ABB OmniCore User manual

ROBOTICS
Operating manual
OmniCore

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Workspace 20A version a2
Checked in 2020-02-21
Skribenta version 5.3.033

Operating manual
OmniCore
Robotware 7.0.2
Document ID: 3HAC065036-001
Revision: D
© Copyright 20192020 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, damages 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 20192020 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
11Product documentation ....................................................................................................................
131 Introduction to OmniCore
131.1 About this section .............................................................................................
141.2 The OmniCore controller ....................................................................................
151.3 The FlexPendant ...............................................................................................
201.4 RobotStudio .....................................................................................................
212 Navigating and handling the FlexPendant
212.1 Overview .........................................................................................................
222.2 The user interface .............................................................................................
222.2.1 Introduction ............................................................................................
232.2.2 Status bar ..............................................................................................
312.2.3 FlexPendant applications ..........................................................................
342.3 Personalizing the FlexPendant .............................................................................
342.3.1 Basic settings .........................................................................................
342.3.1.1 Introduction ................................................................................
352.3.1.2 System information ......................................................................
362.3.1.3 Changing date and time ................................................................
372.3.1.4 Configuring the interface language .................................................
382.3.1.5 Identity settings ...........................................................................
392.3.1.6 Changing programmable keys .......................................................
412.4 Updating the applications ...................................................................................
433 OmniCore controller operating modes
433.1 Introduction ......................................................................................................
443.2 Changing operating modes .................................................................................
453.3 Locking and unlocking operating modes ................................................................
494 Calibration
494.1 Introduction ......................................................................................................
504.2 How to check if the robot needs calibration ............................................................
524.3 Fine calibration .................................................................................................
544.4 Calibration .......................................................................................................
564.5 Updating revolution counters ...............................................................................
595 Jogging
595.1 Introduction to jogging .......................................................................................
615.2 Coordinate systems for jogging ...........................................................................
665.3 Basic settings for jogging ...................................................................................
685.4 Reading the exact position ..................................................................................
705.5 Restrictions to jogging .......................................................................................
715.6 Lead-through ....................................................................................................
725.7 Supervision ......................................................................................................
735.8 Align tool .........................................................................................................
756 Programming and testing
756.1 Introduction ......................................................................................................
766.2 Before you start programming .............................................................................
776.3 Programming concept ........................................................................................
776.3.1 Handling of programs ..............................................................................
816.3.2 Handling of modules ................................................................................
856.3.3 Handling of routines ................................................................................
966.3.4 Handling of instructions ............................................................................
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986.3.5 Example: Add movement instructions .........................................................
1006.3.6 About the Program and Motion Pointers ......................................................
1016.4 Data types .......................................................................................................
1016.4.1 View data in specific tasks, modules, or routines ...........................................
1026.4.2 Creating new data instance .......................................................................
1046.4.3 Editing data instances ..............................................................................
1066.5 Tools ..............................................................................................................
1066.5.1 What is a tool? ........................................................................................
1086.5.2 What is the tool center point? ....................................................................
1106.5.3 Creating a tool ........................................................................................
1126.5.4 Defining the tool frame .............................................................................
1176.5.5 Editing the tool data .................................................................................
1196.5.6 Deleting a tool ........................................................................................
