ABB OmniCore User manual

ROBOTICS
Operating manual
OmniCore

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Workspace 21D version a1
Checked in 2021-11-26
Skribenta version 5.4.005

Operating manual
OmniCore
Robotware 7.5
Document ID: 3HAC065036-001
Revision: J
© Copyright 2019-2021 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 2019-2021 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
13Product documentation ....................................................................................................................
151 Introduction to OmniCore
151.1 About this section .............................................................................................
161.2 The OmniCore controller ....................................................................................
171.3 The FlexPendant ...............................................................................................
221.4 RobotStudio .....................................................................................................
231.5 Directory structure on OmniCore ..........................................................................
252 Navigating and handling the FlexPendant
252.1 Overview .........................................................................................................
262.2 The user interface .............................................................................................
262.2.1 FlexPendant touch screen ........................................................................
292.2.2 Status bar ..............................................................................................
382.2.3 FlexPendant applications ..........................................................................
432.3 Personalizing the FlexPendant .............................................................................
432.3.1 Introduction ............................................................................................
442.3.2 System information ..................................................................................
452.3.3 Configuring the identity settings .................................................................
462.3.4 Configuring date and time .........................................................................
472.3.5 Configuring the interface language .............................................................
482.3.6 Configuring the default view during system events ........................................
492.3.7 Configuring the programmable keys ...........................................................
512.3.8 Adapting the FlexPendant for left-handed users ............................................
522.4 Basic procedures ..............................................................................................
522.4.1 Using the soft keyboard ............................................................................
542.4.2 Messages on the FlexPendant ...................................................................
552.4.3 Capturing screenshots .............................................................................
562.4.4 Filtering data ..........................................................................................
572.4.5 Settings search .......................................................................................
582.4.6 Granting access for RobotStudio ................................................................
592.4.7 Logging on and off ..................................................................................
612.5 Updating the applications ...................................................................................
633 OmniCore controller operating modes
633.1 Introduction ......................................................................................................
643.2 Changing operating modes .................................................................................
653.3 Locking and unlocking operating modes ................................................................
694 Calibration
694.1 Introduction ......................................................................................................
704.2 How to check if the robot needs calibration ............................................................
735 Jogging
735.1 Introduction to jogging .......................................................................................
765.2 Coordinate systems for jogging ...........................................................................
815.3 Basic settings for jogging ...................................................................................
835.4 Reading the exact position ..................................................................................
855.5 Incremental movement for precise positioning ........................................................
865.6 Restrictions to jogging .......................................................................................
875.7 Lead-through ....................................................................................................
895.8 Motion supervision ............................................................................................
915.9 Align tool .........................................................................................................
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925.10 Working with SmartGripper .................................................................................
925.10.1 Introduction ............................................................................................
965.10.2 Gripper configuration ...............................................................................
975.10.3 Smart Gripper function .............................................................................
996 Programming and testing
996.1 Introduction ......................................................................................................
1006.2 Before you start programming .............................................................................
1016.3 Programming concept ........................................................................................
1016.3.1 Handling of programs ..............................................................................
1066.3.2 Handling of modules ................................................................................
1116.3.3 Handling of routines ................................................................................
1196.3.4 Handling of instructions ............................................................................
1246.3.5 Example: Add movement instructions .........................................................
1266.3.6 Program and motion pointers ....................................................................
1276.4 Debugging the program ......................................................................................
1296.5 Data types .......................................................................................................
1296.5.1 Edit data in specific tasks, modules, or routines ............................................
1306.5.2 Creating new data instance .......................................................................
1326.5.3 Editing data instances ..............................................................................
1346.6 Tools ..............................................................................................................
1346.6.1 What is a tool? ........................................................................................
1366.6.2 What is the tool center point? ....................................................................
1386.6.3 Creating a tool ........................................................................................
1406.6.4 Copying a tool ........................................................................................
1416.6.5 Defining the tool frame .............................................................................
1466.6.6 Editing the tool data .................................................................................
1486.6.7 Deleting a tool ........................................................................................
1496.6.8 Setup for stationary tools ..........................................................................
1516.7 Work objects ....................................................................................................
