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3 Installation and commissioning

3.1 Introduction to installation and commissioning

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.

Product manual - OmniCore C90XT

51

3HAC073706-001 Revision: D

© Copyright 2020-2021 ABB. All rights reserved.

3 Installation and commissioning

3.1 Introduction to installation and commissioning

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Summary of Contents for OmniCore C90XT

Page 1: ...ROBOTICS Product manual OmniCore C90XT ...

Page 2: ...Trace back information Workspace 21A version a14 Checked in 2021 03 30 Skribenta version 5 4 005 ...

Page 3: ...Product manual OmniCore C90XT OmniCore Document ID 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty by ABB for losses damage to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained f...

Page 5: ...6 2 5 Network security 47 2 6 Open source and 3rd party components in RobotWare 48 2 7 ABB Ability 51 3 Installation and commissioning 51 3 1 Introduction to installation and commissioning 52 3 2 Installation activities 53 3 3 Transporting and handling 53 3 3 1 Lifting the controller cabinet 54 3 3 2 Unpacking 55 3 3 3 Storing 56 3 4 On site installation 56 3 4 1 Required installation space 58 3 4...

Page 6: ...unction tests 165 4 5 1 Function test of emergency stop 166 4 5 2 Function test of manual auto and manual full speed mode with FlexPendant 167 4 5 3 Function test of three position enabling device 168 4 5 4 Function test of contactors A1 Q1 and A1 Q2 inside the power unit 169 4 5 5 Function test of auto stop 170 4 5 6 Function test of external emergency stop 171 4 5 7 Function test of ESTOP_STATUS...

Page 7: ...roblem starting or connecting the FlexPendant 373 7 2 6 Problem using the joystick 374 7 2 7 Controller fails to start 375 7 2 8 Reflashing firmware failure 376 7 2 9 Inconsistent path accuracy 378 7 3 Troubleshooting units 378 7 3 1 Troubleshooting LEDs in the controller 379 7 3 2 Troubleshooting the FlexPendant 380 7 3 3 Troubleshooting the drive unit 382 7 3 4 Troubleshooting the power unit 387...

Page 8: ...ipulator cables 442 9 3 2 Customer cables CP CS connectors option 443 9 3 3 Customer cables Ethernet floor cable 445 Index 8 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved Table of contents ...

Page 9: ...ystem Who should read this manual This manual is intended for installation personnel maintenance personnel repair personnel 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 ...

Page 10: ...e 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 C Published in release 21A The following updates are made in this revision Minor corrections in section Connections on the main computer o...

Page 11: ...ning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application ma...

Page 12: ...he manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 12 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved Product documentation Continued ...

Page 13: ...ion 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 Spare parts and equipment ABB supplies o...

Page 14: ...s an option Performance level for OmniCore C90XT The OmniCore C90XT controller safety system has a safety category 3 with performance level PL d according to EN ISO 13849 1 and thus fulfils the safety performance requirement of the robot safety standard EN ISO 10218 1 The following data is applicable for OmniCore C90XT together with all supported ABB manipulators PFHD 1 hour DC Calculated MTTFD ye...

Page 15: ...0 144 Tool Speed Supervision TSP category 0 stop category 1 stop 4 29E 08 90 144 Axis Position Supervision APO category 0 stop category 1 stop 4 29E 08 90 144 Tool Position Supervision TPO category 0 stop category 1 stop 4 29E 08 90 144 Tool Orientation Supervision TOR category 0 stop category 1 stop 4 29E 08 90 144 Control Error Supervision Product manual OmniCore C90XT 15 3HAC073706 001 Revision...

Page 16: ...e 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 Personal protective equipment Use personal protective equipment as stated in the product manual 16 Product manual OmniCore C90XT 3HAC073706 001 Rev...

Page 17: ...which if not avoided will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous sit...

Page 18: ...o indicate where to find additional information or how to do an operation in an easier way TIP 18 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 19: ...ator 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 Symbols on safety labels Descrip...

Page 20: ...ution together with UL mark xx1700000353 SafeMove label for SafeMove Basic and SafeMove Pro soft ware xx1700000355 Rating label example xx1900001805 Continues on next page 20 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on controller labels Continued ...

Page 21: ...tallation Enclosure environmental type rating is type 1 Inserting fingers or foreign objects into opening may cause personal injury xx1800000836 High voltage inside the module even if the main switch is in the OFF position xx1400001156 ESD sensitive components inside the controller xx1400001162 Product manual OmniCore C90XT 21 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 1...

Page 22: ... to achieve the stop and then re moval of power when the stop is achieved Stop category 1 As defined in IEC 60204 1 a controlled stop with power remain ing available to the machine actuators Stop category 2 Safety inputs to initiate a protective stop or an emergency stop Protective stop and emergency stop inputs will initiate a stop selectable of category 0 or category 1 Description Safety inputs ...

Page 23: ...tomatic Stop Category1ES is used to configure the emergency stop in automatic and manual mode The default configura tion is FALSE stop category 0 The input is connected to the emergency stop on the FlexPendant and can also be connected to external devices Category1ESi Emergency Stop i In RobotWare 7 0 there are two values for the safety input Emergency Stop named Category1EES for external emergenc...

Page 24: ...gement is only possible by an intentional human action on the device where the command has been initiated The disengagement of the device shall not restart the machinery but only permit restarting After actuation and before disengaging the emergency stop device the machinery shall be inspected in order to detect the reason for actuation Recover from emergency stops 1 Make sure the hazardous situat...

Page 25: ...ered 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 The single point of control cannot be guaranteed in automatic mode External clients cannot be denied access CAUTION On the IRB 14050 the three position enabling device is not active unless a valid SafeMove configuration is ac...

Page 26: ...n the operating manual for the controller Note The manual full speed mode is not available in all markets 26 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 1 Safety 1 3 3 Enabling device and hold to run functionality Continued ...

Page 27: ...ormed at the reduced speed in conjunction with the TPU consisting of the three position enabling switch WARNING Wherever possible the manual mode of operation shall be performed with all persons outside the safeguarded space Tasks normally performed in manual reduced speed mode The following tasks are normally performed in manual reduced speed mode Set or reset I O signals Creating and editing RAP...

Page 28: ...ssed the speed is reset to 3 of programmed speed but not exceeding 250 mm s Editing RAPID programs and jogging the manipulator are disabled Tasks normally performed in manual high speed mode The following tasks can be performed in the manual high speed mode Starting and stopping program execution for program verification Stepping program execution Setting speed 0 100 Setting program pointer to Mai...

Page 29: ...ams Increase or decrease the speed in the interval zero to programmed speed of the manipulator Restore backups Only possible when robot is at stop Return to operation after protective stops or emergency stop including regain to path Limitations in automatic mode See the integrator s documentation for the machinery robot system for details on which tasks are to be performed in automatic mode Safegu...

Page 30: ...eleased 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 workin...

Page 31: ...ble 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 ...

Page 32: ...anual for the manipulator Verify the safety functions Before the robot system is put into operation verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level 32 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 1 Safety 1 5 Installation and commissi...

Page 33: ...horized personnel Safety actuators not in use Devices with safety actuators that are not connected to the robot or robot system cannot initiate emergency stops or protective stops These must be stored out of reach and sight so that they cannot be mistaken for being in use Product manual OmniCore C90XT 33 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 1 Safety 1 6 Operation ...

Page 34: ...nder rated conditions the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside There is a hazard in case of abuse mechanical thermal electrical which leads to the activation of safety valves and or the rupture of the battery container As a result under certain circumstances electrolyte leakage electrode materials reaction with moisture water or batt...

Page 35: ...ime DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers A risk assessment must be done to address both robot and robot system specific hazards Related information See also the safety information related to installation operation maintenance and repair Product manual OmniCore C90XT 35 3HAC073706 001 Revision D Copyright 2...

Page 36: ...1 9 Decommissioning General See section Decommissioning on page 351 36 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 1 Safety 1 9 Decommissioning ...

Page 37: ...rs a compact solution suitable for most applications with room for some additional equipment inside It is used to control an ABB manipulator used in industrial applications such as material handling and machine tending Product manual OmniCore C90XT 37 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 2 Controller description 2 1 OmniCore C90XT ...

Page 38: ...ctor Baseline X4 HMI connector TPU Baseline X1 Motor connector Baseline K5 1 Scalable I O Option K5 2 K5 3 Additional I O Option X17 IP20 DeviceNet Option B1 Conveyor tracker module Baseline A2 K3 Motion Safety Baselinei K7 Connected Services Gateway with antenna for 3G and WiFi Option K4 Ethernet switch Continues on next page 38 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 20...

Page 39: ...ue Parameter 500 mm Width 355 mm Depth 520 mm Height Extension box Value Parameter 500 mm Width 355 mm Depth 295 mm Height Weight The table shows the weight of the controller Weight Controller 46 kg not including the extension box OmniCore C90XT 25 kg Extension Box Note The weight does not include any mounting kits fitted on the controller Transportation and storage conditions Value Parameter 25 C...

Page 40: ...mps Protection classes Protection class IP54 Controller cabinet IP54 Extension box cabinet IP54 Controller electronics IP54 FlexPendant 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 prope...

Page 41: ...ing 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 Description Current A Robot 10 A 220 230 VAC 1 phase IRB 1100 10 A 220 230 VAC 1 phase IRB 1300 10 A 220 230 VAC 1...

Page 42: ...wing illustration xx1900001446 There is an additional wrist strap button on the main computer 42 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 2 Controller description 2 2 Technical data for OmniCore C90XT controller Continued ...

Page 43: ... 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 stati...

Page 44: ...stead use your finger or a stylus Never clean the FlexPendant with solvents scouring agent or scrubbing sponges See the product manual for the robot controller section Cleaning the FlexPendant Always close the protective cap on the USB port when no USB device is connected The port can break or malfunction if exposed to dirt or dust CAUTION The FlexPendant touch screen is made of glass If the devic...

Page 45: ... button to make sure it works if a custom connection cable is used Product manual OmniCore C90XT 45 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 2 Controller description 2 4 Handling of FlexPendant Continued ...

Page 46: ...ls 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 unauthori...

Page 47: ...cense licensor will provide licensee on demand a machine readable copy of the corresponding source code This offer is valid for a period of three years after delivery of the product ABB software is licensed under the ABB end user license agreement which is provided separately For RobotWare there is license information in the folder licenses in the RobotWare distribution package For OleOS the Linux...

Page 48: ...y procedures which includes commercially reasonable technical and organizational measures in order to protect the data against security breaches accidental or unlawful destruction loss alteration and unauthorized disclosure of or access to the data The cellular data connection is not required for the operation of the hardware and the connectivity settings can be adjusted and turned off at any give...

Page 49: ...lity General Terms and Conditions ABB Ability Terms and Conditions https ability abb com terms Special Terms and Conditions for ABB Ability Connected Services https new abb com products robotics service robot registration Product manual OmniCore C90XT 49 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 2 Controller description 2 7 ABB Ability Continued ...

Page 50: ...This page is intentionally left blank ...

Page 51: ...s 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 page13 before performing any installation work Note If the OmniCore C90XT is connected to power always make sure that ...

Page 52: ...g a FlexPendant on page 76 Connect the FlexPendant to the controller 6 How to connect industrial networks for example EtherNet is described in the re spective application manual Connect for example EtherNet antenna PC and other connections 7 How to connect to a network and a PC is described in section Set up the network connection on page84 See also Operating manual RobotStudio See also Descriptio...

Page 53: ...e between the lifting straps when lifting the controller The weight of the controller module is detailed in section Weight on page 39 0 6 xx1900001445 Note After removing the lifting lock tighten the plastic screws Torque 0 8 Nm 1 Nm for the controller cabinet Product manual OmniCore C90XT 53 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3...

Page 54: ...to handle the weight of the controller 5 If the controller is not installed directly it must be stored as described in Transportation and storage conditions on page 39 6 Make sure that the expected operating environment of the controller conforms to the specifications as described in Operating conditions on page 40 7 The controller can be taken to its installation site as described in section On s...

Page 55: ... controller For storing see Transportation and storage conditions on page 39 Product manual OmniCore C90XT 55 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 3 3 Storing ...

Page 56: ...e of the controller is required if the controller is mounted on a desk not rack mounted Do not place any cables over the left cover as it leads to inefficient cooling A free space of 520 mm on the right sides of the controller is required if the controller is mounted on a desk not rack mounted Do not place any cables over the right covers as it leads to inefficient cooling The following illustrati...

Page 57: ... controller to a concrete foundation or steel platform with anchor bolts during stacking Note According to IEC60204 1 the power operated switch should be installed between 600 mm to 1 900 mm above the servicing level The switch will be easily accessible Product manual OmniCore C90XT 57 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 4 1 Requ...

Page 58: ... Holder w t E stop cover 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 Mounting the FlexPendant holder onto a flat surface Horizontally Use this procedure to mount the FlexPendant holder onto a flat surface like the top of the controller desktop and so on Note illustration Action Clean the surface and make sure it...

