ABB OmniCore E10 Product Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Robotics
  5. OmniCore E10
  6. Product manual

ABB OmniCore E10 Product Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
ROBOTICS
Product manual
OmniCore E10

Advertisement

Table of Contents
loading

Related Manuals for ABB OmniCore E10

Summary of Contents for ABB OmniCore E10

  • Page 1 ROBOTICS Product manual OmniCore E10...
  • Page 2 Trace back information: Workspace 22A version a10 Checked in 2022-03-02 Skribenta version 5.4.005...
  • Page 3 Product manual OmniCore E10 OmniCore Document ID: 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Decommissioning ....................Controller description OmniCore E10 ....................Technical data for OmniCore E10 controller ............Safety functions and safety related data for OmniCore E10 ........The unit is sensitive to ESD ................. Handling of FlexPendant ..................Network security ....................Open source and 3rd party components in RobotWare ..........
  • Page 6 Troubleshooting units ..................6.3.1 Troubleshooting LEDs in the controller ............6.3.2 Troubleshooting the FlexPendant ............... 6.3.3 Troubleshooting the drive unit ..............6.3.4 Troubleshooting the power unit ..............Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 7 FlexPendant parts ..................... Manipulator cables .................... 9.3.1 Manipulator cables .................. 9.3.2 Customer cables - CP/CS connectors (option) ..........9.3.3 Customer cables - Ethernet floor cables ............Index Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview Of This Manual

    Product manual scope The manual covers all variants and designs of the OmniCore E10. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
  • Page 10 Information about I/O Network added in section Firewall settings on page • Updated safety data, see Safety functions and safety related data for OmniCore E10 on page 40 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 11: Product Documentation

    Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
  • Page 12 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 13: Safety

    The installation and/or use of non-original spare parts and equipment can negatively affect the safety, function, performance, and structural properties of the robot. ABB is not liable for damages caused by the use of non-original spare parts and equipment.

  • Page 14: Safety Data

    Performance level data The performance level data for the respective controller variant is presented in section Safety functions and safety related data for OmniCore E10 on page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 15: Requirements On Personnel

    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 instructions. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 16: Safety Signals And Symbols

    NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 17 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 18: Safety Symbols On Controller Labels

    Description Read the user manual before use. xx1400001152 The robot is delivered to start in automatic mode xx2100000104 CE label xx1800000835 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 19 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 E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 20: Robot Stopping Functions

    AS / GS, a dedicated discrete protective stop input on the robot controller, will when the protective stop function is configured as Automatic Stop (AS) initiate the protective stop function in automatic mode only. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 21 Note A safety input used to initiate a protective stop must remain active for at least 100 ms. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 22: About Emergency Stop

    1 Inspect the machinery in order to detect the reason for the emergency stop device actuation. 2 Locate and disengage the emergency stop device or devices that initiated the emergency stop function. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 23: Enabling Device And Hold-To-Run Functionality

    How to use the hold-to-run function for manual high speed mode is described in the operating manual for the controller. Note The manual high speed mode is not available in all markets. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 24: Robot Operating Modes

    Teach or tune programmed manipulator positions The mode manual high speed The mode manual high speed, is used for program verification only. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 25 Setting program pointer (to Main, to routine, to cursor, to service routine, etc.) • Starting and stopping program execution • Stepping program execution • Manually adjusting speed (0–100%) Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 26: About The Automatic Mode

    Automatic Stop, AS, or General Stop, GS.) Note Prior to allowing the robot control system to operate in automatic mode, ensure that any suspended safeguards are returned to full functionality. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 27: Safety During Installation And Commissioning

    When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 28 Water • Compressed air • Hydraulics End-effector hazards require particular attention for applications which involve close human collaboration with the robot. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 29 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. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 30: Safety During Operation

    Safety devices that are not connected to the robot or robot system cannot initiate a protective or emergency stop. These must be stored out of sight so that they cannot be mistaken for being in use. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 31: Safety During Maintenance And Repair

    See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Related information See also the safety information related to installation and operation. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 32: Safety During Troubleshooting

    The manipulator can move unexpectedly at any time. 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.

  • Page 33: Decommissioning

    1 Safety 1.9 Decommissioning 1.9 Decommissioning General See section Decommissioning on page 195. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 34 This page is intentionally left blank...

