clicking sound.

xx1900001446 xx1900001913 xx1900001912


282




5 Repair


Continued


4

Action

Connect the adapter cable to the conveyor tracking module.

• B1.X1 - K2.X19.1 & K2.X19.2

• B1.X7 - K4.X1-5

Stick the other connector onto the side of the digital base with the self-adhesive part.


1

2

Action

Close the door.





.




283

5 Repair

5.2.14 Replacing the air filter

5.2.14 Replacing the air filter

Location

The illustration shows the location of the air filter on the controller.

xx1900001473


Note


Note Spare part

Air filter-coarse filter

Air filter-Fine filter

Air filter (Polymeric)

Article number

3HAC068415-001

3HAC068416-001

3HAC068543-001 Filter element of fine filter


Equipment

Standard toolkit -




.



284




5 Repair


Continued




Note

Removing the air filter

Preparations

Action

1

DANGER





1

Action



2 Remove the air filter.

xx1900001491 xx1900001492





285

5 Repair


Continued

Removing the polymeric filter element

1

Action

Take out the polymeric filter element from the filter.


Refitting the air filter

Refitting the polymeric filter element

1

Action

Insert the polymeric filter element to the filter and secure with the metallic line.



Action

1

DANGER





286




2

Action

Refit the air filter to the cabinet.


5 Repair


Continued



1

Action







287

5 Repair

5.3.1 Replacing the manipulator signal connector (SMB)

5.3 Replacing parts on the panels

5.3.1 Replacing the manipulator signal connector (SMB)

Location

The illustration shows the location of the manipulator signal connector.

xx1900001476


Note


Spare part

Harness Single SMB connection

Article number

3HAC069674-001

Harness Double SMB connection 3HAC069675-001

Note

Harness single SMB

Harness double SMB


288




5 Repair


Continued


Equipment

Standard toolkit -




.





Note

Removing the manipulator signal connector

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446





289

5 Repair


Continued

Removing the manipulator signal connector

1

Action


• SMB - K6.X4, K6.X5



xx1900001914 xx1900001915

3

4

Push the manipulator signal connector into the cabinet.

Take the manipulator signal connector out.

Refitting the manipulator signal connector

Refitting the manipulator signal connector

Action

1

DANGER





290




5 Repair


Continued

Action

2


(ESD)



ESD on page 43 .


3

4

Insert the manipulator signal connector into the cover from inner side of the cabinet.




• K6.X4, K6.X5 - SMB.

xx1900001915 xx1900001914


1

2

Action

Close the door.





.




291

5 Repair

5.3.2 Replacing the motor connector

5.3.2 Replacing the motor connector

Location

The illustration shows the location of the motor connector in the controller.

xx1900001478


Note


Spare part

Harness Motors power LV 6-axis

Article number

3HAC069672-001

Note


Equipment

Standard toolkit -




.



292

-




5 Repair

5.3.2 Replacing the motor connector

Continued




Note





293

5 Repair

5.3.2.1 Replacing the motor connector

5.3.2.1 Replacing the motor connector

Removing the motor connector

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Removing the motor connector

1

Action

Disconnect the following connectors for the motor connector:

• T4.X7, T4.X8, T4.X9

• X1 - K2.X7 & X22

• PE.5 & PE.6



294




5 Repair


Continued

2

Action

Remove the attachment screws on the cover.


3

4

Push the motor connector into the cabinet.

Take the motor connector cable out from the velcro in the cabinet.

Note

Make records about the sequence that cables are removed. The cables need to be installed in the same position.

5 Take the motor connector out.

Refitting the motor connector

Refitting the motor connector

Action

1

DANGER








295

5 Repair


Continued

2



(ESD)




ESD on page 43 .

xx1900001446

3 Insert the motor connector into the cover from inner side of the cabinet and fasten it with the screws.


4

5

Reconnect:

• T4.X7, T4.X8, T4.X9

• X1 - K2.X7 & X22

• PE.5 & PE.6

Secure the motor connector cables with the velcro on the frame of the cabinet.

Tip

Use the same position as from removing the motor connector.


1

Action

Close the door.



.


296




5 Repair


Continued

2

Action







297

5 Repair

5.3.3 Replacing the fieldbus adapter slave

5.3.3 Replacing the fieldbus adapter slave

Location

The illustration shows the location of the fieldbus adapter slave in the controller.

xx1900001474


Note


Note Spare part

Fieldbus slot cover

Article number

3HAC062390-001

DeviceNet Slave Fieldbus adaptor

[3030-1]

3HAC045973-001

ProfiNet Board [3022-1]

Ethernet Unit [3025-1]

3HAC031670-001

3HAC027652-001

DSQC1004

DSQC 688

DSQC 669


Equipment

Standard toolkit -




.





Note

Removing the fieldbus slot cover (baseline)

Action

1

DANGER





298




5 Repair


Continued

2

3

Action

Open the door.



.


(ESD)




ESD on page 43 .

xx1900001446

4 Remove the fieldbus slot cover with a screwdriver.

Refitting the fieldbus slot cover (baseline)

Action

1

DANGER




2


(ESD)




ESD on page 43 .

3 Push the fieldbus slot cover into the main computer until you hear a clear 'click' sound.

xx1900001446





299

5 Repair


Continued

4

5

Action

Close the door.





.

Removing the fieldbus adapter slave (option)

Action

1

DANGER




2

3

Open the door.


(ESD)



ESD on page 43 .


.

4 Loosen the screws and take the fieldbus adapter slave out.

xx1900001917

Refitting the fieldbus adapter slave (option)

Action

1

DANGER





300




5 Repair


Continued

Action

2


(ESD)



ESD on page 43 .


3 Insert the fieldbus adapter slave tighten the screws.

xx1900001917

4

5

Close the door.




.




301

5 Repair

5.3.4 Replacing the power inlet

5.3.4 Replacing the power inlet

Location

The illustration shows the location of the power inlet in the controller.

xx1900001479


Note


Spare part

Harness AC input with SW

Connector AC power inlet

Handle for 6 mm switch

Article number

3HAC067661-001

3HAC070308-001

3HAC037699-001

Note

Harness-Mains connection


Equipment

Standard toolkit -




.



302

-




5 Repair


Continued




Note

Removing the power inlet

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Removing the power inlet

1

Action

Disconnect the mains switch from the handle for 6 switch by pressing the push hook.






303

5 Repair


Continued

2

3

Action

Disconnect:

• X0 - Q0.

X0 - A1.X1.

• PE.3 & PE.4.



4

5

Push the power inlet into the cabinet.

Take the power inlet out.

Refitting the power inlet

Refitting the power inlet


1

DANGER



2


(ESD)




ESD on page 43 .


304 xx1900001446




5 Repair


Continued

3

4

Action

Insert the power inlet into the cover of the cabinet.




5

6

Reconnect:

• X0 - Q0.

X0 - A1.X1.

• PE.3 & PE.4.

Reconnect the mains switch to the handle for 6 switch.

xx1900001918 xx1900001920


1

2

Action

Close the door.





.




305

5 Repair

5.3.5 Replacing the HMI signal (FlexPendant) connector

5.3.5 Replacing the HMI signal (FlexPendant) connector

Location

The illustration shows the location of the HMI signal connector in the controller.

xx1900001475


Note


Spare part

Harness TPU connection

Article number

3HAC069673-001

Note

Harness-TPU


Equipment

Standard toolkit -




.



306




5 Repair


Continued




Note

Removing the HMI signal connector

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446

Removing the HMI signal connector

1

Action

Remove the cables out from the clips in the cabinet carefully.


Note


2 Disconnect:

• TPU (X4) - K2.X9 & X13





307

5 Repair


Continued

3

Action

Remove the screws.


4 Remove the cover plate.

xx1900001921 xx1900001922


308




5 Repair


Continued

5

Action

Remove the attachment screws on the door.


6

7

Push the HMI signal connector into the cabinet.

Take the HMI signal connector out.

Refitting the HMI signal connector

Refitting the HMI signal connector

Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx1900001446





309

5 Repair


Continued

3


Insert the HMI signal connector into the cover from inside the cabinet.


Screws: Torx, countersunk screw M4x10 (4 pcs)

4

5

Connect:

• TPU (X4) - K2.X9 & X13

Secure the cables on HMI signal connector into the clips on the cabinet.

Tip

Use the same position as from removing the HMI signal connector.

6 Refit the cover plate.

xx1900001923 xx1900001922


310




5 Repair


Continued

7

Action





1

2

Action

Close the door.





.




311

5 Repair

5.3.6 Replacing the cable grommet assembly

5.3.6 Replacing the cable grommet assembly

Location


xx1900001481

Note





Note


Spare part

Cable grommet asm

Article number

3HAC066396-001

Note


312




5 Repair


Continued


Equipment

Standard toolkit -




.





Note

Removing the cable grommet assembly

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446





313

5 Repair


Continued

Removing the cable grommet assembly

1

Action



Note



xx1900002340

3

4

Push the cable grommet assembly into the cabinet.

Take the cable grommet assembly out.

Releasing the cables from the cable grommet assembly

1

Action

Unscrew the cable entry frame from the enclosure wall.



314




5 Repair


Continued

2

Action

Take out the cables with the cable entry frame through the cut-out.


3 Remove the attachment screws on the frame and cover strip.

xx1900002333

4 Remove the cover strip from the frame.

xx1900002334 xx1900002335





315

5 Repair


Continued

5

Action

Take out the grommets with the cables that need to be removed one by one.


Tip

Remove the grommets in the upper row first and then the second row.

6 Remove the cable from the corresponding KT grommet.

xx1900002336 xx1900002337


316




5 Repair


Continued



1

Action



2 Slide the grommets into the frame halves.

Note


Note


xx1900002337 xx1900002336


xx1900002335





317

5 Repair


Continued

4


Secure the frame and cover strip with the screws.




5 Route the cables through the cut-out.

xx1900002334 xx1900002333


318




5 Repair


Continued

6


Refit the cable entry frame to the enclosure wall and secure with the screws.



xx1900002332


Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx1900001446





319

5 Repair


Continued

3


Insert the cable grommet assembly into the cover of the cabinet.




1

2

Action

Close the door.





.

320




5 Repair


5.3.7 Replacing the cable grommet assembly

Location


xx1900001480

Note





Note


Spare part

Blind plate

Article number

3HAC069954-001

Note





5 Repair


Continued

Spare part

Cable grommet asm


Equipment

Standard toolkit

Article number

3HAC066396-001

Note

-




.





Note

Removing the cable grommet assembly

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446


322




5 Repair


Continued

Removing the cable grommet assembly

1

Action



Note



xx1900002445

3

4

Push the cable grommet assembly into the cabinet.

Take the cable grommet assembly out.

Releasing the cables from the cable grommet assembly

1

Action

Unscrew the cable entry frame from the enclosure wall.






323

5 Repair


Continued

2

Action

Take out the cables withe the cable entry frame through the cut-out.


3 Remove the attachment screws on the frame and cover strip together.

xx1900002333

4 Remove the cover strip from the frame.

xx1900002334 xx1900002335


324




5 Repair


Continued

5

Action

Take out the grommets with the cables that need to be removed one by one.


Tip

Remove the grommets in the upper row first and then the second row.

