ABB OmniCore C30 User manual

ROBOTICS
Product manual
OmniCore C30

Trace back information:
Workspace 22B version a4
Checked in 2022-06-01
Skribenta version 5.5.019

Product manual
OmniCore C30
OmniCore
Document ID: 3HAC060860-001
Revision: P
© Copyright 2019-2022 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 2019-2022 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
13Product documentation ....................................................................................................................
151 Safety
151.1 Safety information .............................................................................................
151.1.1 Limitation of liability .................................................................................
161.1.2 Safety data .............................................................................................
171.1.3 Requirements on personnel ......................................................................
181.2 Safety signals and symbols .................................................................................
181.2.1 Safety signals in the manual ......................................................................
201.2.2 Safety symbols on controller labels ............................................................
231.3 Robot stopping functions ....................................................................................
231.3.1 Protective stop and emergency stop ...........................................................
251.3.2 About emergency stop .............................................................................
261.3.3 Enabling device and hold-to-run functionality ...............................................
271.4 Robot operating modes ......................................................................................
271.4.1 About the manual mode ...........................................................................
291.4.2 About the automatic mode ........................................................................
301.5 Safety during installation and commissioning .........................................................
331.6 Safety during operation ......................................................................................
341.7 Safety during maintenance and repair ...................................................................
351.8 Safety during troubleshooting ..............................................................................
361.9 Safety during decommissioning ...........................................................................
372 Controller description
372.1 OmniCore C30 ..................................................................................................
382.2 Technical data for OmniCore C30 controller ...........................................................
442.3 Safety functions and safety related data for OmniCore C30 .......................................
472.4 The unit is sensitive to ESD .................................................................................
482.5 Handling of FlexPendant ....................................................................................
492.6 Network security ...............................................................................................
502.7 Open source and 3rd party components in RobotWare .............................................
512.8 ABB Ability .......................................................................................................
533 Installation and commissioning
533.1 Introduction to installation and commissioning .......................................................
543.2 Installation activities ..........................................................................................
553.3 Transporting and handling ..................................................................................
553.3.1 Unpacking .............................................................................................
563.3.2 Storing ..................................................................................................
573.4 On-site installation ............................................................................................
573.4.1 Required installation space .......................................................................
613.4.2 Mounting the controller with 19" rack mounting kit [3002-1] .............................
643.4.3 Mounting the controller with vertical mounting kit [3002-2] ..............................
683.4.4 Replacing the controller from vertical mounting kit to19" rack mounting kit ........
713.4.5 Mounting the controller with desktop mounting kit [3001-2] .............................
753.4.6 Mounting the FlexPendant holder ...............................................................
813.4.7 Changing the fan control functionality .........................................................
823.5 Electrical connections ........................................................................................
823.5.1 Connectors on the OmniCore C30 controller ................................................
853.5.2 Connecting cables to the controller .............................................................
913.5.3 Connecting the manipulator to the controller ................................................
923.5.4 Fitting the connector ................................................................................
973.5.5 Connecting power supply to and grounding the controller ...............................
1003.5.6 Detaching and attaching a FlexPendant .......................................................
1043.5.7 Ethernet networks on OmniCore ................................................................
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1123.5.8 Descriptions for connectors ......................................................................
1263.5.9 Configuring robot stopping functions ..........................................................
1303.5.10 Programmable stop functions ....................................................................
1333.6 I/O system .......................................................................................................
1333.6.1 Available industrial networks .....................................................................
1353.6.2 Scalable I/O, internal and external ..............................................................
1363.7 Installing options ...............................................................................................
1363.7.1 Installing the harness for double SMB .........................................................
1413.7.2 Installing the scalable I/O devices ..............................................................
1453.7.3 Installing the Ethernet extension switch .......................................................
1523.7.4 Installing the power supply optional device and the harness 24 V extension .......
1673.7.5 Installing the fieldbus master and the DeviceNet harness ...............................
1943.8 Installing add-on devices ....................................................................................
1943.8.1 Installing the scalable I/O add-on devices ....................................................
1953.8.2 Installing the conveyor tracking module .......................................................
1973.8.3 Installing Integrated Vision ........................................................................
2003.9 Initial test before commissioning ..........................................................................
2014 Maintenance
2014.1 Maintenance schedule, OmniCore ........................................................................
2034.2 Inspection activities ...........................................................................................
2034.2.1 Inspection of controller .............................................................................
2054.3 Cleaning activities .............................................................................................
2054.3.1 Cleaning of the controller cabinet ...............................................................
2064.3.2 Cleaning the FlexPendant .........................................................................
2084.4 Changing/replacing activities ...............................................................................
2084.4.1 Replacement of air filter element for the controller with vertical mounting kit ......
2124.5 Function tests ...................................................................................................
2124.5.1 Function test of emergency stop ................................................................
2134.5.2 Function test of manual, auto, and manual full speed mode with FlexPendant ....
2144.5.3 Function test of three-position enabling device .............................................
2154.5.4 Function test of safety switches .................................................................
2164.5.5 Function test of Automatic Stop .................................................................
2174.5.6 Function test of General Stop ...................................................................
