ABB OmniCore E10 User manual

ROBOTICS
Product manual
OmniCore E10

Trace back information:
Workspace 22A version a10
Checked in 2022-03-02
Skribenta version 5.4.005

Product manual
OmniCore E10
OmniCore
Document ID: 3HAC079399-001
Revision: C
© 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 ...................................................................................................................
11Product documentation ....................................................................................................................
131 Safety
131.1 Safety information .............................................................................................
131.1.1 Limitation of liability .................................................................................
141.1.2 Safety data .............................................................................................
151.1.3 Requirements on personnel ......................................................................
161.2 Safety signals and symbols .................................................................................
161.2.1 Safety signals in the manual ......................................................................
181.2.2 Safety symbols on controller labels ............................................................
201.3 Robot stopping functions ....................................................................................
201.3.1 Protective stop and emergency stop ...........................................................
221.3.2 About emergency stop .............................................................................
231.3.3 Enabling device and hold-to-run functionality ...............................................
241.4 Robot operating modes ......................................................................................
241.4.1 About the manual mode ...........................................................................
261.4.2 About the automatic mode ........................................................................
271.5 Safety during installation and commissioning .........................................................
301.6 Safety during operation ......................................................................................
311.7 Safety during maintenance and repair ...................................................................
321.8 Safety during troubleshooting ..............................................................................
331.9 Decommissioning ..............................................................................................
352 Controller description
352.1 OmniCore E10 ..................................................................................................
362.2 Technical data for OmniCore E10 controller ...........................................................
402.3 Safety functions and safety related data for OmniCore E10 .......................................
412.4 The unit is sensitive to ESD .................................................................................
422.5 Handling of FlexPendant ....................................................................................
432.6 Network security ...............................................................................................
442.7 Open source and 3rd party components in RobotWare .............................................
452.8 ABB Ability .......................................................................................................
473 Installation and commissioning
473.1 Introduction to installation and commissioning .......................................................
483.2 Installation activities ..........................................................................................
493.3 Transporting and handling ..................................................................................
493.3.1 Unpacking .............................................................................................
503.3.2 Storing ..................................................................................................
513.4 On-site installation ............................................................................................
513.4.1 Required installation space .......................................................................
533.4.2 Mounting the controller with 19" rack mounting kit ........................................
553.4.3 Mounting the FlexPendant holder ...............................................................
613.4.4 Changing the fan control functionality .........................................................
623.5 Electrical connections ........................................................................................
623.5.1 Connectors on the OmniCore E10 controller .................................................
653.5.2 Connecting cables to the controller .............................................................
713.5.3 Connecting the manipulator to the controller ................................................
723.5.4 Fitting the connector ................................................................................
733.5.5 Connecting power supply to and grounding the controller ...............................
753.5.6 Detaching and attaching a FlexPendant .......................................................
793.5.7 Ethernet networks on OmniCore ................................................................
853.5.8 Descriptions for connectors ......................................................................
963.5.9 Configuring robot stopping functions ..........................................................
993.5.10 Programmable stop functions ....................................................................
Product manual - OmniCore E10 5
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© Copyright 2019-2022 ABB. All rights reserved.
Table of contents

