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Omnicore c90xt
Omnicore c90xt
Product manual
OmniCore C90XT
Trace back information:
Workspace 21A version a14
Checked in 2021-03-30
Skribenta version 5.4.005
Product manual
OmniCore C90XT
OmniCore
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 11
1 Safety 13
1.1 Safety information ............................................................................................. 13
1.1.1 Limitation of liability ................................................................................. 13
1.1.2 Safety data ............................................................................................. 14
1.1.3 Requirements on personnel ...................................................................... 16
1.2 Safety signals and symbols ................................................................................. 17
1.2.1 Safety signals in the manual ...................................................................... 17
1.2.2 Safety symbols on controller labels ............................................................ 19
1.3 Robot stopping functions .................................................................................... 22
1.3.1 Protective stop and emergency stop ........................................................... 22
1.3.2 About emergency stops ............................................................................ 24
1.3.3 Enabling device and hold-to-run functionality ............................................... 25
1.4 Robot operating modes ...................................................................................... 27
1.4.1 About the manual mode ........................................................................... 27
1.4.2 About the automatic mode ........................................................................ 29
1.5 Installation and commissioning ............................................................................ 30
1.6 Operation ........................................................................................................ 33
1.7 Maintenance and repair ...................................................................................... 34
1.8 Troubleshooting ................................................................................................ 35
1.9 Decommissioning .............................................................................................. 36
2 Controller description 37
2.1 OmniCore C90XT .............................................................................................. 37
2.2 Technical data for OmniCore C90XT controller ....................................................... 38
2.3 The unit is sensitive to ESD ................................................................................. 43
2.4 Handling of FlexPendant .................................................................................... 44
2.5 Network security ............................................................................................... 46
2.6 Open source and 3rd party components in RobotWare ............................................. 47
2.7 ABB Ability ....................................................................................................... 48
4 Maintenance 155
4.1 Maintenance schedule, OmniCore ........................................................................ 155
4.2 Inspection activities ........................................................................................... 156
4.2.1 Inspection of controller ............................................................................. 156
4.3 Cleaning activities ............................................................................................. 157
4.3.1 Cleaning air filter ..................................................................................... 157
4.3.2 Cleaning of the controller cabinet ............................................................... 159
4.3.3 Cleaning the FlexPendant ......................................................................... 160
4.4 Changing/replacing activities ............................................................................... 162
4.4.1 Replacement of air filter ............................................................................ 162
4.5 Function tests ................................................................................................... 165
4.5.1 Function test of emergency stop ................................................................ 165
4.5.2 Function test of manual, auto, and manual full speed mode with FlexPendant .... 166
4.5.3 Function test of three-position enabling device ............................................. 167
4.5.4 Function test of contactors A1.Q1 and A1.Q2 inside the power unit .................. 168
4.5.5 Function test of auto stop ......................................................................... 169
4.5.6 Function test of external emergency stop .................................................... 170
4.5.7 Function test of ESTOP_STATUS output ..................................................... 171
4.5.8 Function test of reduced speed control ........................................................ 172
5 Repair 173
5.1 Introduction to repair ......................................................................................... 173
5.2 Replacement of controller parts ........................................................................... 174
5.2.1 Opening the robot controller ...................................................................... 174
5.2.2 Replacing the axis computer ..................................................................... 175
5.2.3 Replacing the fans ................................................................................... 181
5.2.3.1 Replacing the standard fans .......................................................... 182
5.2.3.2 Replacing the heat exchanger ........................................................ 186
5.2.4 Replacing the robot signal exchange proxy .................................................. 192
5.2.5 Replacing the Ethernet switch ................................................................... 198
5.2.6 Replacing the Connected Services Gateway ................................................ 202
5.2.7 Replacing the scalable I/O unit ................................................................... 208
5.2.8 Replacing the main computer .................................................................... 213
5.2.9 Replacing the power unit .......................................................................... 242
5.2.10 Replacing the power supply ...................................................................... 247
5.2.11 Replacing the drive unit ............................................................................ 257
5.2.12 Replacing the fieldbus master .................................................................... 265
5.2.13 Replacing the conveyor tracking module(CTM) ............................................. 279
5.2.14 Replacing the air filter .............................................................................. 284
6 Decommissioning 351
6.1 Introduction ...................................................................................................... 351
6.2 Environmental information .................................................................................. 352
7 Troubleshooting 355
7.1 Introduction to troubleshooting ............................................................................ 355
7.2 Troubleshooting fault symptoms .......................................................................... 357
7.2.1 No LEDs are lit on the controller ................................................................. 358
7.2.2 Start-up failure ........................................................................................ 361
7.2.3 System update failure .............................................................................. 364
7.2.4 Problem releasing the robot brakes ............................................................ 365
7.2.5 Problem starting or connecting the FlexPendant ........................................... 369
7.2.6 Problem using the joystick ........................................................................ 373
7.2.7 Controller fails to start .............................................................................. 374
7.2.8 Reflashing firmware failure ........................................................................ 375
7.2.9 Inconsistent path accuracy ....................................................................... 376
7.3 Troubleshooting units ........................................................................................ 378
7.3.1 Troubleshooting LEDs in the controller ........................................................ 378
7.3.2 Troubleshooting the FlexPendant ............................................................... 379
7.3.3 Troubleshooting the drive unit ................................................................... 380
7.3.4 Troubleshooting the power unit .................................................................. 382
7.3.5 Troubleshooting fieldbuses and I/O ............................................................ 387
7.3.6 Troubleshooting the Connected Services Gateway ........................................ 388
7.3.7 Troubleshooting the Ethernet switch ........................................................... 394
7.3.8 Troubleshooting the axis computer ............................................................. 396
7.3.9 Troubleshooting the main computer ............................................................ 398
7.3.10 Troubleshooting the power supply .............................................................. 401
7.3.11 Troubleshooting the fieldbus adapter slave .................................................. 406
7.3.12 Troubleshooting the robot signal exchange proxy ......................................... 407
Index 445
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
Prerequisites
A maintenance/repair/installation craftsman working with an ABB robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• be trained to respond to emergencies or abnormal situations.
References
Revisions
Revision Description
A First edition.
B Published in release 20C. The following updates are made in this revision:
• Updated information about safety data.
• Updated information about robot signal exchange proxy.
C Published in release 20D. The following updates are made in this revision:
• Section Mounting the FlexPendant holder on page 58 has been
updated with new installation method for the FlexPendant holder.
• Section Network connections on OmniCore on page 79 has been
updated with NOTE regarding correct usage of the MGMT port.
D Published in release 21A. The following updates are made in this revision:
• Minor corrections in section Connections on the main computer
on page 80.
• Added extension cable spare parts in section FlexPendant parts
on page 440.
• Minor corrections in section Descriptions for connectors on
page 87.
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
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.
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.
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.
1 Safety
1.1 Safety information
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.
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. The Extended Safety Functions is an option.
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.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
For more information, see standard ISO 13849.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
Introduction to symbols
This section describes safety symbols used on labels (stickers) on the controller.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 19.
The information labels can contain information in text.
Label Description
Read the user manual before use.
xx1400001152
xx2100000104
Label Description
CE label
xx1800000835
xx1400002061
xx1700000353
xx1700000355
xx1900001805
Label Description
Electrical shock
xx1400001151
xx1800000836
xx1400001156
xx1400001162
Stop categories
Note
For OmniCore, a safety input that is initiated must remain active for at least 100
ms.
CAUTION
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.
CAUTION
CAUTION
On the IRB 14050, the three-position enabling device is not active unless a valid
SafeMove configuration is active in the controller.
CAUTION
How to use the hold-to-run function for manual full speed mode is described in the
operating manual for the controller.
Note
Safeguard mechanisms
• Protective stops through
- Three-position enabling switch
WARNING
Wherever possible, the manual mode of operation shall be performed with all
persons outside the safeguarded space.
WARNING
Wherever possible, the manual mode of operation shall be performed with all
persons outside the safeguarded space.
Note
Safeguard mechanisms
• Protective stop through
- Automatic Stop, AS
Layout
The robot integrated to a robot system shall be designed to allow safe access to
all areas during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing
the working area.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand
the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum
speed.
• The maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed
in the section Robot motion in the product specification for the respective
manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall be considered.
Consider hazards from other equipment in the robot system, for example, that
guards remain active until identified hazards are reduced to an acceptable level.
Allergenic material
See Environmental information on page 352 for specification of allergenic materials
in the product, if any.
Electrical safety
The mains power must be installed to fulfill national regulations.
The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Hazards due to stored electrical energy in the controller must be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.
Wherever possible, power on/off or rebooting the robot controller shall be performed
with all persons outside the safeguarded space.
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.
Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.
Other hazards
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
The risk assessment should also consider other hazards arising from the
application, such as, but not limited to:
• Water
• Compressed air
• Hydraulics
Collaborative applications
If a robot is intended for a collaborative application, where occasional contact
between the robot and the operator is expected, the safety aspects must still be
addressed. See the product manual for the manipulator.
1.6 Operation
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Never use the robot as a ladder, which means, do not climb on the controller,
manipulator, including motors, or other parts. There are hazards of slipping and
falling. The robot might be damaged.
Make sure that there are no loose screws, turnings, or other unexpected parts
remaining after work on the robot has been performed.
When the work is completed, verify that the safety functions are working as
intended.
Hot surfaces
Surfaces can be hot after running the robot. Touching the surfaces may result in
burns.
Allow the parts to cool down before maintenance or repair.
Related information
See also the safety information related to installation and operation.
1.8 Troubleshooting
General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.
DANGER
Related information
See also the safety information related to installation, operation, maintenance, and
repair.
1.9 Decommissioning
General
See section Decommissioning on page 351.
2 Controller description
2.1 OmniCore C90XT
xx1900001447
OmniCore C90XT
Basic box Baseline
Extension box Option
Drive T4 Baseline
Power unit A1 Baseline
SMB connector X2 Baseline
Force control connector X3 Option
HMI connector (TPU) X4 Baseline
Motor connector X1 Baseline
Scalable I/O K5.1 Baseline
Additional I/O K5.2/K5.3 Option
IP20 DeviceNet X17 Option
Conveyor tracker module B1 Option
Motion Safety A2.K3 Baseline
Connected Services Gateway (with antenna for 3G and K7 Baseline i
WiFi)
Ethernet switch K4 Option
OmniCore C90XT
Standard fan G1 Baseline
Heat exchanger G2 Baseline
Axis computer K6 Baseline
Main computer A2 Baseline
Power supply T2 Baseline
Power supply T5 Option
ODVA power supply T5 Option
Fieldbus adapter slave X18 Option
Process Connector X81 Option
Filter Option
Power inlet switch Q0 Baseline
Power inlet connector X0 Baseline
Robot signal exchange proxy K2 Baseline
i Baseline is 3G. Wired or WiFi available as option.
Dimensions
Parameter Value
Width 500 mm
Depth 355 mm
Height 520 mm
Extension box
Parameter Value
Width 500 mm
Depth 355 mm
Height 295 mm
Weight
The table shows the weight of the controller.
Controller Weight
OmniCore C90XT 46 kg (not including the extension box)
Extension Box 25 kg
Note
The weight does not include any mounting kits fitted on the controller.
Parameter Value
Minimum ambient temperature -25°C (-13°F)
Parameter Value
Maximum ambient temperature +55°C (+131°F)
Maximum ambient temperature (less than 24 +70°C (+158°F)
hrs)
Maximum ambient humidity Maximum 95% at constant temperature.
Vibration Max. Grms = 4 m/s 2 (X & Y axis), Grms =
12.8 m/s 2 (Z axis)
Bumps Max. 5 g = 50 m/s 2 (11 ms)
After storage, the operating conditions must be met for at least 4 hours before
switching on the controller (see Operating conditions on page 40).
Operating conditions
The table shows the allowed operating conditions for the controller.
Parameter Value
Minimum ambient temperature +5°C (+41°F)
Maximum ambient temperature +45°C (+113°F)
Maximum ambient humidity Maximum 95% at constant temperature.
Maximum ambient altitude 2,000 m
Vibration Max. Grms = 2.86 m/s2 (X, Y, Z axis)
Bumps Max. 5 g = 50 m/s2 (11 ms)
Protection classes
Protection class
Controller cabinet IP54
Extension box cabinet IP54
Controller electronics IP54
FlexPendant IP54
The cabinet must be closed properly when the robot system is in production. If the
cabinet is not properly closed, then it does not comply with the protection class
(IP54). The shield for electromagnetic compatibility (EMC) is also affected if the
controller is not properly closed.
If the door is not closed, this can also affect parts inside cabinet due to dust or
moisture, especially important in cases with high heat and humidity, or much
pollution.
Note
To comply with IP54, all openings to the controller cabinet must be covered. This
includes unconnected connectors which must be fitted with covers.
Power supply
Mains Value
Voltage for OmniCore C90XT 220/230 VAC, 1 phase
Voltage tolerance +10%, -15%
Frequency 50/60 Hz
Frequency tolerance ±3%
Note
The use of three phase power with delta connection (as sometimes used in North
Americas and some Asian countries) voids warranty. If the facility has a substation
with any type of delta connection, a grounded Y-configured transformer must be
installed before the robot controller.
Line fusing
There is no integrated fuse inside the OmniCore C90XT controller. Add an external
fuse (time-delay) or circuit breaker (class K) according to full load current, as
marked on the controller nameplate. The following table shows the recommended
rating for an external fuse or circuit breaker.
Robot Current (A) Description
IRB 1100 220/230 VAC, 1 phase 10 A
IRB 1300 220/230 VAC, 1 phase 10 A
IRB 910INV 220/230 VAC, 1 phase 10 A
xx1900001446
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Safe handling
Use one of the following alternatives:
• Use a wrist strap. The wrist strap button is located inside the controller.
Wrist straps must be tested frequently to ensure that they are not damaged
and are operating correctly.
• Use an ESD protective floor mat.
The mat must be grounded through a current-limiting resistor.
• Use a dissipative table mat.
The mat should provide a controlled discharge of static voltages and must
be grounded.
Detached FlexPendant
A FlexPendant that is not connected to the robot or robot system cannot initiate
emergency stops or protective stops. This must be stored out of reach and sight
so that it cannot be mistaken for being in use.
CAUTION
Always test the emergency stop button to make sure it works if a custom connection
cable is used.
Network security
This product is designed to be connected to and to communicate information and
data via a network interface. It is your sole responsibility to provide, and
continuously ensure, a secure connection between the product and to your network
or any other network (as the case may be).
You shall establish and maintain any appropriate measures (such as, but not limited
to, the installation of firewalls, application of authentication measures, encryption
of data, installation of anti-virus programs, etc) to protect the product, the network,
its system and the interface against any kind of security breaches, unauthorized
access, interference, intrusion, leakage and/or theft of data or information. ABB
Ltd and its entities are not liable for damage and/or loss related to such security
breaches, any unauthorized access, interference, intrusion, leakage and/or theft
of data or information.
Data
ABB will not acquire any right, title and interest in the data other than the rights
granted by Customer to ABB, but ABB will have the right to collect, store, aggregate,
analyze or otherwise use the data for (i) providing and maintaining the hardware,
services and/or the ABB software to Customer; (ii) prevent-ing, detecting and
repairing problems related to the security and/or the operation of the hardware,
the platform, software; (iii) improving and developing existing services, technologies,
products and/or software and developing new services, technologies, products
and/or software, and all improvements and developments (including all resulting
intellectual property Rights) are exclusively owned by us. In addition, we have the
right to use the data for benchmarking purposes if and to the extent it is anonymized
or non-confidential.
General
This chapter contains assembly instructions and information for installing the
OmniCore C90XT controller at the working site.
See also the product manual for the manipulator.
The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.
Safety information
Before any installation work is commenced, it is extremely important that all safety
information is observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 13 before performing any installation
work.
Note
If the OmniCore C90XT is connected to power, always make sure that the robot
is connected to protective earth and a residual current device (RCD) before
starting any installation work.
Lifting device
Use the four lifting eyes (Torque: 11.3 Nm-12.6 Nm) or a fork lift when lifting the
controller, as shown below.
The following figure shows the maximum angle between the lifting straps when
lifting the controller. The weight of the controller module is detailed in section
Weight on page 39.
60°
xx1900001445
Note
After removing the lifting lock, tighten the plastic screws (Torque: 0.8 Nm-1 Nm)
for the controller cabinet.
3.3.2 Unpacking
Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.
Note
3.3.3 Storing
Dimensions
The following illustration shows the required installation space for the OmniCore
C90XT controller.
200
355
41 418 11(4X)
38
233
xx1900001449
Note
Fix the controller to a concrete foundation or steel platform with anchor bolts
during stacking.
Note
Note
To avoid dropping the FlexPendant from height, the holder should be placed in
a comfortable working height.
Always use and store the FlexPendant in such a way that the cable does not
become a tripping hazard.
When not using the device, place it so it does not accidentally fall.