Page 59: ...ike the door of the controller Tip The bracket is included when the FlexPendant is purchased Note illustration Action xx2000002354 Hang the FlexPendant holder to the bracket according to the screws on the bracket 1 Continues on next page Product manual OmniCore C90XT 59 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 4 2 Mounting the FlexPen...

Page 60: ... the FlexPendant holder to the desired place Note illustration Action xx2000002356 Remove the four screws 1 Separate the rear part from the FlexPend ant holder 2 Clean the surface and make sure it is dry 3 Continues on next page 60 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 4 2 Mounting the FlexPendant hold...

Page 61: ...4 Press the holder onto the desired place 5 xx2000002358 Use two M5 screws to secure the holder 6 Product manual OmniCore C90XT 61 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 4 2 Mounting the FlexPendant holder Continued ...

Page 62: ...r replace any damaged parts Connectors The following details the connection interface on the OmniCore C90XT controller xx2000000338 Description Manipulator signal connector A Cable grommet assembly option B Cable grommet assembly C Power inlet connector D Motor connector E Continues on next page 62 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved ...

Page 63: ...r G ETH outlet connector H Motors on lamp J Power inlet switch K Product manual OmniCore C90XT 63 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 5 1 Connectors on the OmniCore C90XT controller Continued ...

Page 64: ...er and analog I O Measurement signals This class covers ordinary analogue signals such as analogue sig 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 Class 2 slightly sens itive Gateway fieldbus connection computer link Data communication signals Applies to cables carrying very sensitive signals Signals with a ful...

Page 65: ... the cabinet at both ends of the cable Any unshielded cable must be as short as possible The manipulator power cables are routed on the floor and along the left side of the controller cabinet Cables should not be wound up like coils This could cause an magnetic field disturbing the signals There will also be a risk of overheating depending on the load Power signals These signals are very sensitive...

Page 66: ...lid 360 connection shown below with the ground plane or chassis Shielding example The below example shows the shielding of a d type connector xx1700001320 A A dimpled connector body makes multiple bonds to the mating connector body all around its periphery 360 bonding B Metal or metallized back shell makes 360 bond to the connector body C The cable shield is exposed and 360 clamped to the back she...

Page 67: ...rew 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...

Page 68: ... 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 0 V 24 V DC 1 2 3 0 V 24 V AC DC 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 dimensione...

Page 69: ...edback from any position switches Position switch cables option Handles communication with equipment fitted on the manipulator by the customer Customer cables option Handles power supply to and control of the external axes motors as well as feedback from the servo system Additional axes cables option These categories above are divided into sub categories which are specified in spare part manual Se...

Page 70: ...oller xx1900001461 Detailed view A B C D xx1900001457 Description Female insert quick lock A Angle hood M20 B Cable gland M20 C Sealing screw D Continues on next page 70 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 5 4 Fitting the connector ...

Page 71: ...1 3HAC070308 001 Power connector Procedure Use the following procedure to fit the connectors Note illustration Action Cut the cable to desired length 1 xx1900001454 Connect the wires according to the illus tration 2 For single phase 1 Live L 2 Neutral N 3 Not used 4 Not used 5 Not used PE Protective Earth grounding Continues on next page Product manual OmniCore C90XT 71 3HAC073706 001 Revision D C...

Page 72: ...d 3 xx1900001459 Push fine stranded wires into the Han Quick Lock contact and push the slide with a screw driver until it comes to a stop 4 72 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 5 4 Fitting the connector Continued ...

Page 73: ...nt device RCD must be installed Location of power supply connection xx1900001479 Location of grounding point Note The whole cabinet ground is connected to the X0 PE point Continues on next page Product manual OmniCore C90XT 73 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 5 5 Connecting power supply to and grounding the controller ...

Page 74: ...ntegrated 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 Connecting the power The following procedure describes how to connect the main power to the controller CAUTION Always inspect the connector for dirt or damage before connecting it to the controller Clean or replace...

Page 75: ...ing the hook Tip When you hear a clear clicking sound it is locked 1 xx1900001456 Product manual OmniCore C90XT 75 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 5 5 Connecting power supply to and grounding the controller Continued ...

Page 76: ...ight so that it cannot be mistaken for being in use CAUTION The FlexPendant connector can only be used to connect a FlexPendant and CANNOT be used to connect any other devices All external safety devices must be connected from the customer interface on robot signal exchange proxy Location of FlexPendant connector The FlexPendant connector is located on the front panel on the controller Detaching t...

Page 77: ... When the countdown is progressing loosen the locking ring and detach the FlexPendant from the controller Continues on next page Product manual OmniCore C90XT 77 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 5 6 Connecting and detaching a FlexPendant Continued ...

Page 78: ...de when connecting the FlexPendant 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 78 Product manual OmniCore C90XT 3HAC073706 001 Revisi...

Page 79: ...ng to the robot s Ability network ABB Ability 2 WAN port that can be used to host a public industri al network WAN 3 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 MGMT Management 4 Note The management port shall never be used for more than one client at a time ABB Robotics ...

Page 80: ...work Factory Network X23 WAN 10 100 1000 AXC MGMT LAN1 LAN2 LAN3 Network Interface LAN4 WAN Address 192 168 127 1 Address 192 168 125 1 IP configuration Address 192 168 126 2 Address Specified in Robot Studio or on FlexPendant 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 Private Network segments of multiple robot contr...

Page 81: ...twork 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 One EtherNet IP network connected to the robot controller EtherNet IP Adapter is only available on the public network via WAN Ethernet IP Scanner can be used on both the private an...

Page 82: ...ntroller Defining network settings in RobotStudio 1 In the Configuration browser right click the controller and select Properties and then Network settings xx2000000488 2 In the Network settings window set the values for IP address The IP address for the OmniCore controller on the EtherNet network Subnet mask The subnet mask Default gateway The default gateway xx2000000489 Continues on next page 8...

Page 83: ...th other non industrial network traffic The following figure illustrates the network when connecting a controller and a device to the WAN port of the main computer Factory Network Industrial Network Private Robot Controller 1 MGMT LAN1 LAN2 LAN3 WAN PLC Camera Public Cell I O I O I O PROFINET Private Robot Controller 2 MGMT LAN1 LAN2 LAN3 WAN Public xx1900001102 Product manual OmniCore C90XT 83 3H...

Page 84: ...botStudio or the FlexPendant By default the IP address is blank Note It is not recommended using leading zeros in dot decimal notation of IP addresses The numbers may wrongly be interpreted as octal numbers Different behaviors on virtual and real controllers may be experienced Note The WAN port cannot use any of the following IP addresses which are allocated for other functions on the controller 1...

Page 85: ...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 b...

Page 86: ... the Firewall Manager and can only change the parameters Enable on Public Network and Enable on Private Network for pre registered Network Services 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 m...

Page 87: ...gh the cable grommet and fasten on the cabinet 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 Continues on next page Product manual OmniCore C90XT 87 3HAC073706 001 Revision D Copyright 2020 2021 A...

Page 88: ...ts 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 Continues on next page 88 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyrig...

Page 89: ...it should go through the cable grommet and fasten on the cabinet 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 Continues ...

Page 90: ...odule should go through the cable grommet and fasten on the cabinet 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 Continues on next page 90 Product manual OmniCore C90XT 3HAC073706 001 Revision D ...

Page 91: ...OmniCore C90XT 3HAC065464 009 Customer cable layout It is recommended to use multicore cable for the customer connection The cables connected by customer to the 24V terminal block should go through the cable grommet and fasten on the cabinet 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 lev...

Page 92: ... tested regularly X14 Description Customer safety interface emergency stop and automatic stop Connection Weidmüller S2L 3 50 90F Type S2L 3 50 16 90F 3 5SN BK BX 2 8 pins 1728680000 or equivalent Article number Continues on next page 92 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 5 9 Descriptions for connect...

Page 93: ...ach channel has 4 pins on the connectors and the pin descriptions are shown in the following table Description Pin 24 V power supplied by robot controller for stop switch use only It must not be used for any other functions 24V_CH1 2 Safety loop high side of automatic stop input AS1 AS2 Safety loop low side of automatic stop input AS1 AS2 Safety loop high side of external emergency stop input ES1 ...

Page 94: ...following figures for the best safety performance When the 24 V power is provided by customer instead of 24V_CH1 2 it shall be within the tolerance of 24 V 0 10 Customer provided power 0V_CH1_CH2 24V_CH1 AS1 ES1 AS1 ES1 0V_CH1_CH2 24V_CH2 AS2 ES2 AS2 ES2 0V_CH1_CH2 24V_CH1 AS1 ES1 AS1 ES1 0V_CH1_CH2 24V_CH2 AS2 ES2 AS2 ES2 0V_CH1_CH2 24V_CH1 AS1 ES1 AS1 ES1 0V_CH1_CH2 24V_CH2 AS2 ES2 AS2 ES2 0V_CH...

Page 95: ...ocal ABB for support X15 Description Customer optional interface Connection Weidmüller S2L 3 50 90F Type S2L 3 50 16 90F 3 5SN BK BX 2 9 pins 1728690000 or equivalent Article number 2 4 6 1 3 5 8 10 12 7 9 11 14 16 13 15 18 17 xx1800000555 Description Pin Description Pin NC 18 NC 17 NC 16 NC 15 ESOUT1 14 ESOUT1 13 ESOUT2 12 ESOUT2 11 NC 10 NC 9 NC 8 NC 7 NC 6 NC 5 24V_MON 4 MON_LAMP 3 24V_MON 2 MO...

Page 96: ...tton input interface MON_PB Note The device connected to the ESOUT pins shall fulfill the IEC 61131 2 type 1 Input Note Logic low of Emergency stop output shall be recognized as Emergency stop triggered Note The maximum length of the cable connected to the ESOUT pins shall be 10 m Note The cable shall be protected from external EM disturbance suggested to use separate multicore cables Note The Fle...

Page 97: ...in X15 for an optional Motors On push button and an indication lamp Both have 2 pins on the connectors 24V_MON MON_PB 24V_MON MON_LAMP Lamp Push Bu on xx1900000598 X19 Description Customer IO power supply Connection Weidmüller SC 3 81 90F Type SC 3 81 08 90F 3 2SN BK BX 8 Pins 1793380000 or equivalent Article number Continues on next page Product manual OmniCore C90XT 97 3HAC073706 001 Revision D ...

Page 98: ...llowing table Value Parameter 24V DC Voltage 3 10 Voltage tolerance 3 A Max output current X20 Description Customer optional power input Reserved Connection Weidmüller SC 3 81 90F Type SC 3 81 06 90F 3 2SN BK BX 6 Pins 1793370000 or equivalent Article number 98 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 5 9...

Page 99: ...guration 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 syst...

Page 100: ...ntrol system it is possible to define system input signals to be set reset through different interactions for example through networks I O blocks RobAPI etc See next release version Description Pre defined system input The manipulator is stopped on the path with no deviation SoftStop This is a faster stop of the manipulator than SoftStop This stop is more stressing for the mechanics than SoftStop ...

Page 101: ...cution will be stopped immediately as a normal program stop A restart will contin ue the program execution BREAK The current move instruction and the program execution will be stopped immediately as a normal program stop After stop the Pro gram Pointer has to be reset to Main EXIT The current move instruction and program execution will be stopped immediately The Program Pointer will be reset to Ma...

Page 102: ...hen restarting a machine that is stopped due to a collision The robot might make a limited movement when restarted Stop at collision WARNING The revolution counters might need to be updated after a colli sion to ensure path accuracy 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 ...

Page 103: ...ldbuses are connected directly to one of the Ethernet ports D C B A xx1700000748 Fieldbus adapter slave A Slot for fieldbus adapters B Slot for fieldbus PCI express card C Fieldbus board master D Available board The following master board is available Type designation Article number Description DSQC1006 3HAC043383 001 DeviceNet Board Available software based fieldbuses The following software based...

Page 104: ...ter References For more information on how to install and configure the fieldbuses see the respective manual Article number Manual title 3HAC066562 001 Application manual DeviceNet Master Slave 104 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 6 1 Available fieldbuses Continued ...

Page 105: ...The base device has a Plug Produce interface and communicates over the default EtherNet IP communication protocol to the robot controller When using the standard interface no additional RobotWare options or hardware options are required to communicate with the robot controller When using the RobotWare option EtherNet IP Scanner Adapter more configuration possibilities are available For more inform...

Page 106: ... date See the latest spare parts of the OmniCore C90XT via myABB Business Portal www abb com myABB Note Article number Spare part Harness single SMB 3HAC069674 001 Harness Single SMB connection Harness double SMB 3HAC069675 001 Harness Double SMB connection Continues on next page 106 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation ...

Page 107: ...k inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Continues on next page Product manual OmniC...

Page 108: ... manipulator signal connector out 4 Refitting the harness for double SMB Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page 108 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 7 1 Insta...