2184.5.7 Function test of external emergency stop ....................................................
2194.5.8 Function test of ESTOP_STATUS output .....................................................
2204.5.9 Function test of reduced speed control ........................................................
2215 Repair
2215.1 Introduction to repair .........................................................................................
2225.2 Replacing parts inside the controller .....................................................................
2225.2.1 Opening the robot controller ......................................................................
2315.2.2 Replacing the axis computer .....................................................................
2365.2.3 Replacing the fans ...................................................................................
2385.2.3.1 Replacing the standard fans ..........................................................
2515.2.3.2 Replacing the small fans ...............................................................
2645.2.3.3 Replacing the main computer fan ...................................................
2825.2.4 Replacing the robot signal exchange proxy ..................................................
2905.2.5 Replacing the Ethernet switch ...................................................................
2995.2.6 Replacing the connected services gateway ..................................................
3085.2.7 Replacing the scalable I/O unit ...................................................................
3135.2.8 Replacing the safety digital base device ......................................................
3185.2.9 Replacing the main computer ....................................................................
3585.2.10 Replacing the power unit ..........................................................................
3655.2.11 Replacing the power supply ......................................................................
3735.2.12 Replacing the drive unit ............................................................................
3845.2.13 Replacing the fieldbus master ....................................................................
4115.3 Replacing parts on the front panel ........................................................................
4115.3.1 Replacing the manipulator signal connector (SMB) ........................................
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4165.3.2 Replacing the motor connector ..................................................................
4185.3.2.1 Replacing the motor connector ......................................................
4245.3.2.2 Replacing the motor connector for CRB 15000 controller ....................
4345.3.3 Replacing the incoming mains connector .....................................................
4395.3.4 Replacing the HMI signal (FlexPendant) connector ........................................
4555.3.5 Replacing the process connectors ..............................................................
4715.3.6 Replacing the harness CFI connection ........................................................
4755.3.7 Replacing the IP20 power outlet connector ..................................................
4915.4 Replacing parts on the FlexPendant .....................................................................
4915.4.1 Replacing the power cable and power cable cover ........................................
4955.4.2 Replacing the joystick protection ................................................................
4985.4.3 Replacing the fasten strip .........................................................................
4996 Troubleshooting
4996.1 Introduction to troubleshooting ............................................................................
5016.2 Troubleshooting fault symptoms ..........................................................................
5026.2.1 No LEDs are lit on the controller .................................................................
5076.2.2 Start-up failure ........................................................................................
5116.2.3 System update failure ..............................................................................
5126.2.4 Problem releasing the robot brakes ............................................................
5176.2.5 Problem starting or connecting the FlexPendant ...........................................
5226.2.6 Problem using the joystick ........................................................................
5236.2.7 Controller fails to start ..............................................................................
5246.2.8 Reflashing firmware failure ........................................................................
5256.2.9 Inconsistent path accuracy .......................................................................
5276.2.10 Controller is overheated ...........................................................................
5286.3 Troubleshooting units ........................................................................................
5286.3.1 Troubleshooting LEDs in the controller ........................................................
5296.3.2 Troubleshooting the FlexPendant ...............................................................
5306.3.3 Troubleshooting the drive unit ...................................................................
5326.3.4 Troubleshooting the power unit ..................................................................
5376.3.5 Troubleshooting fieldbuses and I/O ............................................................
5386.3.6 Troubleshooting the connected services gateway .........................................
5436.3.7 Troubleshooting the Ethernet switch ...........................................................
5456.3.8 Troubleshooting the axis computer .............................................................
5476.3.9 Troubleshooting the main computer ............................................................
5506.3.10 Troubleshooting the power supply ..............................................................
5556.3.11 Troubleshooting the robot signal exchange proxy .........................................
5637 Decommissioning
5637.1 Introduction to decommissioning .........................................................................
5647.2 Environmental information ..................................................................................
5678 Reference information
5678.1 Introduction ......................................................................................................
5688.2 Applicable standards .........................................................................................
5698.3 Unit conversion .................................................................................................
5708.4 Standard toolkit for controller ..............................................................................
5718.5 Screw joints .....................................................................................................
5728.6 Weight specifications .........................................................................................
5738.7 Lifting accessories and lifting instructions ..............................................................
5759 Spare parts
5769.1 Controller parts .................................................................................................
5799.1.1 Controller system parts ............................................................................
5829.1.2 Logic parts .............................................................................................
5849.1.3 Application parts .....................................................................................
5879.1.4 Cabinet parts ..........................................................................................
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5899.1.5 Miscellaneous parts .................................................................................
5929.1.6 Cables ..................................................................................................
5969.2 FlexPendant parts .............................................................................................
5979.3 Manipulator cables ............................................................................................
5979.3.1 Manipulator cables ..................................................................................
5999.3.2 Customer cables - CP/CS connectors (option) ..............................................
6009.3.3 Customer cables - Ethernet floor cables ......................................................
601Index
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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 risk assessment of the final
application.
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.
Product manual scope
The manual covers all variants and designs of the OmniCore C30. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
References
Document IDDocument name
3HAC065034-001Product specification - OmniCore C line
Continues on next page
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Overview of this manual