Required equipment
Note
The FlexPendant should always be placed in the holder when it is not used and
it is not allowed to use by unauthorized person.
xx2000002352
Action Note/illustration
3 Press the holder onto the desired place.
xx2000002353
Tip
Action Note/illustration
1 Hang the FlexPendant holder to the
bracket according to the screws on the
bracket.
xx2000002354
Action Note/illustration
2 Hang the holder with the bracket to the
desired place.
xx2000002355
Hanging the front part of the FlexPendant holder with screws (Vertically)
Use this procedure to hang the front part of the FlexPendant holder to the desired
place.
Action Note/illustration
1 Remove the four screws.
2 Separate the rear part from the FlexPend-
ant holder.
xx2000002356
Action Note/illustration
4 Remove the protective liner from the
tape.
xx2000002357
xx2000002358
General
The following section describes the connectors on the covers of the OmniCore
C90XT controller.
CAUTION
Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.
Connectors
The following details the connection interface on the OmniCore C90XT controller.
xx2000000338
Description
A Manipulator signal connector
B Cable grommet assembly (option)
C Cable grommet assembly
D Power inlet connector
E Motor connector
Description
F TPU cover
G FlexPendant connection (TPU connector)
H ETH outlet connector
J Motors on lamp
K Power inlet switch
General
A good and proper electrical installation of the robot system is necessary to ensure
the best performance and prolong the lifetime of the whole robot system.
This section includes important information on how to connect cables and signals
to the controller.
Signal classes
Different rules apply to the different classes when selecting and laying cables.
Signals from different classes must not be mixed.
Signal class Description
Power signals Supplies external motors and brakes.
Class 4 (noisy) Applies to the cables associated with the power inputs and outputs
of variable speed drives. Cables carrying strongly interfering signals
such as motor cables, DC-link load sharing, unsuppressed inductive
loads, DC motors, welding equipment, etc.
Control signals Digital operating and data signals (digital I/O, protective stop, etc.).
Class 3 (slightly Applies to cables carrying slightly interfering signals: AC power
noisy) supply (<1 kV), DC power (24 V), power to equipment with RFI/EMI
filters, control circuits with resistive or suppressed inductive loads
(such as contactors and solenoids), direct-on-line induction motors,
etc.
Measurement signals Analog measurement and control signals (resolver and analog I/O).
Class 2 (slightly sens- This class covers ordinary analogue signals such as analogue sig-
itive) nals (4-20 mA, 0-10V, or signals below 1 MHz), low-speed digital
signals (RS232, RS485), digital (on/off) signals, limit switches, en-
coders, etc.
Data communication Gateway (fieldbus) connection, computer link.
signals Applies to cables carrying very sensitive signals. Signals with a full-
Class 1 (sensitive) scale range less than 1 V or 1 mA, and/or a source impedance >1
kOhm, and/or a signal frequency >1 Mhz. For example high-speed
digital communication (Ethernet), thermocouples, thermistors, strain
gauges and flowmeters.
Selecting cables
All cables laid in the control cabinet must be capable of withstanding 70°C. In
addition, the following rules apply to the cables of certain signal classes:
Signal class Cable type
Power signals Shielded cable with an area of at least 0.75 mm² or AWG 18.
Control signals Shielded cable.
Measurement signals Shielded cable with twisted pair conductors.
Data communication Shielded cable with twisted pair conductors. A specific cable
signals should be used for field bus connections and Ethernet, according
to the standard specification of the respective bus.
Note
Any local standards and regulations concerning insulation and area must always
be complied with.
Shielding cables
When peripheral devices are connected to the robot system, a shielded cable is
necessary to reduce coupling of the inner cable conductors to the environment
they pass through.
In such cases one end grounding may be used. The grounding point should
then be at the robot controller side.
• Cables carrying analog low-level signals is another exception where the
shield should be grounded at only one end.
• Most data network and field bus types have defined grounding topologies.
If such grounding schemes exist, they should be followed.
• In complex interference environments, two-layer shielding may be required.
The inner shield should be grounded at the controller side only end and the
outer shield should be grounded at both ends. The optimum shielding is a
combination of foil and braid screens.
• The best connection is one in which the shielding is extended up to and
makes a solid 360° connection (shown below) with the ground plane or
chassis.
Shielding example
The below example shows the shielding of a d-type connector:
xx1700001320
xx1700001321
Grounding requirements
The controller cabinet ground must come from the mains power supply PE.
• The grounding cable color shall be green-yellow.
• The ground for the controller cabinet, robot manipulator and peripheral
devices must be the same, preferably an equipotential ground grid (mesh).
• Ground connection points must have stable inter-metallic bonding, like screw
fixation. Paint, dirt, rust, and other insulating material must be removed from
the contacting surfaces.
For requirements on the marking of the supply ground connection inside the control
cabinet refer to UL 508C. For further details on how grounding systems should be
designed refer to IEC 61000-5-2. For details of cross-sectional area of PE refer to
IEC 60204-1.
Grounding installation
For information on how to install the ground for the manipulator, see the
corresponding product manual.
Examples
The following figure shows 2 examples on how the ground and the signal cable
screens can be connected:
Example 1
Example 2
xx1200000960
Example 1:
• Where a good ground is available on all units, the best shielding is obtained
by grounding all screens at both ends on all units.
Example 2:
• If the cable is terminated where a good ground is not available a noise
suppression capacitor can be used. The screens of the 2 cables must be
connected as shown in the figure, but not connected to the chassis of the
unit.
Interference elimination
Internal relay coils and other units that can generate interference inside the control
cabinet are neutralized. External relay coils, solenoids and other units must be
clamped in a similar way. The illustration below shows how this can be done.
Note that the turn-off time for DC relays increases after neutralization, especially
if a diode is connected across the coil. Varistors give shorter turn-off times.
Neutralizing the coils lengthens the life of the switches that control them.
+24 V DC 0V
1)
2)
+24 V AC/DC 0V
3)
xx1200000961
1 The diode should be dimensioned for the same current as the relay coil, and
a voltage of twice the supply voltage.
2 The varistor should be dimensioned for the same energy as the relay coil,
and a voltage of twice the supply voltage.
3 When AC voltage is used, the components needs to be dimensioned for >500
V max voltage and 125 V nominal voltage.
The resistor should be 100 Ω, and the capacitor should be 1W 0.1 - 1 µF
(typically 0.47 µF).
General
Connect the manipulator and the controller to each other after installing them. The
lists below specify which cables to be used in each application.
All connectors on the controller are shown in section Connectors on the OmniCore
C90XT controller on page 62.
These categories above are divided into sub-categories which are specified in
spare part manual. See Manipulator cables on page 441.
Action
1 Connect the manipulator cable to the connector X1.
2 Lock the connector with the lever.
3 Secure the cables to avoid tripping or wear.
General
This section describes how to manufacture a cable for connecting the main power
to the controller.
xx1900001461
Detailed view
D A
xx1900001457
Description
A Female insert, quick lock
B Angle hood M20
C Cable gland M20
D Sealing screw
Specifications
The following describes the cable requirements for the main power connection to
the OmniCore C90XT controller.
Component Description
Cable type Flexible oil resistant rubber
Cable area 3C x 2.5 mm 2 or AWG14
Included parts
The following parts are included in the delivery.
Part Order number Quantity
Power connector 3HAC070308-001 1
Procedure
Use the following procedure to fit the connectors.
Action Note/illustration
1 Cut the cable to desired length.
2 Connect the wires according to the illus-
tration.
xx1900001454
Action Note/illustration
3 Remove cable jacket and strip the fine
stranded wires about 10 mm if needed.
xx1900001458
xx1900001459
Note
DANGER
xx1900001479
Note
xx1900001455
Description
1 Live (L)
2 Neutral (N)
3 Not used
4 Not used
5 Not used
PE Protective Earth, grounding
Required equipment
Equipment Note
Main connection cable (single phase) L, N, PE
Details see Fitting the connector
on page 70.
External earth fault protection (residual current device, 30 mA
RCD)
Standard toolkit See Standard toolkit for controller
on page 417.
Circuit diagram Circuit diagram - OmniCore
C90XT, 3HAC065464-009
Line fusing
There is no integrated fuse in side OmniCore C90XT controller. An external fuse
or circuit breaker must be added by the integrator, according to the full load current
rating. See Line fusing on page 41.
CAUTION
Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.
Action
1 Connect the main power cable to the power inlet connector X0 and lock it by
pressing the hook.
Tip
xx1900001456
Introduction
When the controller is in automatic mode the FlexPendant can be detached from
the controller without interrupting ongoing processes. This is possible only if the
logged in user has the Safety Services grant.
CAUTION
CAUTION
CAUTION
A FlexPendant that is not connected to the robot or robot system cannot initiate
emergency stops or protective stops. This must be stored out of reach and sight
so that it cannot be mistaken for being in use.
CAUTION
4 Tap Detach.
A popup window with 30 seconds countdown timer is displayed.
5 When the countdown is progressing, loosen the locking ring and detach the
FlexPendant from the controller.
Note
WARNING
CAUTION
Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.
Plug in the connector on the controller and tighten the locking ring.
xx1900000975
CAUTION
Make sure that the emergency stop button is not pressed in when connecting
the FlexPendant.
Note
1 1 2 3 1 4
xx1800003138
Label Description
1 I/O + LAN + ETHERNET Port to the robot's private network. Intended for
SWITCH connecting ABB Scalable I/O units and network
based process equipment to the controller.
2 ABB Ability™ This port only exists if the wired variant of the Con-
nected Services Gateway is used. Intended for
connecting to the robot's Ability™ network.
3 WAN WAN port that can be used to host a public industri-
al network.
4 MGMT (Management) Port to the robot's private network. The MGMT port
shall be used by service personnel in close proxim-
ity to the controller, with a single client connected
to the controller.
Note
A factory wide I/O network should be connected to the Ethernet port WAN on the
controller.
An I/O network that is local for a specific robot should be connected to the Ethernet
port LAN, I/O or the ETHERNET SWITCH on the controller.
Note
Network segment Private Network Ability Network Public Network Drive Network
10/100/1000
10/100/1000
10/100
10/100
10/100
10/100
LAN 4
LAN 2
LAN 3
MGMT
LAN 1
WAN
AXC
L
X2
X3
X6
X4
X23
X9
X5
Service PC FlexPendant PLC Connected Services Factory Network Axis computer
Gateway
Cameras,
sensors, I/O
xx1800003053
Private Network
The ports X3 (MGMT), X6 (LAN 1), and X4 (LAN 2) and X2 (LAN 3) belong to the
Private Network segment.
Note
Note
The management port shall never be used for more than one client at a time.
ABB Robotics assumes no responsibility for any errors/hazards that may appear
when more than one client is attached to the management port.
The LAN1, LAN2 and LAN3 ports are intended for connecting robot controller
internal computers or network based process equipment to the controller, for
example cameras, and welding equipment.
Ability Network
Port X5 (LAN 4) belongs to the Ability Network segment. The LAN4 port is intended
for connecting to the Connected Services Gateway module for a firewalled access
to ABB Ability™ Cloud server.
The connectivity is done through an embedded Connected Services Gateway
(Wired, Wi-Fi, or 3G).
Public Network
The port X23 (WAN) belongs to the Public Network segment. The WAN port is the
public network interface to the controller, typically connected to the industrial
network with a public IP address provided by the network administrator.
The Public Network segment is used for:
• connecting a PC running RobotStudio
• mounting FTP or NFS disks from the controller
• running Industrial Ethernet.
Note
Drive Network
The X9 (AXC) port is intended to be connected to the robot drive system.
The AXC port is always connected to the axis computer. If MultiMove is used, AXC
is connected to a switch that connects to all the axis computers.
Cell I/O
PLC
I/O I/O
EtherNet/IP
MGMT LAN1 LAN2 LAN3 WAN MGMT LAN1 LAN2 LAN3 WAN
Private I/O
xx1800003192
Note
The Firewall Manager settings must be set to YES if the EtherNet/IP is to be used
on the public network. Configuration is done in RobotStudio under Configuration
-> Communication -> Firewall Manager. See Operating manual - Integrator's
guide OmniCore for more information.
xx2000000488
xx2000000489
Cell I/O
PLC
I/O I/O
MGMT LAN1 LAN2 LAN3 WAN MGMT LAN1 LAN2 LAN3 WAN
Camera
xx1900001102
Management port
The management port is intended for service engineers and programmers
connecting directly to the controller with a PC.
The management port is configured with the fixed IP address 192.168.125.1, which
is the same for all controllers and cannot be changed, and has a DHCP server that
automatically assigns an IP address to the connected PC.
Note
Note
For more information about connecting a PC to the management port, see section
Working online in Operating manual - RobotStudio.
WAN port
The WAN port is a public network interface to the controller, typically connected
to the factory network with a public IP address provided by the network
administrator.
The WAN port can be configured with fixed IP address, or DHCP, from RobotStudio
or the FlexPendant. By default the IP address is blank.
Note
Note
The WAN port cannot use any of the following IP addresses which are allocated
for other functions on the controller:
• 192.168.125.0 - 255
• 192.168.126.0 - 255
• 192.168.127.0 - 255
The WAN port cannot be on a subnet which overlaps with any of the above
reserved IP addresses. If a subnet mask in the class B range has to be used,
then a private address of class B must be used to avoid any overlapping. Contact
your local network administrator regarding network overlapping.
See the section Communication in Technical reference manual - System
parameters.
Note
For more information about connecting a PC to the WAN port, see Operating
manual - RobotStudio.
LAN port
The LAN port on the front of the controller belongs to the controllers private network.
It is intended for connecting network based process equipment to the controller.
The LAN port is configured with the fixed IP address 192.168.125.1, which is the
same for all controllers and cannot be changed, and has a DHCP server which can
assign IP addresses to connected devices.
Note
Ability port
The Ability port is a specific network interface to the controller, available on the
Connected Services Gateway wired (DSQC1041), connected to an Internet gateway
with an IP address provided by the network administrator.
The Ability port must be configured with fixed IP address from RobotStudio or the
FlexPendant. By default the IP address is blank. An external gateway and DNS
need to be provided.
For security reasons, only outbound access on port 53 DNS and 443 HTTP are
allowed. The inbound access is blocked by an internal firewall and cannot be
unblocked.
Note
The Ability port cannot use any of the following IP addresses which are allocated
for other functions on the controller:
• 192.168.125.0 - 255
• 192.168.127.0 - 255
The Ability port cannot be on a subnet which overlaps with any of the above
reserved IP addresses. If a subnet mask in the class B range has to be used,
then a private address of class B must be used to avoid any overlapping. Contact
your local network administrator regarding network overlapping.
See the section Communication in Technical reference manual - System
parameters.
Note
For more information about connecting the Ability port to the internet, see
Application manual - Controller software OmniCore.
Firewall settings
The Firewall Management function is used to configure the network firewall on the
controller. Configuration is done in RobotStudio under Configuration ->
Communication -> Firewall Manager where pre-configured Network Services can
be enabled or disabled:
xx1900000352
Note
Note
Only users with UAS grant Modify network security properties can modify the
firewall settings.
For more information, see Technical reference manual - System parameters.
Related information
See more information about network configuration in Operating manual - Integrator's
guide OmniCore.
Internet connectors
The Connected Services Gateway unit has either an Ability port or an antenna
connector on the front. See installation procedures in section On-site installation
on page 56.
xx1900002450
Note
The end user need to buy proper grommets according to the diameter of the
cables which need to go through the grommet.
This will affect the protection level of the cabinet if it's not executed correctly.
It is recommended to use icotek KT grommet.
xx2000000436
xx1900002448
The connectors contain 16 digital input signals, 16 digital output signals, 24 V and
0 V for the outputs, and 0 V for the inputs.
CAUTION
The process power supply should be supplied separately. Connecting the process
power supply through the logical power supply connector (X19) may damage
the device.
If the process power supply is supplied by the logical power supply connector
(X19), a surge protector must be installed to protect the device.
11 12
IN OUT
9 10
3 4
xx1800002551
Note
The end user need to buy proper grommets according to the diameter of the
cables which need to go through the grommet.
This will affect the protection level of the cabinet if it's not executed correctly.
It is recommended to use icotek KT grommet.
The cable layout is recommended as the following illustration.
xx2000000434
xx1800000941
Note
The end user need to buy proper grommets according to the diameter of the
cables which need to go through the grommet.
This will affect the protection level of the cabinet if it's not executed correctly.
It is recommended to use icotek KT grommet.
xx2000000435
Note
The 24 V terminal block power supply is isolated from the internal logical circuit
of the controller.
For connection details, see Circuit diagram - OmniCore C90XT, 3HAC065464-009.
Note
The end user need to buy proper grommets according to the diameter of the
cables which need to go through the grommet.
This will affect the protection level of the cabinet if it's not executed correctly.
It is recommended to use icotek KT grommet.
xx2000000433
xx1900002449
CAUTION
Safety functions must be verified before use. Safety functions must be tested
regularly.