1206.5.7 Setup for stationary tools ..........................................................................
1226.6 Work objects ....................................................................................................
1226.6.1 What is a work object? .............................................................................
1236.6.2 Creating a work object .............................................................................
1246.6.3 Defining a work object ..............................................................................
1266.6.4 Defining the work object coordinate system .................................................
1306.6.5 Editing the work object data ......................................................................
1316.6.6 Deleting a work object ..............................................................................
1326.6.7 Setup stationary work object .....................................................................
1336.7 Payloads .........................................................................................................
1336.7.1 Overview ...............................................................................................
1346.7.2 Creating a payload ..................................................................................
1366.7.3 Editing the payload data ...........................................................................
1386.7.4 Deleting a payload ...................................................................................
1396.8 Testing ............................................................................................................
1396.8.1 Using the hold-to-run function ...................................................................
1416.8.2 Running the program from a specific instruction ...........................................
1426.8.3 Running a specific routine ........................................................................
1436.8.4 Stepping instruction by instruction .............................................................
1466.9 Service routines ................................................................................................
1466.9.1 Running a service routine .........................................................................
1496.9.2 Connected Services Reset service routine ...................................................
1506.9.3 Battery shutdown service routine ...............................................................
1516.9.4 Calibration Pendulum service routine ..........................................................
1526.9.5 Service Information System service routine ..................................................
1536.9.6 Load identification service routine ..............................................................
1626.9.7 Brake check service routine ......................................................................
1686.9.8 Cyclic Brake Check service routine .............................................................
1737 Running in production
1737.1 Introduction ......................................................................................................
1747.2 Basic procedures ..............................................................................................
1747.2.1 Starting programs ...................................................................................
1777.2.2 Stopping programs ..................................................................................
1787.2.3 Using multitasking programs .....................................................................
1817.2.4 Returning the robot to the path ..................................................................
1837.3 Managing Dashboards .......................................................................................
1867.4 Connecting and detaching a FlexPendant ..............................................................
1897.5 Modifying positions ...........................................................................................
1918 Handling inputs and outputs, I/O
1918.1 Introduction ......................................................................................................
1928.2 Viewing signal lists ............................................................................................
1938.3 Setting signals as favorite signals ........................................................................
1948.4 Simulating the signals and changing the signal values .............................................
1958.5 I/O devices .......................................................................................................
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1979 Handling the event log
1979.1 Introduction ......................................................................................................
1989.2 Accessing the event log .....................................................................................
1999.3 Saving log entries .............................................................................................
2009.4 Clearing the log entries ......................................................................................
20110 Install, update, restart, and other configuration
20110.1 Introduction ......................................................................................................
20210.2 Start installer ....................................................................................................
20310.3 Restart ............................................................................................................
20410.4 Back up the system ...........................................................................................
20610.5 Restore the system ............................................................................................
20710.6 Reset user data ................................................................................................
20810.7 FlexPendant logs ..............................................................................................
20910.8 Connection log .................................................................................................
21010.9 System diagnostics ...........................................................................................
211Index
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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 provide safety and user guides for the
robot system.
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.
References
Documentation referred to in the manual, is listed in the table below.
Document IDDocument name
3HAC060860-001Product manual - OmniCore C30
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 - SafeMove2
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Overview of this manual