Document IDDocument name
3HAC059896-009,
3HAC063898-009,
3HAC072448-009
Circuit diagram - OmniCore C30,Circuit diagram - OmniCore C30
for IRB 14050,Circuit diagram - OmniCore C30 for CRB 15000
3HAC032104-001Operating manual - RobotStudio
3HAC065036-001Operating manual - OmniCore
3HAC065037-001Operating manual - Integrator's guide OmniCore
3HAC070206-001Application manual - Force control with software and hardware
3HAC065041-001Technical reference manual - System parameters
3HAC066559-001Application manual - Functional safety and SafeMove
3HAC028879-001Application manual - Connected Services
3HAC066561-001Application manual - Conveyor tracking
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore con-
troller
Revisions
DescriptionRevision
First edition.A
Published in release 19C. The following updates are made in this revision:
• The safety section is updated.
• Added section about operating modes.
• Updated information about residual current device.
• Added IRB 1100.
• Updated safety information related to IRB 14050.
B
Published in release 19D. The following updates are made in this revision:
• Removed fieldbus adapters that are not yet available.
D
Published in release 20A. The following updates are made in this revision:
• Added information about SafeMove.
• Added information about single point of control.
•Information regarding how to restore the hardware settings has been
added in section Replacing the main computer on page 318.
E
Published in release 20B. The following updates are made in this revision:
•Updated NOTE regarding IP addresses in section "Set up the network
connection".
• Updated spare part levels.
• Updated spare part names of cable length.
• Added the note for TPU connector in desktop version.
• Updated information about safety data.
• Added ABB Ability on page 51.
F
Published in release 20C. The following updates are made in this revision:
• Added the replacement for filter element in vertical version.
• Updated information about safety data.
• Updated information about robot signal exchange proxy.
G
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Overview of this manual
Continued