1516.7.1 What is a work object? .............................................................................
1526.7.2 Creating a work object .............................................................................
1536.7.3 Copying a workobject ...............................................................................
1546.7.4 Defining a work object ..............................................................................
1566.7.5 Defining the work object coordinate system .................................................
1606.7.6 Editing the work object data ......................................................................
1616.7.7 Deleting a work object ..............................................................................
1626.7.8 Setup stationary work object .....................................................................
1636.8 Payloads .........................................................................................................
1636.8.1 Overview ...............................................................................................
1646.8.2 Creating a payload ..................................................................................
1666.8.3 Copying a payload ...................................................................................
1676.8.4 Editing the payload data ...........................................................................
1696.8.5 Deleting a payload ...................................................................................
1706.9 Testing ............................................................................................................
1706.9.1 Using the hold-to-run function ...................................................................
1726.9.2 Running the program from a specific instruction ...........................................
1736.9.3 Running a specific routine ........................................................................
1746.9.4 Stepping instruction by instruction .............................................................
1776.10 Service routines ................................................................................................
1776.10.1 Running a service routine .........................................................................
1806.10.2 Connected Services Reset service routine ...................................................
1816.10.3 Battery shutdown service routine ...............................................................
1826.10.4 Axis Calibration service routine ..................................................................
1836.10.5 Calibration Pendulum service routine ..........................................................
1846.10.6 Service Information System service routine ..................................................
1856.10.7 Load identification service routine ..............................................................
1966.10.8 Brake check service routine ......................................................................
2026.10.9 Cyclic Brake Check service routine .............................................................
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2066.10.10 Wrist optimization service routine ...............................................................
2077 Running in production
2077.1 Introduction ......................................................................................................
2087.2 Basic procedures ..............................................................................................
2087.2.1 Starting programs ...................................................................................
2117.2.2 Stopping programs ..................................................................................
2127.2.3 Using multitasking programs .....................................................................
2157.2.4 Returning the robot to the path ..................................................................
2167.2.5 Using motion supervision and non motion execution .....................................
2187.3 Managing Dashboards .......................................................................................
2217.4 Managing positions ...........................................................................................
2217.4.1 Introduction ............................................................................................
2227.4.2 Teach position .......................................................................................
2277.4.3 Go To position ........................................................................................
2287.4.4 Working with displacements and offsets ......................................................
2307.5 Connecting and detaching a FlexPendant ..............................................................
2358 Handling inputs and outputs, I/O
2358.1 Introduction ......................................................................................................
2368.2 Viewing signal lists ............................................................................................
2378.3 Setting signals as favorite signals ........................................................................
2388.4 Simulating the signals and changing the signal values .............................................
2408.5 I/O devices .......................................................................................................
2439 Handling the event log
2439.1 Introduction ......................................................................................................
2449.2 Accessing the event log .....................................................................................
2459.3 Saving log entries .............................................................................................
2469.4 Clearing the log entries ......................................................................................
24710 Install, update, restart, and other configuration
24710.1 Introduction ......................................................................................................
24810.2 Start installer ....................................................................................................
24910.3 Restart ............................................................................................................
25110.4 Back up the system ...........................................................................................
25310.5 Restore the system ............................................................................................
25410.6 Reset user data ................................................................................................
25510.7 FlexPendant logs ..............................................................................................
25610.8 Update FlexPendant ..........................................................................................
25810.9 Connection log .................................................................................................
25910.10 Connected Services log ......................................................................................
26010.11 System diagnostics ...........................................................................................
261Index
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Overview of this manual
About this manual
This manual contains instructions for operation of OmniCore controller based
robots.
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.
Note
Screenshots in this manual are generally intended to show a language version
corresponding to the language of the manual. In some cases, a translated manual
still uses English screenshots if the localized user interface was not available at
the time of publishing the manual.
Usage
This manual should be used during operation.
Some actions that are more advanced, or not used in the daily operation, are
described in Operating manual - Integrator's guide OmniCore.
Note
Before any work on or with the robot is performed, the safety information in the
product manual for the controller and manipulator must be read.
Who should read this manual?
This manual is intended for:
• operators
• product technicians
• service technicians
• robot programmers
Prerequisites
The reader should:
• Have read and understood the safety instructions in the product manuals for
the robot.
• Be trained in robot operation.
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Overview of this manual