6 Remove the cable form the corresponding KT grommet.

xx1900002336 xx1900002337





325

5 Repair


Continued



1

Action



2 Slide the grommets into the frame halves.

Note


Note


xx1900002337 xx1900002336



326 xx1900002335




5 Repair


Continued

4


Secure the frame and cover strip with the screws.




5 Route the cables through the cut-out.

xx1900002334 xx1900002333





327

5 Repair


Continued

6


Refit the cable entry frame to the enclosure wall and secure with the screws.



xx1900002332


Action

1

DANGER




2


(ESD)




ESD on page 43 .

xx1900001446


328




5 Repair


Continued

3


Insert the cable grommet assembly into the cover of the cabinet.




1

2

Action

Close the door.





.




329

5 Repair

5.3.8 Replacing the harness ETH outlet with cable

5.3.8 Replacing the harness ETH outlet with cable

Location

The illustration shows the location of the harness ETH outlet with cable.

xx1900001482


Note


Spare part

Harness ETH outlet with cable

Article number

3HAC070053-001

Note


Equipment

Standard toolkit -




.



330




5 Repair


Continued




Note

Removing the harness ETH outlet with cable

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446





331

5 Repair


Continued

Removing the harness ETH outlet with cable

1

Action

Remove the screws.



xx1900001921 xx1900001922


332




5 Repair


Continued

3

Action

Remove the attachment screws on the door.


4

5

6

Push the harness ETH outlet with cable into the cabinet.

Disconnect:

• X24 - A2.X3


Note


7 Take the harness ETH outlet with cable out from the upper side.

Refitting the harness ETH outlet with cable

Refitting the harness ETH outlet with cable

Action

1

DANGER




2


(ESD)



ESD on page 43 .

3 Insert the harness ETH outlet with cable into the cover from inner side of the cabinet.





5 Repair


Continued

4

Action



Screws: Torx, countersunk screw M4x10 (4 pcs)

5

6

Connect:

• X24 - A2.X3

Secure the harness ETH outlet with cables with the clips on the cabinet.

Tip

Use the same position as from removing the harness ETH outlet with cable.


xx1900001924 xx1900001922


334




8

Action


5 Repair


Continued




1

2

Action

Close the door.





.




335

5 Repair

5.3.9 Replacing the LED indicator

5.3.9 Replacing the LED indicator

Location

The illustration shows the location of the LED indicator.

xx1900001483


Note


Spare part

LED indicator

Article number

3HAC065549-001

Note


Equipment

Standard toolkit -




.



336




5 Repair


Continued




Note

Removing the LED indicator

Preparations

Action

1

DANGER




2

3

Open the door.


.


(ESD)




ESD on page 43 .

xx1900001446





337

5 Repair


Continued

Removing the LED indicator

1

Action

Remove the screws.



xx1900001921 xx1900001922


338




5 Repair


Continued

3

Action

Loose the attachment screws locking the cable.


4

5

6

Remove the terminals (X1&X2) of the cable from the lamp.

Turn the MON_LAMP screw anti-clockwise to remove the screw.

Take the LED indicator out.

Refitting the LED indicator

Refitting the LED indicator

Action

1

DANGER




2


(ESD)



ESD on page 43 .

3 Insert the LED indicator into the cover from outer side of the door and the screw from inner side and screw them up.





339

5 Repair


Continued

4

Action

Insert the terminals (X1 & X2) of cables into the lamp and secure with the screws.



xx1900001926 xx1900001922


340




6

Action


5 Repair


Continued




1

2

Action

Close the door.





.




341

5 Repair

5.4.1 Replacing the power cable and power cable cover

5.4 Replacing parts on the FlexPendant

5.4.1 Replacing the power cable and power cable cover

Location

The illustration shows the location of the power cable, power cable gasket, and power cable cover in the FlexPendant.

A

B xx1800001154

A

B

Power cable cover

Power cable


Note


Spare part

Harness TPU connection

Article number

3HAC069673-001

Note

Harness-TPU


Equipment

Standard toolkit -




.


342




5 Repair


Continued

Equipment






Note

Removing the power cable and power cable cover

Action

1


(ESD)



ESD on page 43 .


2

3

Disconnect the FlexPendant from the controller.

Remove the attachment screws for the power cable cover.

4 Remove the power cable cover.

xx1800001189 xx1800001190





343

5 Repair


Continued

5

Action

Disconnect two connectors to the Flex-

Pendant.


6 Remove the power cable.

xx1800001748 xx1800001192

Refitting the power cable and power cable cover

Action

1


(ESD)



ESD on page 43 .



344




2

Action

Refit the power cable.

5 Repair


Continued


3 Reconnect the power cable to the Flex-

Pendant.

xx1800001193 xx1800001748

4 Refit the power cable cover and tighten the screws.


5 Perform the function tests to verify that the safety features work properly, see


xx1800001196




345

5 Repair

5.4.2 Replacing the joystick protection

5.4.2 Replacing the joystick protection

Location

The illustration shows the location of the joystick protection on the FlexPendant.

xx1800001197


Note


Spare part

Joystick guard

Article number

3HAC065408-001

Note


Equipment

Standard toolkit -




.




Note


346




5 Repair


Continued

Removing the joystick protection

Action

1


(ESD)



ESD on page 43 .


2

3

Disconnect the FlexPendant from the controller.


4 Remove the joystick protection.

xx1800001198 xx1800001199

Refitting the joystick protection

Action

1


(ESD)



ESD on page 43 .






5 Repair


Continued

2

Action

Refit the joystick protection.


3 Secure the screws.

xx1800001200 xx1800001206

Countersunk head screw: ST2.9 X 10 (6 pcs)

348




5 Repair

5.4.3 Replacing the fasten strip

5.4.3 Replacing the fasten strip

Location

The illustration shows the location of the fasten strip on the FlexPendant.

xx1900000771


Note


Spare part

Fasten strip

Article number

3HAC065419-001

Note

Replacing the fasten strip

1

2

3

4

Action

Open the velcro on the fasten strip.

Take the fasten strip out from the holes.

Insert the new fasten strip into the holes one by one.

Secure the velcro in a suitable length.





349


6 Decommissioning

6.1 Introduction


6.1 Introduction

Introduction

This section contains information to consider when taking a product, robot or controller, out of operation.

It deals with how to handle potentially dangerous components and potentially hazardous materials.

General

All used grease/oils and dead batteries must be disposed of in accordance with the current legislation of the country in which the robot and the control unit are installed.

If the robot or the control unit is partially or completely disposed of, the various parts must be grouped together according to their nature (which is all iron together and all plastic together), and disposed of accordingly. These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed.

Disposal of storage media

Before disposal of any storage equipment (anything from an SD card to a complete controller), make sure that all sensitive information has been deleted.

Tip

To remove all data from the OmniCore controller, use the Delete user data function (part of Delete RobotWare system function) in RobotWare. See

Operating manual - Integrator's guide OmniCore .




351


6.2 Environmental information

6.2 Environmental information

Symbol

The following symbol indicates that the product must not be disposed of as common garbage. Handle each product according to local regulations for the respective content (see table below).

xx1800000058

Hazardous material

The table specifies some of the materials in the product and their respective use throughout the product.

Dispose components properly according to local regulations to prevent health or environmental hazards.

Material

Aluminium

Batteries, Lithium

Copper

Example application

Heat sinks on power supplies and drive units

Main computer

Cables

Plastic/rubber

Silicone

Cables, connectors, etc.

Power supply i i

Steel Cabinet structure, plates, screws, etc.

The product does not contain silicone by design but there might be a minimal risk of contamination during production.


352





6.2 Environmental information

Continued

China RoHS symbol

The following symbol shows the information to hazardous substances and the environmental protection use period of OmniCore C90XT according to "Management

Methods for the Restriction of the Use of Hazardous Substances in Electrical and

Electronic Products (SJ/T 11364-2014) ".

xx1900000803

Green symbol with "e" in it: The product does not contain any hazardous substances exceeding concentration limits and is a green environmentally friendly product which can be recycled.




353


7 Troubleshooting

7.1 Introduction to troubleshooting


7.1 Introduction to troubleshooting

Introduction

The product manual and the circuit diagram contains information that can be good when troubleshooting.

For OmniCore, all event logs from the software can be seen on the FlexPendant, or in Technical reference manual - Event logs for RobotWare 7 .

Make sure to read through the section

Safety on page 13

before starting.

Troubleshooting strategies

1 Isolate the fault to pinpoint the cause of the problem from consequential problems.

2 Divide the fault chain in two.

3 Check communication parameters and cables.

4 Check that the software version is compatible with the hardware.

Work systematically

1 Take a look around to make sure that all screws, connectors, and cables are secured, and that the robot and other parts are clean, not damaged, and correctly fitted.

2 Replace one thing at a time.

3 Do not replace units randomly.

4 Make sure that there are no loose screws, turnings, or other unexpected parts remaining after work has been performed.

5 When the work is completed, verify that the safety functions are working as intended.

Keep a track of history

• Make a historical fault log to keep track of problems over time.

• Consult those working with the robot when the problem occurred.

Basic scenarios

What to look for during troubleshooting depends on when the fault occurred. Was the robot recently installed or was it recently repaired? The following table gives hints on what to look for in specific situations.

The robot has recently been installed

Check:

• the configuration files

• connectors

• options and their configuration

• changes in the robot working area/movements.





355


7.1 Introduction to troubleshooting

Continued

The robot has recently been repaired

Check:

• all connections to the replaced part

• power supplies

• that the correct part has been fitted

• the last repair documents.

The robot recently had a software upgrade

Check:

• software versions

• compatibilities between hardware and software

• options and their configuration

The robot has recently been moved from one site to another (an already working robot)

Check:

• connections

• software versions

356





7.2 Troubleshooting fault symptoms

7.2 Troubleshooting fault symptoms

Fault symptoms described in this manual

This manual describes how to troubleshoot the following fault symptoms:

•

No LEDs are lit on the controller on page 358

•

Start-up failure on page 361

•

Problem releasing the robot brakes on page 365

•

Problem starting or connecting the FlexPendant on page 369

•

Problem using the joystick on page 373

•

Controller fails to start on page 374

•

Reflashing firmware failure on page 375

•

Inconsistent path accuracy on page 376





357


7.2.1 No LEDs are lit on the controller

7.2.1 No LEDs are lit on the controller

Description

No LEDs at all are lit in the controller.

Required test equipment

Equipment needed for troubleshooting:

Equipment

Multimeter

Insulating gloves

Note

Preparations

1

2

Action

Make sure that the controller is switched on.

Wait 30 s - 1 min to enable start-up sequence.

Check the FlexPendant for errors and warnings.

DANGER


Recommended working procedure

If no LEDs are lit on the controller during start-up, use this procedure to troubleshoot what might cause the problem.

Look at the following block diagram to understand how power is connected from incoming and forward.