  • Page 35: Controller Description

    2.1 OmniCore E10 About OmniCore E10 The OmniCore E10 controller is part of the modular controller family. It will target mainly on 3C Electronics robot market. It is used to control an ABB manipulator used in industrial applications such as material handling and machine tending.

  • Page 36: Technical Data For Omnicore E10 Controller

    2 Controller description 2.2 Technical data for OmniCore E10 controller 2.2 Technical data for OmniCore E10 controller Overview of the controller xx2100001294 Reference to circuit OmniCore E10 diagram Power inlet switch Baseline Power inlet connector Baseline Motor connector Baseline Manipulator signal connector (SMB)
  • Page 37 2 Controller description 2.2 Technical data for OmniCore E10 controller Continued Weight The table shows the weight of the controller. Controller Weight OmniCore E10 12 kg Note The weight does not include any mounting kits fitted on the controller. Transportation and storage conditions...
  • Page 38 Load current There is no integrated fuse inside the OmniCore E10 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.
  • Page 39 2 Controller description 2.2 Technical data for OmniCore E10 controller Continued Residual current An external earth fault protection (residual current device, RCD) is required based on the following data: Robot Residual Current in controller (mA) IRB 1100 < 30 mA IRB 1200 <...

  • Page 40: Safety Functions And Safety Related Data For Omnicore E10

    2.3 Safety functions and safety related data for OmniCore E10 2.3 Safety functions and safety related data for OmniCore E10 Basic Safety Functions The safety data is valid for the Basic Safety Functions for applicable ABB manipulators The OmniCore E10 provides safety with structure category 3 with performance level d according to EN ISO 13849-1.

  • Page 41: The Unit Is Sensitive To Esd

    The mat should provide a controlled discharge of static voltages and must be grounded. Wrist strap button The location of the wrist strap button is shown in the following illustration. xx2100001295 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 42: Handling Of Flexpendant

    To reduce the risk of cuts if the glass chips or cracks, do not touch or attempt to remove the broken glass. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 43: Network Security

    ABB Ltd and its entities are not liable for damage and/or loss related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

  • Page 44: Open Source And 3Rd Party Components In Robotware

    The third party license terms apply only to the respective software to which the license pertains, and the third party license terms do not apply to ABB products. With regard to programs provided under the GNU general public license and the GNU lesser general public license licensor will provide licensee on demand, a machine-readable copy of the corresponding source code.

  • Page 45: Abb Ability

    Data ABB will not acquire any right, title and interest in the data other than the rights granted by Customer to ABB, but ABB will have the right to collect, store, aggregate, analyze or otherwise use the data for (i) providing and maintaining the hardware, services and/or the ABB software to Customer;...
  • Page 46 2.8 ABB Ability Continued ABB Ability™ Connected Services For as far as the robot installation includes ABB Ability™ Connected Services, this agreement is entered pursuant to and governed by the ABB Ability™ General Terms and Conditions. ABB Ability™ Terms and Conditions: https://ability.abb.com/terms...

  • Page 47: Installation And Commissioning

    Safety on page 13 before performing any installation work. Note Always connect the OmniCore E10 and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. Product manual - OmniCore E10 3HAC079399-001 Revision: C ©...

  • Page 48: Installation Activities

    Descriptions for connectors on page Install options and add-ons (optional). Installing add-on devices on page 102. Initial test before commissioning. Initial test before commissioning on page 104. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 49: Transporting And Handling

    Check for any visible transport damage. Note Stop unpacking and contact ABB if transport damage is found. Clean the unit with a lint-free cloth, if necessary. Make sure that the lifting accessory used (if applicable) is suitable to handle the weight of the controller.