Page 109: ...M4x8 4 pcs Secure it with the attachment screws 4 xx2000000440 xx2000000439 Reconnect and secure K6 X4 K6 X5 SMB 5 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 109 3HAC073706 001 Revision D Copyright 2020 2021 ABB ...

Page 110: ...I O Digital base 3032 1 3HAC060919 001 Connectors digital base add on DSQC1031 3HAC058664 001 Digital add on 3033 2 DSQC1032 3HAC058665 001 Analog add on 3034 2 3HAC060925 001 Connectors I O Analog DSQC1033 3HAC058666 001 Relay add on 3035 2 3HAC060926 001 Connectors I O Relay Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller o...

Page 111: ...fety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 xx1900002447 Push the digital base into the bracket until you hear a clear clicking sound 3 Continues on next page Product manual OmniCore C90XT 111 3HAC073706 001 Revision D...

Page 112: ...ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 Prepare the scalable I O units for external mounting as described in Application manual Scalable I O 3 Opening the door on page 174 Open the door 4 Connect the external base device to the internal base device X3 or the Ethernet switch u...

Page 113: ...d 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 Article number Spare part DSQC1035 3HAC059187 001 Ethernet Extension switch 3014 1 Continues on next page Product manual OmniCore C90XT 113 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 7 3 Installing the Ethe...

Page 114: ...31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Refitting the Ethernet extension switch option Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains p...

Page 115: ...ap between the upper surface of the Ethernet extension switch and the lower surface of highest bracket on the main computer xx1800000972 3 Reconnect K2 X2 K4 X8 A2 X1 K4 X7 K5 1 X5 K4 X6 A2 X4 4 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Prod...

Page 116: ...art DSQC3035 3HAC071301 001 Power supply DSQC 609 3HAC14178 1 DSQC 609 power supply DSQC 634 3HAC13398 2 DSQC 634 power supply 3HAC069617 001 Harness AC input of power supply 3HAB7983 1 End clamp Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Continues on next page 116 P...

Page 117: ... button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Installing the 24V terminal block Note Illustration Action Hang the 24V terminal block to the bracket and push the lower part until you hear a clear clicking sound 1 Continues on next page Product manual OmniCore C9...

Page 118: ... DSQC 634 Hang the power supply to the bracket and push the lower part until you hear a clear clicking sound 1 Screws Cross recessed cheese head screw M4x8 1 pcs xx1900001908 For DSQC 634 xx1900001950 Continues on next page 118 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 7 4 Installing the power supply optio...

Page 119: ...in the illustration when the power supply optional is not selected 3 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 119 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commiss...

Page 120: ...1 DSQC 669 3HAC027652 001 Ethernet Unit 3025 1 Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC065464 009 Circuit diagram OmniCore C90XT Installing the fieldbus adapter slave variants Note Illustration Action DANGER Befo...

Page 121: ... Remove the fieldbus slot cover with a screwdriver 4 xx1900001917 Insert the fieldbus adapter slave and se cure the screws 5 Closing the door on page 174 Close the door 6 Perform the function tests to verify that the safety features work properly see Function tests on page 165 7 Product manual OmniCore C90XT 121 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation a...

Page 122: ...rtal www abb com myABB Note Article number Spare part DSQC1006 3HAC043383 001 DeviceNet Board Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC065464 009 Circuit diagram OmniCore C90XT Continues on next page 122 Product m...

Page 123: ...assembly Note Illustration Action 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 1 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...

Page 124: ... K3 X6 A2 K3 X7 K6 X2 A2 X9 A2 X5 K7 X2 A2 X4 K4 X6 K5 1 X5 Note If the Ethernet extension switch is installed connect and disconnect the connector A2 X4 to from K4 X6 If the Ethernet extension switch is not installed connect and discon nect the connector A2 X4 to from K5 1 X5 xx1900001877 Remove the screws holding the main computer 2 Continues on next page 124 Product manual OmniCore C90XT 3HAC07...

Page 125: ...cted Services Gateway wired there is no power cable Removing the robot signal exchange proxy Note Illustration Action Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 Continues on next page Product manual OmniCore C90XT 125 3HAC073706 001 Revision D Copyright...

Page 126: ...ation Action Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 Continues on next page 126 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 7 6 Installing the fieldbus master ...

Page 127: ... xx1800003414 Remove the attachment screw on the cover of the fieldbus master and take out the cover 3 Note The Connected Services Gateway and Ether net extension switch are omitted on the illus tration to make it more clear Continues on next page Product manual OmniCore C90XT 127 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 7 6 Installin...

Page 128: ... tration to make it more clear Screw Screw with flange M3x6 1 pcs xx1800003416 Secure the DeviceNet board with the screw 5 Note The Connected Services Gateway and Ether net extension switch are omitted on the illus tration to make it more clear Continues on next page 128 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissio...

Page 129: ...NGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2000000419 Continues on next page Product manual OmniCore C90XT 129 3HAC07...

Page 130: ...g the main computer assembly to the cabinet Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page 130 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 7 6 Installing the fieldbus master Con...

Page 131: ...wrist strap button located on the side of the computer 2 xx1900001446 xx1900001885 Refit the assembly onto the mounting plate 3 xx1900001878 Continues on next page Product manual OmniCore C90XT 131 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 7 6 Installing the fieldbus master Continued ...

Page 132: ...3 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 X3i K7 X2 A2 X5 Note The connector K7 X2 is locked grab the connector push it in to release it and then remove the connector Con...

Page 133: ...led connect and discon nect the connector A2 X4 to from K5 1 X5 i For Connected Services Gateway wired there is no power cable Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 133 3HAC073706 001 Revision D Copyright 20...

Page 134: ... can be out of date See the latest spare parts of the OmniCore C90XT via myABB Business Portal www abb com myABB Note Article number Spare part DSQC2000 3HNA027579 001 Conveyor tracking module 3103 1 3HNA029345 001 CONNECTOR KIT DSQC2000 Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protecti...

Page 135: ...on see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Opening the door on page 174 Open the door 3 Continues on next page Product manual OmniCore C90XT 135 3HAC073706 001 Revision D Copyright 2020 2021 ABB Al...

Page 136: ...input and output connectors as required 6 Closing the door on page 174 Close the door 7 Perform the function tests to verify that the safety features work properly see Function tests on page 165 8 For more information about the option Conveyor Tracking see Application manual Conveyor tracking 136 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 ...

Page 137: ... it s not executed correctly It is recommended to use icotek KT grommet Required spare 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 Note Article number Spare part 3HAC066396 001 Cable grommet asm Continues on next page Product manual OmniCore C90XT 137 3HAC073706 001 Re...

Page 138: ... any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Continues on next page 138 Product ...

Page 139: ...rommet assembly Refitting the cables to the cable grommet assembly Note Illustration Action xx1900002337 Insert and equip the cable to the corres ponding KT grommet 1 Continues on next page Product manual OmniCore C90XT 139 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 7 8 Installing the cable grommet assembly Continued ...

Page 140: ... rest on each other When using single row frames the fl at side has to point towards the cover strip 2 xx1900002335 Refit the cover strip onto the frame 3 Screws Hex socket head cap screw M5x50 12 9 Gleitmo 603 Geomet 500 3 pcs Secure the frame and cover strip with the screws 4 Tightening torque 2 Nm 3 Nm xx1900002334 Continues on next page 140 Product manual OmniCore C90XT 3HAC073706 001 Revision...

Page 141: ... xx1900002332 Refitting the cable grommet assembly Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page Product manual OmniCore C90XT 141 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 7 8 Installing the cable gromme...

Page 142: ...able grommet assembly into the cover of the cabinet 3 xx1900002340 Secure it with the screws Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 142 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 ...

Page 143: ... number Spare part 3HAC068415 001 Air filter coarse filter 3HAC068416 001 Air filter Fine filter Filter element of fine filter 3HAC068543 001 Air filter Polymeric Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Continues on next page Product manual OmniCore C90XT 143 3HAC...

Page 144: ...wer For more information see Electrical safety on page 31 1 xx1900001492 Fit the air filter to the cabinet Secure it with the screws 2 Perform the function tests to verify that the safety features work properly see Function tests on page 165 3 144 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 7 9 Installing th...

Page 145: ...re else as a standalone equipment xx1900001453 Note Connect PE19 as grounding for the extension box in any use case Required equipment Information Equipment See Standard toolkit for controller on page 417 Standard toolkit Continues on next page Product manual OmniCore C90XT 145 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 8 1 Installing t...

Page 146: ...ntity Order number Part 1 3HAC074661 001 Connector for X106 Procedure Use this procedure to stack an extension box to a basic box Info illustration Action Place the controller in desired place 1 Anchor bolts M8 X 4 Fix the basic box to a concrete foundation or steel platform with anchor bolts 2 Tighten torque 11 3 Nm 12 6 Nm xx1900001450 Remove the four plastic screw 3 Continues on next page 146 P...

Page 147: ...x upright the basic box with lifting accessory Lock them with screws 5 Opening the door on page 174 Open the door of the extension box 6 Continues on next page Product manual OmniCore C90XT 147 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 8 1 Installing the extension box Continued ...

Page 148: ... the cable grommet assembly on page314 and Refitting the cables to the cable grommet assembly on page 317 xx2000000446 Connect through the cable grommet PE19 X106 8 xx2000000689 Continues on next page 148 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 8 1 Installing the extension box Continued ...

Page 149: ...tion for customer installing extern al devices It is the system builder s responsibly to en sure the complacence with electrical safety for example the Low Voltage Directive 9 Product manual OmniCore C90XT 149 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 8 1 Installing the extension box Continued ...

Page 150: ... can be out of date See the latest spare parts of the OmniCore C90XT via myABB Business Portal www abb com myABB Note Article number Spare part DSQC2000 3HNA027579 001 Conveyor tracking module 3103 1 3HNA029345 001 CONNECTOR KIT DSQC2000 Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protecti...

Page 151: ...button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Opening the door on page 174 Open the door of the extension box 3 xx1900001913 Fit the conveyor tracking module by snapping it onto the mounting rail 4 Continues on next page Product manual OmniCore C90XT 151 3HAC073...

Page 152: ...es to the con veyor tracking module see Application manual Conveyor tracking Connect wires to the input and output connectors as required 7 Closing the door on page 174 Close the door 8 Perform the function tests to verify that the safety features work properly see Function tests on page 165 9 For more information about the option Conveyor Tracking see Application manual Conveyor tracking 152 Prod...

Page 153: ...psulation 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 1 Low Voltage Directive Product manual OmniCore C90XT 153 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 9 Installing external devices ...

Page 154: ...perform the function tests in section Function tests on page 165 to verify that the safety features work properly 154 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 3 Installation and commissioning 3 10 Initial test before commissioning ...

Page 155: ...nd manual full speed mode with FlexPend ant Function test of three position en abling device on page 167 12 months Function test Enable device Function test of contactors A1 Q1 and A1 Q2 inside the power unit on page 168 12 months Function test Contactors A1 Q1 and A1 Q2 Function test of auto stop on page 169 12 months Function test Auto stop tested if used Function test of external emergency stop...

Page 156: ...ling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Inspect connectors and cabling to make sure they are securely fastened and cabling not damaged 3 Inspect the fans and ventilation holes to make sure they are clean 4 After inspection Temporarily turn the power supply on Inspect the fans to make sure they function correctly Switch the power ...

Page 157: ...lacing the air filter on page 284 Remove the air filter 1 If a fine filter is used remove the polymeric filter element first 2 Clean the filter three or four times 3 Note Do not wring the filter to press out water Allow the filter to dry in one of these ways Lying flat on a flat surface Blow with compressed air in opposite direction of filter airflow 4 If a fine filter us used refit a new polymeri...

Page 158: ...Note Illustration Action Refit the air filter 6 158 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 3 1 Cleaning air filter Continued ...

Page 159: ...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 Product manual OmniCore C90XT 159 3H...

Page 160: ... using a soft cloth and water or a mild cleaning agent 3 Unlock the screen by tapping the buttons 4 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 dev...

Page 161: ...cleaner Do not clean the device operating panel and operating elements with compressed air solvents scouring agent or scrubbing sponges Product manual OmniCore C90XT 161 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 3 3 Cleaning the FlexPendant Continued ...

Page 162: ...d procedures may be required See references to these procedures in the step by step instructions below Removing the air filter Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page 162 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 A...

Page 163: ... the air filter 2 Removing the polymeric filter element Note Illustration Action xx2000000421 Take out the polymeric filter element from the filter 1 Continues on next page Product manual OmniCore C90XT 163 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 4 Maintenance 4 4 1 Replacement of air filter Continued ...

Page 164: ...abinet disconnect the mains power For more information see Electrical safety on page 31 1 xx1900001492 Refit the air filter to the cabinet Secure it with the screws 2 Concluding procedure Note Illustration Action Perform the function tests to verify that the safety features work properly see Function tests on page 165 1 164 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 202...