X14
Description
Connection Customer safety interface: emergency stop
and automatic stop
Type Weidmüller S2L 3.50 90F
S2L 3.50/16/90F 3.5SN BK BX 2*8 pins
Article number 1728680000 (or equivalent)
Note
15 13 11 9 7 5 3 1
16 14 12 10 8 6 4 2
xx1800000553
The automatic stop and external emergency stop interfaces located in X14 are
dual-channel safety inputs.
Each channel has 4 pins on the connectors, and the pin descriptions are shown
in the following table.
Pin Description
24V_CH1/2 24 V power supplied by robot controller for stop switch use only. It
must not be used for any other functions.
AS1+/ AS2+ Safety loop high side of automatic stop input.
AS1-/ AS2- Safety loop low side of automatic stop input.
ES1+/ ES2+ Safety loop high side of external emergency stop input.
ES1-/ ES2- Safety loop low side of external emergency stop input.
0V_CH1_CH2 24V power reference ground.
The controller is shipped with a default configuration that the automatic stop circuit
is opened and emergency stop circuit is bypassed (short-circuited). The controller
CANNOT work.
To enable the controller without any additional/external safety equipment, connect
the safety circuit as shown in the following figure.
K2-X4 K2-X4
8 24V_CH1 16 24V_CH1
6 ES1+ 14 AS1+
5 ES1- 13 AS1-
7 0V_CH1_CH2 15 0V_CH1_CH2
2 24V_CH2 10 24V_CH2
4 ES2+ 12 AS2+
3 ES2- 11 AS2-
1 0V_CH1_CH2 9 0V_CH1_CH2
xx1900000060
24V_CH1 24V_CH1
0V_CH1_CH2 0V_CH1_CH2
24V_CH2 24V_CH2
0V_CH1_CH2 0V_CH1_CH2
(A) (B)
Customer_24V_CH1
24V_CH1 24V_CH1
Customer_24V_CH1
AS1+ / ES1+ AS1+ / ES1+
Customer_24V_CH2
24V_CH2 24V_CH2
Customer_24V_CH2
AS2+ / ES2+ AS2+ / ES2+
(C) (D)
xx1900000600
Note
24V_CH1 24V_CH1
0V_CH1_CH2 0V_CH1_CH2
24V_CH2 24V_CH2
0V_CH1_CH2 0V_CH1_CH2
(A) (B)
xx1900000599
For more connections other than those illustrated above, carefully assess the risk
before use and contact your local ABB for support.
X15
Description
Connection Customer optional interface
Type Weidmüller S2L 3.50 90F
S2L 3.50/16/90F 3.5SN BK BX 2*9 pins
Article number 1728690000 (or equivalent)
17 15 13 11 9 7 5 3 1
18 16 14 12 10 8 6 4 2
xx1800000555
Note
NC means those pins are reserved. They cannot be electrically connected to any
external signal, ground, or voltage.
Pin Description
ESOUT1+ High side terminal of Emergency stop output Channel 1.
ESOUT1- Low side terminal of Emergency stop output Channel 1.
ESOUT2+ High side terminal of Emergency stop output Channel 2.
ESOUT2- Low side terminal of Emergency stop output Output Channel 2.
24V_MON 24 V power supplied by robot controller for motors on lamp and
motors on push button use only. It must not be used for any other
functions.
MON_LAMP Motors on lamp output interface. The max sink current is 50mA.
MON_PB Motors on push button input interface.
Note
The device connected to the ESOUT pins shall fulfill the IEC 61131-2 type 1 Input.
Note
Note
The maximum length of the cable connected to the ESOUT pins shall be 10 m.
Note
Note
Safety PLC
ESOUT1 + Or
Relay
Relay Output for
Indicator Safety Input of
Next Stage
ESOUT 1-
Controller
Interface Isola!on
Safety PLC
ESOUT2 + Or
Relay
Relay Output for
Indicator Safety Input of
Next Stage
ESOUT 2-
Isola!on
xx2000001763
24V_MON
MON_PB
Lamp
24V_MON
MON_LAMP
xx1900000598
X19
Description
Connection Customer IO power supply
Type Weidmüller SC 3.81 90F
SC 3.81/08/90F 3.2SN BK BX 8 Pins
Article number 1793380000 (or equivalent)
1 2 3 4 5 6 7 8
xx1800000556
Pin Description
1 24V_IO_EXT
2 0V_IO_EXT
3 24V_IO_EXT
4 0V_IO_EXT
5 24V_IO_EXT
6 0V_IO_EXT
7 24V_IO_EXT
8 0V_IO_EXT
24V_IO_EXT is the 24 V power supply for the customer. The characteristics are
shown in the following table.
Parameter Value
Voltage 24V DC
Voltage tolerance -3% ~ +10%
Max output current 3A
X20
Description
Connection Customer optional power input (Reserved)
Type Weidmüller SC 3.81 90F
SC 3.81/06/90F 3.2SN BK BX 6 Pins
Article number 1793370000 (or equivalent)
Introduction
The automatic stop (AS) and the general stop (GS) are configured using the Visual
SafeMove functionality in RobotStudio.
Note
The automatic stop cannot be configured in RobotWare 7.0 and RobotWare 7.1.
In RobotWare 7.0 and 7.1, the stops are configured in the system parameters.
Configuration
The automatic stop is configurable to be either an automatic stop or a general stop,
where the general stop will stop the robot in manual reduced speed mode.
After the configuration is done in the Visual SafeMove, the safety configuration
must be written to the controller and then a restart of the controller is required.
WARNING
The new settings must be verified by test before the system is used.
• ProtectiveStop is the AS/GS input
• ExternalEmergencyStop is the ES input
• InternalEmergencyStop is the emergency stop button on the FlexPendant
Note
When upgrading RobotWare systems from 7.0 or 7.1, the stop configuration is
done using system parameters.
See also the circuit diagram, Circuit diagram - OmniCore C90XT.
Stopping functions
There are different methods to stop the robot, in addition to manually initiated
stops.
• Stop with system input signals
• Stop with RAPID instructions
• Other stops
All of these stops are performed without using the brakes, and the power is never
disconnected. The program execution can be continued directly, for example by
activating a start signal.
Note
Only safety rated input signals are allowed to be used for safety.
WARNING
WARNING
Stopping time/distance
Stopping time/distance for emergency stop (category 0), program stop (category1)
at max speed, max stretched out and max load, categories according to EN 60204-1.
All results are from tests on one moving axis. All stop distances are valid for floor
mounted robot, without any tilting.
For detail stopping time/distance for each robot, see Product specification Robot
stopping distances according to ISO 10218-1.
General
The controller can be fitted with a number of different fieldbus adapters, fieldbus
boards, and software based fieldbuses. The software based fieldbuses do not
require any hardware.
Fieldbus connections
There is one slot available for installing a fieldbus board (PCIe) on the main
computer, with process connectors on the front panel, and one slot for installing
a fieldbus adapter (slave).
The software based fieldbuses are connected directly to one of the Ethernet ports.
A B C D
xx1700000748
Available board
The following master board is available.
Description Article number Type designation
DeviceNet Board 3HAC043383-001 DSQC1006
Available adapter
The following fieldbus adapter slave is available.
Description Article number Type designation
DeviceNet Slave Fieldbus Adapter 3HAC045973-001 DSQC1004
References
For more information on how to install and configure the fieldbuses, see the
respective manual.
Manual title Article number
Application manual - DeviceNet Master/Slave 3HAC066562-001
General
The controller can be fitted with an internal I/O unit, DSQC1030, with 16 digital
inputs and 16 digital outputs. The controller can also use external I/O units, with
DSQC1030 as base unit and add-on units as extension.
Location
The illustration shows the location of the harness double SMB in the controller.
xx2000000448
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Loosen the screw and disconnect:
• SMB - K6.X4
xx1900001914
xx1900001915
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
xx2000000440
xx2000000439
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165 .
Location
The location of the base unit used as a scalable I/O internal unit is shown in the
following illustration.
xx1900001467
The base unit can also be used as a scalable I/O external unit, with or without
add-on devices.
For more information about installing, configuring, and using the scalable I/O units,
see Application manual - Scalable I/O.
Required parts
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
xx1900002447
Action Note/Illustration
4 Connect the adapter cable to the digital
base.
• K5.1.X5 - A2.X4/K4.X7
Note
• K5.1.X4 - K2.X3
• The harness connected to I/O unit
by customer
2
ELECTROSTATIC DISCHARGE
(ESD)
Location
The illustration shows the location of the Ethernet extension switch in the controller.
xx1900001465
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
Note
xx1900002330
xx1800000972
4 Reconnect:
• K2.X2 - K4.X8, A2.X1
• K4.X7 - K5.1.X5
• K4.X6 - A2.X4
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the power supply optional device in the
controller.
xx2000000447
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Hang the 24V terminal block to the
bracket and push the lower part until you
hear a clear clicking sound.
Action Note/Illustration
1 Fit the power supply to the bracket. For DSQC 609:
Screws: Cross recessed cheese head screw
Note M4x8 (1 pcs)
xx1900001908
xx1900001950
Action Note/Illustration
2 Refit the end clamp besides the power For DSQC 609:
supply.
xx1900001907
xx1900002443
3 Connect:
• T5.X1-AC Terminal block
• T5.X2-24V Terminal block
Note
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the fieldbus adapter slave devices in the
controller.
xx1900001474
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
xx1900001917
Location
The illustration shows the location of the fieldbus master in the main computer.
xx1800003420
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect all the connectors on the as-
sembly group of the robot signal ex-
change proxy, Ethernet switch (option),
Connected Services Gateway, and main
computer.
For the robot signal exchange proxy:
• K2.X8 - A2.X6
• (option): K2.X2 - K4.X8, A2.X1
• K2.X12 - A2.K3.X6, A2.K3.X7
• K2.X10 - A1.X13
• K2.X21 - TempSensor
• K2.X4 - A1.X9
• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,
K7.X1
• K2.X1 - T2.X2
• K2.X17 - G2.X1, G1.X2
• K2.X6, K2.X11 - A1.X2
• K2.X7, K2.X22 - Harn. LV robot
power
• K2.X9 & X13 - FlexPendant
Action Note/Illustration
For the Ethernet extension switch (op-
tion):
• K2.X2 - K4.X8, A2.X1
• K4.X7 - K5.1.X5
• K4.X6 - A2.X4
For the Connected Services Gateway:
• K7.X1 - K2.X3 i
• K7.X2 - A2.X5
Note
Note
xx1900001877
Action Note/Illustration
3 Remove the assembly from the mounting
plate.
Note
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001885
Action Note/Illustration
1 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx2000000419
Action Note/Illustration
2 Pull the cable ties out from the locking
holes.
xx1900001879
xx1900001880
Action Note/Illustration
1 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx2000000419
Action Note/Illustration
2 Remove the screws on top of the main
computer and take the cover off.
xx1800003415
Note
xx1800003414
Note
Action Note/Illustration
4 Insert the DeviceNet board into the card
slots along the guide rail in the main
computer. B
xx1800003417
A Card slots
B Guide rail
Note
5 Secure the DeviceNet board with the Screw: Screw with flange M3x6 (1 pcs)
screw.
xx1800003416
Note
Action Note/Illustration
6 Refit the cover on the main computer and Screws: Hexalobular socket pan head screw
secure the screws. M3x6 (4 pcs)
xx1800003418
Note
Action Note/Illustration
1
DANGER
xx2000000419
Action Note/Illustration
3 Fit the robot signal exchange proxy and Screws: Torx pan head screw M4x8 (4 pcs)
secure the screws.
xx1900001880
xx1900001879
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
xx1900001885
xx1900001878
Action Note/Illustration
4 Fasten the assembly with the screws.
xx1900001877
Note
Action Note/Illustration
For the main computer:
• A2.X3 - X24
• K2.X8 - A2.X6
• K2.X2 - K4.X8, A2.X1
• K2.X12 - A2.K3.X6, A2.K3.X7
• K6.X2 - A2.X9
• A2.X5 - K7.X2
• A2.X4 - K4.X6/K5.1.X5
Note
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Overview
The conveyor tracking module uses network communication to share conveyor
speed and position data with one or more robot controllers. It contains a WAN port,
which is used to connect to the robot controllers and two LAN ports that can be
used for installation and service purposes.
xx1800000941
Required parts
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
4 Fit the conveyor tracking module and
push the lower part until you hear a clear
clicking sound.
xx1900001913
xx1900001912
5 Connect:
• B1.X1 - K2.X19.1, K2.X19.2(Power
cable)
• B1.X7 - K4.X1-5 (Ethernet cable)
6 Connect wires to the input and output See Application manual - Conveyor tracking.
connectors as required.
7 Close the door. Closing the door on page 174.
8 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
For more information about the option Conveyor Tracking, see Application
manual - Conveyor tracking.
Location
The illustration shows the location of the cable grommet assembly on the controller.
xx1900001480
Note
The end user need to buy proper grommets according to the diameter of the
cables which need to go through the grommet.
This will affect the protection level of the cabinet if it's not executed correctly.
It is recommended to use icotek KT grommet.
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Remove the attachment screws.
xx1900002444
Action Note/Illustration
1 Insert and equip the cable to the corres-
ponding KT grommet.
xx1900002337
Action Note/Illustration
2 Slide the grommets into the frame halves.
Note
Note
xx1900002336
xx1900002335
4 Secure the frame and cover strip with the Screws: Hex socket head cap screw M5x50
screws. 12.9 Gleitmo 603+Geomet 500 (3 pcs)
Tightening torque: 2 Nm - 3 Nm.
xx1900002334
Action Note/Illustration
5 Route the cables through the cut-out.
xx1900002333
6 Refit the cable entry frame to the enclos- Screws: Torx pan head screw M4x8 (4 pcs)
ure wall and secure with the screws. Tightening torque: 1.5 Nm.
xx1900002332
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
3 Insert the cable grommet assembly into Screws: Torx pan head screw M4x8 (4 pcs)
the cover of the cabinet.
Secure it with the screws.
xx1900002340
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the air filter on the controller.
xx1900001473
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001492
General
As an option an empty extension box can be purchased, to use for custom
equipment. The extension box can be installed on the basic box or anywhere else
as a standalone equipment.
xx1900001453
Note
Connect PE19 as grounding for the extension box in any use case.
Required equipment
Equipment Information
Standard toolkit See Standard toolkit for controller on
page 417.
Specifications
It is recommended to use multicore cable for the customer connection.
The following describes the cable requirements for the X106 connection in the
extension box.
Component Description
Cable type Flexible oil resistant rubber
Cable area 4C x 0.5 mm 2 or AWG20
Included parts
The following parts are included in the delivery when the extension box is selected.
Part Order number Quantity
Connector for X106 3HAC074661-001 1
Procedure
Use this procedure to stack an extension box to a basic box.
Action Info/illustration
1 Place the controller in desired place.
2 Fix the basic box to a concrete foundation Anchor bolts: M8 X 4
or steel platform with anchor bolts. Tighten torque: 11.3 Nm-12.6 Nm
3 Remove the four plastic screw.
xx1900001450
Action Info/illustration
4 Assemble the hexalobular socket pan head
screws onto the cabinet.
xx1900001451
xx1900001452
6 Open the door of the extension box. Opening the door on page 174.
Action Info/illustration
7 Fit the connector (3HAC074661-001) for
X106.
xx2000000690
1 24 V
2 0V
3 24 V
4 0V
8 Connect through the cable grommet: How to insert cable through cable grom-
• PE19 met, see Releasing the cables from the
• X106 cable grommet assembly on page 314 and
Refitting the cables to the cable grommet
assembly on page 317.
xx2000000446
xx2000000689
Action Info/illustration
9 Install the equipment to the extension box
according to your requirements.
WARNING
Overview
The conveyor tracking module uses network communication to share conveyor
speed and position data with one or more robot controllers. It contains a WAN port,
which is used to connect to the robot controllers and two LAN ports that can be
used for installation and service purposes.
xx1800000941
Required parts
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
3 Open the door of the extension box. Opening the door on page 174.
4 Fit the conveyor tracking module by
snapping it onto the mounting rail .
xx1900001913
Action Note/Illustration
5 Connect the 24V power supply to the How to insert cable through cable grommet,
conveyor tracking module from the basic see Releasing the cables from the cable
box or other power supply. grommet assembly on page 314 and Refitting
the cables to the cable grommet assembly
6 Connected to Ethernet through the cable on page 317.
grommet:
• B1.X7 - K4.X1-5 For details on connecting wires to the con-
veyor tracking module, see Application
7 Connect wires to the input and output manual - Conveyor tracking.
connectors as required.
8 Close the door. Closing the door on page 174.
9 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
For more information about the option Conveyor Tracking, see Application
manual - Conveyor tracking.
General
WARNING
WARNING
ABB only offers the extension box as an encapsulation for customer installing
external devices.
It is the system builder's responsibly to ensure the complacence with electrical
safety, for example the Low Voltage Directive.
Function tests
When the installation is complete, perform the function tests in section Function
tests on page 165 to verify that the safety features work properly.