Block diagram

AC input Power inlet

X0

Main switch

Q0

PE

Power unit

A1

X1 X6

X9

AC

LED

Power supply

X1 T2 X2

PS

LED

Robot signal

X2 exchange

X1 proxy

K2

X13

24V HMI

HMI

LED

MS

LED

X4

24V PC

PC

LED

X1

Main computer

A2

HMI connection

X4

24V HMI

FlexPendant

24V SYS DRV xx2000000443


358






Continued

Troubleshooting flowchart

No LEDs are lit

Not lit

Off

Check switch Q0

On

Switch on Q0

Check input power

Abnormal

Troubleshoot mains

Normal

Connection not ok

Check connector X0 Repair connection

Connection ok

Check AC input cable

Broken cable

Replace cable

Cable ok

Abnormal

Check Q0 power out

Ok

Replace Q0

Abnormal

Check T2.X1

Ok

Troubleshoot power unit

Troubleshoot power supply

Ok

Check LED status

Lit

Problem solved xx2000000444





359



Continued

Detailed working procedure

1

Action

Make sure that the power inlet switch (Q0) has been switched on.

Note

2

3 xx2000000445

Make sure that the system is supplied with power.

• Measure incoming mains voltage and make sure the voltage is within the normal range.

• Make sure that the circuit breaker (if used) is closed.

Use a multimeter and insulating gloves.

If the incoming power is not ok, the problem is not in the robot controller. Troubleshoot the incoming power.

Check that the connector (X0) is properly connected.

4

5

6

7

Tip

For more details, see Circuit diagram - OmniCore

C90XT .

Check that the AC input cable is properly connected.

Check the output voltage of (Q0).

• Make sure that (Q0) is closed.


Replace if damaged, see

Replacing the power inlet on page 302 .

Check connector T2.X1.

If abnormal, see

Troubleshooting the power unit on page 382 .

Troubleshoot the power supply unit.

Troubleshooting the power supply on page 401

.

360





7.2.2 Start-up failure

7.2.2 Start-up failure

Description

The following are possible symptoms of a start-up failure:

1 The LEDs are not lit on some units.

2 Earth fault protection trips.

3 Miniature circuit breakers/fuses trips.

4 Unable to load the system software.



Equipment

Multimeter

Insulating gloves


Note

3HAC065464-009

Preparations

1

2

Action




DANGER



If there seems to be a power failure during start-up, use this procedure to troubleshoot what might cause the problem.


Block diagram

AC input Power inlet

X0

Main switch

Q0

PE

Power unit

A1

X1 X6

X9

AC

LED

Power supply

X1 T2 X2

PS

LED

X1


K2

X2

X13

24V PC

PC

LED

24V HMI

HMI

LED

MS

LED

X4

X1

Main computer

A2

HMI connection

X4

24V HMI

FlexPendant

24V SYS DRV xx2000000443





361



Continued


Start-up failure

Check LED AC

Green

Red or flashing

Troubleshoot power unit A1

Check LED PS

Green

Not lit

Troubleshoot power supply T2

Check LEDs:

MS, PC, HMI

Green

Not lit

Troubleshoot robot signal exchange proxy K2

Check LEDs:

PC PWR, PC HDD,

PC STAT

Lit

Not lit Troubleshoot main computer



1

Action

Look at the LED PS.


362

2 Look at the LED MS.

Note

LED PS should be green.

• If not, see


.

• If the power supply is ok, see


• If the power unit is ok, check that the power inlet is properly connected and the power inlet switch is turned on.

For more details about the LEDs, see

Troubleshooting the robot signal exchange proxy on page 407 .

LED MS should be green.

• If not, see

Troubleshooting the robot signal exchange proxy on page 407

.






Continued

3

4

Action

Look at the LED AC.

Look at the LEDs PC and HMI.

5 Look at the LEDs PC PWR, PC HDD, and PC

STAT.

6 If the problem remains, contact ABB.

Note

LED AC should be green.

• If not, see


• If the power unit is ok, check that the power inlet is well connected and the power inlet switch is turned on.

LED PC and LED HMI should be green.

• If not, see



Troubleshooting the main computer on page 398

.

Tip

For more details, see Circuit diagram - OmniCore C90XT .




363


7.2.3 System update failure

7.2.3 System update failure

Description

In certain scenarios, such as removing or adding certain optional features or major upgrades of installed software products versions, the previous backup may be incompatible with the newly re-configured system. Automatically reloading backup can therefore fail, resulting in system failure state.

For more information about system update, see Operating manual - Integrator's guide OmniCore .


If there is a system update failure, the RobotWare system must be reset, which will bring the system state to the default empty state for the current configuration.

See Operating manual - Integrator's guide OmniCore for detailed information regarding system reset.

After reset, it is possible to:

A Go forward with the new configuration by re-implementing your programs and configuration, or selectively reloading contents of the previous system backup

B Rollback the changes in the system configuration, that is, make a new system update and load the previous backup, and then manually update as needed

C Perform a complete re-installation of the RobotWare System using RobotWare

Installation Utilities and then reloading the previous backup.

See Operating manual - Integrator's guide OmniCore .

364





7.2.4 Problem releasing the robot brakes

7.2.4 Problem releasing the robot brakes

Description



Equipment

Multimeter

Insulating gloves


Note

3HAC065464-009

Preparations

When starting robot operation or jogging the robot, the internal robot brakes must release in order to allow movement.

1

2

Action




DANGER



If the brakes do not release, no robot movement is possible and a number of error log messages can occur. Use this procedure to troubleshoot what might cause the problem.


Block diagram

Contactor

Q1 & Q2

X2

Brake signal

X6

Robot signal exchange proxy K2

X7

Brake signal

Power unit

A1

Motor connector

X1 Floor cable

Manipulator xx1800001835





365



Continued


Problem releasing brakes

Check connec!on from X1 to manipulator

Connec!on ok

Connec!on not ok

Repair connec!on

Check LED PS

Solid green

Not lit

Check LEDs:

MS, PC, HMI

Abnormal

Solid green (all 3)

Troubleshoot power supply T2

Troubleshoot

- robot signal exchange proxy K2

- power supply

- power unit

- main computer

- FlexPendant

Measure power on

K2.X7

Power is ok

No power

Check connec!on from K2.X7 to X1

Connec!on not ok

Connec!on is ok

Check connec!on

K2.X6 to A1.X2

Connec!on not ok

Connec!on is ok

Brake not ok

Test the brake

Brake is ok

Not ok

Test the brake release

Brake release is ok


Repair connec!on

Troubleshoot

- brake release on manipulator

-main computer A2

- robot signal exchange proxy K2

- power unit A1

Contact ABB


366






Continued


1

Action

Check that the floor cable is connected from the manipulator to the motor connector X1.

Visually inspect the cable for damage or extensive bending marks.

Tip

Note

• If the cable is damaged, replace to a new cable and go to step

8 .

• If the cable is not connected, repair the connection and go to step

8

.

• If the cable is ok, go to the next step.


C90XT .

2

3

4

5

6

Look at the LED PS on the front of the robot signal exchange proxy. LED PS should be solid green.



• If it is not green, see

Troubleshooting the power supply on page 401 .

Look at the LED MS, LED PC and LED HMI. All

LEDs should be solid green.

• If LED MS is not green, see


.

• If LED PC or LED HMI are not green, see

Troubleshooting the power supply on page 401 .

• If the power supply is ok, see


• If the power unit is ok, check that the power inlet is connected and the power inlet switch is turned on.

• If the LED PC is green, but

LED PC_PWR on the main computer is not green, see

Troubleshooting the main computer on page 398 .

• If the LED HMI is green, but the FlexPendant is not starting, see

Troubleshooting the FlexPendant on page 379

.

Measure the power on K2.X7.

Tip


C90XT .


• If there is no power, repair the connection and go to step

8

.

• If it is ok, go to the next step.

Check that the connection from the robot signal exchange proxy to the motor connector is ok:

• K2.X7 - X1.

Check that the connection from main computer to the robot signal exchange proxy is ok:

• K2.X6 - A1.X2

• If it is not, repair the connection and go to step

8

.


• If it is not, repair the connection and go to step

8

.





367




Continued

7

Action

Try jogging the robot.

8 Check that the brake release function is ok.

Note

• If it is not working properly, the brake release board on the manipulator might be broken. Contact your local

ABB for more information.

• If the brakes work normally, troubleshoot the main computer, the robot signal exchange proxy, and the power unit, one by one. If needed, replace faulty units.

Go to step

8 .

For more details on how to release the brakes, see the robot's product manual.

• If it is not ok, contact your local ABB.

368





7.2.5 Problem starting or connecting the FlexPendant

7.2.5 Problem starting or connecting the FlexPendant

Description

The FlexPendant is not responding, either completely or intermittently.

No entries are possible, and no functions are available.

Note

If protective gloves are used, these must be compatible with touchscreens when using the FlexPendant.

The FlexPendant starts but does not display the main interface.

xx1800000722



Equipment

Multimeter

Insulating gloves


Note

3HAC065464-009

Preparations

1

2

Action




DANGER








Continued


If the FlexPendant starts but does not display the main interface during the start-up, use this procedure to troubleshoot what might cause the problem.


Block diagram

24V SYS

X1

Safety controller

A2.K3

X6

X7

Main

X6 computer A2

Dual channel control & feedback

Ethernet

Robot signal exchange proxy K2 X3

X13

X12

X8 X9

ES & EN & MON & 24V HMI

HMI

LED

Ethernet

MS

LED

X2

HMI connection

X4

FlexPendant

X1

24V PC

PC

LED xx1800001830


370






Continued


Problem starting or connecting the FlexPendant

Connection not ok

Check connector X4

Connection ok

Check LEDs:

HMI & PC

Green

Not lit

Check FlexPendant cable

Cable ok

Cable damaged

Check connection

K2.X9 to X4

Connection not ok

Repair connection


Replace FlexPendant cable

Check:

K2.X8 - A2.X6

K2.X2 - A2.X1

K2.X12 - A2.K3.X6,7

K2.X3 - A2.K3.X1

Connection not ok

Connections ok

Replace FlexPendant

Not starting

Start FlexPendant

Ok



1

Action

Try resetting the FlexPendant using the reset button located next to the USB port.

Note

See Operating manual - OmniCore .





371



Continued

2

3

4

5

6

7

8

Action Note

Check that the FlexPendant cable is correctly connected to the controller through the HMI signal connector, X4.

If it is not connected, repair the connection and go to step six.

Check the pins in the connector.

If it is ok, go to the next step.

Check the LED PC and LED HMI, they should be green.



• If the LEDs are not green, see


• If they are ok, go to the next step.

Check the FlexPendant cable for any damage.

Check that the connection from the robot signal exchange proxy to the HMI signal connector is ok, K2.X9, 13 - X4.

Check that the connection from the robot signal exchange proxy to the main computer is ok:

•

•

K2.X8 - A2.X6

K2.X2 - A2.X1

• K2.X12 - A2.K3.X6,7

• K2.X3 - A2.K3.X1

• If damage is found, replace the FlexPendant cable and go to step six.


• If it is not ok, repair the connection and go to step six.


• If any connection fails, repair the connection and go to step six.

• If the connections are ok, go to the next step.

If possible, test by connecting another FlexPendant. This is to eliminate the FlexPendant and cable as error sources; Test the FlexPendant with a different controller to eliminate the controller as error source.

Check that the FlexPendant works normally.

If it is not ok, contact your local

ABB.

Tip

This is detailed in section

Troubleshooting the

FlexPendant on page 379

.

372





7.2.6 Problem using the joystick

7.2.6 Problem using the joystick

Description

The FlexPendant is started and responds when pushing buttons or using the touchscreen but the joystick is not working. It is therefore not possible to jog the robot.