References
Documentation referred to in the manual, is listed in the table below.
Document IDDocument name
3HAC079399-001Product manual - OmniCore E10
3HAC060860-001Product manual - OmniCore C30
Document.ID-1Product manual - OmniCore C90XT
3HAC073447-001Product manual - OmniCore V250XT
3HAC065037-001Operating manual - Integrator's guide OmniCore
3HAC032104-001Operating manual - RobotStudio
3HAC066554-001Application manual - Controller software OmniCore
3HAC065041-001Technical reference manual - System parameters
3HAC066559-001Application manual - Functional safety and SafeMove
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
Revisions
DescriptionRevision
First edition.A
• The safety information is moved to the product manuals for the
controller and the manipulator.
• Updated the section Changing operating modes on page 64.
• Updated the section Connecting and detaching a FlexPendant on
page 230.
B
Released with RobotWare 7.0.1. The following updates are made in this
revision:
•References to the Hold-to run-button is replaced with thumb button
in the manual.
• Section Service Information System service routine updated with
new counter: moved distance.
• Added information about recently used programs in the section
Starting programs on page 208.
• Updated the section Creating new data instance on page 130.
C
Released with RobotWare 7.0.2. The following updates are made in this
revision:
• FlexPendant terminology updated in entire manual.
• Added information about SafeMove.
• Updated information about queueing backups.
• Added the section Locking and unlocking operating modes on
page 65.
• Added the section Go To position on page 227.
• Updated the section QuickSet window on page 30.
• Updated the section Connecting and detaching a FlexPendant on
page 230.
• Updated the section Creating new data instance on page 130.
•The directory of BC_config_IO.sys file is corrected in the section
Description of the I/O setup on page 198.
D
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Continued

DescriptionRevision
Released with RobotWare 7.1. The following updates are made in this
revision:
•Removed information from Calibration chapter and inserted refer-
ences to product manuals.
• Added information about OmniCore C90XT in the section Omni-
Core C line on page 16.
• Added information about Array data in various sections.
• Updated the section Restart on page 249.
• Added the section Working with SmartGripper on page 92.
• Added the section Copying a data instance on page 133.
• Added the section Managing positions on page 221.
• Added the section Update position on page 120.
• Added the section Capturing screenshots on page 55.
• Added the section Debugging the program on page 127.
• Added the section Updating the FlexPendant applications on
page 256.
E
Released with RobotWare 7.2. The following updates are made in this
revision:
• Added the section Directory structure on OmniCore on page 23.
• Added the section Shifting an instruction on page 123.
• Added the section Motion supervision on page 89.
• Added the section Incremental movement for precise positioning
on page 85.
• Added the section File Explorer on page 41.
•Added information about task bar in the section FlexPendant touch
screen on page 26.
• A NOTE is added in section Reset user data on page 254 that the
TEMP folder is emptied at controller restart if RAPID and system
parameters are reset.
• A Footnote is added in the section FlexPendant applications on
page 38 stating for what manipulators the lead-through function-
ality is applicable.
F
Released with RobotWare 7.3. The following updates are made in this
revision:
• Updated the section Configuring the interface language on
page 47.
• Updated the section Configuring date and time on page 46.
• Updated information about grant in the section Connecting and
detaching a FlexPendant on page 230.
• Updated the section File Explorer on page 41.
• Updated the section Locking and unlocking operating modes on
page 65.
G
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Overview of this manual
Continued