4 Maintenance
4.1 Maintenance schedule, OmniCore
General
The controller must be maintained at regular intervals to ensure its function. The
activities and intervals are described in this section.
Action Note/illustration
1
DANGER
xx1900001446
Location
The air filter is located as shown in the illustration below.
xx1900001473
Required equipment
Equipment Note
Cleaning agent Water 30-40°C with cleansing liquid or detergent.
Compressed air
Cleaning
The procedure below details how to clean the moist dust filter.
Action Note/Illustration
1 Remove the air filter. How to remove the air filter is detailed
in section Replacing the air filter on
page 284.
2 If a fine filter is used, remove the polymeric
filter element first.
3 Clean the filter three or four times.
4 Allow the filter to dry in one of these ways:
• Lying flat on a flat surface Note
• Blow with compressed air in opposite
direction of filter airflow. Do not wring the filter to press out water.
Action Note/Illustration
6 Refit the air filter.
Required equipment
Cleaning considerations
This section specifies some special considerations when cleaning the controller.
• Always use ESD protection.
• Always use cleaning equipment as specified above. Any other cleaning
equipment may shorten the life of paint work, rust inhibitors, signs, or labels.
• Always make sure that all protective covers are fitted to the controller before
cleaning.
• Never remove any covers or other protective devices when cleaning the
outside of the controller.
• Never use compressed air or spray with a high pressure cleaner.
• Never leave the door open when cleaning the exterior.
Location
The surfaces to clean are shown in the illustration below.
A B
xx1800000128
A Touch screen
B Hard buttons
Required equipment
Cleaning considerations
The section below specifies some special considerations when cleaning the
FlexPendant:
• Use ESD Protection
• Use cleaning equipment as specified above. Any other cleaning equipment
may shorten the life time of the touch screen.
• Check that all protective covers are fitted to the device before cleaning.
• Make sure that no foreign objects or liquids can penetrate into the device.
Continues on next page
160 Product manual - OmniCore C90XT
3HAC073706-001 Revision: D
© Copyright 2020-2021 ABB. All rights reserved.
4 Maintenance
4.3.3 Cleaning the FlexPendant
Continued
Location
The air filter is located as shown in the illustration below.
xx1900001473
Required equipment
Equipment Note
Air filter
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the step- tools required.
by-step instructions below.
Action Note/Illustration
1
DANGER
Action Note/Illustration
1 Loosen the attachment screws on the air
filter.
xx1900001491
xx1900001492
Action Note/Illustration
1 Take out the polymeric filter element from
the filter.
xx2000000421
Action Note/Illustration
1 Insert the polymeric filter element to the
filter and secure with the metallic line.
xx2000000421
Action Note/Illustration
1
DANGER
xx1900001492
Concluding procedure
Action Note/Illustration
1 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Overview
Perform this test on the FlexPendant emergency stop button.
Action Note
1 Make a visual inspection of the emergency If any damage is found on the emergency
stop button to make sure it is not physically stop button, it must be replaced.
damaged.
2 Pull and rotate the emergency stop button
clockwise to verify that it is not pressed in.
3 Start the robot system.
4 Press the emergency stop button. The test is passed if the event message
10013 Emergency stop state appears in
Note the event log.
4.5.2 Function test of manual, auto, and manual full speed mode with FlexPendant
Overview
Perform this function test to change the mode on the FlexPendant using the
following operation:
• Status bar > Common Settings > Operating Mode (Auto/Manual/Man FS).
For more detailed information, see Operating manual - OmniCore, 3HAC065036-001.
Action Note
1 Start the robot system.
2 Change to Automatic operating mode and This test is passed if it is possible to run
Motors ON state, and then run the robot in the robot program in auto mode.
auto mode. If it is not possible to run the robot pro-
gram, this test is failed and the root cause
of the failure must be found.
3 Change to Manual operating mode and This test is passed if it is possible to run
Motors ON state, and then run the robot in the robot program in manual mode.
manual mode. If it is not possible to run the robot pro-
gram, this test is failed and the root cause
of the failure must be found.
4 Change to Manual Full Speed mode and This test is passed if it is possible to run
Motors ON state, and then run the robot in the robot program in manual full speed
manual full speed mode. mode.
If it is not possible to run the robot pro-
Note gram, this test is failed and the root cause
of the failure must be found.
Manual full speed mode is not available in
USA or Canada.
Action Note
1 Start the robot system and turn the mode
switch to manual mode.
2 Press the three-position enabling device This test is passed if the event message
to the middle position and then hold the 10011 Motors ON state appears in the
enabling device in this position. event log.
If the event message 10011 Motors ON
state does not appear, or if the event
message 20224 Enabling device conflict
appears in the event log, then the test has
failed and the root cause of the failure must
be found.
3 While still holding the three-position en- This test is passed if the event message
abling device pressed, press the enabling 10012 safety guard stop state appears in
device harder to the enable the device's the event log.
third position. If the event message 10012 Safety guard
stop state does not appear, or if the event
message 20224 Enabling device conflict
appears in the event log, then the test has
failed and the root cause of the failure must
be found.
4.5.4 Function test of contactors A1.Q1 and A1.Q2 inside the power unit
Action Note
1 Start the robot system and change the op-
erating mode to manual.
2 Press the three-position enabling device This test is passed if the event message
to the middle position and then hold the 10011 Motors ON state appears in the
enabling device in this position. event log.
If the event message 37001 Motor on activ-
ation error appears in the event log, then
the test has failed and the root cause of the
failure must be found.
3 Release the three-position enabling device. This test is passed if the event message
10012 Safety guard stop state appears in
the event log.
If the event message 20227 Motor contact-
or conflict appears in the event log, then
the test has failed and the root cause of the
failure must be found.
Action Note
1 Start the robot system and change the op-
erating mode to manual.
2 Press the three-position enabling device This test is passed if the brakes are disen-
to the middle position and then hold the gaged and the manipulator can be moved.
enabling device in this position. If the event message 50056 Joint collision
While having eye contact with the manipu- appears in the event log, then the test has
lator, move the joystick slightly in any dir- failed and the root cause of the failure must
ection to disengage the brakes. be found.
3 Release the three-position enabling device This test is passed if the event message
to engage the brakes. 10012 Safety guard stop state appears in
the event log.
If the event message 37101 Brake failure
appears in the event log, then the test has
failed and the root cause of the failure must
be found.
Action Note
1 Start the robot system and change the op-
erating mode to auto mode.
2 Activate the auto stop, for example by The test is passed if the event message
opening the connected robot cell door, 20205 Auto stop open appears in the event
which has interlock connection with auto log.
stop. If the event message 20205 Auto stop
open does not appear or if the event mes-
sage 20225 Auto stop conflict appears in
the event log, then the test has failed and
the root cause of the failure must be found.
Overview
Perform this test on the external emergency stop device.
Action Note
1 Make a visual inspection of the external If any damage is found on the external
emergency stop device and the connection emergency stop device or the connection
harness to make sure they are not physic- harness, it must be replaced.
ally damaged.
2 Pull and rotate the button on the external
emergency stop device clockwise to verify
that it is not pressed in.
Note
Overview
Perform this test on the FlexPendant emergency stop button or the external
emergency stop device, with the accessory device.
Action Note
1 Make a visual inspection of the emergency If any damage is found, it must be replaced.
stop button, external emergency stop
device, accessory device and the connec-
tion harness to make sure they are not
physically damaged.
2 Pull and rotate the emergency stop button
clockwise to verify that it is not pressed in.
Note
Action Note
1 Start the robot system and change the op-
erating mode to manual.
2 Create a test program where the robot The distance and speed must be adapted
moves along a known distance with a pro- to the current installation and robot model.
grammed speed higher than 250 mm/s.
3 Start the program in manual mode and This test is passed if the speed of the robot
measure the time it takes for the robot to does not exceed 250 mm/s, otherwise the
travel the distance. test is failed and the root cause of the fail-
ure must be found.
Tip
5 Repair
5.1 Introduction to repair
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Otherwise damage to the mechanics and electronics may occur.
Required equipment
The details of the equipment required to perform a specific repair activity are listed
in the respective procedures.
Safety information
There are general safety information and specific safety information. The specific
safety information describes the danger and safety risks while performing specific
steps in a procedure. Make sure to read through the chapter Safety on page 13
before commencing any service work.
WARNING
Wait at least three minutes after powering off the controller before opening it and
at least fifteen minutes until all LED indicators are off before replacing modules.
Note
When replacing a part on the OmniCore C90XT, report to your local ABB the
serial number, the article number, and the revision of both the replaced unit and
the replacement unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Required documents
Action Info/illustration
1
DANGER
Action Info/illustration
1 Insert the key to the door and turn it anti-
clockwise.
2 Pull out the handle and turn it anti-clock-
wise.
3 Pull out the door with the handle.
Action Info/illustration
1 Push the door back.
2 Turn the handle clockwise and push it
back into the lock.
3 Turn the key back and take it out.
Location
The illustration shows the location of the axis computer in the controller.
xx1900001462
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect:
• K6.X11 - A1.X3
• K6.X2 - A2.X9
• K6.X1 - K2.X3.
2 Loosen the screw and disconnect:
• K6.X4, K6.X5 - SMB.
Action Note/Illustration
3 Remove the screws on the bracket.
xx1900001484
Tip
xx1900001485
xx1900001486
Action Note/Illustration
1 Remove the bracket screws.
xx1900001487
Action Note/Illustration
1 Refit the axis computer to the bracket Screws: Torx pan head screw M4x8 (4 pcs)
and secure the screws.
xx1900001487
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
3 Fit the axis computer bracket and secure Screws: Torx pan head screw M4x8 (4 pcs)
the screws.
xx1900001486
xx1900001484
4 Reconnect:
• K6.X11 - A1.X3
• K6.X2 - A2.X9
• K6.X1 - K2.X3
Action Note/Illustration
5 Reconnect and secure the screw:
• K6.X4, K6.X5 - SMB.
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the fans in the controller.
xx1900001463
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect standard fan:
• G1.X2-K2.X17
2 Remove the fan bracket screws.
xx1900001488
Action Note/Illustration
3 Take out the fan with the bracket.
Action Note/Illustration
1 Remove the screws on the fan to the
bracket.
2 Remove the fan from the bracket.
Tip
xx1900001498
xx1900001489
Action Note/Illustration
1 Refit the standard fan to the bracket. Screws: Torx pan head screw M4x8 (4 pcs)
Tip
xx1900001498
xx1900001489
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Refit the standard fan with the bracket
into position according to the location
pin.
4 Secure the screws. Screws: Torx pan head screw M4x8 (2 pcs)
xx1900001488
5 Reconnect:
• G1.X2-K2.X17
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Loosen the attachment screws on the air
filter.
xx1900001491
Action Note/Illustration
2 Remove the air filter.
xx1900001492
Action Note/Illustration
1 Disconnect heat exchanger:
• G3.X1-K2.X17
2 Remove the screws locking the sensor
and pull out the sensor.
xx1900001490
Action Note/Illustration
3 Remove the heat exchanger attachment
screws.
xx1900001493
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
xx1900001494
Action Note/Illustration
4 Secure the attachment screws. Screws: Torx, countersunk screw M4x10 (10
pcs)
xx1900001493
5 Reconnect:
• G3.X1-K2.X17
6 Refit the sensor cable and secure with Screws: Torx pan head screw M4x8 (2 pcs)
screws.
xx1900001490
Action Note/Illustration
1
DANGER
xx1900001492
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the robot signal exchange proxy in the
controller.
xx1900001464
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
WARNING
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect:
• K2.X8 - A2.X6
• (option): K2.X2 - K4.X8, A2.X1
• K2.X12 - A2.K3.X6, A2.K3.X7
• K2.X10 - A1.X13
• K2.X21 - TempSensor (G3.TEMP)
• K2.X4 - A1.X9
• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,
K7.X1
• K2.X1 - T2.X2
• K2.X17 - G3.X1, G1.X2
• K2.X6, K2.X11 - A1.X2
• K2.X7, K2.X22 - Harn. LV robot
power (X1)
• K2.X9 & X13 - FlexPendant (X4)
2 Remove the mating connectors by
loosening their attachment screws.
xx1900002339
xx1900001495
Action Note/Illustration
4 Remove the screws and lift out the robot
signal exchange proxy.
xx1900001496
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Fit the robot signal exchange proxy and Screws: Torx pan head screw M4x8 (4 pcs)
secure the screws.
xx1900001496
xx1900001495
xx1900002339
Action Note/Illustration
6 Reconnect:
• K2.X8 - A2.X6
• (option): K2.X2 - K4.X8, A2.X1
• K2.X12 - A2.K3.X6, A2.K3.X7
• K2.X10 - A1.X13
• K2.X21 - TempSensor (G3.TEMP)
• K2.X4 - A1.X9
• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,
K7.X1
• K2.X1 - T2.X2
• K2.X17 - G3.X1, G1.X2
• K2.X6, K2.X11 - A1.X2
• K2.X7, K2.X22 - Harn. LV robot
power (X1)
• K2.X9 & X13 - FlexPendant (X4)
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the Ethernet switch in the controller.
xx1900001465
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect:
• K2.X2 - K4.X8, A2.X1
• K4.X7 - K5.1.X5
• K4.X6 - A2.X4
Action Note/Illustration
2 Carefully pull the side of the Ethernet
extension switch and rotate it tightly to
take it out from the bracket.
xx1900001499
xx1900002328
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
Note
xx1900002330
xx1800000972
4 Reconnect:
• K2.X2 - K4.X8, A2.X1
• K4.X7 - K5.1.X5
• K4.X6 - A2.X4
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the Connected Services Gateway in the
controller. For the 3G variant, there is a sim card is located inside the unit.
xx1900001466
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect the antenna cable from the
Connected Services Gateway by rotating
the connector.
xx1900001948
xx1900001949
Action Note/Illustration
1 Disconnect:
• K7.X1 - K2.X3 i
• K7.X2 - A2.X5
Note
Action Note/Illustration
2 Carefully pull the side of the Connected
Services Gateway and rotate it tightly to
take it out from the bracket.
xx1900001500
xx1900002329
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
Note
xx1900002331
4 Reconnect:
• K7.X1 - K2.X3 i
• K7.X2 - A2.X5
i For Connected Services Gateway wired, there is no power cable.
Action Note/Illustration
1 Insert the cable from the cable grommet. Refitting the cable grommet assembly on
page 317.
2 Refit the cable in the cabinet according
to the record during the disassembly.
Action Note/Illustration
3 Connect the antenna cable to the Connec-
ted Services Gateway by rotating.
xx1900001948
xx1900001949
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the scalable I/O in the controller.
xx1900001467
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect:
• K5.1.X5 - A2.X4/K4.X7
Note
• K5.1.X4 - K2.X3
• The harness connected to I/O unit
by customer
2 Push the buckle of the digital base
slightly and take out the digital base.
xx1900002446
xx1900002447
Action Note/Illustration
1
DANGER
xx1900001446
xx1900002447
Action Note/Illustration
4 Connect the adapter cable to the digital
base.
• K5.1.X5 - A2.X4/K4.X7
Note
• K5.1.X4 - K2.X3
• The harness connected to I/O unit
by customer
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the main computer in the controller.
xx1900001468
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Note
For robots with the controller delivered to start in automatic mode, a FlexPendant
is required after the replacement to be able to change to automatic mode.
Required documents
Note
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect all the connectors on the as-
sembly group of the robot signal ex-
change proxy, Ethernet switch (option),
Connected Services Gateway, and main
computer.
For the robot signal exchange proxy:
• K2.X8 - A2.X6
• (option): K2.X2 - K4.X8, A2.X1
• K2.X12 - A2.K3.X6, A2.K3.X7
• K2.X10 - A1.X13
• K2.X21 - TempSensor
• K2.X4 - A1.X9
• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,
K7.X1
• K2.X1 - T2.X2
• K2.X17 - G2.X1, G1.X2
• K2.X6, K2.X11 - A1.X2
• K2.X7, K2.X22 - Harn. LV robot
power
• K2.X9 & X13 - FlexPendant
For the Ethernet extension switch (op-
tion):
• K2.X2 - K4.X8, A2.X1
• K4.X7 - K5.1.X5
• K4.X6 - A2.X4
For the Connected Services Gateway:
• K7.X1 - K2.X3 i
• K7.X2 - A2.X5
Note
Note
Action Note/Illustration
2 Remove the screws holding the main
computer.
xx1900001877
Note
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001885
Action Note/Illustration
1 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx2000000419
xx1900001879
xx1900001880
Action Note/Illustration
1 Carefully pull the side of the Ethernet
extension switch and rotate it tightly to
take it out from the bracket.
xx1900001881
xx1800000491
Action Note/Illustration
1 Carefully pull the side of the Connected
Services Gateway and rotate it tightly to
take it out from the bracket.
xx1900001883
xx1800000495
TOP VIEW
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx2000000419
Note
xx1800000497
TOP VIEW
xx1900001884
Action Note/Illustration
1
DANGER
xx2000000419
Action Note/Illustration
3 Hook up the Ethernet extension switch
to the bracket and then push the switch
into position.