Page 165: ...te For collaborative robots the event mes sage 90518 Safety controller Emergency stop triggered appears by default The message 10013 Emergency stop state is also available in the event log Press the emergency stop button Note If the event message 20223 Emergency stop conflict appears in the event log or the event message 10013 Emergency stop state and 90518 Safety controller Emer gency stop trigge...

Page 166: ...be found This test is passed if it is possible to run the robot program in manual mode Change to Manual operating mode and Motors ON state and then run the robot in manual mode 3 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 This test is passed if it is possible to run the robot program in manual full speed mode Change to Manual...

Page 167: ...g then the test has failed and the root cause of the failure must be found This test is passed if the event message 10012 safety guard stop state appears in the event log While still holding the three position en abling device pressed press the enabling device harder to the enable the device s third position 3 If the event message 10012 Safety guard stop state does not appear or if the event messa...

Page 168: ...he brake function test Note Action Start the robot system and change the op erating mode to manual 1 This test is passed if the brakes are disen gaged and the manipulator can be moved Press the three position enabling device to the middle position and then hold the enabling device in this position 2 If the event message 50056 Joint collision appears in the event log then the test has failed and th...

Page 169: ...r example by opening the connected robot cell door which has interlock connection with auto stop 2 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 Product manual OmniCore C90XT 169 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights ...

Page 170: ... test is passed if the event message 10013 Emergency stop state appears in the event log Note For collaborative robots the event mes sage 90518 Safety controller Emergency stop triggered appears by default The message 10013 Emergency stop state is also available in the event log Press the emergency stop button Note If the event message 20223 Emergency stop conflict appears in the event log or the ...

Page 171: ...nt log Note For collaborative robots the event mes sage 90518 Safety controller Emergency stop triggered appears by default The message 10013 Emergency stop state is also available in the event log Press the emergency stop button Note If the event message 20223 Emergency stop conflict appears in the event log or the event message 10013 Emergency stop state and 90518 Safety controller Emer gency st...

Page 172: ...ed speed higher than 250 mm s 2 This test is passed if the speed of the robot does not exceed 250 mm s otherwise the test is failed and the root cause of the fail ure must be found Start the program in manual mode and measure the time it takes for the robot to travel the distance Tip To get accurate results use sensors or I O signals to measure the time 3 172 Product manual OmniCore C90XT 3HAC0737...

Page 173: ...epair 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 powerin...

Page 174: ...any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Opening the door Info illustration Action Insert the key to the door and turn it anti clockwise 1 Pull out the handle and turn it anti clock wise 2 Pull out the door with the handle 3 Closing the door Closing the door Info illustration Action Push the door back 1 Turn the handle clockwise...

Page 175: ... myABB Note Article number Spare part DSQC 668 3HAC029157 001 Axis Computer Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC065464 009 Circuit diagram OmniCore C90XT Continues on next page Product manual OmniCore C90XT 1...

Page 176: ...D The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the axis computer from the cabinet Note Illustration Action Disconnect K6 X11 A1 X3 K6 X2 A2 X9 K6 X1 K2 X3 1 Loosen the screw and disconnect K6 X4 K6 X5 SMB 2 Continues on next page 176 Product manual OmniCore C90XT 3HAC073706 001 Revision...

Page 177: ...the bracket from the cabinet Tip Be careful with the locking hole on the cabinet when doing assembling or disas sembling work 4 xx1900001486 Continues on next page Product manual OmniCore C90XT 177 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 2 Replacing the axis computer Continued ...

Page 178: ...the axis computer to the bracket and secure the screws 1 xx1900001487 Refitting the axis computer to the frame Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page 178 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repa...

Page 179: ... sensitive to ESD on page 43 2 xx1900001446 Screws Torx pan head screw M4x8 4 pcs Fit the axis computer bracket and secure the screws 3 xx1900001486 xx1900001484 Reconnect K6 X11 A1 X3 K6 X2 A2 X9 K6 X1 K2 X3 4 Continues on next page Product manual OmniCore C90XT 179 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 2 Replacing the axis computer Continued ...

Page 180: ...tion Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 180 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 2 Replacing the axis computer Continued ...

Page 181: ...ticle number Spare part 3HAC059214 001 Standard fan 3HAC065526 001 Heat exchanger Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC065464 009 Circuit diagram OmniCore C90XT Continues on next page Product manual OmniCore C...

Page 182: ...Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the standard fan Note Illustration Action Disconnect standard fan G1 X2 K2 X17 1 xx1900001488 Remove the fan bracket screws 2 Continues on next page 182 Product manual OmniCore C90XT ...

Page 183: ...ews on the fan to the bracket 1 Remove the fan from the bracket Tip Be careful with the locking hole on the cabinet when doing assembling or disas sembling work xx1900001498 2 Continues on next page Product manual OmniCore C90XT 183 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 3 1 1 Replacing the standard fan Continued ...

Page 184: ...ote Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page 184 Product ma...

Page 185: ...econnect G1 X2 K2 X17 5 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 185 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 3 1 1 Replacing the standard fan Continued ...

Page 186: ...ion of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the air filter Note Illustration Action xx1900001491 Loosen the attachment screws on the air filter 1 Continues on next page 186 Product manual OmniCore C90XT 3HAC073706 001 Revision D Cop...

Page 187: ...n Action Disconnect heat exchanger G3 X1 K2 X17 1 xx1900001490 Remove the screws locking the sensor and pull out the sensor 2 Continues on next page Product manual OmniCore C90XT 187 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 3 2 Replacing the heat exchanger Continued ...

Page 188: ...he heat exchanger Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page 188 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 3 2 Replacing the heat exchanger Continued ...

Page 189: ...fety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 xx1900001494 Refit the heat exchanger into position according to the location pin 3 Continues on next page Product manual OmniCore C90XT 189 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 3 2 Replacing the heat exchanger Continued ...

Page 190: ...493 Reconnect G3 X1 K2 X17 5 Screws Torx pan head screw M4x8 2 pcs Refit the sensor cable and secure with screws 6 xx1900001490 Continues on next page 190 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 3 2 Replacing the heat exchanger Continued ...

Page 191: ...filter to the cabinet Secure it with the screws 2 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 191 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 3 2 Replacing the heat exchanger...

Page 192: ...ABB Business Portal www abb com myABB Note Article number Spare part DSQC3037 3HAC064662 001 Signal exchange Mating connector for robot signal exchange proxy 3HAC065107 001 Harness Short circuit connector Harness K2 X2 K4 X8 A2 X1 3HAC064091 001 Harness 24_PC Harness K2 X12 K3 X6 K3 X7 3HAC059273 001 Harness dual channel safety Continues on next page 192 Product manual OmniCore C90XT 3HAC073706 00...

Page 193: ... robot signal exchange proxy Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The ...

Page 194: ... 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 1 xx1900002339 Remove the mating connectors by loosening their attachment screws 2 xx1900001495 Pull the cable ties out from the locking holes 3 Continues on next page 194 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 4 Replacing the...

Page 195: ...the mains power For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page Product manual OmniCore C90XT 195 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights re...

Page 196: ...96 xx1900001495 Insert the cable ties into the locking holes 4 xx1900002339 Refit the mating connectors and secure their attachment screws 5 Continues on next page 196 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 4 Replacing the robot signal exchange proxy Continued ...

Page 197: ... K2 X7 K2 X22 Harn LV robot power X1 K2 X9 X13 FlexPendant X4 6 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 197 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 4 Replacing the ro...

Page 198: ...e 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 Article number Spare part DSQC1035 3HAC059187 001 Ethernet Extension switch 3014 1 Continues on next page 198 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 5 Replacing the Ethernet switch ...

Page 199: ...power For more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the Ethernet extension switch option Note Illustration Action Disconnect K2 ...

Page 200: ...switch option Refitting the Ethernet extension switch option Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page 200 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 5 Replacing the Ethernet switch Continued ...

Page 201: ...re should be no gap between the upper surface of the Ethernet extension switch and the lower surface of highest bracket on the main computer xx1800000972 3 Reconnect K2 X2 K4 X8 A2 X1 K4 X7 K5 1 X5 K4 X6 A2 X4 4 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests o...

Page 202: ... via myABB Business Portal www abb com myABB Note Article number Spare part DSQC1039 3HAC060960 001 Connected Services 3G 3013 3 3HAC028459 001 Magnetic roof antenna 3G DSQC1040 3HAC060962 001 Connected Services WiFi 3013 2 3HAC059424 001 Magnetic roof antenna WiFi DSQC1041 3HAC061701 001 Connected Services Wired 3013 1 Harness A2 X5 K7 X2 3HAC061136 001 Harness Ethernet with Mini IO Continues on ...

Page 203: ... doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Continues on next page Produc...

Page 204: ...he cable grom met 3 xx1900001949 Remove the magnet part of the antenna from the top the cabinet 4 Removing the Connected Services Gateway Note Illustration Action Disconnect K7 X1 K2 X3i K7 X2 A2 X5 Note The connector K7 X2 is locked grab the connector push it in to release it and then remove the connector 1 Continues on next page 204 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyrig...

Page 205: ...Refitting the Connected Services Gateway Refitting the Connected Services Gateway Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page Product manual OmniCore C90XT 205 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 6 Replacing the Connec...

Page 206: ...Gateway and the upper surface of the main computer should be zero 3 Reconnect K7 X1 K2 X3i K7 X2 A2 X5 4 i For Connected Services Gateway wired there is no power cable Reconnecting the antenna Note Illustration Action Refitting the cable grommet assembly on page 317 Insert the cable from the cable grommet 1 Refit the cable in the cabinet according to the record during the disassembly 2 Continues o...

Page 207: ...abinet 4 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 207 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 6 Replacing the Connected Services Gateway Continued ...

Page 208: ...2 1 3HAC060919 001 Connectors digital base add on DSQC1031 3HAC058664 001 Digital add on 3033 2 DSQC1032 3HAC058665 001 Analog add on 3034 2 3HAC060925 001 Connectors I O Analog DSQC1033 3HAC058666 001 Relay add on 3035 2 3HAC060926 001 Connectors I O Relay Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard ...

Page 209: ...r more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Continues on next page Product manual OmniCore C90XT 209 3HAC073706 001 Revision D Copyright ...

Page 210: ...tch is not installed connect and discon nect the connector K5 1 X5 to from A2 X4 K5 1 X4 K2 X3 The harness connected to I O unit by customer 1 xx1900002446 Push the buckle of the digital base slightly and take out the digital base 2 xx1900002447 Continues on next page 210 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 7 Replacing th...

Page 211: ...n ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 xx1900002447 Push the digital base into the bracket until you hear a clear clicking sound 3 Continues on next page Product manual OmniCore C90XT 211 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 ...

Page 212: ...con nect the connector K5 1 X5 to from A2 X4 K5 1 X4 K2 X3 The harness connected to I O unit by customer 4 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 212 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All righ...

Page 213: ...ber Spare part 3HAC063061 001 Main computer module assembly Required tools and equipment 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 Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit Continues on next page Product...

Page 214: ...of the computer see Removing the main computer by parts on page 227 Removing the main computer by assembly group Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is se...

Page 215: ...p tion K2 X2 K4 X8 A2 X1 K4 X7 K5 1 X5 K4 X6 A2 X4 For the Connected Services Gateway K7 X1 K2 X3i K7 X2 A2 X5 Note The connector K7 X2 is locked grab the connector push it in to release it and then remove the connector For the main computer 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 If the Ethernet extension switch is installed connect ...

Page 216: ... ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 3 xx1900001885 i For Connected Services Gateway wired there is no power cable Continues on next page 216 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continu...

Page 217: ...rist strap button located on the side of the computer 1 xx2000000419 xx1900001879 Pull the cable ties out from the locking holes 2 xx1900001880 Remove the screws and lift out the robot signal exchange proxy 3 Continues on next page Product manual OmniCore C90XT 217 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 218: ...pull the side of the Ethernet extension switch and rotate it tightly to take it out from the bracket 1 xx1800000491 Continues on next page 218 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 219: ...itting the main computer by assembly group Refitting the Connected Services Gateway Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page Product manual OmniCore C90XT 219 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main...

Page 220: ...TOP VIEW Hook up the Connected Services Gate way to the bracket and push carefully into position Note During the installation the gap between the lower surface of the Connected Ser vices Gateway and the upper surface of the main computer should be zero 3 xx1900001884 Continues on next page 220 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Rep...

Page 221: ...age 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2000000419 Continues on next page Product manual OmniCore C90XT 221 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 222: ...r surface of highest bracket on the main computer xx1800000972 3 xx1900001882 Refitting the robot signal exchange proxy Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page 222 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserv...

Page 223: ...ensitive to ESD on page 43 2 xx2000000419 Screws Torx pan head screw M4x8 4 pcs xx1900001880 Fit the robot signal exchange proxy and secure the screws 3 xx1900001879 Insert the cable ties into the locking holes 4 Continues on next page Product manual OmniCore C90XT 223 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 224: ...safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 2 xx1900001446 Continues on next page 224 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 225: ...econnect all the connectors on as sembly of the robot signal exchange proxy ethernet extension seven port switch option ABB ability connected services and main computer 5 Continues on next page Product manual OmniCore C90XT 225 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 226: ...or K7 X2 is locked grab the connector push it in to release it and then remove the connector 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 If the Ethernet extension switch is installed connect and disconnect the connector A2 X4 to from K4 X6 If the Ethernet extension switch is not installed connect and discon...

