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 ....................................................................
Product manual - OmniCore C90XT 5
3HAC073706-001 Revision: E
© Copyright 2020-2021 ABB. All rights reserved.
Table of contents

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 ..............................................................................
6 Product manual - OmniCore C90XT
3HAC073706-001 Revision: E
© Copyright 2020-2021 ABB. All rights reserved.
Table of contents

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 .............................................................................................
Product manual - OmniCore C90XT 7
3HAC073706-001 Revision: E
© Copyright 2020-2021 ABB. All rights reserved.
Table of contents

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
8 Product manual - OmniCore C90XT
3HAC073706-001 Revision: E
© Copyright 2020-2021 ABB. All rights reserved.
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
Continues on next page
Product manual - OmniCore C90XT 9
3HAC073706-001 Revision: E
© Copyright 2020-2021 ABB. All rights reserved.
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
10 Product manual - OmniCore C90XT
3HAC073706-001 Revision: E
© Copyright 2020-2021 ABB. All rights reserved.
Overview of this manual
Continued