Note
xx1800000493
xx1800000972
xx1900001882
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx2000000419
3 Fit the robot signal exchange proxy and Screws: Torx pan head screw M4x8 (4 pcs)
secure the screws.
xx1900001880
xx1900001879
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Refit the assembly onto the mounting
plate.
xx1900001885
xx1900001878
xx1900001877
Action Note/Illustration
For the robot signal exchange proxy:
• K2.X8 - A2.X6
• (option): K2.X2 - K4.X8, A2.X1
• K2.X12 - A2.K3.X6, A2.K3.X7
• K2.X10 - A1.X13
• K2.X21 - TempSensor (G3.TEMP)
• K2.X4 - A1.X9
• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,
K7.X1
• K2.X1 - T2.X2
• K2.X17 - G3.X1, G1.X2
• K2.X6, K2.X11 - A1.X2
• K2.X7, K2.X22 - Harn. LV robot
power (X1)
• K2.X9 & X13 - FlexPendant (X4)
For the Ethernet extension switch (op-
tion):
• K2.X2 - K4.X8, A2.X1
• K4.X7 - K5.1.X5
• K4.X6 - A2.X4
For the Connected Services Gateway:
• K7.X1 - K2.X3 i
• K7.X2 - A2.X5
Note
Note
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Restore the hardware settings. Restoring the hardware settings on page 241.
3 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect all the connectors on the as-
sembly group of the robot signal ex-
change proxy, Ethernet switch (option),
Connected Services Gateway, scalable
I/O (option), and main computer.
Action Note/Illustration
For the robot signal exchange proxy:
• K2.X8 - A2.X6
• (option): K2.X2 - K4.X8, A2.X1
• K2.X12 - A2.K3.X6, A2.K3.X7
• K2.X10 - A1.X13
• K2.X21 - TempSensor (G3.TEMP)
• K2.X4 - A1.X9
• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,
K7.X1
• K2.X1 - T2.X2
• K2.X17 - G3.X1, G1.X2
• K2.X6, K2.X11 - A1.X2
• K2.X7, K2.X22 - Harn. LV robot
power (X1)
• K2.X9 & X13 - FlexPendant (X4)
For the Ethernet extension switch:
• K2.X2 - K4.X8, A2.X1
• K4.X7 - K5.1.X5
• K4.X6 - A2.X4
For the Connected Services Gateway:
• K7.X1 - K2.X3 i
• K7.X2 - A2.X5
Note
Note
Action Note/Illustration
1 Pull the cable ties out from the locking
holes.
xx1900001886
xx1900001887
Action Note/Illustration
1 Carefully pull the side of the Ethernet
extension switch and rotate it tightly to
take it out from the bracket.
xx1900001888
xx1800000491
Action Note/Illustration
1 Carefully pull the side of the Connected
Services Gateway and rotate it tightly to
take it out from the bracket.
xx1900001890
xx1800000495
TOP VIEW
Action Note/Illustration
1 Remove the screws holding the main
computer.
xx1900001892
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001893
xx1900001894
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Fit the main computer to the mounting
plate.
xx1900001894
xx1900001893
4 Fasten the main computer with the Screws: Torx pan head screw M4x8 (2 pcs)
screws.
xx1900001892
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Note
xx1900001890
xx1800000495
TOP VIEW
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Hook up the Ethernet extension switch
to the bracket and then push the switch
into position.
Note
xx1900001888
xx1800000972
xx1800000491
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
3 Fit the robot signal exchange proxy and Screws: Torx pan head screw M4x8 (4 pcs)
secure the screws.
xx1900001887
xx1900001886
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
For the Connected Services Gateway:
• K7.X1 - K2.X3 i
• K7.X2 - A2.X5
Note
Note
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Restore the hardware settings. Restoring the hardware settings on page 241.
3 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Note
When replacing the main computer, both the serial number and licences are lost.
The serial number must be restored as described below. Licences however, can
either be restored automatically when the RobotWare system is installed, or
manually through Manage Licences in RobotWare Installation Utilities.
Action Note/Illustration
1 Download the hardware information file
(hwsettings.rsf) from MyABB, or from a
previous system backup.
2 Access the RobotWare Installation Utilit-
ies.
xx1900000110
xx2000000007
7 Tap Browse to open the hardware inform- The system compares the downloaded file
ation file from its location. The restoration and the manually entered serial number to
of the serial number is completed. ensure that there is a match.
Location
The illustration shows the location of the power unit in the controller.
xx1900001469
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect:
• A1.X13 - K2.X10
• A1.X9 - K2.X4
• A1.X4 - T4.X5
• A1.X5 - T4.X1
• A1.X12 - T4.X3
• A1.X1 - Power inlet (X0)
• A1.X6 A1.X7-T2.X1 and AC Termin-
al block
Action Note/Illustration
2 Remove the screws and pull the power
unit out from the two snaps on the
mounting plate.
CAUTION
xx1900001895
xx1900001896
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
3 Push the power unit until it snaps on the Screws: Torx pan head screw M4x8 (2 pcs)
mounting plate and secure the screws.
xx1900001895
xx1900001896
Action Note/Illustration
4 Reconnect:
• A1.X13 - K2.X10
• A1.X9 - K2.X4
• A1.X4 - T4.X5
• A1.X5 - T4.X1
• A1.X12 - T4.X3
• A1.X1 - Power inlet (X0)
• A1.X6 A1.X7-T2.X1 and AC Termin-
al block
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the power supply in the controller.
xx1900001470
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
WARNING
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect:
• T2.X1 - A1.X6
• T2.X2 - K2.X1
Action Note/Illustration
2 Remove the screws and the power sup-
ply.
xx1900001897
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Fit the power supply and fasten it with Screws: Torx pan head screw M4x8 (4 pcs)
screws.
xx1900001897
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Action Note/Illustration
1
DANGER
Action Note/Illustration
3 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
Action Note/Illustration
1 Remove the end clamp besides the
power supply with a screwdriver.
xx1900001907
Action Note/Illustration
2 Disconnect:
• T5.X1-AC Terminal block
• T5.X2-24V Terminal block
3 Remove the screw and the power supply.
xx1900001908
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Fit the power supply to the bracket and Screws: Cross recessed cheese head screw
fasten it with screw. M4x8 (1 pcs)
4 Reconnect:
• T5.X1-AC Terminal block
• T5.X2-24V Terminal block
xx1900001908
xx1900001907
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Remove the end clamp besides the
power supply with a screwdriver.
xx1900002443
Action Note/Illustration
2 Disconnect:
• T5.X1-AC Terminal block
• T5.X2-24V Terminal block
3 Press the lower buckle to release and
remove the power supply.
xx1900001950
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Hang the power supply into the bracket
and push the lower of it until you hear a
clear clicking sound.
4 Reconnect:
• T5.X1-AC Terminal block
• T5.X2-24V Terminal block
xx1900001950
xx1900002443
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the drive unit in the controller.
xx1900001471
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect:
• T2.X1 - A1.X6
• T2.X2 - K2.X1
Action Note/Illustration
2 Remove the screws and the power sup-
ply.
xx1900001897
Action Note/Illustration
1 Disconnect:
• T4.X7, T4.X8, T4.X9
• T4.X5 - A1.X4
• T4.X3 - A1.X12
• T4.X1 - A1.X5
2 Cut the cable tie for the DC-bus cable
and move it to the other side.
xx1900001900
xx1900002338
Action Note/Illustration
4 Remove the attachment screws and pull Lengthened screwdriver
the drive unit out from the two snaps.
xx1900001898
xx1900001899
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Push the drive unit into the snaps on the Screws: Torx pan head screw M4x8 (4 pcs)
mounting plate and secure the screws.
xx1900001898
xx1900001899
Action Note/Illustration
4 Fasten the DC-bus cable with a new
cable tie to the drive unit.
xx1900001900
xx1900002338
6 Reconnect:
• T4.X7, T4.X8, T4.X9
• T4.X5 - A1.X4
• T4.X3 - A1.X12
• T4.X1 - A1.X5
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
3 Fit the power supply and fasten it with Screws: Torx pan head screw M4x8 (4 pcs)
screws.
xx1900001897
4 Reconnect:
• T2.X1 - A1.X6
• T2.X2 - K2.X1.
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the fieldbus master in the controller.
xx1800003420
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Note
Preparations
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect all the connectors on the as-
sembly group of the robot signal ex-
change proxy, Ethernet switch (option),
Connected Services Gateway, and main
computer.
Action Note/Illustration
For the robot signal exchange proxy:
• K2.X8 - A2.X6
• (option): K2.X2 - K4.X8, A2.X1
• K2.X12 - A2.K3.X6, A2.K3.X7
• K2.X10 - A1.X13
• K2.X21 - TempSensor
• K2.X4 - A1.X9
• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,
K7.X1
• K2.X1 - T2.X2
• K2.X17 - G2.X1, G1.X2
• K2.X6, K2.X11 - A1.X2
• K2.X7, K2.X22 - Harn. LV robot
power
• K2.X9 & X13 - FlexPendant
For the Ethernet extension switch (op-
tion):
• K2.X2 - K4.X8, A2.X1
• K4.X7 - K5.1.X5
• K4.X6 - A2.X4
For the Connected Services Gateway:
• K7.X1 - K2.X3 i
• K7.X2 - A2.X5
Note
Note
Action Note/Illustration
2 Remove the screws holding the main
computer.
xx1900001877
Note
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001885
Action Note/Illustration
1 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx2000000419
xx1900001879
xx1900001880
Action Note/Illustration
1 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx2000000419
xx1900001909
Note
Action Note/Illustration
3 Remove the attachment screw on the
fieldbus master and take out the fieldbus
master.
Note
xx1900001910
Note
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
Action Note/Illustration
1 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx2000000419
xx1900001911
Note
Action Note/Illustration
3 Secure the fieldbus adapter with the Screws: Screw with flange M3x6 (1 pcs)
screw.
xx1900001910
Note
4 Refit the cover of the main computer and Screws: Hexalobular socket pan head screw
secure the screws. M3x6 (4 pcs)
xx1900001909
Note
Action Note/Illustration
1
DANGER
xx2000000419
3 Fit the robot signal exchange proxy and Screws: Torx pan head screw M4x8 (4 pcs)
secure the screws.
xx1900001880
Action Note/Illustration
4 Insert the cable ties into the locking
holes.
xx1900001879
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Refit the assembly onto the mounting
plate.
xx1900001885
xx1900001878
xx1900001877
Action Note/Illustration
For the robot signal exchange proxy:
• K2.X8 - A2.X6
• (option): K2.X2 - K4.X8, A2.X1
• K2.X12 - A2.K3.X6, A2.K3.X7
• K2.X10 - A1.X13
• K2.X21 - TempSensor (G3.TEMP)
• K2.X4 - A1.X9
• K2.X3 - K6.X1, A2.K3.X1, K5.1.X4,
K7.X1
• K2.X1 - T2.X2
• K2.X17 - G3.X1, G1.X2
• K2.X6, K2.X11 - A1.X2
• K2.X7, K2.X22 - Harn. LV robot
power (X1)
• K2.X9 & X13 - FlexPendant (X4)
For the Ethernet extension switch (op-
tion):
• K2.X2 - K4.X8, A2.X1
• K4.X7 - K5.1.X5
• K4.X6 - A2.X4
For the Connected Services Gateway:
• K7.X1 - K2.X3 i
• K7.X2 - A2.X5
Note
Note
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the conveyor tracking module in the controller.
xx1900001472
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect:
• B1.X1 - K2.X19.1 & K2.X19.2
• B1.X7 - K4.X1-5
Action Note/Illustration
2 Pull on the lower side of the conveyor
tracking module slightly and take out the
conveyor tracking module.
Note
xx1900001912
xx1900001913
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
xx1900001913
xx1900001912
Action Note/Illustration
4 Connect the adapter cable to the convey-
or tracking module.
• B1.X1 - K2.X19.1 & K2.X19.2
• B1.X7 - K4.X1-5
Stick the other connector onto the side
of the digital base with the self-adhesive
part.
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the air filter on the controller.
xx1900001473
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
Action Note/Illustration
1 Loosen the attachment screws on the air
filter.
xx1900001491
xx1900001492
Action Note/Illustration
1 Take out the polymeric filter element from
the filter.
xx2000000421
Action Note/Illustration
1 Insert the polymeric filter element to the
filter and secure with the metallic line.
xx2000000421
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Refit the air filter to the cabinet.
Secure it with the screws.
xx1900001492
Concluding procedure
Action Note/Illustration
1 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the manipulator signal connector.
xx1900001476
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Loosen the screw and disconnect:
• SMB - K6.X4, K6.X5
xx1900001914
xx1900001915
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001915
xx1900001914
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the motor connector in the controller.
xx1900001478
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect the following connectors for
the motor connector:
• T4.X7, T4.X8, T4.X9
• X1 - K2.X7 & X22
• PE.5 & PE.6
Action Note/Illustration
2 Remove the attachment screws on the
cover.
xx1900001916
Note
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
3 Insert the motor connector into the cover Screws: Torx pan head screw M4x8 (4 pcs)
from inner side of the cabinet and fasten
it with the screws.
xx1900001916
4 Reconnect:
• T4.X7, T4.X8, T4.X9
• X1 - K2.X7 & X22
• PE.5 & PE.6
5 Secure the motor connector cables with
the velcro on the frame of the cabinet.
Tip
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
Action Note/Illustration
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the fieldbus adapter slave in the controller.
xx1900001474
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
Action Note/Illustration
2 Open the door. Opening the door on page 174.
3 Location of wrist strap button:
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001446
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
4 Close the door. Closing the door on page 174.
5 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Action Note/Illustration
1
DANGER
xx1900001917
Action Note/Illustration
1
DANGER
Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)
xx1900001917
Location
The illustration shows the location of the power inlet in the controller.
xx1900001479
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Disconnect the mains switch from the
handle for 6 switch by pressing the push
hook.
xx1900001919
Action Note/Illustration
2 Disconnect:
• X0 - Q0.
X0 - A1.X1.
• PE.3 & PE.4.
3 Remove the attachment screws.
xx1900001918
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Insert the power inlet into the cover of
the cabinet.
4 Secure it with the screws. Screws: Torx pan head screw M4x8 (4 pcs)
xx1900001918
5 Reconnect:
• X0 - Q0.
X0 - A1.X1.
• PE.3 & PE.4.
6 Reconnect the mains switch to the
handle for 6 switch.
xx1900001920
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the HMI signal connector in the controller.
xx1900001475
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Remove the cables out from the clips in
the cabinet carefully.
Note
2 Disconnect:
• TPU (X4) - K2.X9 & X13
Action Note/Illustration
3 Remove the screws.
xx1900001921
xx1900001922
Action Note/Illustration
5 Remove the attachment screws on the
door.
xx1900001923
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Insert the HMI signal connector into the Screws: Torx, countersunk screw M4x10 (4
cover from inside the cabinet. pcs)
Secure it with the screws.
xx1900001923
4 Connect:
• TPU (X4) - K2.X9 & X13
5 Secure the cables on HMI signal connect-
or into the clips on the cabinet.
Tip
xx1900001922
Action Note/Illustration
7 Secure it with the screws. Screws: Torx pan head screw M4x8 (3 pcs)
xx1900001921
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the cable grommet assembly on the controller.
xx1900001481
Note
The end user need to buy proper grommets according to the diameter of the
cables which need to go through the grommet.
This will affect the protection level of the cabinet if it's not executed correctly.
It is recommended to use icotek KT grommet.
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Remove the cables out from the clips in
the cabinet carefully.
Note
xx1900002340
Action Note/Illustration
1 Unscrew the cable entry frame from the
enclosure wall.
xx1900002332
Action Note/Illustration
2 Take out the cables with the cable entry
frame through the cut-out.
xx1900002333
xx1900002334
xx1900002335
Action Note/Illustration
5 Take out the grommets with the cables
that need to be removed one by one.
Tip
xx1900002336
xx1900002337
Action Note/Illustration
1 Insert and equip the cable to the corres-
ponding KT grommet.
xx1900002337
Note
Note
xx1900002336
xx1900002335
Action Note/Illustration
4 Secure the frame and cover strip with the Screws: Hex socket head cap screw M5x50
screws. 12.9 Gleitmo 603+Geomet 500 (3 pcs)
Tightening torque: 2 Nm - 3 Nm.
xx1900002334
xx1900002333
Action Note/Illustration
6 Refit the cable entry frame to the enclos- Screws: Torx pan head screw M4x8 (4 pcs)
ure wall and secure with the screws. Tightening torque: 1.5 Nm.
xx1900002332
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Insert the cable grommet assembly into Screws: Torx pan head screw M4x8 (4 pcs)
the cover of the cabinet.