  • Page 50: Storing

    3 Installation and commissioning 3.3.2 Storing 3.3.2 Storing Storing the controller For storing, see Transportation and storage conditions on page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 51: On-Site Installation

    Dimensions The following illustration shows the required installation space for the OmniCore E10 controller. A free space is required for connecting ABB cables. Do not place any cables over the left and right covers as it leads to inefficient cooling.
  • Page 52 The following illustration shows the dimensions between the feet of the OmniCore E10 controller, as seen from below. 31.00 381.00 xx2100001297 • The feet should only be used for positioning, not for mounting or fastening. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 53: Mounting The Controller With 19" Rack Mounting Kit

    3.4.2 Mounting the controller with 19" rack mounting kit 3.4.2 Mounting the controller with 19" rack mounting kit General The OmniCore E10 controller is designed to fit in a 19" cabinet. xx2100001562 Note If the controller is installed in a rack (cabinet), it must be fastened in a way that prevents distortion of the controller cabinet.
  • Page 54 Place the controller into the 19" cabinet and Torx pan head screw M6x16 (4 pcs) fasten it with the screws. Tightening torque: 1.7-1.8 Nm xx2100001563 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 55: Mounting The Flexpendant Holder

    The FlexPendant should always be placed in the holder when it is not used and it is not allowed to use by unauthorized person. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 56 Use this procedure to mount the bracket for the emergency stop to the FlexPendant holder. Action Note/illustration Remove the four screws. Separate the rear part from the FlexPend- ant holder. xx2000002356 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 57 Refit the rear part and secure with the Screws: BN33 Phillips pan head tapping screws. screw ST3.5x16 (4 pcs) Tightening torque: 9.4 Nm-12.2 Nm xx2000002356 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 58 Use this procedure to hang the FlexPendant holder on any place where can hold the bracket, like the door of the equipment. The bracket is included when the FlexPendant is purchased. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 59 Remove the four screws. Separate the rear part from the FlexPend- ant holder. xx2000002356 Clean the surface and make sure it is dry. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 60 Note/illustration Remove the protective liner from the tape. xx2000002357 Press the holder onto the desired place. Use two M5 screws to secure the holder. xx2000002358 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 61: Changing The Fan Control Functionality

    3.4.4 Changing the fan control functionality General The cooling fan on OmniCore E10 controller will work on reduced speed or shut off while the controller is in motors off state to lower the sound level. This is called fan control functionality.

  • Page 62: Electrical Connections

    3 Installation and commissioning 3.5.1 Connectors on the OmniCore E10 controller 3.5 Electrical connections 3.5.1 Connectors on the OmniCore E10 controller General The following section describes the connectors on the front panel of the OmniCore E10 controller. CAUTION Always inspect connectors for dirt or damage before connecting them to the controller.
  • Page 63 3 Installation and commissioning 3.5.1 Connectors on the OmniCore E10 controller Continued Description Label Reference on the circuit dia- gram I/O interface A2.X6 FlexPendant adaptor connector (HMI) A2.X8 WAN1 port WAN1 A2.X1 WAN2 port WAN2 A2.X2 Customer safety interface MON, AS/GS, ES, A2.X5...
  • Page 64 3 Installation and commissioning 3.5.1 Connectors on the OmniCore E10 controller Continued 4mm(5/32”) 14~18mm 30mm xx2100001310 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 65: Connecting Cables To The Controller

    Shielded cable with twisted pair conductors. A specific cable signals should be used for field bus connections and Ethernet, according to the standard specification of the respective bus. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 66 Multi wire 4 pair 1.0//17 Multi wire 6 pair 1.0//17 Multi wire 9 pair 1.0//17 0.75//18 three phase 1.0//17 three phase 10.3 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 67 • Cables carrying analog low-level signals is another exception where the shield should be grounded at only one end. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 68 Shield pigtail termination, as shown below, shall be avoided. If a pigtail connection cannot be avoided, make it as short as possible. xx1700001321 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 69 The following figure shows 2 examples on how protective earth and the signal cable screens can be connected: External unit Control cabinet Example 1 Example 2 xx1200000960 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 70 V max voltage and 125 V nominal voltage. The resistor should be 100 Ω, and the capacitor should be 1W 0.1 - 1 µF (typically 0.47 µF). Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 71: Connecting The Manipulator To The Controller

    Connecting the cables from the manipulator to the controller Action Connect the manipulator cable to the connector X1. Lock the connector with the lever. Secure the cables to avoid tripping or wear. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 72: Fitting The Connector

    The following describes the cable requirements for the main power connection to the OmniCore E10 controller. Component Description Cable type Flexible oil resistant rubber Cable area 3C x 1.5 mm or AWG16 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 73: Connecting Power Supply To And Grounding The Controller

    Location of power supply connection xx2100001301 Location of grounding point xx2100001302 Description Live (L1) Neutral (N) or Live (L2) Protective Earth (PE), grounding Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 74 Circuit diagram - OmniCore E10, 3HAC076810-008 Line fusing There is no integrated fuse inside the OmniCore E10 controller. An external fuse or circuit breaker must be added by the integrator, according to the full load current rating. See Load current on page Connecting the power The following procedure describes how to connect the main power to the controller.