If there are warnings or messages on the FlexPendant, see


.


1

2

3

4

Action Information

Make sure that the joystick lock is not activated.

See Operating manual - OmniCore .

Make sure the controller is in manual mode.

Make sure the FlexPendant is connected correctly to the controller.

Press the reset button located next to the USB port on the back of the FlexPendant.

If the joystick is still not working, then replace the FlexPendant.

Note

The reset button only resets the FlexPendant, not the system on the controller.




373


7.2.7 Controller fails to start

7.2.7 Controller fails to start

Description

The system has startup problems or the FlexPendant cannot connect to the system.

Function description

The robot controller always runs in one of the following two modes:

• Normal operation mode (a user-created system is selected to run)

• RobotWare Installation Utilities mode (advanced maintenance mode)

In rare occasions, a serious error (in the software or the configuration of the installed system), may prevent the controller from starting properly in the normal operation mode. A typical case is when a controller is restarted after a network configuration change, causing the controller to be non-responsive from FlexPendant, RobotStudio, or FTP. To restore the robot controller from this situation, the controller can be forced to start in RobotWare Installation Utilities mode.

Forcing startup of the RobotWare Installation Utilities mode

Repeat the following action two times in a row:

1 Turn on the main power switch.

2 Wait for approximately 15 seconds.

Note

The PC STAT LED should be in flashing red state.

3 Turn off the main power switch.

The installed system is de-selected and in the next startup, the RobotWare

Installation Utilities mode is started.

This has no effect if the controller is already in RobotWare Installation Utilities mode.

Note

Force starting the RobotWare Installation Utilities mode will not affect the files in the directories belonging to the installed system.

See also


.

How to install systems is described in Operating manual - Integrator's guide

OmniCore .

374





7.2.8 Reflashing firmware failure

7.2.8 Reflashing firmware failure

Description

When reflashing firmware, the automatic process can fail which will stop the system.

A message is generated in the event log.

This fault usually occurs due to a lack of compatibility between hardware and software.


If the controller stops with a message about firmware failure, use this procedure to troubleshoot what might cause the problem.

3

4

1

2

5

Action

Read the message to see which unit has failed.

If the relevant unit has been replaced recently, make sure that the versions of the old and the new unit are identical.

Check the software versions.

If RobotWare has been updated recently, make sure that the versions of the old and the new unit are identical.

If the problem remains, contact your local ABB for information about which firmware version is compatible with your hardware.

Note




375


7.2.9 Inconsistent path accuracy

7.2.9 Inconsistent path accuracy

Description

The path of the robot TCP is not consistent. It varies from time to time, and is sometimes accompanied by noise emerging from bearings, gearboxes, or other locations.

Possible causes

The symptom can be caused by (the causes are listed in order of probability):

• Robot not calibrated correctly.

• Robot TCP not correctly defined.

• Parallel bar damaged (applies to robots fitted with parallel bars only).

• Mechanical joint between motor and gearbox damaged. This often causes noise to be emitted from the faulty motor.

• Bearings damaged or worn (especially if the path inconsistency is coupled with clicking or grinding noises from one or more bearings).

• The wrong robot type may be connected to the controller.

• The brakes may not be releasing correctly.


The path accuracy depends on many factors. The following table describes the most common causes of problems with the path accuracy. Depending on your installation, the recommended working procedure is to work step by step, starting with the step that seems most plausible given your circumstances.

1

2

3

4

5

6

7

Action Note

Study the path of the robot in motion, to find if an external force, for example, an external cable package, is colliding with or restricting the movement of the robot.

Remove the obstacles.

In high temperature environments, the material in the robot can expand, thereby causing inconsistent path accuracy.

Improve the ventilation around the robot.

Make sure the robot tool and work object are correctly defined.

How to define these are described in Operating manual - OmniCore .

Check the positions of the revolution counters.

Update if required.

If required, re-calibrate the robot axes.

How to calibrate the robot is described in the product manual for the robot.

If you hear noise that has not been there before, locate the source to define if a motor or bearing is faulty.

Study the path of the robot TCP to establish which axis, and thus which motor, may be faulty.

Replace the faulty motor, gearbox, or bearing as specified in the product manual for the robot.

Check the trueness of the parallel bar

(applies to robots fitted with parallel bars only).

Replace the faulty parallel bar as specified in the product manual for the robot.


376





7.2.9 Inconsistent path accuracy

Continued

8

9

10

Action Note

Make sure the correct robot type is connected as specified in the system.

Update the system with the correct robot type, see Operating manual - Integrator's guide OmniCore .

Make sure the robot brakes work properly.

Proceed as detailed in section


.

If applicable: Check the setting for the swivel.

The swivel has an in-built resistance that needs to be set in the system parameters.




377


7.3.1 Troubleshooting LEDs in the controller

7.3 Troubleshooting units

7.3.1 Troubleshooting LEDs in the controller

Description

The controller features a number of indication LEDs, which provide important information for troubleshooting purposes. If no LEDs light up at all when switching the system on, troubleshoot as detailed in this section.

All LEDs on the respective units, and their significance, are described in the following sections.

Units with LEDs in the controller

Drive unit

Power unit

Scalable I/O

ABB Ability™ Connected Services

Ethernet switch

Axis computer

Main computer

Power supply

Fieldbus adapter slave


Troubleshooting the drive unit on page 380

Troubleshooting the power unit on page 382

Troubleshooting fieldbuses and I/O on page 387

Troubleshooting the Connected Services Gateway on page 388

Troubleshooting the Ethernet switch on page 394

Troubleshooting the axis computer on page 396



Troubleshooting the fieldbus adapter slave on page 406


378





7.3.2 Troubleshooting the FlexPendant

7.3.2 Troubleshooting the FlexPendant

Description

The FlexPendant communicates with the main computer. The FlexPendant is physically connected to the panel board. The cable contains the +24 V supply, two enabling device chains and emergency stop.

Procedure

The procedure below describes what to do if the FlexPendant does not work correctly.

1

2

Action

Try resetting the FlexPendant using the reset button located next to the USB port.

Note

See Operating manual - Omni-

Core .

If the FlexPendant is not responding or does not operate correctly, see

Problem starting or connecting the FlexPendant on page 369

.

Note

If protective gloves are used, these must be compatible with touchscreens when using the FlexPendant.

3

4

5

Check the cable for connections and integrity.

Check the 24 V power supply.

Read the error event log message and follow any instructions of references.

For more information on the FlexPendant, see Operating manual - OmniCore .




379


7.3.3 Troubleshooting the drive unit

7.3.3 Troubleshooting the drive unit

Location

The illustration shows the location of the drive unit in the controller.

LEDs xx1900001471

The illustration below shows the indication LEDs on the drive unit.

OmniCore C90XT

B C

A B A xx1800000575

A

B

C

Ethernet LEDs (yellow)

Ethernet LEDs (green)

Status LED


380





7.3.3 Troubleshooting the drive unit

Continued

Description Significance

Ethernet LEDs Shows the status of Ethernet communication between the drive unit and the power unit.

Green:

• Off: 10 Mbps data rate is selected.

• On: 100 Mbps data rate is selected.

Yellow:

• Flashing: The two units are communicating on the Ethernet channel.

• Steady: A LAN link is established.

• Off: A LAN link is not established.

Drive unit status

LED

The status indicator LED can be used to identify the following status during startup/power on:

1 Red, steady: Default when power is available.

2 Red, flashing: Power is on, self-test is ongoing, operating system is loading.

3 Green, flashing: Application is loaded and waiting for communication.

4 Green, steady: Drive unit is operational.

If the LED does not turn steady green after 30-60 sec, the status indicator

LED can be used to identify the following issues:

• No color: Power to the drive unit is missing.

• Red, steady: Internal error.

• Red, flashing: Firmware error or self-test failure.

• Green, flashing: Communication error to another module.




381


7.3.4 Troubleshooting the power unit

7.3.4 Troubleshooting the power unit

Location

The illustration below shows the location of the power unit in the controller.

LEDs xx1900001469

The illustration below shows the LEDs on the power unit.

OmniCore C90XT

A B A B C

A

B

C xx1800000576

Ethernet LEDs (yellow)

Ethernet LEDs (green)

Status LED


382






Continued

Description

Power unit status

LED


1 Red, steady: Default when power is available.

2 Red, flashing: Power is on, self-test is ongoing, operating system is loading.

3 Green, flashing: Application is loaded and waiting for communication.

4 Green, steady: Power unit is operational.

If the LED does not turn steady green after 30-60sec, then the status indicator LED can be used to identify the following issues:

• No color: Power to the power unit is missing.

• Red, steady: Internal error.





Equipment

Multimeter

Insulating gloves


Note

3HAC065464-009

Preparations

1

2

3

Action


Power the controller off. Wait one minute, power the controller on.

Make sure that the control system power supply is in run-time mode.

Wait 30-60 seconds after power-on.





383



Continued

Troubleshooting flowchart

Trouble shooting power unit

Check contactors

Q1,Q2 & X2

Connection not ok

Repair connection

Ok

Turn on power and wait 1 minute

Repair connection

Not lit or solid red

DC = 24V

Check LED MS

Green

Measure X5, X9, 24V

DC input voltage

DC < 24V

Check LEDs of

Ethernet ports X3,

X12

Normal

Connection not ok

Check connection to robot signal exchange proxy

A1.X9 - K2.X4

Connection ok

Measure X13,

AC OK signal

0 V

Measure X6, X7,

AC output voltage

Abnormal

Normal

Flashing red or flashing red/green

Abnormal

24 V

Repair connection

Check connection of Ethernet cables

Connection ok

Measure X1,

AC input voltage

Abnormal

Replace power unit

Connection not ok

Normal

Repair connection


Troubleshoot robot signal exchange proxy

Check elog

DC-link voltage

Normal

Warning

Power unit is ok

Check connection power inlet to power unit

Connection ok

Troubleshoot no

LEDs are lit

Connection not ok xx1800002357


384






Continued

Troubleshooting procedure

The troubleshooting table is supposed to be used as a detailed instruction together with the troubleshooting flowchart.

1

2

3

4

5

Action

Check the connections between connectors Q1, Q2 & X2.

Tip


Note

Open the door of the controller and check the connections between connectors Q1, Q2 & adapter X2.

How to open the controller is described in

Opening the robot controller on page 174

.

• If the connection is OK, proceed with step

2

.

• If there is a problem with the connection, repair the connection and start over.

Power on the controller. Check the indicator LED MS on the power unit.

Make sure that the controller power supply is in run-time mode.

Wait at least 1 min after power-on.

If the LED MS is:

• Green, proceed with step

8 .

• Flashing red/green: a firmware upgrade error has occurred. This is not supposed to happen during runtime mode, proceed with step

12 .

• Pulsing red: replace the power unit, step

12

.

• Not lit or red: The controller does not have sufficient DC input voltage. Proceed with step

3

.

Measure the 24 V DC input voltage to the power unit.

• X5

• X9


The input voltage should be 24 V.

Make sure that connectors X5, X9 are connected properly on both ends.

• If the 24 V DC input voltage is normal, proceed with step

8 .

• If the 24 V DC input voltage is abnormal, proceed with the next step.

Check connection to the robot signal exchange proxy.