Secure it with the screws.
xx1900002340
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the cable grommet assembly on the controller.
xx1900001480
Note
The end user need to buy proper grommets according to the diameter of the
cables which need to go through the grommet.
This will affect the protection level of the cabinet if it's not executed correctly.
It is recommended to use icotek KT grommet.
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Remove the cables out from the clips in
the cabinet carefully.
Note
xx1900002445
Action Note/Illustration
1 Unscrew the cable entry frame from the
enclosure wall.
xx1900002332
Action Note/Illustration
2 Take out the cables withe the cable entry
frame through the cut-out.
xx1900002333
xx1900002334
xx1900002335
Action Note/Illustration
5 Take out the grommets with the cables
that need to be removed one by one.
Tip
xx1900002336
xx1900002337
Action Note/Illustration
1 Insert and equip the cable to the corres-
ponding KT grommet.
xx1900002337
Note
Note
xx1900002336
xx1900002335
Action Note/Illustration
4 Secure the frame and cover strip with the Screws: Hex socket head cap screw M5x50
screws. 12.9 Gleitmo 603+Geomet 500 (3 pcs)
Tightening torque: 2 Nm - 3 Nm.
xx1900002334
xx1900002333
Action Note/Illustration
6 Refit the cable entry frame to the enclos- Screws: Torx pan head screw M4x8 (4 pcs)
ure wall and secure with the screws. Tightening torque: 1.5 Nm.
xx1900002332
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
3 Insert the cable grommet assembly into Screws: Torx pan head screw M4x8 (4 pcs)
the cover of the cabinet.
Secure it with the screws.
xx1900002340
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the harness ETH outlet with cable.
xx1900001482
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Remove the screws.
xx1900001921
xx1900001922
Action Note/Illustration
3 Remove the attachment screws on the
door.
xx1900001924
Note
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Action Note/Illustration
4 Secure it with the attachment screws. Screws: Torx, countersunk screw M4x10 (4
pcs)
xx1900001924
5 Connect:
• X24 - A2.X3
6 Secure the harness ETH outlet with
cables with the clips on the cabinet.
Tip
xx1900001922
Action Note/Illustration
8 Secure it with the screws. Screws: Torx pan head screw M4x8 (3 pcs)
xx1900001921
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the LED indicator.
xx1900001483
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
DANGER
xx1900001446
Action Note/Illustration
1 Remove the screws.
xx1900001921
xx1900001922
Action Note/Illustration
3 Loose the attachment screws locking the
cable.
xx1900001926
Action Note/Illustration
1
DANGER
2
ELECTROSTATIC DISCHARGE
(ESD)
Action Note/Illustration
4 Insert the terminals (X1 & X2) of cables
into the lamp and secure with the screws.
xx1900001926
xx1900001922
Action Note/Illustration
6 Secure it with the screws. Screws: Torx pan head screw M4x8 (3 pcs)
xx1900001921
Concluding procedure
Action Note/Illustration
1 Close the door. Closing the door on page 174.
2 Perform the function tests to verify that
the safety features work properly, see
Function tests on page 165.
Location
The illustration shows the location of the power cable, power cable gasket, and
power cable cover in the FlexPendant.
A B
xx1800001154
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
ELECTROSTATIC DISCHARGE
(ESD)
xx1800001189
xx1800001190
Action Note/Illustration
5 Disconnect two connectors to the Flex-
Pendant.
xx1800001748
xx1800001192
Action Note/Illustration
1
ELECTROSTATIC DISCHARGE
(ESD)
Action Note/Illustration
2 Refit the power cable.
xx1800001193
xx1800001748
4 Refit the power cable cover and tighten Screws: Torx pan head screw M4x8 (3 pcs)
the screws.
xx1800001196
Location
The illustration shows the location of the joystick protection on the FlexPendant.
xx1800001197
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Required documents
Action Note/Illustration
1
ELECTROSTATIC DISCHARGE
(ESD)
xx1800001198
xx1800001199
Action Note/Illustration
1
ELECTROSTATIC DISCHARGE
(ESD)
Action Note/Illustration
2 Refit the joystick protection.
xx1800001200
xx1800001206
Location
The illustration shows the location of the fasten strip on the FlexPendant.
xx1900000771
Note
The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the OmniCore C90XT via myABB Business Portal,
www.abb.com/myABB.
Action Note/Illustration
1 Open the velcro on the fasten strip.
2 Take the fasten strip out from the holes.
3 Insert the new fasten strip into the holes
one by one.
4 Secure the velcro in a suitable length.
6 Decommissioning
6.1 Introduction
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
General
All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.
Tip
To remove all data from the OmniCore controller, use the Delete user data
function (part of Delete RobotWare system function) in RobotWare. See
Operating manual - Integrator's guide OmniCore.
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Aluminium Heat sinks on power supplies and drive units
Batteries, Lithium Main computer
Copper Cables
Plastic/rubber Cables, connectors, etc.
Silicone Power supply i
Steel Cabinet structure, plates, screws, etc.
i The product does not contain silicone by design but there might be a minimal risk of contamination
during production.
xx1900000803
Green symbol with "e" in it: The product does not contain any hazardous substances
exceeding concentration limits and is a green environmentally friendly product
which can be recycled.
7 Troubleshooting
7.1 Introduction to troubleshooting
Introduction
The product manual and the circuit diagram contains information that can be good
when troubleshooting.
For OmniCore, all event logs from the software can be seen on the FlexPendant,
or in Technical reference manual - Event logs for RobotWare 7.
Make sure to read through the section Safety on page 13 before starting.
Troubleshooting strategies
1 Isolate the fault to pinpoint the cause of the problem from consequential
problems.
2 Divide the fault chain in two.
3 Check communication parameters and cables.
4 Check that the software version is compatible with the hardware.
Work systematically
1 Take a look around to make sure that all screws, connectors, and cables are
secured, and that the robot and other parts are clean, not damaged, and
correctly fitted.
2 Replace one thing at a time.
3 Do not replace units randomly.
4 Make sure that there are no loose screws, turnings, or other unexpected
parts remaining after work has been performed.
5 When the work is completed, verify that the safety functions are working as
intended.
Basic scenarios
What to look for during troubleshooting depends on when the fault occurred. Was
the robot recently installed or was it recently repaired? The following table gives
hints on what to look for in specific situations.
The robot has recently Check:
been installed • the configuration files
• connectors
• options and their configuration
• changes in the robot working area/movements.
Description
No LEDs at all are lit in the controller.
Preparations
Action
1 Make sure that the controller is switched on.
Wait 30 s - 1 min to enable start-up sequence.
2 Check the FlexPendant for errors and warnings.
DANGER
Block diagram
Robot 24V PC X1 Main computer
24V TRUNK
X2
signal PC
A2
L,N,PE
L,N,PE
exchange
AC input Power inlet Main switch Power unit Power LED
L,N
L,N
proxy
A1 supply HMI 24V HMI
X0 Q0 X1 X6 X1 X1 K2 X13 24V HMI
connection FlexPendant
AC
T2 X2 PS
X9 HMI X4
PE LED LED
LED
MS
X4
LED
24V SYS DRV
xx2000000443
Troubleshooting flowchart
Off
Check switch Q0 Switch on Q0
On
Abnormal Troubleshoot
Check input power
mains
Normal
Connection
not ok
Check connector X0 Repair connection
Connection ok
Broken cable
Check AC input cable Replace cable
Cable ok
Abnormal
Check Q0 power out Replace Q0
Ok
Abnormal Troubleshoot
Check T2.X1
power unit
Ok
Troubleshoot power
supply
Ok
Not lit
Check LED status
Lit
Problem solved
xx2000000444
Action Note
1 Make sure that the power inlet switch (Q0) has
been switched on.
xx2000000445
2 Make sure that the system is supplied with power. Use a multimeter and insulating
• Measure incoming mains voltage and make gloves.
sure the voltage is within the normal range. If the incoming power is not ok, the
• Make sure that the circuit breaker (if used) problem is not in the robot control-
is closed. ler. Troubleshoot the incoming
power.
3 Check that the connector (X0) is properly connec-
ted.
Tip
Description
The following are possible symptoms of a start-up failure:
1 The LEDs are not lit on some units.
2 Earth fault protection trips.
3 Miniature circuit breakers/fuses trips.
4 Unable to load the system software.
Preparations
Action
1 Make sure that the controller is switched on.
Wait 30 s - 1 min to enable start-up sequence.
2 Check the FlexPendant for errors and warnings.
DANGER
Block diagram
Robot 24V PC X1 Main computer
24V TRUNK
X2
signal PC
A2
L,N,PE
L,N,PE
exchange
AC input Power inlet Main switch Power unit Power LED
L,N
L,N
proxy
A1 supply HMI 24V HMI
X0 Q0 X1 X6 X1 X1 K2 X13 24V HMI
connection FlexPendant
AC
T2 X2 PS
X9 HMI X4
PE LED LED
LED
MS
X4
LED
24V SYS DRV
xx2000000443
Troubleshooting flowchart
Start-up failure
Green
Green
Troubleshoot robot
Check LEDs: Not lit
signal exchange
MS, PC, HMI proxy K2
Green
Lit
Problem solved
xx1800001829
Action Note
1 Look at the LED PS. LED PS should be green.
• If not, see Troubleshooting
the power supply on
page 401.
• If the power supply is ok,
see Troubleshooting the
power unit on page 382.
• If the power unit is ok, check
that the power inlet is prop-
erly connected and the
power inlet switch is turned
on.
For more details about the LEDs,
see Troubleshooting the robot sig-
nal exchange proxy on page 407.
2 Look at the LED MS. LED MS should be green.
• If not, see Troubleshooting
the robot signal exchange
proxy on page 407.
Continues on next page
362 Product manual - OmniCore C90XT
3HAC073706-001 Revision: D
© Copyright 2020-2021 ABB. All rights reserved.
7 Troubleshooting
7.2.2 Start-up failure
Continued
Action Note
3 Look at the LED AC. LED AC should be green.
• If not, see Troubleshooting
the power unit on page 382.
• If the power unit is ok, check
that the power inlet is well
connected and the power
inlet switch is turned on.
4 Look at the LEDs PC and HMI. LED PC and LED HMI should be
green.
• If not, see Troubleshooting
the robot signal exchange
proxy on page 407
5 Look at the LEDs PC PWR, PC HDD, and PC For more details about the LEDs,
STAT. see Troubleshooting the main
computer on page 398.
6 If the problem remains, contact ABB.
Tip
Description
In certain scenarios, such as removing or adding certain optional features or major
upgrades of installed software products versions, the previous backup may be
incompatible with the newly re-configured system. Automatically reloading backup
can therefore fail, resulting in system failure state.
For more information about system update, see Operating manual - Integrator's
guide OmniCore.
Description
When starting robot operation or jogging the robot, the internal robot brakes must
release in order to allow movement.
Preparations
Action
1 Make sure that the controller is switched on.
Wait 30 s - 1 min to enable start-up sequence.
2 Check the FlexPendant for errors and warnings.
DANGER
Block diagram
Contactor
Q1 & Q2
Robot signal
exchange
Motor connector Manipulator
proxy K2
Brake signal Brake signal X1 Floor cable
X6 X7
X2
Power unit
A1
xx1800001835
Troubleshooting flowchart
Power is ok
Troubleshoot
Connec!on
not ok - brake release on
Check connec!on
manipulator
from K2.X7 to X1
-main computer A2
- robot signal exchange
Connec!on is ok proxy K2
- power unit A1
Connec!on
Check connec!on not ok
K2.X6 to A1.X2
Connec!on is ok
Brake not ok
Test the brake
Brake is ok
Not ok
Test the brake release Contact ABB
Brake release is ok
Problem solved
xx1800001836
Action Note
1 Check that the floor cable is connected from the • If the cable is damaged, re-
manipulator to the motor connector X1. place to a new cable and go
to step 8.
Visually inspect the cable for damage or extensive
bending marks. • If the cable is not connected,
repair the connection and
go to step 8.
Tip • If the cable is ok, go to the
next step.
For more details, see Circuit diagram - OmniCore
C90XT.
2 Look at the LED PS on the front of the robot signal For more details about the LEDs,
exchange proxy. LED PS should be solid green. see Troubleshooting the robot sig-
nal exchange proxy on page 407.
• If it is not green, see
Troubleshooting the power
supply on page 401.
3 Look at the LED MS, LED PC and LED HMI. All • If LED MS is not green, see
LEDs should be solid green. Troubleshooting the robot
signal exchange proxy on
page 407.
• If LED PC or LED HMI are
not green, see
Troubleshooting the power
supply on page 401.
• If the power supply is ok,
see Troubleshooting the
power unit on page 382.
• If the power unit is ok, check
that the power inlet is con-
nected and the power inlet
switch is turned on.
• If the LED PC is green, but
LED PC_PWR on the main
computer is not green, see
Troubleshooting the main
computer on page 398.
• If the LED HMI is green, but
the FlexPendant is not
starting, see Troubleshoot-
ing the FlexPendant on
page 379.
4 Measure the power on K2.X7. Use a multimeter and insulating
gloves.
• If there is no power, repair
Tip the connection and go to
step 8.
For more details, see Circuit diagram - OmniCore • If it is ok, go to the next
C90XT. step.
5 Check that the connection from the robot signal • If it is not, repair the connec-
exchange proxy to the motor connector is ok: tion and go to step 8.
• K2.X7 - X1. • If it is ok, go to the next
step.
6 Check that the connection from main computer • If it is not, repair the connec-
to the robot signal exchange proxy is ok: tion and go to step 8.
• K2.X6 - A1.X2 • If it is ok, go to the next
step.
Action Note
7 Try jogging the robot. • If it is not working properly,
the brake release board on
the manipulator might be
broken. Contact your local
ABB for more information.
• If the brakes work normally,
troubleshoot the main com-
puter, the robot signal ex-
change proxy, and the
power unit, one by one. If
needed, replace faulty units.
Go to step 8.
8 Check that the brake release function is ok. For more details on how to release
the brakes, see the robot's product
manual.
• If it is not ok, contact your
local ABB.
Description
The FlexPendant is not responding, either completely or intermittently.
No entries are possible, and no functions are available.
Note
If protective gloves are used, these must be compatible with touchscreens when
using the FlexPendant.
The FlexPendant starts but does not display the main interface.
xx1800000722
Preparations
Action
1 Make sure that the controller is switched on.
Wait 30 s - 1 min to enable start-up sequence.
2 Check the FlexPendant for errors and warnings.
DANGER
Block diagram
24V SYS
X1 Robot signal
exchange
Safety
Dual channel proxy K2 X3
controller X6
A2.K3 control & feedback ES & EN & MON & 24V HMI
X13
X12
X7 HMI
HMI connection FlexPendant
LED
X4
Ethernet Ethernet
Main X6 X8 X9
computer A2 MS
LED X2
X1
24V PC
PC
LED
xx1800001830
Troubleshooting flowchart
Problem starting or
connecting the FlexPendant
Connection not ok
Check connector X4 Repair connection
Connection ok
Green
Cable
damaged Replace FlexPendant
Check FlexPendant
cable cable
Cable ok
Connection
Check connection not ok
K2.X9 to X4
Check:
K2.X8 - A2.X6 Connection
K2.X2 - A2.X1 not ok
K2.X12 - A2.K3.X6,7
K2.X3 - A2.K3.X1
Connections ok
Replace FlexPendant
Not starting
Start FlexPendant
Ok
Problem solved
xx1800001831
Action Note
1 Try resetting the FlexPendant using the reset See Operating manual - OmniCore.
button located next to the USB port.
Action Note
2 Check that the FlexPendant cable is correctly If it is not connected, repair the
connected to the controller through the HMI signal connection and go to step six.
connector, X4. Check the pins in the connector.
If it is ok, go to the next step.
3 Check the LED PC and LED HMI, they should be For more details about the LEDs,
green. see Troubleshooting the robot sig-
nal exchange proxy on page 407.
• If the LEDs are not green,
see Troubleshooting the ro-
bot signal exchange proxy
on page 407.
• If they are ok, go to the next
step.
4 Check the FlexPendant cable for any damage. • If damage is found, replace
the FlexPendant cable and
go to step six.
• If it is ok, go to the next
step.
5 Check that the connection from the robot signal • If it is not ok, repair the con-
exchange proxy to the HMI signal connector is nection and go to step six.
ok, K2.X9, 13 - X4. • If it is ok, go to the next
step.
6 Check that the connection from the robot signal • If any connection fails, re-
exchange proxy to the main computer is ok: pair the connection and go
• K2.X8 - A2.X6 to step six.
• K2.X2 - A2.X1 • If the connections are ok, go
to the next step.
• K2.X12 - A2.K3.X6,7
• K2.X3 - A2.K3.X1
7 If possible, test by connecting another FlexPend-
ant. This is to eliminate the FlexPendant and cable
as error sources; Test the FlexPendant with a
different controller to eliminate the controller as
error source.
8 Check that the FlexPendant works normally. If it is not ok, contact your local
ABB.