  • Page 75: Detaching And Attaching A Flexpendant

    The FlexPendant connector shall only be used to connect the FlexPendant. All external safety devices must be connected from the customer safety interface. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 76 1 On the status bar, tap the QuickSet button. 2 Tap the Logout/Restart tab. 3 In the FlexPendant section, tap Detach FlexPendant. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 77 4 Tap Detach. A popup window with 30 seconds countdown timer is displayed. 5 When the countdown is progressing, detach the FlexPendant. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 78 Always inspect the connector for dirt or damage before attaching. Clean or replace any damaged parts. Attach the connector to the controller and tighten the locking ring or screws. Note The OmniCore E10 controller has an adapter cable in between the controller and the FlexPendant. xx2100001343 CAUTION Make sure that the emergency stop device is not pressed in before attaching the FlexPendant.

  • Page 79: Ethernet Networks On Omnicore

    ABB service personnel. HMI (FlexPendant) FlexPendant connection. Ability Net- WAN 2 ABB Ability™ connection. work Public Net- WAN 1 Public/factory network. work Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 80 Note The management port shall never be used for more than one client at a time. ABB Robot- ics assumes no responsibility for any er- rors/hazards that may appear when more than one client is used.
  • Page 81 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. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 82 Most protocols are disabled by default in the controller firewall. See Firewall settings on page 84 for information about how to enable these protocols. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 83 • Defining network settings on the FlexPendant: 1 On the start screen, tap Settings, and then select Network from the menu. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 84 Note Only users with UAS grant Modify network security properties can modify the firewall settings. For more information, see Technical reference manual - System parameters. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 85: Descriptions For Connectors

    3 Installation and commissioning 3.5.8 Descriptions for connectors 3.5.8 Descriptions for connectors I/O connectors - X5 - I/O interface xx2100001306 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 86 CAUTION The process power supply(PWR_DO, GND_DO) should be supplied separately. The 24V_IO_EXT rails must handle maximum output current of 4 A in total. For connection details, see Circuit diagram - OmniCore E10, 3HAC076810-008. Customer safety interface - X9 Note The FlexPendant connector can only be used to connect a FlexPendant and CANNOT be used to connect any other devices.
  • Page 87 24 V power supplied by robot controller for motors on lamp and motors on push button use only. It must not be used for any other functions. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 88 24 V power reference ground. The controller is shipped with a default configuration that the automatic stop/general stop circuit is opened. The controller CANNOT work. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 89 In most applications it is required to connect automatic/general stop switches. It is highly recommended to connect the stop switches as one of the following figures Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 90 0V_CH1_CH2 0V_CH1_CH2 xx2100001571 For more connections other than those illustrated above, carefully assess the risk before use and contact your local ABB for support. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 91 In most applications it is required to connect external emergency stop switches. It is highly recommended to connect the stop switches as one of the following Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 92 0V_CH1_CH2 0V_CH1_CH2 xx2100001573 For more connections other than those illustrated above, carefully assess the risk before use and contact your local ABB for support. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 93 The device connected to the ESOUT pins shall fulfill the IEC 61131-2 Type 1 Input. If the device cannot meet the requirement, a safety PLC or relay is needed. ABB Safety Relay E1T 1 s, 24DC is recommended. Customer provided device K2.X15...
  • Page 94 ES pins on another OmniCore controller. See Configuring robot stopping functions on page For more connections other than those illustrated above, carefully assess the risk before use and contact your local ABB for support. Customer optional power input - X6 xx2100001308 24V_EXT...
  • Page 95 PLC. The power requirements are shown in the following table. Parameter Value Voltage 24 V DC Voltage tolerance -5% to +5% Rated current 2.5 A Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 96: Configuring Robot Stopping Functions