Page 227: ...g the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Disconnecting the connectors to the main computer assembly Note Illustration Action Disconnect all the connectors on the as sembly group of the robot sig...

Page 228: ...7 X2 is locked grab the connector push it in to release it and then remove the connector 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 If the Ethernet extension switch is installed connect and disconnect the connector A2 X4 to from K4 X6 If the Ethernet extension switch is not installed connect and discon nec...

Page 229: ...e ties out from the locking holes 1 xx1900001887 Remove the screws and lift out the robot signal exchange proxy 2 Continues on next page Product manual OmniCore C90XT 229 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 230: ...pull the side of the Ethernet extension switch and rotate it tightly to take it out from the bracket 1 xx1800000491 Continues on next page 230 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 231: ... side of the Connected Services Gateway and rotate it tightly to take it out from the bracket 1 xx1800000495 TOP VIEW Continues on next page Product manual OmniCore C90XT 231 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 232: ...puter ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 2 xx1900001894 Continues on next page 232 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 233: ...fety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page Product manual OmniCore C90XT 233 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Cont...

Page 234: ...xx1900001893 Screws Torx pan head screw M4x8 2 pcs Fasten the main computer with the screws 4 xx1900001892 Continues on next page 234 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 235: ... section The unit is sensitive to ESD on page 43 2 xx1900001890 Hook up the Connected Services Gate way to the bracket and push carefully into position Note During the installation the gap between the lower surface of the Connected Ser vices Gateway and the upper surface of the main computer should be zero 3 xx1800000495 TOP VIEW Continues on next page Product manual OmniCore C90XT 235 3HAC073706 ...

Page 236: ...age 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page 236 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 237: ...r surface of highest bracket on the main computer xx1800000972 3 xx1800000491 Refitting the robot signal exchange proxy Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page Product manual OmniCore C90XT 237 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserv...

Page 238: ...ensitive to ESD on page 43 2 xx1900001446 Screws Torx pan head screw M4x8 4 pcs Fit the robot signal exchange proxy and secure the screws 3 xx1900001887 xx1900001886 Insert the cable ties into the locking holes 4 Continues on next page 238 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 239: ...ethernet extension seven port switch option ABB ability connected services scalable I O digital base op tion and main computer 3 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 ...

Page 240: ...X6 If the Ethernet extension switch is not installed connect and discon nect the connector A2 X4 to from K5 1 X5 i For Connected Services Gateway wired there is no power cable Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Restoring the hardware settings on page241 Restore the hardware settings 2 Perform the function tests to verify that the safety feat...

Page 241: ...rom a previous system backup 1 xx1900000110 Access the RobotWare Installation Utilit ies 2 Tap Advanced and then Restore Hard ware Settings 3 The Restore Hardware Settings window is displayed 4 Follow the instructions and tap Next to proceed Carefully read the information and then check all boxes to confirm that you agree with the ABB conditions Tap Next to proceed 5 xx2000000007 Read the serial n...

Page 242: ... myABB Note Article number Spare part DSQC3044 3HAC059152 001 Power unit Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC065464 009 Circuit diagram OmniCore C90XT Continues on next page 242 Product manual OmniCore C90XT ...

Page 243: ...t is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the power unit Note Illustration Action 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 1 Continues on next page Product manual OmniCore C90XT 243 3HAC073706 001...

Page 244: ... the filter on the power unit 2 xx1900001896 Refitting the power unit Refitting the power unit Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page 244 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 9 Replaci...

Page 245: ...n The unit is sensitive to ESD on page 43 2 xx1900001446 Screws Torx pan head screw M4x8 2 pcs Push the power unit until it snaps on the mounting plate and secure the screws 3 xx1900001895 xx1900001896 Continues on next page Product manual OmniCore C90XT 245 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 9 Replacing the power unit Continued ...

Page 246: ...ck 4 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 246 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 9 Replacing the power unit Continued ...

Page 247: ...umber Spare part DSQC3035 3HAC071301 001 Power supply DSQC 609 3HAC14178 1 DSQC 609 power supply DSQC 634 3HAC13398 2 DSQC 634 power supply 3HAC069617 001 Harness AC input of power supply 3HAB7983 1 End clamp WARNING Do not touch the power supply when the DC OK Led is on There is residual voltage in the power supply even the controller is power off in a short time Continues on next page Product ma...

Page 248: ... the mains power For more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the power supply baseline Note Illustration Action Disconnect T2 ...

Page 249: ... For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page Product manual OmniCore C90XT 249 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair...

Page 250: ... that the safety features work properly see Function tests on page 165 2 Removing the DSQC 609 power supply Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Continues on next page 250 Product manual OmniCore C90XT 3HAC073706 001 Revisi...

Page 251: ...ection The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the power supply Note Illustration Action xx1900001907 Remove the end clamp besides the power supply with a screwdriver 1 Continues on next page Product manual OmniCore C90XT 251 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 10 Replacing the power supply Continued ...

Page 252: ...net disconnect the mains power For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page 252 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 AB...

Page 253: ...Refit the end clamp besides the power supply 5 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Continues on next page Product manual OmniCore C90XT 253 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 10 Replacing...

Page 254: ...CTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the power supply Note Illustration Action xx1900002443 Remove the end clamp besides the power supply with a screwdriver 1 Continues on next page 254 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 20...

Page 255: ...ide the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page Product manual OmniCore C90XT 255 3HAC073706 001 Revision D Copyright ...

Page 256: ...002443 Refit the end clamp besides the power supply 5 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 256 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 10 Replacing the power suppl...

Page 257: ...are part DSQC3041 3HAC063913 001 Drive Harness A1 X4 T4 X5 3HAC063344 001 Harness DC BUS Harness A1 X5 T4 X1 3HAC064389 001 Harness 24_SYS_DRV Harness T4 X3 A1 X12 3HAC059894 001 Harness EtherCAT Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Continues on next page Produ...

Page 258: ... page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the power supply baseline Note Illustration Action Disconnect T2 X1 A1 X6 T2 X2 K2 X1 1 Continues on next page 258 Product manual OmniCore C90XT 3HAC073706 0...

Page 259: ...9 T4 X5 A1 X4 T4 X3 A1 X12 T4 X1 A1 X5 1 xx1900001900 Cut the cable tie for the DC bus cable and move it to the other side 2 xx1900002338 Cut the cable tie for the EtherCAT cable 3 Continues on next page Product manual OmniCore C90XT 259 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 11 Replacing the drive unit Continued ...

Page 260: ...hment screws and pull the drive unit out from the two snaps 4 xx1900001898 xx1900001899 Continues on next page 260 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 11 Replacing the drive unit Continued ...

Page 261: ... page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page Product manual OmniCore C90XT 261 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 11 Replacing the drive unit Continued ...

Page 262: ...rive unit into the snaps on the mounting plate and secure the screws 3 xx1900001898 xx1900001899 Continues on next page 262 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 11 Replacing the drive unit Continued ...

Page 263: ... T4 X9 T4 X5 A1 X4 T4 X3 A1 X12 T4 X1 A1 X5 6 Refitting the power supply Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page Product manual OmniCore C90XT 263 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 11 Replacing the drive unit Con...

Page 264: ...4x8 4 pcs Fit the power supply and fasten it with screws 3 xx1900001897 Reconnect T2 X1 A1 X6 T2 X2 K2 X1 4 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 264 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rig...

Page 265: ... myABB Note Article number Spare part DSQC1006 3HAC043383 001 DeviceNet Board Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC065464 009 Circuit diagram OmniCore C90XT Continues on next page Product manual OmniCore C90XT...

Page 266: ... 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the main computer assembly Note Illustration Action Disconnect all the connectors on the as sembly group of the robot signal ex chan...

Page 267: ...K7 X2 A2 X5 Note The connector K7 X2 is locked grab the connector push it in to release it and then remove the connector For the main computer 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 If the Ethernet extension switch is installed connect and disconnect the connector A2 X4 to from K4 X6 If the Ethernet extension switch is not installed ...

Page 268: ...LECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 3 xx1900001885 i For Connected Services Gateway wired there is no power cable Continues on next page 268 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 12 Replacing the fieldbus master Contin...

Page 269: ...ist strap button located on the side of the computer 1 xx2000000419 xx1900001879 Pull the cable ties out from the locking holes 2 xx1900001880 Remove the screws and lift out the robot signal exchange proxy 3 Continues on next page Product manual OmniCore C90XT 269 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 12 Replacing the fieldbus master Continued ...

Page 270: ... side of the computer 1 xx2000000419 xx1900001909 Remove the attachment screws and take the cover off 2 Note The Connected Services Gateway and Ether net extension switch are omitted on the illus tration to make it more clear Continues on next page 270 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 12 Replacing the fieldbus master C...

Page 271: ...er Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 xx1900001446 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 Continues on next page Product manual OmniCore C90X...

Page 272: ... computer 1 xx2000000419 xx1900001911 Insert the fieldbus master straight into the card slots along the guide rail 2 Note The Connected Services Gateway and Ether net extension switch are omitted on the illus tration to make it more clear Continues on next page 272 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 12 Replacing the fiel...

Page 273: ...clear Screws Hexalobular socket pan head screw M3x6 4 pcs Refit the cover of the main computer and secure the screws 4 xx1900001909 Note The Connected Services Gateway and Ether net extension switch are omitted on the illus tration to make it more clear Continues on next page Product manual OmniCore C90XT 273 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 12 Rep...

Page 274: ...RGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2000000419 Screws Torx pan head screw M4x8 4 pcs xx1900001880 Fit the robot signal exchange proxy and secure the screws 3 Continues on next page 274 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Rep...

Page 275: ...ower For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 2 xx1900001446 Continues on next page Product manual OmniCore C90XT 275 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 12 Replac...

Page 276: ...onnect all the connectors on as sembly of the robot signal exchange proxy ethernet extension seven port switch option ABB ability connected services and main computer 5 Continues on next page 276 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 12 Replacing the fieldbus master Continued ...

Page 277: ...r K7 X2 is locked grab the connector push it in to release it and then remove the connector 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 If the Ethernet extension switch is installed connect and disconnect the connector A2 X4 to from K4 X6 If the Ethernet extension switch is not installed connect and discon ...

Page 278: ...e the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 278 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 12 Replacing the fieldbus master Continued ...

Page 279: ... myABB Note Article number Spare part DSQC2000 3HNA027579 001 Conveyor tracking module 3103 1 3HNA029345 001 CONNECTOR KIT DSQC2000 Power cable of CTM 3HAC069618 001 Harness 24V_CTM Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Continues on next page Product manual Omni...

Page 280: ...ing the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the conveyor tracking module option Note Illustration Action Disconnect B1 X1 K2 X19 1 K2 X19 2 B1 X7 K4 X1 5 1 Continues on next page 280 Pro...

Page 281: ...as sembling work 2 xx1900001913 Refitting the conveyor tracking module option Refitting the conveyor tracking module option Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page Product manual OmniCore C90XT 281 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights re...

Page 282: ...it is sensitive to ESD on page 43 2 xx1900001446 xx1900001913 Hang the conveyor tracking module into the bracket and push the lower of it until you hear a clear clicking sound 3 xx1900001912 Continues on next page 282 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 13 Replacing the conveyor tracking module CTM Continued ...

Page 283: ...elf adhesive part 4 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 283 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 13 Replacing the conveyor tracking module CTM Continued ...

Page 284: ...Note Article number Spare part 3HAC068415 001 Air filter coarse filter 3HAC068416 001 Air filter Fine filter Filter element of fine filter 3HAC068543 001 Air filter Polymeric Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Continues on next page 284 Product manual OmniCor...

Page 285: ...isconnect the mains power For more information see Electrical safety on page 31 1 Removing the air filter Note Illustration Action xx1900001491 Loosen the attachment screws on the air filter 1 xx1900001492 Remove the air filter 2 Continues on next page Product manual OmniCore C90XT 285 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 14 Replacing the air filter Co...

Page 286: ...rt the polymeric filter element to the filter and secure with the metallic line 1 Refitting the air filter Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page 286 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5...

Page 287: ...cluding procedure Note Illustration Action Perform the function tests to verify that the safety features work properly see Function tests on page 165 1 Product manual OmniCore C90XT 287 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 2 14 Replacing the air filter Continued ...

Page 288: ... can be out of date See the latest spare parts of the OmniCore C90XT via myABB Business Portal www abb com myABB Note Article number Spare part Harness single SMB 3HAC069674 001 Harness Single SMB connection Harness double SMB 3HAC069675 001 Harness Double SMB connection Continues on next page 288 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5...

Page 289: ...oing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Continues on next page Product ...

