ABB Robotics OmniCore C90XT User manual

ROBOTICS
Product manual
OmniCore C90XT

Trace back information:
Workspace 21B version a6
Checked in 2021-05-31
Skribenta version 5.4.005

Product manual
OmniCore C90XT
OmniCore
Document ID: 3HAC073706-001
Revision: E
© 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.
© Copyright 2020-2021 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
11Product documentation ....................................................................................................................
131 Safety
131.1 Safety information .............................................................................................
131.1.1 Limitation of liability .................................................................................
141.1.2 Safety data .............................................................................................
161.1.3 Requirements on personnel ......................................................................
171.2 Safety signals and symbols .................................................................................
171.2.1 Safety signals in the manual ......................................................................
191.2.2 Safety symbols on controller labels ............................................................
221.3 Robot stopping functions ....................................................................................
221.3.1 Protective stop and emergency stop ...........................................................
241.3.2 About emergency stops ............................................................................
251.3.3 Enabling device and hold-to-run functionality ...............................................
261.4 Robot operating modes ......................................................................................
261.4.1 About the manual mode ...........................................................................
281.4.2 About the automatic mode ........................................................................
291.5 Installation and commissioning ............................................................................
321.6 Operation ........................................................................................................
331.7 Maintenance and repair ......................................................................................
341.8 Troubleshooting ................................................................................................
351.9 Decommissioning ..............................................................................................
372 Controller description
372.1 OmniCore C90XT ..............................................................................................
382.2 Technical data for OmniCore C90XT controller .......................................................
432.3 The unit is sensitive to ESD .................................................................................
442.4 Handling of FlexPendant ....................................................................................
462.5 Network security ...............................................................................................
472.6 Open source and 3rd party components in RobotWare .............................................
482.7 ABB Ability .......................................................................................................
513 Installation and commissioning
513.1 Introduction to installation and commissioning .......................................................
523.2 Installation activities ..........................................................................................
533.3 Transporting and handling ..................................................................................
533.3.1 Lifting the controller cabinet ......................................................................
543.3.2 Unpacking .............................................................................................
553.3.3 Storing ..................................................................................................
563.4 On-site installation ............................................................................................
563.4.1 Required installation space .......................................................................
583.4.2 Mounting the FlexPendant holder ...............................................................
643.5 Electrical connections ........................................................................................
643.5.1 Connectors on the OmniCore C90XT controller .............................................
663.5.2 Connecting cables to the controller .............................................................
713.5.3 Connecting the manipulator to the controller ................................................
723.5.4 Fitting the connector ................................................................................
753.5.5 Connecting power supply to and grounding the controller ...............................
783.5.6 Connecting and detaching a FlexPendant ....................................................
813.5.7 Network connections on OmniCore ............................................................
863.5.8 Set up the network connection ...................................................................
893.5.9 Descriptions for connectors ......................................................................
1023.5.10 Configuring safety stops ...........................................................................
1053.5.11 Programmable stop functions ....................................................................
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1083.6 I/O system .......................................................................................................
1083.6.1 Available fieldbuses .................................................................................
1103.6.2 Scalable I/O, internal and external ..............................................................
1113.7 Installing options ...............................................................................................
1113.7.1 Installing the harness for double SMB .........................................................
1153.7.2 Installing the scalable I/O devices ..............................................................
1183.7.3 Installing the Ethernet extension switch .......................................................
1213.7.4 Installing the power supply optional device ..................................................
1253.7.5 Installing the fieldbus adapter slave devices .................................................
1283.7.6 Installing the fieldbus master .....................................................................
1403.7.7 Installing the conveyor tracking module .......................................................
1433.7.8 Installing the cable grommet assembly ........................................................
1493.7.9 Installing the filter ....................................................................................
1513.8 Installing add-on devices ....................................................................................
1513.8.1 Installing the extension box .......................................................................
1563.8.2 Installing the conveyor tracking module to extension box ...............................
1593.9 Installing external devices ...................................................................................
1603.10 Initial test before commissioning ..........................................................................
1614 Maintenance
1614.1 Maintenance schedule, OmniCore ........................................................................
1624.2 Inspection activities ...........................................................................................
1624.2.1 Inspection of controller .............................................................................
1634.3 Cleaning activities .............................................................................................
1634.3.1 Cleaning air filter .....................................................................................
1654.3.2 Cleaning of the controller cabinet ...............................................................
1664.3.3 Cleaning the FlexPendant .........................................................................
1684.4 Changing/replacing activities ...............................................................................
1684.4.1 Replacement of air filter ............................................................................
1714.5 Function tests ...................................................................................................