• A1.X9 (Power unit) - K2.X4

If the connection is OK, proceed with the next step.

If there is a problem with the connection, repair the connection and go to step

2 .

Measure the AC output voltage.


The output voltage should be 230 V.

Make sure that connectors X6, X7 are connected properly on both ends.

• If the output voltage is normal,


, and then


• If the output voltage is abnormal, proceed with step

6

.

xx1900000043





385



Continued

6

7

8

9

10

11

12

Action Note

Measure the AC input voltage.

• A1.X1 - A1.K1

Check the connection from the power inlet to the power unit.

Check the LEDs of the Ethernet ports X3, X12 on the power unit.

Check the connection of the Ethernet cables.


The AC input voltage should be 230 V.

Make sure that connector X1 is connected properly on both ends.

• If the input voltage is normal, proceed with step

12 .

• If the input voltage is abnormal, proceed with the next step.

• If the connection is OK, troubleshoot

No

LEDs are lit on the controller on page 358 .


• If the LEDs are normal, proceed with step

10

.

• If the LEDs are abnormal, proceed with the next step.


12 .

• If there is a problem with the connection, repair the connection and go to step

8 .

Measure the AC OK signal.

Check event log if there is a message about DC-link voltage.


The AC OK should be 0 V.


• If the AC OK signal is 24 V, proceed with step

12 .

• If the AC OK signal is 0 V, proceed with the next step.

If message numbers 34401/34402, proceed with step

12

.

If not, power unit is ok.

The power unit may be faulty, replace it and verify that the fault has been fixed.

How to replace the unit is detailed in

Replacing the power unit on page 242 .

386





7.3.5 Troubleshooting fieldbuses and I/O

7.3.5 Troubleshooting fieldbuses and I/O

Further information

Information about how to troubleshoot the fieldbuses and I/O units can be found in the manual for the respective fieldbus or I/O unit. See

References on page 9 .




387


7.3.6 Troubleshooting the Connected Services Gateway

7.3.6 Troubleshooting the Connected Services Gateway

Location

The illustration shows the location of the Connected Services Gateway in the controller.

xx1900001466


388






Continued

LEDs for options 3G or WiFi

The illustration below shows the LEDs on the Connected Services Gateway (3G or WiFi).

A

B

C

D xx1800000634

A

B

C

D

LINK

LINK



STATUS LED

LINK, 3G status or WiFi status LED

RF, signal strength status LEDs

Factory reset pin hole

Description

STATUS LED

(red/green)

Significance

Startup sequence:

1 Red continuously: Default at power up.

2 Red, flashing: Power on self-test ongoing, operating system is loading.

3 Green flashing: Loading application.

4 Green solid: Startup completed OK.

If the LED does not turn steady green after 30-60sec, it can be used to identify the following issues:

Fault indication:

• No color: Power to the unit is missing.

• Red, solid or flashing: Internal error. Replace the unit.

• Green, flashing continuously: Communication error to another module, view error messages.

For the Connected Services 3G, an orange LED indicator, externally visible on the front, indicates the status of the 3G connection.

Orange:

• ON, flashing: 3G modem on, searching network.

• ON, solid: 3G modem on and connected to network.

For the Connected Services Wi-Fi, an orange LED indicator, externally visible on the front, indicates the status of the Wi-Fi connection.

Orange:

• ON, flashing: Wi-Fi transceiver on, searching network.

• ON, solid: Wi-Fi transceiver on and connected to network.


389




Continued

Description

RF, signal strength status

LEDs

Significance

Three (3) LEDs indicating the Wi-Fi or 3G signal level.

• ON: The unit is connected to the network and working ok.

• OFF: Problem with connector, antenna, or sim card.



Equipment

Multimeter

Insulating gloves

Note

Preparations

1

2

3

Action






390






Continued

Troubleshooting flowchart for options 3G or WiFi

Troubleshooting Connected

Services Gateway 3G or WiFi

Red/green flashing

Check LED STATUS

Not lit

Check LED LINK

Not lit or solid

Measure input voltage

Ok

Not ok

Not ok

Check connector X2

Ok

Not ok

Check LED RF

Ok

Not ok

Check connector X3

Ok

Not ok

Check antenna, sim card etc.

Ok

Replace the Connected

Services Gateway xx1900000139


Repair connection

Troubleshoot connectivity of 3G/sim card/WiFi, antenna





391



Continued

Troubleshooting procedure for options 3G or WiFi


1

2

3

Action Note

Check the STATUS LED on the Connected Services Gateway.

If the LED is:

• Red/green, flashing: An internal error has occurred, proceed with step

11 .

• OFF, the unit is faulty, or it does not have sufficient input voltage, or the connection of the connector

X2 is not ok. Proceed with step

3 .

Check the LINK LED on the Connected

Services Gateway.

If the LED is:

• OFF, the unit is faulty, or it does not have sufficient input voltage, or the connection of the connector

X2 is not ok. Proceed with step

3 .

• Flashing: An internal error has occurred, proceed with step

11

.

Measure the input voltage to the Connected Services Gateway.





4

.

• If the input voltage is abnormal,


4

5

6

Tip


Check that the connector X2 is well connected and the network connection properties are available.



5 .

• If there is a problem with the connection, repair the connection and go back to step

1 .

Check the indicator RF LEDs on the

Connected Services Gateway.

If the RF LEDs are:

• ON, the Connected Services Gateway is connected to network and works well.

• OFF, the Connected Services

Gateway is faulty or the connection of the connector X3 is not ok. Proceed with step

6

.

Check that the connector X3 is well connected.



7 .

• If there is a problem with the connection, repair the connection and go back to step

5 .


392






Continued

7

8

9

10

11

Action

Check that the right type of the antenna is connected properly.

Tip

Try moving the antenna to different locations if the RF signal level is low.

Note

• If the antenna is not working, repair the connection or move the antenna to a location with better RF signal.

• If the antenna is ok, proceed with step

11 .

On the FlexPendant, check the connection log in Backup and Restore .

For 3G, use a cell phone to test that the sim card is working.

For WiFi, use a cell phone to verify the

WiFi access.

Verify that the configuration is done correctly.

Verify that the mobile operator is detected

(for 3G).

See the Connected Services Gateway configuration in Operating manual - Integrator's guide OmniCore .

Note

When testing with a cell phone, use the same configuration on the cell phone.

For 3G and WiFi, check the antenna connectivity.

The Connected Services Gateway may be faulty, replace it and verify that the problem is resolved.

How to replace the unit is described in

Replacing the Connected Services Gateway on page 202

.




393


7.3.7 Troubleshooting the Ethernet switch

7.3.7 Troubleshooting the Ethernet switch

Location

The illustration shows the location of the Ethernet switch in the controller.

xx1900001465


394




LEDs


7.3.7 Troubleshooting the Ethernet switch

Continued

The illustration below shows the indication LEDs on the Ethernet switch.

A xx1800000584

A Status LED

Description

Status LED

Ethernet LEDs

Significance

Startup sequence:

1 No color: Input voltage is outside specified voltage or internal fault in the switch.

2 Green, solid: The switch is operational.

If the LED does not turn steady green, the status indicator LED can be used to identify the following issues:

Fault indication:

• No color: If input voltage is within specified voltage limits and the

LED is not lit then replace the switch.

Shows the status of Ethernet links.

Green:

• Off:10 Mbps data rate is selected.

• On:100/1000 Mbps data rate is selected.

Yellow:

• Flashing: The Ethernet is active on link.

• Solid: A LAN link is established.





395


7.3.8 Troubleshooting the axis computer

7.3.8 Troubleshooting the axis computer

Location

The illustration shows the location of the axis computer in the controller.

LEDs xx1900001462

The illustration below shows the LEDs on the axis computer.

C B B B

A A A xx1800000581

A

B

C

Ethernet LED (yellow)

Ethernet LED (green)

Status LED


396





7.3.8 Troubleshooting the axis computer

Continued

Description

Axis computer status LED

Ethernet LED

Significance

Normal sequence during startup:

1 Red, solid: Default at power-up.

2 Red, flashing: Establish connection to main computer and load program to axis computer.

3 Green, flashing: Start-up of axis computer program and connect peripheral units.

4 Green, solid: Start-up sequence ready. Application is running.

The following indicates errors:

• No color: No power to axis computer or internal error (hardware/firmware).

• Red, solid: The axis computer has failed to initialize basic hardware.

• Red, flashing continuously: Missing connection to main computer, main computer start-up problem or RobotWare installation problem.

• Green, flashing continuously: Missing connections to peripheral units or RobotWare start-up problem.

Shows the status of Ethernet communication.

Green:

• Off:10 Mbps data rate is selected.

• On:100 Mbps data rate is selected.

Yellow:

• Flashing: The two units are communicating on the Ethernet channel.

• Solid: A LAN link is established.





397


7.3.9 Troubleshooting the main computer

7.3.9 Troubleshooting the main computer

Location

The illustration shows the location of the main computer in the controller.

LEDs xx1900001468

The illustration below shows the LEDs on the main computer:

A B C xx1800000585

A


398

Power status LED






Continued

B

C

HDD status LED

Status LED


Power status, PC

PWR (green)

The power status LED indicates the status of the power supply and the main computer hardware and firmware.

Normal behavior:

• Off: During a normal startup the LED is off, until the COM Express module inside the computer unit is started.

• On solid: After completion of startup the LED is steady on.

Failure during startup (off between blinks). One to four short blinks, one second off. This is repeated until power off.

• Internal fail of power, FPGA, and/or the COM Express module.

• Replace the computer unit.

Power failure during runtime (fast flashing between blinks). One to five blinks, 20 fast flashing blinks. This is repeated until power off.

• Temporary voltage drop, cycle the power to the controller.

• Check the power supply voltage to the computer unit.

• Replace the computer unit.

Disk status, PC

HDD

The disk status LED indicates access to the main computer persistent memory.

Normal behavior:

• No color at power on: R34 FPGA is loaded on the main board.

• Yellow: Access (read/write) to internal mass memory.

Computer status,

PC STAT

(red/green)

The computer status LED indicates the startup progress of RobotWare on the main computer.

Normal behavior:

1 Red, solid: Default when turning on the power.

2 Red, flashing: Initial self-test is ongoing and the operating system is loading.

3 Green, even flashing (~1Hz): The operating system is loaded and

RobotWare is initializing.

4 Green, uneven flashing: The RobotWare system failed to load or is not installed.

5 Green, solid: The computer is operational and the RobotWare system is fully loaded.

If the LED does not turn steady green after approximately 5 minutes then the LED can be used to identify the following issues:

• No color: The internal power initialization failed. Restart the controller. Replace the main computer if the problem remains.

• Red, solid: Internal error. Restart the controller. Replace the main computer if the problem remains.

• Red, flashing continuously: Failed to load the operating system.

Restart the controller. See

Controller fails to start on page 374 .

Replace the main computer if the problem remains.

• Green, even flashing continuously (~1Hz): Failure during start up.

Check error messages on FlexPendant. See

Controller fails to start on page 374 .

• Green, uneven flashing: RobotWare Installation Utilities mode.

For information about the LEDs on the AnybusCC slave fieldbus adapter and the

PCIExpress master/slave fieldbus board, see the corresponding fieldbus manual.