DescriptionRevision
Published in release 20D. The following updates are made in this revision:
• Section "Network connections on the OmniCore" has been updated
with NOTE regarding correct usage of the MGMT port.
• Added information about new fans in spare part chapter and repair
chapter.
• Updated dimensions when all ABB cables are connected.
• Section Mounting the FlexPendant holder on page 75 has been up-
dated with new installation method for the FlexPendant holder.
H
Published in release 21A. The following updates are made in this revision:
• Added information about OmniCore C30 for CRB 15000.
• Added supported robot IRB 360.
•Minor corrections in section "Network connections on the OmniCore".
• Updated images in section Fitting the connector on page 92.
• Added Silicone information in section Environmental information on
page 564.
• Updated default safety circuit configuration for X14 in section Robot
signal exchange proxy mating connectors on page 112.
• Added safety stops configuration information in section Configuring
robot stopping functions on page 126.
• Added note for vertical mounting kit and 19" rack mounting kit in
section Mounting the controller with 19" rack mounting kit [3002-1]
on page 61 and Mounting the controller with vertical mounting kit
[3002-2] on page 64.
• Minor corrections in section "Connections on the main computer".
• Added extension cable spare parts in section FlexPendant parts on
page 596.
•Minor corrections in section Descriptions for connectors on page 112.
• Updated information about safety data.
J
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 112.
• Updated the information for configuration of safety stops, see Con-
figuring robot stopping functions on page 126.
• Updated FlexPendant holder assembling procedure.
• Updated information about safety data.
• Updated images related to general stop.
• Added 5,000 mm power inlet cable in section Fitting the connector
on page 92.
K
Published in release 21C. The following updates are made in this revision:
• Deleted the 30 m signal cable for IRB 1300, see Manipulator cables
on page 597.
• Added information, see AC current in CP/CS on page 86.
• Sections "Network connections on OmniCore" and "Set up the net-
work connection" replaced by Ethernet networks on OmniCore on
page 104.
• Update content for ESOUT in section Descriptions for connectors
on page 112.
L
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Overview of this manual
Continued

DescriptionRevision
Published in release 21D. The following updates are made in this revision:
• Added information about safety digital base device.
• Added information about main computer fan.
• Added supported robot IRB 1200, 910INV and 920.
•Updated structure in section Descriptions for connectors on page 112.
• Updated structure in section Controller parts on page 576.
• Updated the section Ethernet networks on OmniCore on page 104.
• Added connector type information of CFI harness in section X2 har-
ness CFI connection (option) on page 121.
• Removed fieldbus adapter slave throughout the manual.
M
Published in release 22A. The following updates are made in this revision:
• Added information on decoupling ES output and ES input, see De-
scriptions for connectors on page 112, and Configuring robot stopping
functions on page 126.
• Part numbers for mating connectors corrected in Robot signal ex-
change proxy mating connectors on page 112.
• Information about I/O Network added in section Firewall settings on
page 111.
N
Published in release 22B. The following updates are made in this revision:
•Minor corrections in section Descriptions for connectors on page 112.
• Added note that the content of the section ABB Ability is only avail-
able in English (also in translated manuals).
• Added related information that the approval code CMIIT ID is finally
displayed on the nameplate of the product in section Troubleshooting
the connected services gateway on page 538.
• Updated manipulator cables in section Manipulator cables on
page 597.
•Information added in section Available industrial networks on page133
that two industrial network masters can be run in parallel on the
OmniCore controller.
P
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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.
Continues on next page
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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.
Performance level data
The performance level data for the respective controller variant is presented in
section Safety functions and safety related data for OmniCore C30 on page 44.
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1 Safety
1.1.2 Safety data

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.
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 safety symbols
Both the manipulator and the controller are marked with labels containing safety
symbols and important information about the product. The purpose of the labels
is to ensure personal safety for all personnel handling the robot, for example during
installation, service, or operation.
The safety symbols are language independent, they only use graphics. The
information labels contain information in text. See Symbols and information on
labels on page 20.
Note
The safety and information labels on the product must be observed.
Symbols and information on labels
Note
The descriptions in this section are generic, the labels can contain additional
information such as values.
DescriptionLabel
Read the user manual before use.
xx1400001152
The robot is delivered to start in automatic mode
xx2100000104
CE label
xx1800000835
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1 Safety
1.2.2 Safety symbols on controller labels
Table of contents
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