Revisions
DescriptionRevision
First edition.A
• The safety information is moved to the product manuals for the
controller and the manipulator.
• Updated the section Procedure on page 44.
• Updated the section Connecting and detaching a FlexPendant on
page 186.
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 174.
• Updated the section Creating new data instance on page 102.
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 45.
• Added the section Modifying positions on page 189.
• Updated the section QuickSet window on page 23.
• Updated the section Connecting and detaching a FlexPendant on
page 186.
• Updated the section Creating new data instance on page 102.
•The directory of BC_config_IO.sys file is corrected in the section
Description of the I/O setup on page 164.
D
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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.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
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.
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.
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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 touch screen 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.
Main parts
These are the main parts of the FlexPendant.
3
4 5
7
2
1
6
xx1700001891
Connector1
Touch screen2
Emergency stop button3
Joystick4
USB port and reset button5
Three-position enabling device6
Thumb button7
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.
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1 Introduction to OmniCore
1.3 The FlexPendant

USB port
Connect a USB memory to the USB port to read or save files. The USB memory
is displayed as drive /USB:Removable in dialogs and FlexPendant Explorer.
Note
Close the protective cap on the USB port when not used.
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.
Hard buttons
Following are the dedicated hard buttons on the FlexPendant. You can assign your
own functions to four of the buttons.
1
5
2
4
3
6
7
10
9
11
8
12
xx1700001892
DescriptionLabel
Select mechanical unit.1
Toggle motion mode, reorient or linear.2
Toggle motion mode, axis 1-3 or axis 4-6.3
Operator messages.4
Programmable keys, 1 - 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.
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1.3 The FlexPendant
Continued

DescriptionLabel
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
Three-position enabling device
CAUTION
The person using the three-position enabling device is responsible to observe
the safeguarded area for hazards due to robot motion and any other hazards
controlled by the robot.
The three-position enabling device is a manually operated, constant pressure
push-button which, when in center-enabled position, allows potentially hazardous
functions.
The three-position enabling device will when continuously held in center-enabled
position permit robot motion and any hazards controlled by the robot. Release of
or compression past the center-enabled position will stop the hazard, for example,
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 three-position
enabling device. This is to enforce single point of control.
A deviation exists in OmniCore from paragraph 5.3.5 Single point of control. Single
point of control cannot be guaranteed in automatic mode because external clients
can connect to the controller over the network. Make sure that only one client is
connected to the controller at a given time.
A deviation exists in IRB 14050 from paragraph 5.8.3 Enabling device. The enabling
device is not supported, unless a SafeMove configuration is active.
Note
To enforce single-point of control from the FlexPendant, press and release the
three-position enabling device twice.
Note
YuMi robots with SafeMove2 requires using the enabling device.
On YuMi robots without SafeMove2 the enabling device is disabled, hence, not
used.
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1.3 The FlexPendant
Continued

Thumb button
For robots used in collaborative application, the thumb button is used to enable
the lead-through functionality.
For robots supporting the mode manual full speed, the button is used as hold-to-run.
How to hold the FlexPendant
The FlexPendant is typically operated while being held in the hand. A right-handed
person uses his left hand to support the device while the other hand performs
operations on the touch screen. A left-hander, however, can easily rotate the display
through 180 degrees and use his right hand to support the device.
xx1800000045
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1.3 The FlexPendant
Continued

Touch screen elements
The illustration shows important elements of the FlexPendant touch screen.
xx1800001181
From any window tap this icon to navigate to the Home
screen of FlexPendant. This is a toggle icon. Tapping this
icon again displays the previously active window.
Applications buttonA
The Home screen view is also the default view of the
FlexPendant during startup.
Allows you to navigate to operator messages, event logs,
and QuickSet window.
Status bar buttonsB
The applications that are required for operating the robot
system are available in the Home Screen. By default, the
Home screen displays all the applications available to you.
If you are in some other window, tap the Applications
button to view the Home screen.
ApplicationsC
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1.3 The FlexPendant
Continued

1.4 RobotStudio
Overview of RobotStudio
RobotStudio is an engineering tool for the configuration and programming of ABB
robots, both real robots on the shop floor and virtual robots in a PC. To achieve
true offline programming, RobotStudio utilizes ABB VirtualRobot™ Technology.
RobotStudio has adopted the Microsoft Office Fluent User Interface. The Office
Fluent UI is also used in Microsoft Office. As in Office, the features of RobotStudio
are designed in a workflow-oriented way.
With add-ins, RobotStudio can be extended and customized to suit the specific
needs. Add-ins are developed using the RobotStudio SDK. With the SDK, it is also
possible to develop custom SmartComponents which exceed the functionality
provided by RobotStudio's base components.
For more information, see Operating manual - RobotStudio.
RobotStudio for real controllers
RobotStudio allows, for example, the following operations when connected to a
real controller:
• Installing and modifying RobotWare systems on controllers, using the
Installation Manager.
• Text-based programing and editing, using the RAPID Editor.
• File manager for the controller.
• Administrating the User Authorization System.
• Configuring system parameters.
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1 Introduction to OmniCore
1.4 RobotStudio