Tip
Description
The FlexPendant is started and responds when pushing buttons or using the
touchscreen but the joystick is not working. It is therefore not possible to jog the
robot.
If there are warnings or messages on the FlexPendant, see Problem releasing the
robot brakes on page 365.
Action Information
1 Make sure that the joystick lock is not activated. See Operating manual - OmniCore.
2 Make sure the controller is in manual mode.
3 Make sure the FlexPendant is connected cor-
rectly to the controller.
4 Press the reset button located next to the USB If the joystick is still not working, then
port on the back of the FlexPendant. replace the FlexPendant.
Note
Description
The system has startup problems or the FlexPendant cannot connect to the system.
Function description
The robot controller always runs in one of the following two modes:
• Normal operation mode (a user-created system is selected to run)
• RobotWare Installation Utilities mode (advanced maintenance mode)
In rare occasions, a serious error (in the software or the configuration of the installed
system), may prevent the controller from starting properly in the normal operation
mode. A typical case is when a controller is restarted after a network configuration
change, causing the controller to be non-responsive from FlexPendant, RobotStudio,
or FTP. To restore the robot controller from this situation, the controller can be
forced to start in RobotWare Installation Utilities mode.
Note
Note
Force starting the RobotWare Installation Utilities mode will not affect the files
in the directories belonging to the installed system.
See also Troubleshooting the main computer on page 398.
How to install systems is described in Operating manual - Integrator's guide
OmniCore.
Description
When reflashing firmware, the automatic process can fail which will stop the system.
A message is generated in the event log.
This fault usually occurs due to a lack of compatibility between hardware and
software.
Description
The path of the robot TCP is not consistent. It varies from time to time, and is
sometimes accompanied by noise emerging from bearings, gearboxes, or other
locations.
Possible causes
The symptom can be caused by (the causes are listed in order of probability):
• Robot not calibrated correctly.
• Robot TCP not correctly defined.
• Parallel bar damaged (applies to robots fitted with parallel bars only).
• Mechanical joint between motor and gearbox damaged. This often causes
noise to be emitted from the faulty motor.
• Bearings damaged or worn (especially if the path inconsistency is coupled
with clicking or grinding noises from one or more bearings).
• The wrong robot type may be connected to the controller.
• The brakes may not be releasing correctly.
Action Note
8 Make sure the correct robot type is con- Update the system with the correct robot
nected as specified in the system. type, see Operating manual - Integrator's
guide OmniCore.
9 Make sure the robot brakes work prop- Proceed as detailed in section Problem re-
erly. leasing the robot brakes on page 365.
10 If applicable: Check the setting for the The swivel has an in-built resistance that
swivel. needs to be set in the system parameters.
Description
The controller features a number of indication LEDs, which provide important
information for troubleshooting purposes. If no LEDs light up at all when switching
the system on, troubleshoot as detailed in this section.
All LEDs on the respective units, and their significance, are described in the
following sections.
Description
The FlexPendant communicates with the main computer. The FlexPendant is
physically connected to the panel board. The cable contains the +24 V supply, two
enabling device chains and emergency stop.
Procedure
The procedure below describes what to do if the FlexPendant does not work
correctly.
Action Note
1 Try resetting the FlexPendant using the reset See Operating manual - Omni-
button located next to the USB port. Core.
2 If the FlexPendant is not responding or does not
operate correctly, see Problem starting or con- Note
necting the FlexPendant on page 369.
If protective gloves are used, these
must be compatible with touch-
screens when using the FlexPend-
ant.
Location
The illustration shows the location of the drive unit in the controller.
xx1900001471
LEDs
The illustration below shows the indication LEDs on the drive unit.
OmniCore C90XT
B C
A B A
xx1800000575
Description Significance
Ethernet LEDs Shows the status of Ethernet communication between the drive unit and
the power unit.
Green:
• Off: 10 Mbps data rate is selected.
• On: 100 Mbps data rate is selected.
Yellow:
• Flashing: The two units are communicating on the Ethernet channel.
• Steady: A LAN link is established.
• Off: A LAN link is not established.
Drive unit status The status indicator LED can be used to identify the following status
LED during startup/power on:
1 Red, steady: Default when power is available.
2 Red, flashing: Power is on, self-test is ongoing, operating system
is loading.
3 Green, flashing: Application is loaded and waiting for communica-
tion.
4 Green, steady: Drive unit is operational.
If the LED does not turn steady green after 30-60 sec, the status indicator
LED can be used to identify the following issues:
• No color: Power to the drive unit is missing.
• Red, steady: Internal error.
• Red, flashing: Firmware error or self-test failure.
• Green, flashing: Communication error to another module.
Location
The illustration below shows the location of the power unit in the controller.
xx1900001469
LEDs
The illustration below shows the LEDs on the power unit.
OmniCore C90XT
A B A B C
xx1800000576
Description
Power unit status The status indicator LED can be used to identify the following status
LED during startup/power on:
1 Red, steady: Default when power is available.
2 Red, flashing: Power is on, self-test is ongoing, operating system
is loading.
3 Green, flashing: Application is loaded and waiting for commu-
nication.
4 Green, steady: Power unit is operational.
If the LED does not turn steady green after 30-60sec, then the status
indicator LED can be used to identify the following issues:
• No color: Power to the power unit is missing.
• Red, steady: Internal error.
• Red, flashing: Firmware error or self-test failure.
• Green, flashing: Communication error to another module.
Preparations
Action
1 Check the FlexPendant for errors and warnings.
2 Power the controller off. Wait one minute, power the controller on.
3 Make sure that the control system power supply is in run-time mode.
Wait 30-60 seconds after power-on.
Troubleshooting flowchart
Connection
Check contactors not ok
Repair connection
Q1,Q2 & X2
Ok
Repair
Green
Repair connection connection
Measure X5, X9, 24V DC = 24V
DC input voltage
0V
Abnormal
Measure X6, X7,
AC output voltage
Abnormal
xx1800002357
Troubleshooting procedure
The troubleshooting table is supposed to be used as a detailed instruction together
with the troubleshooting flowchart.
Action Note
1 Check the connections between Open the door of the controller and check the
connectors Q1, Q2 & X2. connections between connectors Q1, Q2 & ad-
apter X2.
Tip How to open the controller is described in
Opening the robot controller on page 174.
• If the connection is OK, proceed with
For more details, see Circuit dia- step 2.
gram - OmniCore C90XT.
• If there is a problem with the connection,
repair the connection and start over.
2 Power on the controller. Check the Make sure that the controller power supply is
indicator LED MS on the power in run-time mode.
unit. Wait at least 1 min after power-on.
If the LED MS is:
• Green, proceed with step 8.
• Flashing red/green: a firmware upgrade
error has occurred. This is not supposed
to happen during runtime mode, proceed
with step 12.
• Pulsing red: replace the power unit, step
12.
• Not lit or red: The controller does not
have sufficient DC input voltage. Proceed
with step 3.
3 Measure the 24 V DC input voltage Use a multimeter and insulating gloves.
to the power unit. The input voltage should be 24 V.
• X5
Make sure that connectors X5, X9 are connec-
• X9 ted properly on both ends.
• If the 24 V DC input voltage is normal,
proceed with step 8.
• If the 24 V DC input voltage is abnormal,
proceed with the next step.
4 Check connection to the robot sig- If the connection is OK, proceed with the next
nal exchange proxy. step.
• A1.X9 (Power unit) - K2.X4 If there is a problem with the connection, repair
the connection and go to step 2.
5 Measure the AC output voltage. Use a multimeter and insulating gloves.
The output voltage should be 230 V.
Make sure that connectors X6, X7 are connec-
ted properly on both ends.
• If the output voltage is normal,
Troubleshooting the power supply on
page 401, and then Troubleshooting the
robot signal exchange proxy on page 407.
• If the output voltage is abnormal, pro-
ceed with step 6.
xx1900000043
Action Note
6 Measure the AC input voltage. Use a multimeter and insulating gloves.
• A1.X1 - A1.K1 The AC input voltage should be 230 V.
Make sure that connector X1 is connected
properly on both ends.
• If the input voltage is normal, proceed
with step 12.
• If the input voltage is abnormal, proceed
with the next step.
7 Check the connection from the • If the connection is OK, troubleshoot No
power inlet to the power unit. LEDs are lit on the controller on page 358.
• If there is a problem with the connection,
repair the connection and start over.
8 Check the LEDs of the Ethernet • If the LEDs are normal, proceed with step
ports X3, X12 on the power unit. 10.
• If the LEDs are abnormal, proceed with
the next step.
9 Check the connection of the Ether- • If the connection is OK, proceed with
net cables. step 12.
• If there is a problem with the connection,
repair the connection and go to step 8.
10 Measure the AC OK signal. Use a multimeter and insulating gloves.
The AC OK should be 0 V.
Make sure that connector X13 is connected
properly on both ends.
• If the AC OK signal is 24 V, proceed with
step 12.
• If the AC OK signal is 0 V, proceed with
the next step.
11 Check event log if there is a mes- If message numbers 34401/34402, proceed with
sage about DC-link voltage. step 12.
If not, power unit is ok.
12 The power unit may be faulty, re- How to replace the unit is detailed in Replacing
place it and verify that the fault has the power unit on page 242.
been fixed.
Further information
Information about how to troubleshoot the fieldbuses and I/O units can be found
in the manual for the respective fieldbus or I/O unit. See References on page 9.
Location
The illustration shows the location of the Connected Services Gateway in the
controller.
xx1900001466
C
B
A
D
xx1800000634
A STATUS LED
B LINK, 3G status or WiFi status LED
C RF, signal strength status LEDs
D Factory reset pin hole
Description Significance
STATUS LED Startup sequence:
(red/green) 1 Red continuously: Default at power up.
2 Red, flashing: Power on self-test ongoing, operating system is
loading.
3 Green flashing: Loading application.
4 Green solid: Startup completed OK.
If the LED does not turn steady green after 30-60sec, it can be used to
identify the following issues:
Fault indication:
• No color: Power to the unit is missing.
• Red, solid or flashing: Internal error. Replace the unit.
• Green, flashing continuously: Communication error to another
module, view error messages.
LINK For the Connected Services 3G, an orange LED indicator, externally visible
on the front, indicates the status of the 3G connection.
Orange:
• ON, flashing: 3G modem on, searching network.
• ON, solid: 3G modem on and connected to network.
LINK For the Connected Services Wi-Fi, an orange LED indicator, externally
visible on the front, indicates the status of the Wi-Fi connection.
Orange:
• ON, flashing: Wi-Fi transceiver on, searching network.
• ON, solid: Wi-Fi transceiver on and connected to network.
Description Significance
RF, signal Three (3) LEDs indicating the Wi-Fi or 3G signal level.
strength status • ON: The unit is connected to the network and working ok.
LEDs • OFF: Problem with connector, antenna, or sim card.
Preparations
Action
1 Check the FlexPendant for errors and warnings.
2 Power the controller off. Wait one minute, power the controller on.
3 Make sure that the control system power supply is in run-time mode.
Wait 30-60 seconds after power-on.
Troubleshooting Connected
Services Gateway 3G or WiFi
Red/green flashing
Check LED STATUS
Not lit
Not ok
Check connector X2 Repair connection
Ok
Not ok
Check LED RF
Ok
Not ok
Check connector X3
Ok
Not ok Troubleshoot
Check antenna, connectivity of 3G/sim
sim card etc. card/WiFi, antenna
Ok
xx1900000139
Tip
4 Check that the connector X2 is well con- Make sure that connector X2 is connected
nected and the network connection prop- properly on both ends.
erties are available. • If the connection is OK, proceed
with step 5.
• If there is a problem with the con-
nection, repair the connection and
go back to step 1.
5 Check the indicator RF LEDs on the If the RF LEDs are:
Connected Services Gateway. • ON, the Connected Services Gate-
way is connected to network and
works well.
• OFF, the Connected Services
Gateway is faulty or the connection
of the connector X3 is not ok. Pro-
ceed with step 6.
6 Check that the connector X3 is well con- Make sure that connector X3 is connected
nected. properly on both ends.
• If the connection is OK, proceed
with step 7.
• If there is a problem with the con-
nection, repair the connection and
go back to step 5.
Action Note
7 Check that the right type of the antenna • If the antenna is not working, repair
is connected properly. the connection or move the an-
tenna to a location with better RF
signal.
Tip • If the antenna is ok, proceed with
step 11.
Try moving the antenna to different loca-
tions if the RF signal level is low.
8 On the FlexPendant, check the connec- Verify that the configuration is done cor-
tion log in Backup and Restore. rectly.
Verify that the mobile operator is detected
(for 3G).
9 For 3G, use a cell phone to test that the See the Connected Services Gateway
sim card is working. configuration in Operating manual - Integ-
For WiFi, use a cell phone to verify the rator's guide OmniCore.
WiFi access.
Note
Location
The illustration shows the location of the Ethernet switch in the controller.
xx1900001465
LEDs
The illustration below shows the indication LEDs on the Ethernet switch.
A
xx1800000584
A Status LED
Description Significance
Status LED Startup sequence:
1 No color: Input voltage is outside specified voltage or internal fault
in the switch.
2 Green, solid: The switch is operational.
If the LED does not turn steady green, the status indicator LED can be
used to identify the following issues:
Fault indication:
• No color: If input voltage is within specified voltage limits and the
LED is not lit then replace the switch.
Ethernet LEDs Shows the status of Ethernet links.
Green:
• Off:10 Mbps data rate is selected.
• On:100/1000 Mbps data rate is selected.
Yellow:
• Flashing: The Ethernet is active on link.
• Solid: A LAN link is established.
• Off: A LAN link is not established.
Location
The illustration shows the location of the axis computer in the controller.
xx1900001462
LEDs
The illustration below shows the LEDs on the axis computer.
C B B B
A A A
xx1800000581
Description Significance
Axis computer Normal sequence during startup:
status LED 1 Red, solid: Default at power-up.
2 Red, flashing: Establish connection to main computer and load
program to axis computer.
3 Green, flashing: Start-up of axis computer program and connect
peripheral units.
4 Green, solid: Start-up sequence ready. Application is running.
The following indicates errors:
• No color: No power to axis computer or internal error (hard-
ware/firmware).
• Red, solid: The axis computer has failed to initialize basic hard-
ware.
• Red, flashing continuously: Missing connection to main computer,
main computer start-up problem or RobotWare installation problem.
• Green, flashing continuously: Missing connections to peripheral
units or RobotWare start-up problem.
Ethernet LED Shows the status of Ethernet communication.
Green:
• Off:10 Mbps data rate is selected.
• On:100 Mbps data rate is selected.
Yellow:
• Flashing: The two units are communicating on the Ethernet chan-
nel.
• Solid: A LAN link is established.
• Off: A LAN link is not established.
Location
The illustration shows the location of the main computer in the controller.
xx1900001468
LEDs
The illustration below shows the LEDs on the main computer:
A B C
xx1800000585
Description Significance
Power status, PC The power status LED indicates the status of the power supply and the
PWR (green) main computer hardware and firmware.
Normal behavior:
• Off: During a normal startup the LED is off, until the COM Express
module inside the computer unit is started.
• On solid: After completion of startup the LED is steady on.
Failure during startup (off between blinks). One to four short blinks, one
second off. This is repeated until power off.
• Internal fail of power, FPGA, and/or the COM Express module.
• Replace the computer unit.
Power failure during runtime (fast flashing between blinks). One to five
blinks, 20 fast flashing blinks. This is repeated until power off.
• Temporary voltage drop, cycle the power to the controller.
• Check the power supply voltage to the computer unit.
• Replace the computer unit.
Disk status, PC The disk status LED indicates access to the main computer persistent
HDD memory.
Normal behavior:
• No color at power on: R34 FPGA is loaded on the main board.
• Yellow: Access (read/write) to internal mass memory.
Computer status, The computer status LED indicates the startup progress of RobotWare
PC STAT on the main computer.
(red/green) Normal behavior:
1 Red, solid: Default when turning on the power.
2 Red, flashing: Initial self-test is ongoing and the operating system
is loading.
3 Green, even flashing (~1Hz): The operating system is loaded and
RobotWare is initializing.
4 Green, uneven flashing: The RobotWare system failed to load or
is not installed.
5 Green, solid: The computer is operational and the RobotWare
system is fully loaded.
If the LED does not turn steady green after approximately 5 minutes then
the LED can be used to identify the following issues:
• No color: The internal power initialization failed. Restart the con-
troller. Replace the main computer if the problem remains.
• Red, solid: Internal error. Restart the controller. Replace the main
computer if the problem remains.
• Red, flashing continuously: Failed to load the operating system.
Restart the controller. See Controller fails to start on page 374.
Replace the main computer if the problem remains.
• Green, even flashing continuously (~1Hz): Failure during start up.
Check error messages on FlexPendant. See Controller fails to
start on page 374.
• Green, uneven flashing: RobotWare Installation Utilities mode.
For information about the LEDs on the AnybusCC slave fieldbus adapter and the
PCIExpress master/slave fieldbus board, see the corresponding fieldbus manual.
