ABB OmniCore C30 A

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Product manual

OmniCore C30 Type A

OmniCore

Document ID: 3HAC089064-001

Revision: A

Specifications subject to change without notice.

Main Page

Table of Contents5
Overview of this Manual9
Product Documentation11
How to Read the Product Manual13
Safety15
Safety Information15
Limitation of Liability15
Safety Data16
Requirements on Personnel17
Safety Signals and Symbols18
Safety Signals in the Manual18
Safety Symbols on Controller Labels20
Robot Stopping Functions23
Protective Stop and Emergency Stop23
About Emergency Stop25
Enabling Device and Hold-To-Run Functionality26
Robot Operating Modes27
About the Manual Mode27
About the Automatic Mode29
Safety During Installation and Commissioning30
Safety During Operation33
Safety During Maintenance and Repair34
Safety During Troubleshooting35
Safety During Decommissioning36
Controller Description37
Omnicore C30 Type a37
Technical Data for Omnicore C30 Type a Controller38
Safety Functions and Safety Related Data for Omnicore C30 Type a45
The Unit Is Sensitive to ESD47
Handling of Flexpendant48
Network Security49
Open Source and 3Rd Party Components50
ABB Connected Services (ABB Ability)51
Installation and Commissioning55
Introduction to Installation and Commissioning55
Installation Activities56
Transporting and Handling57
Unpacking57
Storing58
On-Site Installation59
Required Installation Space59
Mounting the Controller with 19" Rack Mounting Kit [3002-1]63
Mounting the Controller with Vertical Mounting Kit [3002-2]66
Replacing the Controller from Vertical Mounting Kit To19" Rack Mounting Kit70
Mounting the Controller with Desktop Mounting Kit [3001-2]73
Mounting the Flexpendant Holder77
Changing the Fan Control Functionality83
Connecting the Connected Services Antenna84
Electrical Connections85
Connectors on the Omnicore C30 Type a Controller85
Connecting Cables to the Controller88
Connecting the Manipulator to the Controller95
Fitting the Connector for Incoming Mains96
Connecting Incoming Mains and Protective Earth to the Controller97
Detaching and Attaching a Flexpendant100
Ethernet Networks on Omnicore104
Descriptions for Connectors106
Configuring Robot Stopping Functions121
Programmable Stop Functions125
I/O System128
Available Industrial Networks128
Scalable I/O, Internal and External131
Installing Options132
Installing the Scalable I/O Devices132
Installing the Ethernet Extension Switch137
Installing the Fieldbus Adapter Slave Device144
Installing the Fieldbus Master and the Devicenet Harness146
Installing Add-On Devices169
Installing the Scalable I/O Add-On Devices169
Installing the Conveyor Tracking Module170
Installing Integrated Vision172
Initial Test before Commissioning175
Maintenance177
Maintenance Schedule for the Omnicore Controller177
Inspection Activities178
Inspection of Controller178
Cleaning Activities179
Cleaning of the Controller Cabinet179
Cleaning the Flexpendant180
Changing/Replacing Activities182
Replacement of Air Filter Element for the Controller with Vertical Mounting Kit182
Function Tests185
Function Test of Emergency Stop185
Function Test of Manual, Auto, and Manual Full Speed Mode with Flexpendant186
Function Test of Three-Position Enabling Device187
Function Test of Safety Switches188
Function Test of Automatic Stop189
Function Test of General Stop190
Function Test of External Emergency Stop191
Function Test of ESTOP_STATUS Output192
Function Test of Reduced Speed Control193
Repair195
Introduction to Repair195
Replacing Parts Inside the Controller196
Opening the Robot Controller196
Replacing the Fans207
Replacing the Standard Fans209
Replacing the Small Fans213
Replacing the Robot Signal Exchange Proxy216
Replacing the Ethernet Switch (DSQC1035)221
Replacing the 3G Connected Services Gateway229
Replacing the Scalable I/O Unit237
Replacing the Safety Digital Base Device242
Replacing the Main Computer248
Replacing the Power Unit282
Replacing the Bleeder Box287
Replacing the Power Supply293
Replacing the Drive Unit297
Replacing the Fieldbus Master304
Replacing Parts on the Front Panel327
Replacing the Manipulator Signal Connector (SMB)327
Replacing the Motor Connector331
Replacing the Motor Connector333
Replacing the Motor Connector for CRB 15000 Controller337
Replacing the Incoming Mains Connector341
Replacing the HMI Signal (Flexpendant) Connector345
Replacing the Process Connectors358
Replacing the Harness CFI Connection371
Replacing the IP20 Power Outlet Connector375
Replacing Parts on the Flexpendant388
Replacing the Power Cable and Power Cable Cover388
Replacing the Joystick Protection393
Replacing the Fasten Strip396
Troubleshooting397
Introduction to Troubleshooting397
Troubleshooting Fault Symptoms399
No Leds Are Lit on the Controller400
Start-Up Failure401
System Update Failure403
Problem Releasing the Robot Brakes404
Problem Starting or Connecting the Flexpendant406
Problem Using the Joystick408
Controller Fails to Start409
Reflashing Firmware Failure410
Inconsistent Path Accuracy411
Controller Is Overheated413
Troubleshooting Units414
Troubleshooting Leds in the Controller414
Troubleshooting the Flexpendant415
Troubleshooting the Drive Unit416
Troubleshooting the Power Unit419
Troubleshooting Industrial Networks and I/O Devices425
Troubleshooting the 3G Connected Services Gateway426
Related Information431
Troubleshooting the Ethernet Switch (DSQC1035)432
Troubleshooting the Main Computer434
Troubleshooting Procedure436
Troubleshooting the Power Supply437
Troubleshooting Flowchart438
Troubleshooting the Fieldbus Adapter Slave441
Troubleshooting the Robot Signal Exchange Proxy443
Decommissioning449
Introduction to Decommissioning449
Environmental Information450
Reference Information453
Introduction453
Applicable Standards454
Unit Conversion455
Standard Toolkit for Controller456
Screw Joints457
Weight Specifications458
Lifting Accessories and Lifting Instructions459
Spare Parts461
Controller Parts462
Controller System Parts463
Mains Connection Parts467
Logic Parts468
Application Parts472
Cabinet Parts477
Miscellaneous Parts479
Cables483
Flexpendant Parts485
Manipulator Cables486
Customer Cables - CP/CS Connectors (Option)487
Customer Cables - Ethernet Floor Cables488

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