Page 290: ...r signal connector out 4 Refitting the manipulator signal connector Refitting the manipulator signal connector Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page 290 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repa...

Page 291: ... screw M4x8 4 pcs Secure it with the attachment screws 4 xx1900001915 xx1900001914 Reconnect and secure K6 X4 K6 X5 SMB 5 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 291 3HAC073706 001 Revision D Copyright 2020 20...

Page 292: ... C90XT via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC069672 001 Harness Motors power LV 6 axis Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Continues on next page 292 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 202...

Page 293: ...r Document 3HAC065464 009 Circuit diagram OmniCore C90XT Continues on next page Product manual OmniCore C90XT 293 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 2 Replacing the motor connector Continued ...

Page 294: ...on ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the motor connector Note Illustration Action Disconnect the following connectors for the motor connector T4 X7 T4 X8 T4 X9 X1 K2 X7 X22 PE 5 PE 6 1 Continues on next page 294 Product manual OmniCore C90XT 3HAC07...

Page 295: ... to be installed in the same position 4 Take the motor connector out 5 Refitting the motor connector Refitting the motor connector Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Continues on next page Product manual OmniCore C90XT 295 3HAC073706 001 Revision D Copyright 2020 2021 ABB All ri...

Page 296: ...of the cabinet and fasten it with the screws 3 xx1900001916 Reconnect T4 X7 T4 X8 T4 X9 X1 K2 X7 X22 PE 5 PE 6 4 Secure the motor connector cables with the velcro on the frame of the cabinet Tip Use the same position as from removing the motor connector 5 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Continues on next page 296 Product manual OmniCore C...

Page 297: ...tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 297 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 2 1 Replacing the motor connector Continued ...

Page 298: ...Board 3022 1 DSQC 669 3HAC027652 001 Ethernet Unit 3025 1 Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC065464 009 Circuit diagram OmniCore C90XT Removing the fieldbus slot cover baseline Note Illustration Action DANGE...

Page 299: ...efore doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Push the fieldbus slot cover into the main computer until you hear a ...

Page 300: ...ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001917 Loosen the screws and take the fieldbus adapter slave out 4 Refitting the fieldbus adapter slave option Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more informatio...

Page 301: ... xx1900001917 Insert the fieldbus adapter slave tighten the screws 3 Closing the door on page 174 Close the door 4 Perform the function tests to verify that the safety features work properly see Function tests on page 165 5 Product manual OmniCore C90XT 301 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 3 Replacing the fieldbus adapter slave Continued ...

Page 302: ... Note Article number Spare part Harness Mains connection 3HAC067661 001 Harness AC input with SW 3HAC070308 001 Connector AC power inlet 3HAC037699 001 Handle for 6 mm switch Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Continues on next page 302 Product manual OmniCor...

Page 303: ... Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the power inlet Note Illustration Action xx1900001919 Disconnect the mains switch from the handle for 6 switch by pressing the push hook 1 Continues on next page Product manual OmniC...

Page 304: ...ide the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page 304 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright ...

Page 305: ...Reconnect the mains switch to the handle for 6 switch 6 Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 305 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 4 Replacing the power inle...

Page 306: ...e C90XT via myABB Business Portal www abb com myABB Note Article number Spare part Harness TPU 3HAC069673 001 Harness TPU connection Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Continues on next page 306 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyrigh...

Page 307: ...it is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Removing the HMI signal connector Note Illustration Action Remove the cables out from the clips in the cabinet carefully Note Make records about the sequence that cables are removed The cables need to be installed in the same position 1 Disconnect TPU X4 K2...

Page 308: ...he screws 3 xx1900001922 Remove the cover plate 4 Continues on next page 308 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 5 Replacing the HMI signal FlexPendant connector Continued ...

Page 309: ...he cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page Product manual OmniCore C90XT 309 3HAC073706 001 Revision D Copyright 2020 ...

Page 310: ...X4 K2 X9 X13 4 Secure the cables on HMI signal connect or into the clips on the cabinet Tip Use the same position as from removing the HMI signal connector 5 xx1900001922 Refit the cover plate 6 Continues on next page 310 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 5 Replacing the HMI signal FlexPendant connector Continued ...

Page 311: ...ion Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 311 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 5 Replacing the HMI signal FlexPendant connector Continued ...

Page 312: ...e cabinet if it s not executed correctly It is recommended to use icotek KT grommet Required spare 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 Note Article number Spare part 3HAC066396 001 Cable grommet asm Continues on next page 312 Product manual OmniCore C90XT 3HAC0...

Page 313: ... doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Continues on next page Produc...

Page 314: ...the attachment screws on the cover 2 Push the cable grommet assembly into the cabinet 3 Take the cable grommet assembly out 4 Releasing the cables from the cable grommet assembly Note Illustration Action xx1900002332 Unscrew the cable entry frame from the enclosure wall 1 Continues on next page 314 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved ...

Page 315: ...900002334 Remove the attachment screws on the frame and cover strip 3 xx1900002335 Remove the cover strip from the frame 4 Continues on next page Product manual OmniCore C90XT 315 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 6 Replacing the cable grommet assembly Continued ...

Page 316: ...ve the grommets in the upper row first and then the second row 5 xx1900002337 Remove the cable from the correspond ing KT grommet 6 Continues on next page 316 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 6 Replacing the cable grommet assembly Continued ...

Page 317: ...are point ing to the open side of the frame half flat sides pointing upwards Note The fl at side of the grommets in the up per row have to point downwards so that all flat sides rest on each other When using single row frames the fl at side has to point towards the cover strip 2 xx1900002335 Refit the cover strip onto the frame 3 Continues on next page Product manual OmniCore C90XT 317 3HAC073706 ...

Page 318: ... and cover strip with the screws 4 Tightening torque 2 Nm 3 Nm xx1900002334 xx1900002333 Route the cables through the cut out 5 Continues on next page 318 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 6 Replacing the cable grommet assembly Continued ...

Page 319: ...abinet disconnect the mains power For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page Product manual OmniCore C90XT 319 3HAC073706 001 Revision D Copyright 2020 2021...

Page 320: ...s Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 320 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 6 Replacing the cable grommet assembly Continued ...

Page 321: ... the cabinet if it s not executed correctly It is recommended to use icotek KT grommet Required spare 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 Note Article number Spare part 3HAC069954 001 Blind plate Continues on next page Product manual OmniCore C90XT 321 3HAC0737...

Page 322: ...llustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx19000014...

Page 323: ...the attachment screws on the cover 2 Push the cable grommet assembly into the cabinet 3 Take the cable grommet assembly out 4 Releasing the cables from the cable grommet assembly Note Illustration Action xx1900002332 Unscrew the cable entry frame from the enclosure wall 1 Continues on next page Product manual OmniCore C90XT 323 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved ...

Page 324: ...02334 Remove the attachment screws on the frame and cover strip together 3 xx1900002335 Remove the cover strip from the frame 4 Continues on next page 324 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 7 Replacing the cable grommet assembly Continued ...

Page 325: ...ve the grommets in the upper row first and then the second row 5 xx1900002337 Remove the cable form the correspond ing KT grommet 6 Continues on next page Product manual OmniCore C90XT 325 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 7 Replacing the cable grommet assembly Continued ...

Page 326: ...are point ing to the open side of the frame half flat sides pointing upwards Note The fl at side of the grommets in the up per row have to point downwards so that all flat sides rest on each other When using single row frames the fl at side has to point towards the cover strip 2 xx1900002335 Refit the cover strip onto the frame 3 Continues on next page 326 Product manual OmniCore C90XT 3HAC073706 ...

Page 327: ... and cover strip with the screws 4 Tightening torque 2 Nm 3 Nm xx1900002334 xx1900002333 Route the cables through the cut out 5 Continues on next page Product manual OmniCore C90XT 327 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 7 Replacing the cable grommet assembly Continued ...

Page 328: ...abinet disconnect the mains power For more information see Electrical safety on page 31 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx1900001446 Continues on next page 328 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021...

Page 329: ...s Concluding procedure Note Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 329 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 7 Replacing the cable grommet assembly Continued ...

Page 330: ...C90XT via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC070053 001 Harness ETH outlet with cable Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Continues on next page 330 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 ...

Page 331: ...lectrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Continues on next page Product manual OmniCore C90XT 331 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights...

Page 332: ...n xx1900001921 Remove the screws 1 xx1900001922 Remove the cover plate 2 Continues on next page 332 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 8 Replacing the harness ETH outlet with cable Continued ...

Page 333: ... Refitting the harness ETH outlet with cable Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 31 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 Insert the harness ETH outlet with ...

Page 334: ...H outlet with cables with the clips on the cabinet Tip Use the same position as from removing the harness ETH outlet with cable 6 xx1900001922 Refit the cover plate 7 Continues on next page 334 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 8 Replacing the harness ETH outlet with cable Continued ...

Page 335: ...tion Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 335 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 8 Replacing the harness ETH outlet with cable Continued ...

Page 336: ...C90XT via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC065549 001 LED indicator Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit ESD protective wrist band Continues on next page 336 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rig...

Page 337: ...lectrical safety on page 31 1 Opening the door on page 174 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx1900001446 Continues on next page Product manual OmniCore C90XT 337 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights...

Page 338: ...n xx1900001921 Remove the screws 1 xx1900001922 Remove the cover plate 2 Continues on next page 338 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 9 Replacing the LED indicator Continued ...

Page 339: ...e cabinet disconnect the mains power For more information see Electrical safety on page 31 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 Insert the LED indicator into the cover from outer side of the door and the screw from inner side and screw them up 3 Continues on next page Pr...

Page 340: ...f cables into the lamp and secure with the screws 4 xx1900001922 Refit the cover plate 5 Continues on next page 340 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 9 Replacing the LED indicator Continued ...

Page 341: ...Illustration Action Closing the door on page 174 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 165 2 Product manual OmniCore C90XT 341 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 3 9 Replacing the LED indicator Continued ...

Page 342: ...e table can be out of date See the latest spare parts of the OmniCore C90XT via myABB Business Portal www abb com myABB Note Article number Spare part Harness TPU 3HAC069673 001 Harness TPU connection Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit Continues on next page 342 Product manual OmniCor...

Page 343: ...o ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 1 Disconnect the FlexPendant from the controller 2 xx1800001189 Remove the attachment screws for the power cable cover 3 xx1800001190 Remove the power cable cover 4 Continues on next page Product manual OmniCore C90XT 343 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserv...

Page 344: ...lustration Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 1 Continues on next page 344 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 1 Replacing the power cable and power cable cover Continued ...

Page 345: ...3 pcs xx1800001196 Refit the power cable cover and tighten the screws 4 Perform the function tests to verify that the safety features work properly see Function tests on page 165 5 Product manual OmniCore C90XT 345 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 1 Replacing the power cable and power cable cover Continued ...

Page 346: ...ss Portal www abb com myABB Note Article number Spare part 3HAC065408 001 Joystick guard Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 417 Standard toolkit Required documents Note Article number Document 3HAC065464 009 Circuit diagram OmniCore C90XT Continues on next page 346 Product manual OmniCore C90XT 3HAC073706...

Page 347: ...Remove the attachment screws 3 xx1800001199 Remove the joystick protection 4 Refitting the joystick protection Note Illustration Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 1 Continues on next page Product manual OmniCore C90XT 347 3HAC073706 001 Revision D Copyright 2020 20...

Page 348: ...tick protection 2 xx1800001206 Secure the screws 3 Countersunk head screw ST2 9 X 10 6 pcs 348 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 5 Repair 5 4 2 Replacing the joystick protection Continued ...

Page 349: ...via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC065419 001 Fasten strip Replacing the fasten strip Note Illustration Action Open the velcro on the fasten strip 1 Take the fasten strip out from the holes 2 Insert the new fasten strip into the holes one by one 3 Secure the velcro in a suitable length 4 Product manual OmniCore C90XT 349 3HAC073706 001 Revision D Copyrig...

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Page 351: ...ording 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 Disposal of storage media Before disposal of any storage equipment anything from an SD card to a complete controller make sure that all sensitive inform...

Page 352: ...ing to local regulations to prevent health or environmental hazards Example application Material Heat sinks on power supplies and drive units Aluminium Main computer Batteries Lithium Cables Copper Cables connectors etc Plastic rubber Power supplyi Silicone Cabinet structure plates screws etc Steel i The product does not contain silicone by design but there might be a minimal risk of contamination...

Page 353: ...s Substances in Electrical and Electronic Products SJ T 11364 2014 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 Product manual OmniCore C90XT 353 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 6 Decommissioning 6 2 Environmental...

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Page 355: ... 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 Keep a track of history Make a historical fault log to keep track of problems over time Consult those working with t...

Page 356: ...ties between hardware and software options and their configuration The robot recently had a software upgrade Check connections software versions The robot has recently been moved from one site to another an already working robot 356 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 1 Introduction to troubleshooting Continued ...