1714.5.1 Function test of emergency stop ................................................................
1724.5.2 Function test of manual, auto, and manual full speed mode with FlexPendant ....
1734.5.3 Function test of three-position enabling device .............................................
1744.5.4 Function test of contactors A1.Q1 and A1.Q2 inside the power unit ..................
1754.5.5 Function test of auto stop .........................................................................
1764.5.6 Function test of external emergency stop ....................................................
1774.5.7 Function test of ESTOP_STATUS output .....................................................
1784.5.8 Function test of reduced speed control ........................................................
1795 Repair
1795.1 Introduction to repair .........................................................................................
1805.2 Replacement of controller parts ...........................................................................
1805.2.1 Opening the robot controller ......................................................................
1815.2.2 Replacing the axis computer .....................................................................
1875.2.3 Replacing the fans ...................................................................................
1885.2.3.1 Replacing the standard fans ..........................................................
1925.2.3.2 Replacing the heat exchanger ........................................................
1985.2.4 Replacing the robot signal exchange proxy ..................................................
2045.2.5 Replacing the Ethernet switch ...................................................................
2085.2.6 Replacing the connected services gateway ..................................................
2145.2.7 Replacing the scalable I/O unit ...................................................................
2195.2.8 Replacing the main computer ....................................................................
2485.2.9 Replacing the power unit ..........................................................................
2535.2.10 Replacing the power supply ......................................................................
2635.2.11 Replacing the drive unit ............................................................................
2715.2.12 Replacing the fieldbus master ....................................................................
2855.2.13 Replacing the conveyor tracking module(CTM) .............................................
2905.2.14 Replacing the air filter ..............................................................................
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2945.3 Replacing parts on the panels .............................................................................
2945.3.1 Replacing the manipulator signal connector (SMB) ........................................
2985.3.2 Replacing the motor connector ..................................................................
3005.3.2.1 Replacing the motor connector ......................................................
3045.3.3 Replacing the fieldbus adapter slave ...........................................................
3095.3.4 Replacing the power inlet .........................................................................
3135.3.5 Replacing the HMI signal (FlexPendant) connector ........................................
3195.3.6 Replacing the cable grommet assembly ......................................................
3285.3.7 Replacing the cable grommet assembly ......................................................
3375.3.8 Replacing the harness ETH outlet with cable ................................................
3435.3.9 Replacing the LED indicator ......................................................................
3495.4 Replacing parts on the FlexPendant .....................................................................
3495.4.1 Replacing the power cable and power cable cover ........................................
3535.4.2 Replacing the joystick protection ................................................................
3565.4.3 Replacing the fasten strip .........................................................................
3576 Decommissioning
3576.1 Introduction ......................................................................................................
3586.2 Environmental information ..................................................................................
3617 Troubleshooting
3617.1 Introduction to troubleshooting ............................................................................
3637.2 Troubleshooting fault symptoms ..........................................................................
3647.2.1 No LEDs are lit on the controller .................................................................
3677.2.2 Start-up failure ........................................................................................
3707.2.3 System update failure ..............................................................................
3717.2.4 Problem releasing the robot brakes ............................................................
3757.2.5 Problem starting or connecting the FlexPendant ...........................................
3797.2.6 Problem using the joystick ........................................................................
3807.2.7 Controller fails to start ..............................................................................
3817.2.8 Reflashing firmware failure ........................................................................
3827.2.9 Inconsistent path accuracy .......................................................................
3847.3 Troubleshooting units ........................................................................................
3847.3.1 Troubleshooting LEDs in the controller ........................................................
3857.3.2 Troubleshooting the FlexPendant ...............................................................
3867.3.3 Troubleshooting the drive unit ...................................................................
3887.3.4 Troubleshooting the power unit ..................................................................
3937.3.5 Troubleshooting fieldbuses and I/O ............................................................
3947.3.6 Troubleshooting the connected services gateway .........................................
4007.3.7 Troubleshooting the Ethernet switch ...........................................................
4027.3.8 Troubleshooting the axis computer .............................................................
4047.3.9 Troubleshooting the main computer ............................................................
4077.3.10 Troubleshooting the power supply ..............................................................
4127.3.11 Troubleshooting the fieldbus adapter slave ..................................................
4147.3.12 Troubleshooting the robot signal exchange proxy .........................................
4218 Reference information
4218.1 Introduction ......................................................................................................
4228.2 Applicable standards .........................................................................................
4238.3 Unit conversion .................................................................................................
4248.4 Standard toolkit for controller ..............................................................................
4258.5 Screw joints .....................................................................................................
4268.6 Weight specifications .........................................................................................
4278.7 Lifting accessories and lifting instructions ..............................................................
4299 Spare parts
4309.1 Controller parts .................................................................................................
4489.2 FlexPendant parts .............................................................................................
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4499.3 Manipulator cables ............................................................................................
4499.3.1 Manipulator cables ..................................................................................
4509.3.2 Customer cables - CP/CS connectors (option) ..............................................
4519.3.3 Customer cables - Ethernet floor cable ........................................................
453Index
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Table of contents