DescriptionRevision
Released with RobotWare 7.4. The following updates are made in this
revision:
• Added the section Configuring the default view during system
events on page 48.
• Added the section Edit options on page 121.
• Added the section Connected Services log on page 259.
• Added the section Axis Calibration service routine on page 182.
• Added the section Wrist optimization service routine on page 206.
• Updated the section Connection log on page 258.
•Updated the section Handling inputs and outputs, I/O on page 235.
• Updated the section Editing data in specific tasks, modules, or
routines on page 129.
• Information about OmniCore E line added in the section The
OmniCore controller on page 16.
H
Released with RobotWare 7.5. The following updates are made in this
revision:
•Added the section Adapting the FlexPendant for left-handed users
on page 51.
•Added information for delta robots, see Load identification service
routine on page 185.
•Added information about Update Load in Jog Settings on page 32.
•Information about V line controller added in References on page 10
and The OmniCore controller on page 16.
J
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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 Introduction to OmniCore
1.1 About this section
Overview
This section presents an overview of the FlexPendant, the OmniCore controller,
and RobotStudio.
A robot consists of a robot controller, the FlexPendant, RobotStudio, and one or
several manipulators or other mechanical units.
This manual describes a robot without options, not a robot system. However, in a
few places, the manual gives an overview of how options are used or applied. Most
options are described in detail in their respective application manual.
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1 Introduction to OmniCore
1.1 About this section

1.2 The OmniCore controller
Overview of OmniCore
The OmniCore controller contains all the functions needed to move and control
the manipulator, and delivers flexibility, connectivity, and performance. The
OmniCore controller gives ABB robots the ability to perform their tasks in a highly
efficient manner and also increases the flexibility to incorporate the latest digital
technologies. The controller comes with ABB’s powerful operating system,
RobotWare 7.
The controller can be equipped with additional offerings, such as fieldbus protocols,
vision solutions, and force control.
OmniCore E line
OmniCore E line is an ultra slim controller for confined spaces and high density
lines within the OmniCore family, offering only the essential functions together
with full motion performance and precision. The E line controller is designed for
stand-alone and slave installations and has a very compact design with integrated
hardware and RobotWare functions.
OmniCore E10
The OmniCore E10 controller has only one base configuration without electronic
hardware options. For more information about the OmniCore E10 controller, see
Product manual - OmniCore E10.
OmniCore C line
OmniCore C line is the compact line of controllers within the OmniCore family,
offering significant size reduction and flexible integration possibilities without any
compromise on performance or precision.
OmniCore C30
The OmniCore C30 controller offers a compact solution suitable for applications
where there is less need for additional equipment inside. For more information
about the OmniCore C30 controller, see Product manual - OmniCore C30.
OmniCore C90XT
The OmniCore C90XT controller offers a compact solution suitable for most
applications with room for some additional equipment inside. For more information
about the OmniCore C90XT controller, see Product manual - OmniCore C90XT.
OmniCore V line
OmniCore V line is a versatile and powerful controller with high degree of flexibility
covering a wide range robot and applications. V line supports external axis and
provides flexible configuration opportunities.
OmniCore V250XT
The OmniCore V250XT controller offers a compact, yet flexible, solution for
advanced applications and robots sizes up to IRB6700. For more information about
the OmniCore V250XT controller, see Product manual - OmniCore V250XT.
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1 Introduction to OmniCore
1.2 The OmniCore controller