399



Continued


1

2

3

4

Action Note

If the LEDs do not turn steady after approximately 5 minutes then restart the controller and check the

LEDs again.

See

LEDs on page 398

.

Force start the RobotWare Installation Utilities mode, see

Controller fails to start on page 374

.

Re-install RobotWare, if possible.

The main computer may be faulty, replace it and verify that the fault has been fixed.

See

Replacing the main computer on page 213 .

400





7.3.10 Troubleshooting the power supply

7.3.10 Troubleshooting the power supply

Location

The illustration below shows the location of the system power supply in the controller.

LEDs xx2000000431

The illustration below shows the LEDs on the power supply.

A xx1800000582





401



Continued

A DC OK LED

Description

DC OK LED

Significance

Green: All DC outputs are above the specified minimum levels.

Off: One or more DC outputs are below the specified minimum level.


Equipment needed for troubleshooting.

Equipment

Multimeter

Insulating gloves


Note

3HAC065464-009

Preparations

1

2

3

Action






402






Continued


Troubleshooting the power supply

Repair short circuit

Green

24V < DC < 27V

Short circuit on A1

Check DC LED

Off

DC > 27V

Measure DC output

DC < 24V

Check for short circuit on output

No short circuit

Short circuit on power supply

Repair AC connection

Repair AC input

Measure power supply AC input

AC not ok

Connection not ok

Check AC connection between power supply and A1

Connection ok

AC ok

AC not ok

Measure AC to controller

AC ok

Repair cabling

Faulty cable

Check cabling

Cable ok

Troubleshoot the power unit

Replace power supply

Power supply is ok xx1800001823



1

Test Note

Check the LED (labelled DC OK) on the power supply.

If the LED is:

• Green: the power supply should be working properly.

• Off: either the power supply is faulty or it does not have sufficient input voltage.

Proceed with step

2

.





403



Continued

3

4

2

5

6

7

8

Test

Measure the DC voltage while the output is connected to the robot signal exchange proxy or some other load.

Note


Measure at the DC output connector X2. The voltage should be: +24 V < U < +27 V.

• If the voltage measured at the load falls below +24 V, voltage drops in the cables and connectors.

• If the correct voltage is detected and the

DC OK LED is green, the power supply is working properly.

• If the correct voltage is detected and the

DC OK LED is off, the power supply is regarded as faulty but does not have to be replaced instantly.

• If the DC OK voltage is higher than 27

V, proceed with step

10

.

• If the DC OK voltage is below 24 V, proceed with step

3 .


Power the controller OFF and measure the resistance.

Check for short circuit on DC output.

Check both the DC output connector X2 on the power supply and the input connector X1 on the robot signal exchange proxy.

Measure the resistance between voltage pins and ground. The resistance should not be less than 10 ohm.

Note

Do not measure the resistance between pins.

Dual pins are used for both power supply and ground.

• If no short circuit is found, proceed with step

6 .

• If a short circuit is found on the power supply, proceed with step

10 .

• If a short circuit is found on the robot signal exchange proxy, get that unit working. Verify that the fault has been fixed and restart this guide if necessary.

Switch on power to the controller.

Measure the input voltage on the power supply.

Make sure that the connection between the power supply and the power unit is ok.

Make sure that the supplied input voltage to the controller is correct.


Voltage should be: 172 V < U < 276 V for a 230

V system.

• If the input voltage is correct, proceed with step

10

.

• If no or the wrong input voltage is detected, proceed with step

7

.


8 .

• If the connection is faulty, repair the connection. Verify that the fault has been fixed and restart this guide if necessary.

• If the input voltage is correct, proceed with step

9 .

• If the input voltage is faulty, correct it.

Verify that the fault has been fixed and restart this guide if necessary.


404






Continued

9

10

Test

Check the cabling.

The power supply may be faulty, replace it and verify that the fault has been fixed.

Note

Make sure that the cabling is correctly connected and not faulty.

• If the cabling is OK, see

Troubleshooting the power unit on page 382 . Verify that

the fault has been fixed and restart this guide if necessary.

• If the cabling is found unconnected or faulty, connect/replace it. Verify that the fault has been fixed and restart this guide if necessary.

See

Replacing the power supply on page 247 .




405


7.3.11 Troubleshooting the fieldbus adapter slave

7.3.11 Troubleshooting the fieldbus adapter slave

Location

The illustration shows the location of the fieldbus adapter slave in the controller.

LEDs xx1900001474

The illustration below shows the indication LEDs on the fieldbus adapter slave.

A

B

406 xx1800000586

A

B

Power LED

Status LED


Power LED Fault indication:

• No color: Input voltage is outside of the specified voltage limits.

• Green, solid: Input voltage is within the specified limit.

Fieldbus adapter slave status LED

(red/green)

Startup sequence:

Red:

1 Red, solid: Loading bootloader.

2 Red, flashing: Power on self-test is ongoing, loading operating system.

3 Green, flashing: Loading RobotWare and waiting for communication.

4 Green, solid: System ready.

If the LED does not turn steady green after 30-60 sec, the status indicator

LED can be used to identify the following issues:

Fault indication:

• No color: Power to the fieldbus adapter slave is missing.

• Red, solid: Internal error.

• Red, flashing continuously: Firmware error or self-test failure.

• Green, flashing continuously: Communication error to another module. Check the messages on the FlexPendant.





7.3.12 Troubleshooting the robot signal exchange proxy

7.3.12 Troubleshooting the robot signal exchange proxy

Location

The illustration below shows the location of the robot signal exchange proxy in the controller.

xx1900001464





407



Continued

LEDs

The illustration below shows the LEDs on the robot signal exchange proxy:

MS


Status LED (bi-colored green/red) for the robot signal exchange proxy.


• Red, solid: Default when power is available.

• Red, flashing: Power on self-test ongoing, operating system is loading.

• Green, flashing: Application is loaded and waiting for communication.

• Green, solid: Module is operational.

If the LED does not turn steady green after 30-60 sec, the status LED can be used to identify the following issues:

• No color: Power to the robot signal exchange proxy is missing.

• Red, solid: Internal error.



AS1 &

AS2

ES1 &

ES2

Automatic stop LEDs (green)

AS1：Automatic stop LED channel 1

AS2：Automatic stop LED channel 2

External emergency stop LEDs (green)

ES1：External emergency stop LED channel 1

ES2：External emergency stop LED channel 2

Automatic stop LED can be used to identify the following status:

• No color (not lit): Automatic stop input loop is open.

• Green, solid: Automatic stop input loop is closed.

External emergency stop LED can be used to identify the following status:

• No color (not lit): External emergency stop input loop is open.

• Green, solid: External emergency stop input loop is closed.

ES-

OUT1

& ES-

OUT2

Emergency stop output LEDs (green)

ES1：Emergency stop output LED channel 1

ES2：Emergency stop output LED channel 2

Emergency stop output LED can be used to identify the following status:

• No color (not lit): Emergency stop output logic low (0V) status.

• Green, solid: Emergency stop output logic high (24V) status.

MON Motors_ON LED (white) Motors_ON LED can be used to identify the following status:

• No color: Motors_ON function is off.

• White, solid: Motors_ON function is on.

• White, flashing: safety loop is open, for example after an emergency stop.


408






Continued

AC

PS

PC

HMI

EP


ACOK LED (green) ACOK LED can be used to identify the following status:

• No color: AC OK signal is de-active or logic power failure.

• Green, solid: AC OK signal is active and logic power available.

Internal power (24 V power supply) input

LED (green)

Internal power input LED can be used to identify the following status:

• No color: Internal power input voltage is not in normal range.

• Green, solid: Internal power input voltage is in normal range.

Main computer power output LED (green) Main computer power output LED can be used to identify the following status:

• No color: Main computer power output voltage is not in normal range.

• Green, solid: Main computer power output voltage is in normal range.

FlexPendant power output LED (green)

External power input LED (green)

FlexPendant power output LED can be used to identify the following status:

• No color: FlexPendant power output voltage is not in normal range.

• Green, solid: FlexPendant power output voltage is in normal range.

External power input LED can be used to identify the following status:

• No color: External power input voltage is not in normal range.

• Green, solid: External power input voltage is in normal range.


Equipment needed for troubleshooting.

Equipment

Multimeter

Insulating gloves


Note

3HAC065464-009

Preparations

1

2

3

Action









409



Continued


Troubleshooting robot signal exchange proxy

Turn off power until all LED (except MS) are off, then turn on power and wait 1 min

Replace robot signal exchange proxy

Repair connection

Connection not ok

Not lit Flashing red/green

Check LED MS

Green

Measure 24V

DC input voltage

DC < 24V

DC = 24V

Check connection to power supply

Connection ok


Measure 24V DC output voltage

DC = 24V

DC < 24V

Repair connection

Not lit Check LEDs:

AS1, AS2, ES1, ES2

Lit

Check connector

X14, X15

Connection not ok

Connection ok

Check external safety accessories

Resistance

No resistance

Measure AC OK signal

Low impedance

High impedance

No problem found in robot signal exchange proxy

Troubleshoot power unit

Troubleshoot external equipment xx1800002356



1

Test Action

Check the indicator LED MS.

If the LED_MS is:

• Green, proceed with step

4

.

• Flashing red/green, a firmware upgrade error has occurred. This is not supposed to happen during runtime mode, proceed with step

9

.

• OFF, either the robot signal exchange proxy is faulty or it does not have sufficient input voltage. Proceed with step

2

.


410






Continued

2

3

4

5

6

7

8

9

Test Action

Measure the input voltage to the robot signal exchange proxy.

Tip






4

.

• If the input voltage is abnormal, proceed with step

3

.

Check connection to the power supply unit.

• If the connection is OK,


.


Measure the 24 V DC outputs voltage.


The output voltage should be 24 V.

Make sure that connectors X2, X3, X4, X5, X17 and

X19 are connected properly on both ends.

• If the output voltage is normal, proceed with step

5

.

• If the output voltage is abnormal, proceed with step

9

.

Check the indicator LEDs

AS1, AS2, ES1, ES2.

The indicator LEDs are labelled AS1, AS2, ES1, ES2.

If the LEDs LED_AS1, AS2, ES1, ES2 are:

• On (solid yellow), the robot signal exchange proxy works well.

• Off, either the robot signal exchange proxy is faulty or it does not have sufficient input voltage. Proceed with step

6

.

Check that the customer interface connectors are well connected to X14 and X15.

Tip

If the customer interface connectors are not well connected to X14 and X15, the robot signal exchange proxy cannot work normally.


7

.

• If there is a problem with the connection, repair the connection and go to step

5 .


Check external safety accessories.

Measure the AC OK signal.


Measure the continuity in the connector. If there is resistance, troubleshoot the external equipment.


The AC OK should be 0 V.


• If the AC OK signal is 24 V, see


• If the AC OK signal is 0 V, proceed with step

9

.

The robot signal exchange proxy may be faulty, replace it and verify that the fault has been fixed.

How to replace the unit is detailed in

Replacing the robot signal exchange proxy on page 192 .




411


8 Reference information

8.1 Introduction


8.1 Introduction

General

This chapter includes general information, complementing the more specific information in the different procedures in the manual.




413


8.2 Applicable standards

8.2 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased out or replaced standards are removed from the list when needed.