Page 357: ...eleasing the robot brakes on page 365 Problem starting or connecting the FlexPendant on page 369 Problem using the joystick on page 373 Controller fails to start on page 374 Reflashing firmware failure on page 375 Inconsistent path accuracy on page 376 Continues on next page Product manual OmniCore C90XT 357 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 ...

Page 358: ...ure If no LEDs are lit on the controller during start up use this procedure to troubleshoot what might cause the problem Look at the following block diagram to understand how power is connected from incoming and forward Block diagram AC input Power inlet X0 Main switch Q0 Power unit A1 X1 X6 L N PE PE L N L N PE L N Power supply T2 X1 X2 24V TRUNK X1 X2 PC PS X4 X13 HMI 24V SYS DRV MS AC LED LED L...

Page 359: ...k Check AC input cable Connection ok Replace cable Broken cable Cable ok Ok Ok Check T2 X1 Abnormal Replace Q0 Abnormal Troubleshoot power unit Troubleshoot power supply Ok Problem solved Check Q0 power out xx2000000444 Continues on next page Product manual OmniCore C90XT 359 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 2 1 No LEDs are lit on the contro...

Page 360: ...k that the connector X0 is properly connec ted Tip For more details see Circuit diagram OmniCore C90XT 3 Check that the AC input cable is properly connec ted 4 Use a multimeter and insulating gloves Check the output voltage of Q0 Make sure that Q0 is closed 5 Replace if damaged see Replacing the power inlet on page 302 If abnormal see Troubleshooting the power unit on page 382 Check connector T2 X...

Page 361: ...ed on must be performed by personnel trained by ABB or by ABB field engineers Recommended working procedure If there seems to be a power failure during start up use this procedure to troubleshoot what might cause the problem Look at the following block diagram to understand how power is connected from incoming and forward Block diagram AC input Power inlet X0 Main switch Q0 Power unit A1 X1 X6 L N...

Page 362: ...g 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 Look at the LED PS 1 LED MS should be green If not see Troubleshooting the robot sign...

Page 363: ... Troubleshooting the robot signal exchange proxy on page 407 Look at the LEDs PC and HMI 4 For more details about the LEDs see Troubleshooting the main computer on page 398 Look at the LEDs PC PWR PC HDD and PC STAT 5 If the problem remains contact ABB 6 Tip For more details see Circuit diagram OmniCore C90XT Product manual OmniCore C90XT 363 3HAC073706 001 Revision D Copyright 2020 2021 ABB All r...

Page 364: ...e current configuration See Operating manual Integrator s guide OmniCore for detailed information regarding system reset After reset it is possible to A Go forward with the new configuration by re implementing your programs and configuration or selectively reloading contents of the previous system backup B Rollback the changes in the system configuration that is make a new system update and load t...

Page 365: ...owered on must be performed by personnel trained by ABB or by ABB field engineers Recommended working procedure If the brakes do not release no robot movement is possible and a number of error log messages can occur Use this procedure to troubleshoot what might cause the problem Look at the following block diagram to understand how power is connected from incoming and forward Block diagram Robot s...

Page 366: ...o A1 X2 Connec on is ok Connec on not ok Repair connec on Repair connec on Connec on not ok Measure power on K2 X7 Power is ok No power Connec on is ok Test the brake Test the brake release Brake is ok Brake not ok Brake release is ok Not ok Contact ABB Problem solved Troubleshoot brake release on manipulator main computer A2 robot signal exchange proxy K2 power unit A1 xx1800001836 Continues on n...

Page 367: ...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 Look at the LED MS LED PC and LED HMI All LEDs should be solid green 3 Use a multimeter and in...

Page 368: ...oxy and the power unit one by one If needed replace faulty units Go to step 8 Try jogging the robot 7 For more details on how to release the brakes see the robot s product manual If it is not ok contact your local ABB Check that the brake release function is ok 8 368 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 2 4 Problem ...

Page 369: ...t needed for troubleshooting Note Equipment Multimeter Insulating gloves 3HAC065464 009 Circuit diagram OmniCore C90XT Preparations Action Make sure that the controller is switched on 1 Wait 30 s 1 min to enable start up sequence Check the FlexPendant for errors and warnings 2 DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field en...

Page 370: ...rd Block diagram Robot signal exchange proxy K2 PC X9 X13 HMI Safety controller A2 K3 ES EN MON 24V HMI LED Ethernet LED HMI connection X4 FlexPendant MS LED Main computer A2 Dual channel control feedback X6 X7 Ethernet X12 X8 X6 X1 X1 X3 X2 24V PC 24V SYS xx1800001830 Continues on next page 370 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 T...

Page 371: ... Check connector X4 Connection not ok Connection not ok Connections ok Start FlexPendant Problem solved Ok Not starting Replace FlexPendant Replace FlexPendant cable xx1800001831 Detailed working procedure Note Action See Operating manual OmniCore Try resetting the FlexPendant using the reset button located next to the USB port 1 Continues on next page Product manual OmniCore C90XT 371 3HAC073706 ...

Page 372: ...o to the next step Check that the connection from the robot signal exchange proxy to the HMI signal connector is ok K2 X9 13 X4 5 If any connection fails re pair the connection and go to step six If the connections are ok go to the next step Check that the connection from the robot signal exchange proxy to the main computer is ok K2 X8 A2 X6 K2 X2 A2 X1 K2 X12 A2 K3 X6 7 K2 X3 A2 K3 X1 6 If possib...

Page 373: ...ng manual OmniCore Make sure that the joystick lock is not activated 1 Make sure the controller is in manual mode 2 Make sure the FlexPendant is connected cor rectly to the controller 3 If the joystick is still not working then replace the FlexPendant Press the reset button located next to the USB port on the back of the FlexPendant Note The reset button only resets the FlexPendant not the system ...

Page 374: ...forced to start in RobotWare Installation Utilities mode Forcing startup of the RobotWare Installation Utilities mode Repeat the following action two times in a row 1 Turn on the main power switch 2 Wait for approximately 15 seconds Note The PC STAT LED should be in flashing red state 3 Turn off the main power switch The installed system is de selected and in the next startup the RobotWare Install...

Page 375: ...oblem Note Action Read the message to see which unit has failed 1 If the relevant unit has been replaced recently make sure that the versions of the old and the new unit are identical 2 Check the software versions 3 If RobotWare has been updated recently make sure that the versions of the old and the new unit are identical 4 If the problem remains contact your local ABB for information about which...

Page 376: ...on Remove the obstacles Study the path of the robot in motion to find if an external force for example an external cable package is colliding with or restricting the movement of the robot 1 Improve the ventilation around the robot In high temperature environments the material in the robot can expand thereby causing inconsistent path accuracy 2 How to define these are described in Oper ating manual...

Page 377: ...d in section Problem re leasing the robot brakes on page 365 Make sure the robot brakes work prop erly 9 The swivel has an in built resistance that needs to be set in the system parameters If applicable Check the setting for the swivel 10 Product manual OmniCore C90XT 377 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 2 9 Inconsistent path accuracy Contin...

Page 378: ... unit Troubleshooting fieldbuses and I O on page 387 Scalable I O Troubleshooting the Connected Services Gateway on page 388 ABB Ability Connected Ser vices Troubleshooting the Ethernet switch on page 394 Ethernet switch Troubleshooting the axis computer on page 396 Axis computer Troubleshooting the main computer on page 398 Main computer Troubleshooting the power supply on page 401 Power supply T...

Page 379: ...t to the USB port 1 Note If protective gloves are used these must be compatible with touch screens when using the FlexPend ant If the FlexPendant is not responding or does not operate correctly see Problem starting or con necting the FlexPendant on page 369 2 Check the cable for connections and integrity 3 Check the 24 V power supply 4 Read the error event log message and follow any instructions o...

Page 380: ... illustration below shows the indication LEDs on the drive unit OmniCore C90XT A B A B C xx1800000575 Ethernet LEDs yellow A Ethernet LEDs green B Status LED C Continues on next page 380 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 3 Troubleshooting the drive unit ...

Page 381: ...e 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 Firm...

Page 382: ...LEDs The illustration below shows the LEDs on the power unit OmniCore C90XT A B A B C xx1800000576 Ethernet LEDs yellow A Ethernet LEDs green B Status LED C Continues on next page 382 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 4 Troubleshooting the power unit ...

Page 383: ...y Internal error Red flashing Firmware error or self test failure Green flashing Communication error to another module Power unit status LED Required test equipment Equipment needed for troubleshooting Note Equipment Multimeter Insulating gloves 3HAC065464 009 Circuit diagram OmniCore C90XT Preparations Action Check the FlexPendant for errors and warnings 1 Power the controller off Wait one minute...

Page 384: ...l Check LEDs of Ethernet ports X3 X12 Normal Abnormal Replace power unit Repair connection Repair connection Check connection of Ethernet cables Repair connection Connection ok Flashing red or flashing red green Troubleshoot no LEDs are lit Check connection power inlet to power unit Connection ok Connection not ok Power unit is ok Measure X6 X7 AC output voltage Abnormal Normal Check elog DC link ...

Page 385: ...r does not have sufficient DC input voltage Proceed with step 3 Use a multimeter and insulating gloves Measure the 24 V DC input voltage to the power unit X5 X9 3 The input voltage should be 24 V Make sure that connectors X5 X9 are connec 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 If the c...

Page 386: ...e connection is OK proceed with step 12 If there is a problem with the connection repair the connection and go to step 8 Check the connection of the Ether net cables 9 Use a multimeter and insulating gloves Measure the AC OK signal 10 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 p...

Page 387: ...bleshoot 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 Product manual OmniCore C90XT 387 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 5 Troubleshooting fieldbuses and I O ...

Page 388: ...shows the location of the Connected Services Gateway in the controller xx1900001466 Continues on next page 388 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 6 Troubleshooting the Connected Services Gateway ...

Page 389: ...issing Red solid or flashing Internal error Replace the unit Green flashing continuously Communication error to another module view error messages For the Connected Services 3G an orange LED indicator externally visible on the front indicates the status of the 3G connection LINK Orange ON flashing 3G modem on searching network ON solid 3G modem on and connected to network For the Connected Service...

Page 390: ...ipment Multimeter Insulating gloves Preparations Action Check the FlexPendant for errors and warnings 1 Power the controller off Wait one minute power the controller on 2 Make sure that the control system power supply is in run time mode 3 Wait 30 60 seconds after power on Continues on next page 390 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved...

Page 391: ...enna sim card etc Not ok Ok Not lit or solid Ok Ok Ok Ok Not ok Not ok Repair connection Not ok Troubleshoot robot signal exchange proxy K2 Replace the Connected Services Gateway Troubleshoot connectivity of 3G sim card WiFi antenna xx1900000139 Continues on next page Product manual OmniCore C90XT 391 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 6 Tro...

Page 392: ...ep 4 If the input voltage is abnormal Troubleshooting the robot signal exchange proxy on page 407 Tip For more details see Circuit dia gram OmniCore C90XT Make sure that connector X2 is connected properly on both ends 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 Check that the connector X2 is well con nected and ...

Page 393: ...vices Gateway configuration in Operating manual Integ rator s guide OmniCore For 3G use a cell phone to test that the sim card is working For WiFi use a cell phone to verify the WiFi access Note When testing with a cell phone use the same configuration on the cell phone 9 For 3G and WiFi check the antenna con nectivity 10 How to replace the unit is described in Replacing the Connected Services Gat...

Page 394: ...tion shows the location of the Ethernet switch in the controller xx1900001465 Continues on next page 394 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 7 Troubleshooting the Ethernet switch ...

Page 395: ...ollowing issues Status LED Fault indication No color If input voltage is within specified voltage limits and the LED is not lit then replace the switch Shows the status of Ethernet links Ethernet LEDs 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 Product...

Page 396: ...462 LEDs The illustration below shows the LEDs on the axis computer A A A B B B C xx1800000581 Ethernet LED yellow A Ethernet LED green B Status LED C Continues on next page 396 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 8 Troubleshooting the axis computer ...

Page 397: ...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 Axis computer status LED Shows the status of Ethernet communication Ethernet LED Green Off 10 Mbps data rate is selected On 100 Mbps data rate is selected Yellow Flashing The ...

Page 398: ...e controller xx1900001468 LEDs The illustration below shows the LEDs on the main computer A B C xx1800000585 Power status LED A Continues on next page 398 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 9 Troubleshooting the main computer ...

Page 399: ...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 appro...

Page 400: ...stalla tion Utilities mode see Controller fails to start on page 374 2 Re install RobotWare if possible 3 See Replacing the main computer on page213 The main computer may be faulty replace it and verify that the fault has been fixed 4 400 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 9 Troubleshooting the main computer Con...

Page 401: ...power supply in the controller xx2000000431 LEDs The illustration below shows the LEDs on the power supply A xx1800000582 Continues on next page Product manual OmniCore C90XT 401 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 10 Troubleshooting the power supply ...