1.3 The FlexPendant
Introduction to the FlexPendant
The FlexPendant is a hand held operator unit that is used for many of the tasks
when operating a robot: running programs, jogging the manipulator, modifying
programs, and so on.
The FlexPendant is designed for continuous operation in harsh industrial
environment. Its touchscreen is easy to clean and resistant to water, oil, and
accidental welding splashes.
The FlexPendant consists of both hardware and software and is a complete
computer in itself. It is connected to the robot controller by an integrated cable and
connector.
Note
If protective gloves are used, these must be compatible with touchscreens when
using the FlexPendant.
Main parts
These are the main parts of the FlexPendant.
3
4
8
2
1
7
6
5
xx1700001891
Connector1
Touchscreen2
Emergency stop device3
Joystick4
Reset button5
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1 Introduction to OmniCore
1.3 The FlexPendant

USB port6
Three-position enabling device. For details, see Three-position enabling device
on page 20
7
Thumb button. For details, see Thumb button on page 21.8
Touchscreen
xx1800001181
Allows you to navigate to operator messages, event logs,
and QuickSet window.
Status bar buttonsA
The applications that are required for operating a robot
system are available in the Home Screen. By default, the
Home screen displays all the applications available to you.
ApplicationsB
From any window tap the Home button to navigate to the
Home screen of FlexPendant. The Home screen view is
also the default view of the FlexPendant during startup.
Home buttonC
Emergency stop device
On delivery, the emergency stop device on the FlexPendant is able to initiate the
emergency stop function affecting the manipulator(s) and additional axis only.
Joystick
Use the joystick to move the manipulator. This is called jogging the robot. There
are several settings for how the joystick will move the manipulator.
Reset button
If the FlexPendant freezes during operation, press the reset button to restart the
FlexPendant.
The reset button resets the FlexPendant, not the system on the controller.
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1 Introduction to OmniCore
1.3 The FlexPendant
Continued

USB port
Connect a USB memory to the USB port to read or save files. For example, to load
and save programs and modules, save and restore backups, and so on. The USB
memory name and drive letter (X:) is displayed in dialogs.
Note
Close the protective cap on the USB port when not used.
Hard buttons
The following hard buttons are available on the FlexPendant.
1
5
2
4
3
6
7
10
9
11
8
12
xx1700001892
DescriptionLabel
Mechanical unit button. Allows you to select a mechanical unit.1
Motion mode button 1. Allows you to toggle the motion mode between reorient
and linear.
2
Motion mode button 2. Allows you to toggle the motion mode between axis
1-3 and axis 4-6.
3
Messages button. Allows you to open the QuickSet window.
Note
Press the Messages button for a longer duration to capture a screenshot of
the current screen.
For more details, see Capturing screenshots on page 55.
4
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1.3 The FlexPendant
Continued

DescriptionLabel
Programmable keys, 1 to 4.5, 6, 7, 8
Programmable keys are hardware buttons on the FlexPendant that can be
used for dedicated, specific functions set by the user.
START button. Starts the program execution.9
Step BACKWARD button. Executes one instruction backward.10
STOP button. Stops the program execution.11
Step FORWARD button. Executes one instruction forward.12
Note
The user interface of the panel in Virtual FlexPendant is slightly different. For
more details, see UI elements in Virtual FlexPendant panel on page 27.
Three-position enabling device
CAUTION
The person using the three-position enabling device is responsible to observe
the safeguarded space for hazards due to robot motion and any other hazards
related to the robot.
The three-position enabling device is located on the FlexPendant. When
continuously held in center-enabled position, the three-position enabling device
will permit robot motion and any hazards controlled by the robot. Release of or
compression past the center-enabled position will stop the robot motion.
CAUTION
For safe use of the three-position enabling device, the following must be
implemented:
• The three-position enabling device must never be rendered inoperational
in any way.
• If there is a need to enter safeguarded space, always bring the FlexPendant.
This is to enforce single point of control.
CAUTION
On the IRB 14050, the three-position enabling device is not active unless a valid
SafeMove configuration is active in the controller.
Note
To enforce single-point of control from the FlexPendant, press and release the
three-position enabling device twice.
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1 Introduction to OmniCore
1.3 The FlexPendant
Continued