Troubleshooting procedure
Action Note
1 If the LEDs do not turn steady after See LEDs on page 398.
approximately 5 minutes then re-
start the controller and check the
LEDs again.
2 Force start the RobotWare Installa-
tion Utilities mode, see Controller
fails to start on page 374.
3 Re-install RobotWare, if possible.
4 The main computer may be faulty, See Replacing the main computer on page 213.
replace it and verify that the fault
has been fixed.
Location
The illustration below shows the location of the system power supply in the
controller.
xx2000000431
LEDs
The illustration below shows the LEDs on the power supply.
xx1800000582
A DC OK LED
Description Significance
DC OK LED Green: All DC outputs are above the specified minimum levels.
Off: One or more DC outputs are below the specified minimum level.
Preparations
Action
1 Check the FlexPendant for errors and warnings.
2 Power the controller off. Wait one minute, power the controller on.
3 Make sure that the control system power supply is in run-time mode.
Wait 30-60 seconds after power-on.
Troubleshooting flowchart
Troubleshooting the
power supply
Green
Check DC LED
Off
DC < 24V
No short circuit
Measure power AC ok
supply AC input
AC not ok
Connection
Repair AC not ok Check AC connection
connection between power supply
and A1
Connection ok
AC not ok Measure AC to
Repair AC input
controller
AC ok
Faulty cable
Repair cabling Check cabling
Cable ok
Troubleshoot the
Power supply is ok
power unit
xx1800001823
Troubleshooting procedure
The troubleshooting table is supposed to be used as a detailed instruction together
with the troubleshooting flowchart.
Test Note
1 Check the LED (labelled DC OK) on If the LED is:
the power supply. • Green: the power supply should be
working properly.
• Off: either the power supply is faulty or
it does not have sufficient input voltage.
Proceed with step 2.
Test Note
2 Measure the DC voltage while the Use a multimeter and insulating gloves.
output is connected to the robot Measure at the DC output connector X2. The
signal exchange proxy or some voltage should be: +24 V < U < +27 V.
other load. • If the voltage measured at the load falls
below +24 V, voltage drops in the cables
and connectors.
• If the correct voltage is detected and the
DC OK LED is green, the power supply
is working properly.
• If the correct voltage is detected and the
DC OK LED is off, the power supply is
regarded as faulty but does not have to
be replaced instantly.
• If the DC OK voltage is higher than 27
V, proceed with step 10.
• If the DC OK voltage is below 24 V, pro-
ceed with step 3.
3 Power the controller OFF and Use a multimeter and insulating gloves.
measure the resistance.
4 Check for short circuit on DC out- Measure the resistance between voltage pins
put. and ground. The resistance should not be less
Check both the DC output connect- than 10 ohm.
or X2 on the power supply and the
input connector X1 on the robot Note
signal exchange proxy.
Do not measure the resistance between pins.
Dual pins are used for both power supply and
ground.
• If no short circuit is found, proceed with
step 6.
• If a short circuit is found on the power
supply, proceed with step 10.
• If a short circuit is found on the robot
signal exchange proxy, get that unit
working. Verify that the fault has been
fixed and restart this guide if necessary.
5 Switch on power to the controller.
6 Measure the input voltage on the Use a multimeter and insulating gloves.
power supply. Voltage should be: 172 V < U < 276 V for a 230
V system.
• If the input voltage is correct, proceed
with step 10.
• If no or the wrong input voltage is detec-
ted, proceed with step 7.
7 Make sure that the connection • If the connection is OK, proceed with
between the power supply and the step 8.
power unit is ok. • If the connection is faulty, repair the
connection. Verify that the fault has been
fixed and restart this guide if necessary.
8 Make sure that the supplied input • If the input voltage is correct, proceed
voltage to the controller is correct. with step 9.
• If the input voltage is faulty, correct it.
Verify that the fault has been fixed and
restart this guide if necessary.
Test Note
9 Check the cabling. Make sure that the cabling is correctly connec-
ted and not faulty.
• If the cabling is OK, see Troubleshooting
the power unit on page 382. Verify that
the fault has been fixed and restart this
guide if necessary.
• If the cabling is found unconnected or
faulty, connect/replace it. Verify that the
fault has been fixed and restart this
guide if necessary.
10 The power supply may be faulty, See Replacing the power supply on page 247.
replace it and verify that the fault
has been fixed.
Location
The illustration shows the location of the fieldbus adapter slave in the controller.
xx1900001474
LEDs
The illustration below shows the indication LEDs on the fieldbus adapter slave.
xx1800000586
A Power LED
B Status LED
Description Significance
Power LED Fault indication:
• No color: Input voltage is outside of the specified voltage limits.
• Green, solid: Input voltage is within the specified limit.
Fieldbus adapter Startup sequence:
slave status LED Red:
(red/green) 1 Red, solid: Loading bootloader.
2 Red, flashing: Power on self-test is ongoing, loading operating
system.
3 Green, flashing: Loading RobotWare and waiting for communica-
tion.
4 Green, solid: System ready.
If the LED does not turn steady green after 30-60 sec, the status indicator
LED can be used to identify the following issues:
Fault indication:
• No color: Power to the fieldbus adapter slave is missing.
• Red, solid: Internal error.
• Red, flashing continuously: Firmware error or self-test failure.
• Green, flashing continuously: Communication error to another
module. Check the messages on the FlexPendant.
Location
The illustration below shows the location of the robot signal exchange proxy in the
controller.
xx1900001464
LEDs
The illustration below shows the LEDs on the robot signal exchange proxy:
Description Significance
MS Status LED (bi-colored green/red) for the The status indicator LED can be used to
robot signal exchange proxy. identify the following status during star-
tup/power on:
• Red, solid: Default when power is
available.
• Red, flashing: Power on self-test
ongoing, operating system is
loading.
• Green, flashing: Application is
loaded and waiting for communic-
ation.
• Green, solid: Module is operation-
al.
If the LED does not turn steady green
after 30-60 sec, the status LED can be
used to identify the following issues:
• No color: Power to the robot signal
exchange proxy is missing.
• Red, solid: Internal error.
• Red, flashing: Firmware error or
self-test failure.
• Green, flashing: Communication
error to another module.
AS1 & Automatic stop LEDs (green) Automatic stop LED can be used to
AS2 AS1:Automatic stop LED channel 1 identify the following status:
• No color (not lit): Automatic stop
AS2:Automatic stop LED channel 2 input loop is open.
• Green, solid: Automatic stop input
loop is closed.
ES1 & External emergency stop LEDs (green) External emergency stop LED can be
ES2 ES1:External emergency stop LED used to identify the following status:
channel 1 • No color (not lit): External emer-
gency stop input loop is open.
ES2:External emergency stop LED
channel 2 • Green, solid: External emergency
stop input loop is closed.
ES- Emergency stop output LEDs (green) Emergency stop output LED can be used
OUT1 ES1:Emergency stop output LED chan- to identify the following status:
& ES- nel 1 • No color (not lit): Emergency stop
OUT2 output logic low (0V) status.
ES2:Emergency stop output LED chan-
nel 2 • Green, solid: Emergency stop out-
put logic high (24V) status.
MON Motors_ON LED (white) Motors_ON LED can be used to identify
the following status:
• No color: Motors_ON function is
off.
• White, solid: Motors_ON function
is on.
• White, flashing: safety loop is
open, for example after an emer-
gency stop.
Description Significance
AC ACOK LED (green) ACOK LED can be used to identify the
following status:
• No color: AC OK signal is de-active
or logic power failure.
• Green, solid: AC OK signal is act-
ive and logic power available.
PS Internal power (24 V power supply) input Internal power input LED can be used to
LED (green) identify the following status:
• No color: Internal power input
voltage is not in normal range.
• Green, solid: Internal power input
voltage is in normal range.
PC Main computer power output LED (green) Main computer power output LED can be
used to identify the following status:
• No color: Main computer power
output voltage is not in normal
range.
• Green, solid: Main computer power
output voltage is in normal range.
HMI FlexPendant power output LED (green) FlexPendant power output LED can be
used to identify the following status:
• No color: FlexPendant power out-
put voltage is not in normal range.
• Green, solid: FlexPendant power
output voltage is in normal range.
EP External power input LED (green) External power input LED can be used to
identify the following status:
• No color: External power input
voltage is not in normal range.
• Green, solid: External power input
voltage is in normal range.
Preparations
Action
1 Check the FlexPendant for errors and warnings.
2 Power the controller off. Wait one minute, power the controller on.
3 Make sure that the control system power supply is in run-time mode.
Wait 30-60 seconds after power-on.
Troubleshooting flowchart
Troubleshooting robot
signal exchange proxy
Replace robot
Turn off power until all LED (except MS) are off,
signal exchange
then turn on power and wait 1 min
proxy
Repair Green
connection Measure 24V DC = 24V
DC input voltage
DC < 24V
Connection
Lit not ok
Check connector
X14, X15
Troubleshoot
Connection ok external
equipment
Resistance
Check external safety
accessories
No resistance
Low
impedance
Measure AC OK signal
High impedance
xx1800002356
Troubleshooting procedure
The troubleshooting table is supposed to be used as a detailed instruction together
with the troubleshooting flowchart.
Test Action
1 Check the indicator LED MS. If the LED_MS is:
• Green, proceed with step 4.
• Flashing red/green, a firmware upgrade error
has occurred. This is not supposed to happen
during runtime mode, proceed with step 9.
• OFF, either the robot signal exchange proxy
is faulty or it does not have sufficient input
voltage. Proceed with step 2.
Test Action
2 Measure the input voltage to Use a multimeter and insulating gloves.
the robot signal exchange The input voltage should be 24 V.
proxy.
Make sure that connector X1 is connected properly
on both ends.
Tip • If the input voltage is normal, proceed with
step 4.
For more details, see Circuit • If the input voltage is abnormal, proceed with
diagram - OmniCore C90XT. step 3.
8 Reference information
8.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.
Note
The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.
General
The product is designed in accordance with ISO 10218-1:2011, Robots for industrial
environments - Safety requirements -Part 1 Robots, and applicable parts in the
normative references, as referred to from ISO 10218-1:2011. In case of deviations
from ISO 10218-1:2011, these are listed in the declaration of incorporation which
is part of the product delivery.
Standard Description
ISO 9283:1998 Manipulating industrial robots - Performance criteria and related
test methods
ISO 10218-2 Robots and robotic devices - Safety requirements for industrial
robots - Part 2: Robot systems and integration
ISO 12100 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design
ISO 13850 Safety of machinery - Emergency stop - Principles for design
IEC 60204-1:2005 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
IEC 62061:2005 Safety of machinery - Functional safety of safety-related elec-
trical, electronic and programmable electronic control systems
Standard Description
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
(option 129-1) standards – Emission standard for industrial environments
Standard Description
IEC 60974-10:2014 i Arc welding equipment - Part 10: EMC requirements
ISO 14644-1:2015 ii Classification of air cleanliness
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots.
ii Only robots with protection Clean Room.
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal
General
All service (repair, maintenance and installation) instructions contain lists of tools
required to perform the specified activity. All special tools, that is, all tools that are
not considered as standard tools as defined below, are listed in their instructions
respectively.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instructions.
Tool Description
Screw driver, Torx Tx10
Screw driver, Torx Tx20
Screw driver, Torx Tx25
Ball tipped screw driver, Torx Tx25
Screw driver, flat blade 4 mm
Screw driver, flat blade 8 mm
Screw driver, flat blade 12 mm
Screw driver Phillips-1
Box spanner 8 mm
Tool Note
Normal shop tools Contents as specified above.
Multimeter -
Camera To document problems or procedures
General
This section details how to tighten the various types of screw joints on the controller.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the tables below. Any special
torques are specified in the Repair, Maintenance or Installation procedure
description. Any special torque specified overrides the standard value.
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatical tools.
• Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a
slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for
oil-lubricated screws with slotted or cross-recess heads.
Dimension Tightening torque (Nm)
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0
Definition
In all repair and maintenance instructions, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in
this way.
To avoid injury, ABB recommends the use of lifting equipment when handling
components with a weight exceeding 22 kg.
Example
Below is an example of how a weight specification is presented:
CAUTION
The transformer weighs 55 kg! All lifting equipment used must be sized
accordingly!
General
Many repair and maintenance activities require different pieces of lifting accessories,
which are specified in each procedure.
The use of each piece of lifting accessories is not detailed in the activity procedure,
but in the instruction delivered with each piece of lifting accessories.
This implies that the instructions delivered with the lifting accessories should be
stored for later reference.
9 Spare parts
Spare part level
ABB spare parts are categorized into two levels, L1 and L2. Always check the part
level before conducting a service work on a spare part.
• L1 spare parts
The L1 parts can be replaced in the field. The maintenance and replacement
instructions given in the related product manuals must be strictly followed.
If there are any problems, contact your local ABB for support.
• L2 spare parts
To replace the L2 parts require specialized training and might need special
tools. Only ABB field service personnel or qualified personnel trained by
ABB can replace L2 parts.
Note
Drive units
xx1900001930
Power units
xx1900001931
xx1900001941
xx1900001942
xx1900001943
Blind plate
xx2000000453
xx1900001944
xx1900001939
DeviceNet master
xx1800003420
CTM-01
xx1900001938
xx1900001934
Ethernet switches
xx1900001935
Vision parts
Fans
xx1900001929
Axis computer
xx1900001927
Main computer
xx1900001933
xx1900001932
xx1900001937
xx1900001481
xx1900001928
Air filter
xx1900001945
xx1900001480
xx1900001947
xx1900001946
xx1900001936
End clamp
xx2000000529
xx1900001940
LED indicator
xx1900002451
TPU cover
xx1900002452
Cables
Cables on the frame
Spare part num- Description Type Spare part
ber level
- 3HAC071430-001 Harness AC input package Harness A1.X6, L1
A1.X7 - T2,T5
- 3HAC066527-001 Harness contactors signals Harness A1.X2 L1
- K2.X6, K2.X11
- 3HAC066520-001 Harness AC_OK signal Harness A1.X13 L1
- K2.X10
- 3HAC066521-001 Harness Temp Sensor Harness K2.X21 L1
- TempSensor
- 3HAC066522-001 Harness 24_SYS_DRV Harness K2.X4 L1
- A1.X9
FlexPendant parts
The illustration below shows the placement of the controller system parts in the
recommended spare part list.
A C D
B E D
xx1800000974
Index D
damaged bearings, 376
damaged parallel bar, 376
3 detaching FlexPendant, 76
3rd party software, 47
DeviceNet
A installing, 123
ABB Ability Connected Services Gateway dimensions, 39
replacing, 202 disconnecting FlexPendant, 76
Ability port, 85 disposal of storage media, 351
allergenic material, 30 double SMB harness
aluminum installing, 106
disposal, 352 drive unit
ambient humidity LED, 380
operation, 40 replacing, 257
storage, 39
ambient temperature
E
earth fault protection, 73
operation, 40
Earth fault protection, tripped, 361
storage, 39
emergency stop, 22
AS
definition, 22
configuring, 99
function test, 165
assembly instructions, 51
emergency stops, 24
assessment of hazards and risks, 30
enabling device, 25
automatic mode, 29
function test, 167
automatic stop, 99
EN ISO 13849-1, 14
auto stop
environmental information, 352
function test, 169
ESD
axis computer
damage elimination, 43
LED, 396
sensitive equipment, 43
replacing, 175
esd elimination, 42
B Ethernet
batteries installing, 113
disposal, 352 Ethernet extension switch
brakes not releasing, 365 installing, 113
Ethernet switch
C LED, 395
cabinet lock, 31 replacing, 198
cables, 69 external I/O
carbon dioxide extinguisher, 31 installing, 110
Category1AS, 23 replacing, 208
Category1ES, 23
category 0 stop, 22 F
category 1 stop, 22 fan
category 2 stop, 22 replacing, 181
cleaning faulty calibration, 376
FlexPendant, 44 faulty TCP definition, 376
cleaning of the controller, 159 fieldbus, 103
cleaning the FlexPendant, 160 fieldbus adapter
climbing on robot, 34 installing, 120
Connected Services Gateway fieldbus adapter slave
LED, 389 LED, 406
replacing, 202 fieldbus master
test equipment, 390 installing, 122
troubleshooting flowchart, 391 replacing, 265
connection fire extinguishing, 31
manipulator cables, 69 firewall settings, 86
connections, 79 firmware, reflashing failure, 375
controller FlexPendant
symbols, 19 blue screen, 369
controller fails to start, 374 cleaning, 44
controller mode, 374 connecting, disconnecting, 76
cooling fan storage, 44
replacing, 181 FlexPendant cannot connect to system, 374
copper FlexPendant connector, 137, 143, 284, 306, 312, 321
disposal, 352 FlexPendant holder, 58
FlexPendant joystick not working, 373
FlexPendant not responding, 369
ABB AS
Robotics & Discrete Automation
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Inc.
Robotics & Discrete Automation
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC073706-001, Rev D, en