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 IDDocument name
3HAC065034-001Product specification - OmniCore C line
3HAC065464-009Circuit diagram - OmniCore C90XT
3HAC032104-001Operating manual - RobotStudio
3HAC065036-001Operating manual - OmniCore
3HAC065037-001Operating manual - Integrator's guide OmniCore
3HAC065041-001Technical reference manual - System parameters
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Overview of this manual

Document IDDocument name
3HAC028879-001Application manual - Connected Services
3HAC066561-001Application manual - Conveyor tracking
3HAC070206-001Application manual - Force Control
3HAC066559-001Application manual - SafeMove
Revisions
DescriptionRevision
First edition.A
Published in release 20C. The following updates are made in this revision:
• Updated information about safety data.
• Updated information about robot signal exchange proxy.
B
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 81 has been
updated with NOTE regarding correct usage of the MGMT port.
C
Published in release 21A. The following updates are made in this revision:
• Minor corrections in section Connections on the main computer
on page 82.
• Added extension cable spare parts in section FlexPendant parts
on page 448.
• Minor corrections in section Descriptions for connectors on
page 89.
D
Published in release 21B. The following updates are made in this revision:
•Added information about general stop (GS) in section Descriptions
for connectors on page 89.
• Updated the information for configuration of safety stops, see
Configuring safety stops on page 102.
• Updated FlexPendant holder assembling procedure.
• Updated information about safety data.
• Updated images related to general stop.
E
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Overview of this manual
Continued

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.
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Product documentation

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.
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Product documentation
Continued

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.
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1 Safety
1.1.1 Limitation of liability

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 following performance level data is applicable for OmniCore C90XT together
with all supported ABB manipulators1.
The OmniCore C90XT provides safety with structure category 3 with performance
level daccording to EN ISO 13849-1. This fulfils the safety performance requirement
as stated in the robot safety standard EN ISO 10218-1.
PFHD[1/hour]DC [%]Calculated
MTTFD
[years]
Safety function
4.29E-0893127Emergency Stop on FlexPendant
4.29E-0892142External Emergency Stop (customer
installed device)
4.29E-0892142Automatic Stop (customer installed
device)
4.29E-0894104Three-position Enabling Device on
FlexPendant
1.01E-0780276ESTOP_STATUS Output, Robot
1The supported manipulators are listed in Product specification - OmniCore C line.
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1 Safety
1.1.2 Safety data

Safety data for SafeMove function
The following safety data for the SafeMove function is applicable for OmniCore
C90XT controllers together with all supported ABB manipulators2.
Calculated PFHD
[1/hour]
DCavg
[%]
Calculated
MTTFD
[years]
SafeMove functions
1.01E-0773370Contact Application Tolerance (CAP)
4.29E-0890144Safe Brake Ramp
4.29E-0890144Stand Still Supervision (SST)
4.29E-0890144Axis Speed Supervision (ASP) (category 0
stop/category 1 stop)
4.29E-0890144Tool Speed Supervision (TSP) (category 0
stop/category 1 stop)
4.29E-0890144Axis Position Supervision (APO) (category 0
stop/category 1 stop)
4.29E-0890144Tool Position Supervision (TPO) (category 0
stop/category 1 stop)
4.29E-0890144Tool Orientation Supervision (TOR) (category
0 stop/category 1 stop)
4.29E-0890144Control Error Supervision
2The supported manipulators are listed in Product specification - OmniCore C line.
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1 Safety
1.1.2 Safety data
Continued

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 instructions.
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1 Safety
1.1.3 Requirements on personnel

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.
SignificanceDesignationSymbol
Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
DANGER
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in serious
injury.
WARNING
Signal word used to indicate a potentially hazardous
situation related to electrical hazards which, if not
avoided, could result in serious injury.
ELECTRICAL
SHOCK
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in slight
injury.
CAUTION
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in severe
damage to the product.
ELECTROSTATIC
DISCHARGE (ESD)
Signal word used to indicate important facts and
conditions.
NOTE
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1 Safety
1.2.1 Safety signals in the manual

SignificanceDesignationSymbol
Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.
TIP
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1 Safety
1.2.1 Safety signals in the manual
Continued

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
DescriptionLabel
Read the user manual before use.
xx1400001152
The robot is delivered to start in automatic mode
xx2100000104
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1 Safety
1.2.2 Safety symbols on controller labels

DescriptionLabel
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 soft-
ware).
xx1700000355
Rating label (example)
xx1900001805
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1 Safety
1.2.2 Safety symbols on controller labels
Continued