General

The product is designed in accordance with ISO 10218-1:2011, Robots for industrial environments - Safety requirements -Part 1 Robots, and applicable parts in the normative references, as referred to from ISO 10218-1:2011. In case of deviations from ISO 10218-1:2011, these are listed in the declaration of incorporation which is part of the product delivery.

Normative standards, ISO

Standard

ISO 9283:1998

ISO 10218-2

ISO 12100

ISO 13849-1:2006

ISO 13850

IEC 60204-1:2005

IEC 62061:2005

Description

Manipulating industrial robots - Performance criteria and related test methods

Robots and robotic devices - Safety requirements for industrial robots - Part 2: Robot systems and integration

Safety of machinery - General principles for design - Risk assessment and risk reduction

Safety of machinery - Safety related parts of control systems

- Part 1: General principles for design

Safety of machinery - Emergency stop - Principles for design

Safety of machinery - Electrical equipment of machines - Part

1: General requirements

Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic control systems

Deviations from ISO 10218-1:2011 for OmniCore

A deviation exists in OmniCore from paragraph 5.3.5 Single point of control . Single point of control cannot be guaranteed in automatic mode. See

Three-position enabling device on page 25

.

Other standards used in design

Standard

ISO 9787:2013

IEC 61000-6-2

IEC 61000-6-4

(option 129-1)

ISO 13732-1:2008

IEC 60974-1:2012 i

Description

Robots and robotic devices -- Coordinate systems and motion nomenclatures

Electromagnetic compatibility (EMC) – Part 6-2: Generic standards – Immunity standard for industrial environments

Electromagnetic compatibility (EMC) – Part 6-4: Generic standards – Emission standard for industrial environments

Ergonomics of the thermal environment - Part 1

Arc welding equipment - Part 1: Welding power sources


414





8.2 Applicable standards

Continued

Standard

IEC 60974-10:2014

i

ISO 14644-1:2015 ii

Description

Arc welding equipment - Part 10: EMC requirements

Classification of air cleanliness i ii

IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)

Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots.

Only robots with protection Clean Room.




415


8.3 Unit conversion

8.3 Unit conversion

Converter table

Use the following table to convert units used in this manual.

Quantity

Length

Weight

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 g

1 bar

1 N

1 Nm

1 L

3.28 ft.

2.21 lb.

0.035 ounces

100 kPa

0.225 lbf

0.738 lbf-ft

0.264 US gal

39.37 in

14.5 psi

416





8.4 Standard toolkit for controller

8.4 Standard toolkit for controller

General

All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, that is, all tools that are not considered as standard tools as defined below, are listed in their instructions respectively.

This way, the tools required are the sum of the standard toolkit and any tools listed in the instructions.

Standard toolkit for controller

Tool

Screw driver, Torx

Screw driver, Torx

Screw driver, Torx

Ball tipped screw driver, Torx

Screw driver, flat blade



Screw driver

Box spanner

Description

Tx10

Tx20

Tx25

Tx25

4 mm

8 mm

12 mm

Phillips-1

8 mm

Toolkit recommended for troubleshooting

Tool

Normal shop tools

Multimeter

Camera

Note

Contents as specified above.

-

To document problems or procedures




417


8.5 Screw joints

8.5 Screw joints

General

This section details how to tighten the various types of screw joints on the controller.

The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.

Tightening torque

M2.5

M3

M4

M5

M6

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value.

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.

• Always tighten the joint by hand, and never use pneumatical tools.

• Use the correct tightening technique , i.e.

do not jerk. Tighten the screw in a slow, flowing motion.

• Maximum allowed total deviation from the specified value is 10% !

The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess heads.

Dimension

1.2

2.5

5.0

Tightening torque (Nm)

Class 4.8, oil-lubricated

0.25

0.5

418





8.6 Weight specifications

8.6 Weight specifications

Definition

In all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.

To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg.

Example

Below is an example of how a weight specification is presented:

CAUTION

The transformer weighs 55 kg! All lifting equipment used must be sized accordingly!




419


8.7 Lifting accessories and lifting instructions

8.7 Lifting accessories and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure.

The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories.

This implies that the instructions delivered with the lifting accessories should be stored for later reference.

420




9 Spare parts

9 Spare parts

Spare part level

ABB spare parts are categorized into two levels, L1 and L2. Always check the part level before conducting a service work on a spare part.

• L1 spare parts

The L1 parts can be replaced in the field. The maintenance and replacement instructions given in the related product manuals must be strictly followed.

If there are any problems, contact your local ABB for support.

• L2 spare parts

To replace the L2 parts require specialized training and might need special tools. Only ABB field service personnel or qualified personnel trained by

ABB can replace L2 parts.





421

9 Spare parts

9.1 Controller parts

9.1 Controller parts

Note

Removed parts and spare parts must not be disassembled or opened.

Drive units

Power units xx1900001930

A

Spare part number

Description

3HAC063913-001 Drive

Type

DSQC3041


L1 xx1900001931


422





Description

3HAC059152-001 Power unit A

Harness ETH outlet connection

9 Spare parts


Continued

Type

DSQC3044


L1 xx1900001941

A


Description

3HAC070053-001 Harness ETH outlet with cable

Manipulator signal connectors (SMB)

Type Spare part level

L1 xx1900001942

A


Description

3HAC069674-001 Harness Single SMB connection


L1





9 Spare parts


Continued

B


Description

3HAC069675-001 Harness Double SMB connection

(option)

Type

Harness TPU connection


L1 xx1900001943

A


Description

3HAC069673-001 Harness TPU connection


L1


424




9 Spare parts


Continued

Blind plate xx2000000453

-


Description

3HAC069953-001 Blind plate

Harness motors power


L1 xx1900001944





425

9 Spare parts


Continued

Scalable I/O devices

A


Description

3HAC069672-001 Harness Motors power LV 6-axis


L1

-

A

B

-

C

-

xx1900001939


Description

3HAC060919-001 Connectors digital base/add on

3HAC058663-001 Local I/O Digital base [3032-1] (option)

3HAC058664-001 Digital add-on [3033-2] (Add-on)

3HAC058665-001 Analog add-on [3034-2] (Add-on)

3HAC060925-001 Connectors I/O Analog (Add-on)

3HAC058666-001 Relay add-on [3035-2] (Add-on)

3HAC060926-001 Connectors I/O Relay

(Add-on)

Type

DSQC1030

DSQC1031

DSQC1032

DSQC1033

L1

L1

L1

L1

L1


L1

L1


426




9 Spare parts


Continued

DeviceNet master

CTM-01 xx1800003420

A


Description

3HAC043383-001 DeviceNet Board (option)

Type

DSQC1006


L1

-

A xx1900001938


Description Type

3HNA027579-001 Conveyor tracking module [3103-1] DSQC2000

3HNA029345-001 CONNECTOR KIT - DSQC2000


L1

L1





9 Spare parts


Continued

-


Description

3HAC069618-001 Harness 24V_CTM

Connected Services Gateway


Power cable of

CTM

L1 xx1900001934

A

B

C

D

E


Description

3HAC060960-001 Connected Services-3G [3013-3]

(baseline)

3HAC028459-001 Magnetic roof antenna, 3G (baseline)

Type

3HAC060962-001 Connected Services-WiFi [3013-2]

(option)

3HAC059424-001 Magnetic roof antenna, WiFi (option)

3HAC061701-001 Connected Services-Wired [3013-1]

(option)

DSQC1041

L1

L1

L1

L1


L1


428




9 Spare parts


Continued

Ethernet switches

Vision parts xx1900001935

A


Description

3HAC059187-001 Ethernet Extension switch [3014-1]

(option)

Type

DSQC1035


L1

-

-

-

-

-

-

-

-


Description

3HAC053944-001 8 mm camera lens, LTC-08F

3HAC053944-002 12.5 mm camera lens, LFC-12.5F

3HAC053944-003 16 mm camera lens, LFC-16F1

3HAC053944-004 25 mm camera lens, LFC-25F1

3HAC053953-001 Integr Vision camera med. Res

3HAC053954-001 Integr Vision camera high res

3HAC051753-003 Integr Vision power cable

3HAC051736-003 Integr Vision ethernet cable

Type

DSQC1020

DSQC1021

L1

L1

L1


L1

L1

L1

L1

L1





429

9 Spare parts


Continued

Fans

Axis computer

A

B xx1900001929


Description

3HAC065526-001 Heat exchanger

3HAC059214-001 Standard fan


L1

L1 xx1900001927

A


Description

3HAC029157-001 Axis Computer

Type

DSQC 668


L1


430




9 Spare parts


Continued

Main computer

Power supply device xx1900001933

A


Description

3HAC063061-001 Main computer module assembly


L1

A

B

C xx1900001932


Description

3HAC071301-001 Power supply

3HAC14178-1

3HAC13398-2






Type

DSQC3035

DSQC 609

DSQC 634


L1

L1

L1


431

9 Spare parts


Continued

Fieldbus adapter slaves

-

A xx1900001937


Description

3HAC062390-001 Fieldbus slot cover (baseline)

3HAC045973-001 DeviceNet Slave Fieldbus adaptor

[3030-1] (option)

Type

DSQC1004


L1

L1


432




Process, fieldbus and I/O connectors

9 Spare parts


Continued xx1900001481 xx1900001928

A


Description

3HAC066396-001 Cable grommet asm (option)


L1





9 Spare parts


Continued

Air filter

A

B

C xx1900001945


Description

3HAC068416-001 Air filter-Fine filter

3HAC068543-001 Air filter (Polymeric)

3HAC068415-001 Air filter-coarse filter


L1

L1

L1


434




Cable grommet asm

9 Spare parts


Continued xx1900001480

A

B xx1900001947


Description

3HAC069954-001 Blind plate (baseline)

3HAC066396-001 Cable grommet asm





L1

L1


435

9 Spare parts


Continued

Main power connection xx1900001946

A


Description

3HAC067661-001 Harness AC input with SW

B

C

3HAC037699-001 Handle for 6 mm switch

3HAC070308-001 Connector AC power inlet

Robot signal exchange proxy


Harness-Mains connection

L1

L1

L1 xx1900001936

A


Description

3HAC064662-001 Signal exchange


436

Type

DSQC3037


L1




End clamp

9 Spare parts


Continued

B


Description

3HAC065107-001 Harness Short-circuit connector


Mating connector for robot signal exchange proxy.

