ABB OmniCore C30

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Product manual

OmniCore C30

OmniCore

Document ID: 3HAC060860-001

Revision: P

Specifications subject to change without notice.

Main Page

Table of Contents5
Overview of this Manual9
Product Documentation13
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 C3037
Technical Data for Omnicore C30 Controller38
Safety Functions and Safety Related Data for Omnicore C3044
The Unit Is Sensitive to ESD47
Handling of Flexpendant48
Network Security49
Open Source and 3Rd Party Components in Robotware50
ABB Ability51
Installation and Commissioning53
Introduction to Installation and Commissioning53
Installation Activities54
Transporting and Handling55
Unpacking55
Storing56
On-Site Installation57
Required Installation Space57
Mounting the Controller with 19" Rack Mounting Kit [3002-1]61
Mounting the Controller with Vertical Mounting Kit [3002-2]64
Replacing the Controller from Vertical Mounting Kit To19" Rack Mounting Kit68
Mounting the Controller with Desktop Mounting Kit [3001-2]71
Mounting the Flexpendant Holder75
Changing the Fan Control Functionality81
Electrical Connections82
Connectors on the Omnicore C30 Controller82
Connecting Cables to the Controller85
Connecting the Manipulator to the Controller91
Fitting the Connector92
Connecting Power Supply to and Grounding the Controller97
Detaching and Attaching a Flexpendant100
Ethernet Networks on Omnicore104
Descriptions for Connectors112
Configuring Robot Stopping Functions126
Programmable Stop Functions130
I/O System133
Available Industrial Networks133
Scalable I/O, Internal and External135
Installing Options136
Installing the Harness for Double SMB136
Installing the Scalable I/O Devices141
Installing the Ethernet Extension Switch145
Installing the Power Supply Optional Device and the Harness 24 V Extension152
Installing the Fieldbus Master and the Devicenet Harness167
Installing Add-On Devices194
Installing the Scalable I/O Add-On Devices194
Installing the Conveyor Tracking Module195
Installing Integrated Vision197
Initial Test before Commissioning200
Maintenance201
Maintenance Schedule, Omnicore201
Inspection Activities203
Inspection of Controller203
Cleaning Activities205
Cleaning of the Controller Cabinet205
Cleaning the Flexpendant206
Changing/Replacing Activities208
Replacement of Air Filter Element for the Controller with Vertical Mounting Kit208
Function Tests212
Function Test of Emergency Stop212
Function Test of Manual, Auto, and Manual Full Speed Mode with Flexpendant213
Function Test of Three-Position Enabling Device214
Function Test of Safety Switches215
Function Test of Automatic Stop216
Function Test of General Stop217
Function Test of External Emergency Stop218
Function Test of ESTOP_STATUS Output219
Function Test of Reduced Speed Control220
Repair221
Introduction to Repair221
Replacing Parts Inside the Controller222
Opening the Robot Controller222
Replacing the Axis Computer231
Replacing the Fans236
Replacing the Standard Fans238
Replacing the Small Fans251
Replacing the Main Computer Fan264
Replacing the Robot Signal Exchange Proxy282
Replacing the Ethernet Switch290
Replacing the Connected Services Gateway299
Replacing the Scalable I/O Unit308
Replacing the Safety Digital Base Device313
Replacing the Main Computer318
Replacing the Power Unit358
Replacing the Power Supply365
Replacing the Drive Unit373
Replacing the Fieldbus Master384
Replacing Parts on the Front Panel411
Replacing the Manipulator Signal Connector (SMB)411
Replacing the Motor Connector416
Replacing the Motor Connector418
Replacing the Motor Connector for CRB 15000 Controller424
Replacing the Incoming Mains Connector434
Replacing the HMI Signal (Flexpendant) Connector439
Replacing the Process Connectors455
Replacing the Harness CFI Connection471
Replacing the IP20 Power Outlet Connector475
Replacing Parts on the Flexpendant491
Replacing the Power Cable and Power Cable Cover491
Replacing the Joystick Protection495
Replacing the Fasten Strip498
Troubleshooting499
Introduction to Troubleshooting499
Troubleshooting Fault Symptoms501
No Leds Are Lit on the Controller502
Start-Up Failure507
System Update Failure511
Problem Releasing the Robot Brakes512
Problem Starting or Connecting the Flexpendant517
Problem Using the Joystick522
Controller Fails to Start523
Reflashing Firmware Failure524
Inconsistent Path Accuracy525
Controller Is Overheated527
Troubleshooting Units528
Troubleshooting Leds in the Controller528
Troubleshooting the Flexpendant529
Troubleshooting the Drive Unit530
Troubleshooting the Power Unit532
Troubleshooting Fieldbuses and I/O537
Troubleshooting the Connected Services Gateway538
Troubleshooting the Ethernet Switch543
Troubleshooting the Axis Computer545
Troubleshooting the Main Computer547
Troubleshooting the Power Supply550
Troubleshooting the Robot Signal Exchange Proxy555
Decommissioning563
Introduction to Decommissioning563
Environmental Information564
Reference Information567
Introduction567
Applicable Standards568
Unit Conversion569
Standard Toolkit for Controller570
Screw Joints571
Weight Specifications572
Lifting Accessories and Lifting Instructions573
Spare Parts575
Controller Parts576
Controller System Parts576
Logic Parts582
Application Parts584
Cabinet Parts587
Miscellaneous Parts589
Cables592
Flexpendant Parts596
Manipulator Cables597
Customer Cables - CP/CS Connectors (Option)599
Customer Cables - Ethernet Floor Cables600
Index601

ABB OmniCore C30 - Page 3

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