    Configure the robot stopping functions in Visual SafeMove WARNING The new settings must be verified by test before the robot is used. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 97 4 After the configuration is done, the safety configuration must be written to the controller and then a restart of the controller is required. See also the circuit diagram, Circuit diagram - OmniCore E10. Apply the configuration to the controller...
  • Page 98 In RobotWare releases prior to 7.6, the ES input cannot be decoupled from the ES output. The LocalEmergencyStop was named InternalEmergencyStop prior to RobotWare 7.6. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 99: Programmable Stop Functions

    Note Only safety rated input signals are allowed to be used for safety. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 100 The Program Pointer will be moved to Main and if run- ning mode is continuous, the pro- gram will be restarted. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 101 The robot might make a limited move when restarted. WARNING The revolution counters might need to be updated after a colli- sion to ensure path accuracy. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 102: Installing Add-On Devices

    3.6.1 Installing Integrated Vision Required parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore E10 via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 103 Connect wires to the inputs and output See Application manual - Integrated Vision. connectors as required. For more information about the option Integrated Vision, see Application manual - Integrated Vision. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 104: Initial Test Before Commissioning

    Function tests Before commissioning, perform the function tests in section Function tests on page 110 to verify that the safety features work properly. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 105: Maintenance

    Function test after replacement of component After replacing a component in the controller, the function tests should be performed. See Function tests on page 110. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 106: Inspection Activities

    After inspection: Temporarily turn the power supply on. Inspect the fans to make sure they function correctly. Switch the power off. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 107: Cleaning Activities

    • Never use compressed air or spray with a high pressure cleaner. • Never leave the door open when cleaning the exterior. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 108: Cleaning The Flexpendant

    Check that all protective covers are fitted to the device before cleaning. • Make sure that no foreign objects or liquids can penetrate into the device. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 109 Do not spray with a high pressure cleaner. • Do not clean the device, operating panel and operating elements with compressed air, solvents, scouring agent or scrubbing sponges. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 110: Function Tests

    Release the emergency stop device to re- set the emergency stop state. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 111: Function Test Of Manual, Auto, And Manual Full Speed Mode With Flexpendant

    Note of the failure must be found. Manual full speed mode is not available in USA or Canada. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 112: Function Test Of Three-Position Enabling Device

    20224 Enabling device conflict appears in the event log, then the test has failed and the root cause of the failure must be found. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 113: Function Test Of Safety Switches

    If the event message 37101 Brake failure appears in the event log, then the test has failed and the root cause of the failure must be found. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 114: Function Test Of Automatic Stop

    Protective Stop triggered does not ap- pear in the event log, then the test has failed and the root cause of the failure must be found. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 115: Function Test Of General Stop

    Protective Stop triggered does not ap- pear in the event log, then the test has failed and the root cause of the failure must be found. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 116: Function Test Of External Emergency Stop

    Release the external emergency stop device to reset the external emergency stop state. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 117: Function Test Of Estop_Status Output

    Make sure that the accessory device is not in emergence stop status any more and can be reset. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 118: Function Test Of Reduced Speed Control

    To get accurate results, use sensors or I/O signals to measure the time. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 119: Repair

    LED indicators are off before replacing modules. Note When replacing a part on the OmniCore E10, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.

  • Page 120: Replacing Parts Inside The Controller

    Electrical safety on page Removing the top cover Action Info/illustration Remove the attachment screws. Remove the top cover. xx2100001329 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 121 Refit the top cover using the location Screws: Torx, countersunk screw M4x10 (8 pins. pcs) Tightening torque: 1.7 Nm±10%. Secure it with the screws. xx2100001329 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 122: Replacing The Fans

    The illustration shows the location of the fans in the controller. xx2100001326 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 E10 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 123 5 Repair 5.2.2 Replacing the fans Continued Required documents Document Article number Note Circuit diagram - OmniCore E10 3HAC076810-008 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 124: Replacing The Small Fans

    Remove the top cover of the controller. Removing the controller top cover on page 120. Removing the small fan Action Note/Illustration Disconnect: • G1/G2.X1 xx2100001330 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 125 Note/Illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 126 ESD on page xx2100001295 Refit the fan into the fan bracket as- sembly. xx2100001332 Insert the connector to the bracket. xx2100001331 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 127 Refitting the controller cover on page 121. Perform the function tests to verify that the safety features work properly, see Function tests on page 110. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 128: Replacing The Power Unit