L1 xx2000000529 xx1900001940

A


Description

3HAB7983-1 End clamp


L1





437

9 Spare parts


Continued

LED indicator

TPU cover xx1900002451

-


Description

3HAC065549-001 LED indicator


L1

Cables

Cables on the frame xx1900002452

-


Description

3HAC067213-001 TPU cover

-

-

-

-

-


Description

3HAC071430-001 Harness AC input package

3HAC066527-001 Harness contactors signals

3HAC066520-001 Harness AC_OK signal

3HAC066521-001 Harness Temp Sensor

3HAC066522-001 Harness 24_SYS_DRV


L1


Harness A1.X6,

A1.X7 - T2,T5

L1

Harness A1.X2

- K2.X6, K2.X11

L1

Harness A1.X13

- K2.X10

L1

Harness K2.X21

- TempSensor

L1

Harness K2.X4

- A1.X9

L1


438




9 Spare parts


Continued

-

-

-


Description

3HAC066523-001 Harness 24_SYS

3HAC066524-001 Harness 24_Trunk

3HAC066526-001 Harness 24_Cooling


Harness K2.X3

- K6.X1, K3.X1,

K5.1.X4/

K3.1.X4, K7.X1

L1

Harness K2.X1

- T2.X2

L1

Harness K2.X17

- Cooling

L1

Cables on the drive unit

-

-

-


Description

3HAC063344-001 Harness DC-BUS

3HAC064389-001 Harness 24_SYS_DRV

3HAC059894-001 Harness EtherCAT


Harness A1.X4

- T4.X5

L1

Harness A1.X5

- T4.X1

L1

Harness T4.X3

- A1.X12

L1

Cables on the power supply

-


Description

3HAC069617-001 Harness AC input of power supply


L1

Cables on the robot signal exchange proxy

-


Description

3HAC064091-001 Harness 24_PC

3HAC059273-001 Harness dual channel safety


Harness K2.X2

- K4.X8, A2.X1

L1

Harness K2.X12

- K3.X6, K3.X7

L1




439

9 Spare parts

9.2 FlexPendant parts

9.2 FlexPendant parts

FlexPendant parts

The illustration below shows the placement of the controller system parts in the recommended spare part list.

A C D

B E

F

D

-

-

-

F

C

D

E

A

B xx1800000974


Description

3HAC064211-001 FlexPendant

3HAC064927-001 FlexPendant Holder w/t E-stop cover

3HAC065401-001 Power cable cover

3HAC065408-001 Joystick guard

3HAC064448-002 FlexPendant power cable 3 m

Type

DSQC3060



3HAC065419-001 Fasten strip

3HAC068915-001 FlexPendant extension cable, 15 m



L1

L1

L1

L1

L1

L1

L1

L1

L1

L1


L1

440




9 Spare parts

9.3.1 Manipulator cables

9.3 Manipulator cables

9.3.1 Manipulator cables

Power cables, IRB 1100, 1300, 910INV

Power cable length

Power cable 3 m

Power cable 7 m

Power cable 15 m

Signal cables, IRB 1100, 910INV

Singal cable length

Signal cable, shielded: 3 m



Signal cables, IRB 1300

Singal cable length





Article number

3HAC061139-001

3HAC061139-002

3HAC061139-003

Article number

3HAC067446-001

3HAC067446-002

3HAC067446-003

Article number

3HAC067446-001

3HAC067446-002

3HAC067446-003

3HAC067446-004

Power cable level

L1

L1

L1

Singal cable level

L1

L1

L1

Signal cable level

L1

L1

L1

L1




441

9 Spare parts

9.3.2 Customer cables - CP/CS connectors (option)

9.3.2 Customer cables - CP/CS connectors (option)

CP/CS cables, IRB 1100, 1300, 910INV

CP/CS cable length

3 m

7 m

15 m

Article number

3HAC067449-001

3HAC067449-002

3HAC067449-003

CP/CS cable level

L1

L1

L1

442




9 Spare parts

9.3.3 Customer cables - Ethernet floor cable

9.3.3 Customer cables - Ethernet floor cable

Ethernet floor cables, IRB 1100, 1300, 910INV (option)

One end is RJ45, one end is X-code.

Ethernet floor cable length Article number

Eth.RJ45_X floor cable, 7 m

Eth.RJ45_X floor cable, 15 m

3HAC067447-002

3HAC067447-003

Ethernet floor cable level

L1

L1




443


Index

Index

3

3rd party software, 47

A

ABB Ability Connected Services Gateway

replacing, 202

Ability port, 85

allergenic material, 30

aluminum

disposal, 352

ambient humidity

operation, 40

storage, 39

ambient temperature

operation, 40

storage, 39

AS

configuring, 99

assembly instructions, 51

assessment of hazards and risks, 30

automatic mode, 29

automatic stop, 99

auto stop

function test, 169

axis computer

LED, 396

replacing, 175

B batteries

disposal, 352

brakes not releasing, 365

C

cabinet lock, 31

cables, 69

carbon dioxide extinguisher, 31

Category1AS, 23

Category1ES, 23

category 0 stop, 22 category 1 stop, 22 category 2 stop, 22

cleaning

FlexPendant, 44

cleaning of the controller, 159

cleaning the FlexPendant, 160

climbing on robot, 34

Connected Services Gateway

LED, 389

replacing, 202

test equipment, 390

troubleshooting flowchart, 391

connection

manipulator cables, 69

connections, 79

controller

symbols, 19

controller fails to start, 374 controller mode, 374

cooling fan

replacing, 181

copper

disposal, 352

D

damaged bearings, 376 damaged parallel bar, 376

detaching FlexPendant, 76

DeviceNet

installing, 123

dimensions, 39

disconnecting FlexPendant, 76

disposal of storage media, 351

double SMB harness

installing, 106

drive unit

LED, 380

replacing, 257

E

earth fault protection, 73

Earth fault protection, tripped, 361

emergency stop, 22 definition, 22

function test, 165

emergency stops, 24

enabling device, 25

function test, 167

EN ISO 13849-1, 14

environmental information, 352

ESD

damage elimination, 43 sensitive equipment, 43

esd elimination, 42

Ethernet

installing, 113

Ethernet extension switch

installing, 113

Ethernet switch

LED, 395

replacing, 198

external I/O

installing, 110

replacing, 208

F fan

replacing, 181

faulty calibration, 376 faulty TCP definition, 376

fieldbus, 103

fieldbus adapter

installing, 120

fieldbus adapter slave

LED, 406

fieldbus master

installing, 122

replacing, 265

fire extinguishing, 31

firewall settings, 86

firmware, reflashing failure, 375

FlexPendant

blue screen, 369

cleaning, 44

connecting, disconnecting, 76

storage, 44

FlexPendant cannot connect to system, 374

FlexPendant connector, 137, 143, 284, 306, 312, 321

FlexPendant holder, 58

FlexPendant joystick not working, 373

FlexPendant not responding, 369




Index

FlexPendant not starting, 369

function tests, 165

G

general stop, 99

grounding, 73

GS

configuring, 99

H hanging

installed hanging, 30

harness double SMB

installing, 106

hazard levels, 17

hazardous material, 352

height

installed at a height, 30

hold-to-run, 25

hot surfaces, 34

HRA, 30

humidity

operation, 40

storage, 39

I

I/O connectors, 88

industrial network, 103

installation activities, 52

installation space, 56

instructions for assembly, 51

integrator responsibility, 30

internal I/O

installing, 110

replacing, 208

J

jogging not possible, 373 joystick not working, 373

K

key of the mode switch, 33

L labels

controller, 19

LAN port, 85

LED

axis computer, 396

Connected Services Gateway, 389

drive unit, 380

Ethernet switch, 395

fieldbus adapter slave, 406

main computer, 398

power supply, 401

power unit, 382

robot signal exchange proxy, 408

LEDs , indication, 358

LEDs not lit, 358

licenses, 47

lifting device, 53

limitation of liability, 13

Lithium

disposal, 352

lock and tag, 31

446

M main computer

LED, 398

replacing, 213

main power supply, 91

management port, 84

manipulator cables, 69

manual full speed mode, 27 manual high speed mode, 27 manual mode, 27 manual reduced speed mode, 27

mode switch key, 33

motor contactors

function test, 168

MTTF

D

, 14–15

N

national regulations, 30

network security, 46

noise, 376

normal operation mode, 374

O

open source software, OSS, 47

operating conditions, 40

operating mode

automatic mode, 29

function test, 166

manual full speed mode, 27 manual mode, 27 manual reduced speed mode, 27

optional power supply

installing, 116

original spare parts, 13

P

path accuracy, 376

pedestal

installed on pedestal, 30

performance level, PL, 14

personnel

requirements, 16

PFH

D

, 14–15

PL, performance level, 14

plastic

disposal, 352

ports, 79

power failure during start-up, 361

power supply

LED, 401

replacing, 247

test equipment, 402


power supply optional

installing, 116

power unit

LED, 382

replacing, 242

test equipment, 383


PPE, 16

problem releasing the robot brakes, 365

product standards, 414

protection classes, 40 protection type, 40

protective equipment, 16

protective stop




definition, 22

protective wear, 16

R

RCD, 73

recovering from emergency stops, 24

reduced speed control

function test, 172

reflashing firmware failure, 375

regional regulations, 30

remote I/O

installing, 110

replacing, 208

replacements, report, 173 report replacements, 173

required performance level, PLr, 14

residual current device, 73

responsibility and validity, 13

risk of burns, 34

robot

protection class, 40 protection types, 40

robot signal exchange proxy

connectors, 92

LED, 408

replacing, 192

test equipment, 409


RobotWare Installation Utilities mode, 374

rubber

disposal, 352

S

safeguarding, 22

safeguard mechanisms

automatic mode, 29

manual mode, 27

safety

emergency stop, 22

ESD, 43

fire extinguishing, 31

signals, 17 signals in manual, 17

stop functions, 22

symbols, 17

symbols on controller, 19

safety devices, 31

safety signals

in manual, 17

safety standards, 414

safety stops

configuring, 99

scalable I/O, 105

connectors, 88

installing, 110

replacing, 208

scalable I/O external, 105 scalable I/O internal, 105

signals

safety, 17

sim card

replacing, 202

software licenses, 47

standards, 414

EN IEC, 414

EN ISO, 414

steel

disposal, 352

stop category 0, 22 stop category 1, 22 stop category 2, 22

stops

overview, 22

storage conditions, 39

switch

Ethernet Extension, 113

symbols

safety, 17

system integrator requirements, 30

system update failure, 364

T teach pendant


temperatures

operation, 40

storage, 39

three-position enabling device, 25

function test, 167

tightening torque, 418

TPU


transportation conditions, 39

troubleshooting

safety, 35

U users

requirements, 16

V

validity and responsibility, 13

W

WAN port, 84

weight, 39

wrist strap, 42

X

X45 IP20, 91

Index




447

ABB AB

Robotics & Discrete Automation

S-721 68 VÄSTERÅS, Sweden

Telephone +46 (0) 21 344 400

ABB AS


Nordlysvegen 7, N-4340 BRYNE, Norway

Box 265, N-4349 BRYNE, Norway

Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics & Discrete Automation

No. 4528 Kangxin Highway

PuDong District

SHANGHAI 201319, China

Telephone: +86 21 6105 6666

ABB Inc.


1250 Brown Road

Auburn Hills, MI 48326

USA

Telephone: +1 248 391 9000 abb.com/robotics



ABB OmniCore C90XT Product Manual

Product manual

OmniCore C90XT

Product manual

OmniCore C90XT

Table of contents

Overview of this manual

Product documentation

1 Safety

2 Controller description

3 Installation and commissioning

Indicator

Indicator

4 Maintenance

5 Repair

6 Decommissioning

7 Troubleshooting

8 Reference information

9 Spare parts

Index

Related manuals

Lindy

40165

ABB

IRB 1300

ABB

OmniCore C90XT

ABB

OmniCore C30

ABB

OmniCore E10

ABB

PickMaster Twin - PowerPac

ABB

FlexMT

ABB Robotics

IRB 1100-4/0.58

ABB

IRB 1200

ABB Robotics

IRC5

ABB

IRC5 Compact

ABB

CRB 15000

Table of contents