1023.6 Installing add-on devices ....................................................................................
1023.6.1 Installing Integrated Vision ........................................................................
1043.7 Initial test before commissioning ..........................................................................
1054 Maintenance
1054.1 Maintenance schedule, OmniCore ........................................................................
1064.2 Inspection activities ...........................................................................................
1064.2.1 Inspection of controller .............................................................................
1074.3 Cleaning activities .............................................................................................
1074.3.1 Cleaning of the controller cabinet ...............................................................
1084.3.2 Cleaning the FlexPendant .........................................................................
1104.4 Function tests ...................................................................................................
1104.4.1 Function test of emergency stop ................................................................
1114.4.2 Function test of manual, auto, and manual full speed mode with FlexPendant ....
1124.4.3 Function test of three-position enabling device .............................................
1134.4.4 Function test of safety switches .................................................................
1144.4.5 Function test of Automatic Stop .................................................................
1154.4.6 Function test of General Stop ...................................................................
1164.4.7 Function test of external emergency stop ....................................................
1174.4.8 Function test of ESTOP_STATUS output .....................................................
1184.4.9 Function test of reduced speed control ........................................................
1195 Repair
1195.1 Introduction to repair .........................................................................................
1205.2 Replacing parts inside the controller .....................................................................
1205.2.1 Opening the robot controller ......................................................................
1225.2.2 Replacing the fans ...................................................................................
1245.2.2.1 Replacing the small fans ...............................................................
1285.2.3 Replacing the power unit ..........................................................................
1355.2.4 Replacing the drive unit ............................................................................
1415.2.5 Replacing the computer and logic unit .........................................................
1475.3 Replacing parts on the front panel ........................................................................
147
5.3.1 Replacing the manipulator signal (SMB) and motors power unit harness
assembly ...............................................................................................
1535.3.2 Replacing the incoming mains connector .....................................................
1575.4 Replacing parts on the FlexPendant .....................................................................
1575.4.1 Replacing the power cable and power cable cover ........................................
1615.4.2 Replacing the joystick protection ................................................................
1645.4.3 Replacing the fasten strip .........................................................................
1656 Troubleshooting
1656.1 Introduction to troubleshooting ............................................................................
1676.2 Troubleshooting fault symptoms ..........................................................................
1686.2.1 No LEDs are lit on the controller .................................................................
1716.2.2 Start-up failure ........................................................................................
1726.2.3 System update failure ..............................................................................
1736.2.4 Problem releasing the robot brakes ............................................................
1766.2.5 Problem starting or connecting the FlexPendant ...........................................
1806.2.6 Problem using the joystick ........................................................................
1816.2.7 Controller fails to start ..............................................................................
1826.2.8 Reflashing firmware failure ........................................................................
1836.2.9 Inconsistent path accuracy .......................................................................
1856.2.10 Controller is overheated ...........................................................................
1866.3 Troubleshooting units ........................................................................................
1866.3.1 Troubleshooting LEDs in the controller ........................................................
1876.3.2 Troubleshooting the FlexPendant ...............................................................
1886.3.3 Troubleshooting the drive unit ...................................................................
1916.3.4 Troubleshooting the power unit ..................................................................
6 Product manual - OmniCore E10
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© Copyright 2019-2022 ABB. All rights reserved.
Table of contents

1936.3.5 Troubleshooting the computer and logic unit ................................................
1957 Decommissioning
1957.1 Introduction ......................................................................................................
1967.2 Environmental information ..................................................................................
1998 Reference information
1998.1 Introduction ......................................................................................................
2008.2 Applicable standards .........................................................................................
2018.3 Unit conversion .................................................................................................
2028.4 Standard toolkit for controller ..............................................................................
2038.5 Screw joints .....................................................................................................
2048.6 Weight specifications .........................................................................................
2058.7 Lifting accessories and lifting instructions ..............................................................
2079 Spare parts
2089.1 Controller parts .................................................................................................
2099.1.1 Controller system parts ............................................................................
2129.1.2 Mains connection parts ............................................................................
2139.1.3 Logic parts .............................................................................................
2149.1.4 Cabinet parts ..........................................................................................
2179.1.5 Miscellaneous parts .................................................................................
2199.1.6 Cables ..................................................................................................
2209.2 FlexPendant parts .............................................................................................
2219.3 Manipulator cables ............................................................................................
2219.3.1 Manipulator cables ..................................................................................
2229.3.2 Customer cables - CP/CS connectors (option) ..............................................
2239.3.3 Customer cables - Ethernet floor cables ......................................................
225Index
Product manual - OmniCore E10 7
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Table of contents

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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 E10. Some variants
and designs may have been removed from the business offer and are no longer
available for purchase.
References
Document IDDocument name
3HAC079823-001Product specification - OmniCore E line
3HAC076810-008Circuit diagram - OmniCore E10
Continues on next page
Product manual - OmniCore E10 9
3HAC079399-001 Revision: C
© Copyright 2019-2022 ABB. All rights reserved.
Overview of this manual

Document IDDocument name
3HAC032104-001Operating manual - RobotStudio
3HAC065036-001Operating manual - OmniCore
3HAC065037-001Operating manual - Integrator's guide OmniCore
Document.ID-1Application manual - Product.ProductName
3HAC065041-001Technical reference manual - System parameters
3HAC028879-001Application manual - Connected Services
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore con-
troller
Revisions
DescriptionRevision
First edition.A
Published in release 21D. The following updates are made in this revision:
• Added supported robot IRB 1200, 910INV and 920.
•Updated structure in section Descriptions for connectors on page 85.
• Updated structure in section Controller parts on page 208.
• Updated the section Ethernet networks on OmniCore on page 79.
B
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 85, and Configuring robot stopping
functions on page 96.
• Information about I/O Network added in section Firewall settings on
page 84.
• Updated safety data, see Safety functions and safety related data
for OmniCore E10 on page 40
C
10 Product manual - OmniCore E10
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© Copyright 2019-2022 ABB. All rights reserved.
Overview of this manual
Continued