Page 402: ...3HAC065464 009 Circuit diagram OmniCore C90XT Preparations Action Check the FlexPendant for errors and warnings 1 Power the controller off Wait one minute power the controller on 2 Make sure that the control system power supply is in run time mode 3 Wait 30 60 seconds after power on Continues on next page 402 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All right...

Page 403: ...not ok Connection not ok Faulty cable Cable ok Troubleshoot the power unit Replace power supply xx1800001823 Troubleshooting procedure The troubleshooting table is supposed to be used as a detailed instruction together with the troubleshooting flowchart Note Test If the LED is Green the power supply should be working properly Off either the power supply is faulty or it does not have sufficient inp...

Page 404: ...ctor X1 on the robot signal exchange proxy 4 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 Switch on power to the controller 5 Use a multimeter and insulating gloves Meas...

Page 405: ...und unconnected or faulty connect replace it Verify that the fault has been fixed and restart this guide if necessary Check the cabling 9 See Replacing the power supply on page 247 The power supply may be faulty replace it and verify that the fault has been fixed 10 Product manual OmniCore C90XT 405 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 10 Trou...

Page 406: ...ding 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...

Page 407: ...w shows the location of the robot signal exchange proxy in the controller xx1900001464 Continues on next page Product manual OmniCore C90XT 407 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 7 Troubleshooting 7 3 12 Troubleshooting the robot signal exchange proxy ...

Page 408: ...op LEDs green AS1 Automatic stop LED channel 1 AS2 Automatic stop LED channel 2 AS1 AS2 External emergency stop LED can be used to identify the following status No color not lit External emer gency stop input loop is open Green solid External emergency stop input loop is closed External emergency stop LEDs green ES1 External emergency stop LED channel 1 ES2 External emergency stop LED channel 2 ES...

Page 409: ...olor FlexPendant power out put voltage is not in normal range Green solid FlexPendant power output voltage is in normal range FlexPendant power output LED green HMI 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 External power input LED green EP Required t...

Page 410: ...5 Connection ok Connection not ok Troubleshoot power unit Repair connection No resistance High impedance Resistance Low impedance xx1800002356 Troubleshooting procedure The troubleshooting table is supposed to be used as a detailed instruction together with the troubleshooting flowchart Action Test If the LED_MS is Green proceed with step 4 Flashing red green a firmware upgrade error has occurred ...

Page 411: ...s faulty or it does not have sufficient input voltage Proceed with step 6 If the customer interface connectors are not well connected to X14 and X15 the robot signal exchange proxy cannot work normally If the connection is OK proceed with step 7 If there is a problem with the connection re pair the connection and go to step 5 Check that the customer inter face connectors are well con nected to X14...

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Page 413: ...r includes general information complementing the more specific information in the different procedures in the manual Product manual OmniCore C90XT 413 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 8 Reference information 8 1 Introduction ...

Page 414: ...ery Emergency stop Principles for design ISO 13850 Safety of machinery Electrical equipment of machines Part 1 General requirements IEC 60204 1 2005 Safety of machinery Functional safety of safety related elec trical electronic and programmable electronic control systems IEC 62061 2005 Deviations from ISO 10218 1 2011 for OmniCore A deviation exists in OmniCore from paragraph 5 3 5 Single point of...

Page 415: ... protection provided by enclosures IP code IEC 60529 1989 A2 2013 i Only valid for arc welding robots Replaces IEC 61000 6 4 for arc welding robots ii Only robots with protection Clean Room Product manual OmniCore C90XT 415 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 8 Reference information 8 2 Applicable standards Continued ...

Page 416: ...37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 416 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 8 Reference information 8 3 Unit conversion ...

Page 417: ...nstructions Standard toolkit for controller Description Tool Tx10 Screw driver Torx Tx20 Screw driver Torx Tx25 Screw driver Torx Tx25 Ball tipped screw driver Torx 4 mm Screw driver flat blade 8 mm Screw driver flat blade 12 mm Screw driver flat blade Phillips 1 Screw driver 8 mm Box spanner Toolkit recommended for troubleshooting Note Tool Contents as specified above Normal shop tools Multimeter...

Page 418: ...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 bel...

Page 419: ...jury 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 Product manual OmniCore C90XT 419 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 8 Reference information 8 6 Wei...

Page 420: ...g 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 420 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 8 Reference information 8 7 Lifting accessories and lifti...

Page 421: ...uctions 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 Continues on next page Product manual OmniCore C90XT 421 3HAC073706 001 Revisio...

Page 422: ...ve units xx1900001930 Spare part level Type Description Spare part num ber L1 DSQC3041 Drive 3HAC063913 001 A Power units xx1900001931 Continues on next page 422 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts ...

Page 423: ...t num ber L1 Harness ETH outlet with cable 3HAC070053 001 A Manipulator signal connectors SMB xx1900001942 Spare part level Type Description Spare part num ber L1 Harness Single SMB connection 3HAC069674 001 A Continues on next page Product manual OmniCore C90XT 423 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 424: ...1 B Harness TPU connection xx1900001943 Spare part level Type Description Spare part num ber L1 Harness TPU connection 3HAC069673 001 A Continues on next page 424 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 425: ...on Spare part num ber L1 Blind plate 3HAC069953 001 Harness motors power xx1900001944 Continues on next page Product manual OmniCore C90XT 425 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 426: ... base 3032 1 op tion 3HAC058663 001 A L1 DSQC1031 Digital add on 3033 2 Add on 3HAC058664 001 B L1 DSQC1032 Analog add on 3034 2 Add on 3HAC058665 001 C L1 Connectors I O Analog Add on 3HAC060925 001 L1 DSQC1033 Relay add on 3035 2 Add on 3HAC058666 001 L1 Connectors I O Relay 3HAC060926 001 Add on Continues on next page 426 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 20...

Page 427: ...1 xx1900001938 Spare part level Type Description Spare part num ber L1 DSQC2000 Conveyor tracking module 3103 1 3HNA027579 001 A L1 CONNECTOR KIT DSQC2000 3HNA029345 001 Continues on next page Product manual OmniCore C90XT 427 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 428: ... baseline 3HAC060960 001 A L1 Magnetic roof antenna 3G baseline 3HAC028459 001 B L1 Connected Services WiFi 3013 2 option 3HAC060962 001 C L1 Magnetic roof antenna WiFi option 3HAC059424 001 D L1 DSQC1041 Connected Services Wired 3013 1 option 3HAC061701 001 E Continues on next page 428 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare part...

Page 429: ...C 12 5F 3HAC053944 002 L1 16 mm camera lens LFC 16F1 3HAC053944 003 L1 25 mm camera lens LFC 25F1 3HAC053944 004 L1 DSQC1020 Integr Vision camera med Res 3HAC053953 001 L1 DSQC1021 Integr Vision camera high res 3HAC053954 001 L1 Integr Vision power cable 3HAC051753 003 L1 Integr Vision ethernet cable 3HAC051736 003 Continues on next page Product manual OmniCore C90XT 429 3HAC073706 001 Revision D ...

Page 430: ...d fan 3HAC059214 001 B Axis computer xx1900001927 Spare part level Type Description Spare part num ber L1 DSQC 668 Axis Computer 3HAC029157 001 A Continues on next page 430 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 431: ... Spare part level Type Description Spare part num ber L1 DSQC3035 Power supply 3HAC071301 001 A L1 DSQC 609 DSQC 609 power supply 3HAC14178 1 B L1 DSQC 634 DSQC 634 power supply 3HAC13398 2 C Continues on next page Product manual OmniCore C90XT 431 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 432: ...1 Fieldbus slot cover baseline 3HAC062390 001 L1 DSQC1004 DeviceNet Slave Fieldbus adaptor 3030 1 option 3HAC045973 001 A Continues on next page 432 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 433: ...re part level Type Description Spare part num ber L1 Cable grommet asm option 3HAC066396 001 A Continues on next page Product manual OmniCore C90XT 433 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 434: ...er Fine filter 3HAC068416 001 A L1 Air filter Polymeric 3HAC068543 001 B L1 Air filter coarse filter 3HAC068415 001 C Continues on next page 434 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 435: ...tion Spare part num ber L1 Blind plate baseline 3HAC069954 001 A L1 Cable grommet asm 3HAC066396 001 B Continues on next page Product manual OmniCore C90XT 435 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 436: ...switch 3HAC037699 001 B L1 Connector AC power inlet 3HAC070308 001 C Robot signal exchange proxy xx1900001936 Spare part level Type Description Spare part num ber L1 DSQC3037 Signal exchange 3HAC064662 001 A Continues on next page 436 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 437: ... circuit connector 3HAC065107 001 B End clamp xx2000000529 xx1900001940 Spare part level Type Description Spare part num ber L1 End clamp 3HAB7983 1 A Continues on next page Product manual OmniCore C90XT 437 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 1 Controller parts Continued ...

Page 438: ...r L1 Harness A1 X6 A1 X7 T2 T5 Harness AC input package 3HAC071430 001 L1 Harness A1 X2 K2 X6 K2 X11 Harness contactors signals 3HAC066527 001 L1 Harness A1 X13 K2 X10 Harness AC_OK signal 3HAC066520 001 L1 Harness K2 X21 TempSensor Harness Temp Sensor 3HAC066521 001 L1 Harness K2 X4 A1 X9 Harness 24_SYS_DRV 3HAC066522 001 Continues on next page 438 Product manual OmniCore C90XT 3HAC073706 001 Rev...

Page 439: ...4 X1 Harness 24_SYS_DRV 3HAC064389 001 L1 Harness T4 X3 A1 X12 Harness EtherCAT 3HAC059894 001 Cables on the power supply Spare part level Type Description Spare part num ber L1 Harness AC input of power supply 3HAC069617 001 Cables on the robot signal exchange proxy Spare part level Type Description Spare part num ber L1 Harness K2 X2 K4 X8 A2 X1 Harness 24_PC 3HAC064091 001 L1 Harness K2 X12 K3 ...

Page 440: ...er cable cover 3HAC065401 001 C L1 Joystick guard 3HAC065408 001 D L1 FlexPendant power cable 3 m 3HAC064448 002 E L1 FlexPendant power cable 10 m 3HAC064448 001 L1 FlexPendant power cable 30 m 3HAC064448 003 L1 Fasten strip 3HAC065419 001 F L1 FlexPendant extension cable 15 m 3HAC068915 001 L1 FlexPendant extension cable 22 m 3HAC068915 002 L1 FlexPendant extension cable 30 m 3HAC068915 005 440 P...

Page 441: ...HAC067446 001 Signal cable shielded 3 m L1 3HAC067446 002 Signal cable shielded 7 m L1 3HAC067446 003 Signal cable shielded 15 m Signal cables IRB 1300 Signal cable level Article number Singal cable length L1 3HAC067446 001 Signal cable shielded 3 m L1 3HAC067446 002 Signal cable shielded 7 m L1 3HAC067446 003 Signal cable shielded 15 m L1 3HAC067446 004 Signal cable shielded 30 m Product manual O...

Page 442: ...CP CS cable level Article number CP CS cable length L1 3HAC067449 001 3 m L1 3HAC067449 002 7 m L1 3HAC067449 003 15 m 442 Product manual OmniCore C90XT 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 3 2 Customer cables CP CS connectors option ...

Page 443: ...ode Ethernet floor cable level Article number Ethernet floor cable length L1 3HAC067447 002 Eth RJ45_X floor cable 7 m L1 3HAC067447 003 Eth RJ45_X floor cable 15 m Product manual OmniCore C90XT 443 3HAC073706 001 Revision D Copyright 2020 2021 ABB All rights reserved 9 Spare parts 9 3 3 Customer cables Ethernet floor cable ...

Page 444: ...This page is intentionally left blank ...

Page 445: ...xPendant 76 DeviceNet installing 123 dimensions 39 disconnecting FlexPendant 76 disposal of storage media 351 double SMB harness installing 106 drive unit LED 380 replacing 257 E earth fault protection 73 Earth fault protection tripped 361 emergency stop 22 definition 22 function test 165 emergency stops 24 enabling device 25 function test 167 EN ISO 13849 1 14 environmental information 352 ESD da...

Page 446: ...pply 91 management port 84 manipulator cables 69 manual full speed mode 27 manual high speed mode 27 manual mode 27 manual reduced speed mode 27 mode switch key 33 motor contactors function test 168 MTTFD 14 15 N national regulations 30 network security 46 noise 376 normal operation mode 374 O open source software OSS 47 operating conditions 40 operating mode automatic mode 29 function test 166 ma...

Page 447: ...ler 19 safety devices 31 safety signals in manual 17 safety standards 414 safety stops configuring 99 scalable I O 105 connectors 88 installing 110 replacing 208 scalable I O external 105 scalable I O internal 105 signals safety 17 sim card replacing 202 software licenses 47 standards 414 EN IEC 414 EN ISO 414 steel disposal 352 stop category 0 22 stop category 1 22 stop category 2 22 stops overvi...

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Page 450: ... 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics Discrete Automation No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 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 Copyright 2020 2021 ABB All rights reserved Specifications subject to change without notice ...

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