    The illustration shows the location of the power unit in the controller. xx2100001324 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 E10 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 129 Take photos of the cable ties and locking holes before pulling out, to have as a reference when refitting the cable ties. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 130 Disconnect: • A1.X13 - A2.X12 • A1.X2 - T4.X17 • A1.X11 - T4.X13 • A2.X13 - G1/G2.X1 • A1.X6 - A2.X11 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 131 Note/Illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 132 Screws: Torx pan head screw M4x8 (4 pcs) screws. Tightening torque: 1.7 Nm±10% xx2100001335 Insert the fan connector to the bracket. xx2100001334 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 133 The unit is sensitive to ESD on page xx2100001295 Insert the incoming mains connector into the front panel of the cabinet. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 134 Refitting the controller cover on page 121. Perform the function tests to verify that the safety features work properly, see Function tests on page 110. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 135: Replacing The Drive Unit

    The illustration shows the location of the drive unit in the controller. xx2100001323 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 E10 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 136 The unit is sensitive to ESD on page xx2100001295 Remove the top cover of the controller. Removing the controller top cover on page 120. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 137 A2.X13 - G1/G2.X1 • T4.X5 - A1.X4 • T4.X3 - A2.X9 • T4.X1 - A2.X10 Release the fan connector from the bracket. xx2100001331 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 138 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 xx2100001295 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 139 X1-T4.X7, T4.X8, T4.X9, T4.X15 • X2-T4.X16 • A2.X13 - G1/G2.X1 • T4.X5 - A1.X4 • T4.X3 - A2.X9 • T4.X1 - A2.X10 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 140 Refitting the controller cover on page 121. Perform the function tests to verify that the safety features work properly, see Function tests on page 110. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 141: Replacing The Computer And Logic Unit

    The illustration shows the location of the computer and logic unit in the controller. xx2100001325 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 E10 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 142 Disconnect: • A2.X9 - T4.X3 • A2.X10 - T4.X1 • A1.X6 - A2.X11 • A1.X13 - A2.X12 • A2.X13 - G1/G2.X1 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 143 Note/Illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 144 Note/Illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 145 Manage Licences in RobotWare Installation Utilities. Action Note/Illustration Download the hardware information file (hwsettings.rsf) from MyABB, or from a previous system backup. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 146 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. Read the serial number on the front of the controller and type it in field Serial Number.

  • Page 147: Replacing Parts On The Front Panel

    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 E10 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 148 Disconnect: • A2.X9 - T4.X3 • A2.X10 - T4.X1 • A1.X6 - A2.X11 • A1.X13 - A2.X12 • A2.X13 - G1/G2.X1 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 149 Remove the attachment screws on the front panel. xx2100001340 Slide the harness assembly a little up to release it from the front panel. xx2100001341 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 150 The unit is sensitive to ESD on page Refit the manipulator signal (SMB) and motors power unit harness assembly. xx2100001342 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 151 Note/Illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 152 Refitting the controller cover on page 121. Perform the function tests to verify that the safety features work properly, see Function tests on page 110. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 153: Replacing The Incoming Mains Connector

    The illustration shows the location of the incoming mains connector in the controller. xx2100001328 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 E10 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 154 Take photos of the cable ties and locking holes before pulling out, to have as a reference when refitting the cable ties. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 155 The unit is sensitive to ESD on page xx2100001295 Insert the incoming mains connector into the front panel of the cabinet. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 156 Refitting the controller cover on page 121. Perform the function tests to verify that the safety features work properly, see Function tests on page 110. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 157: Replacing Parts On The Flexpendant

    Power cable 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 E10 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 158 Disconnect the FlexPendant from the controller. Remove the attachment screws for the power cable cover. xx1800001189 Remove the power cable cover. xx1800001190 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 159 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 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 160 Screws: Torx pan head screw M4x8 (3 pcs) the screws. xx1800001196 Perform the function tests to verify that the safety features work properly, see Function tests on page 110. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 161: Replacing The Joystick Protection

    The illustration shows the location of the joystick protection on the FlexPendant. xx1800001197 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 E10 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 162 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 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 163 5.4.2 Replacing the joystick protection Continued Action Note/Illustration Refit the joystick protection. xx1800001200 Secure the screws. xx1800001206 Countersunk head screw: ST2.9 X 10 (6 pcs) Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 164: Replacing The Fasten Strip

    The illustration shows the location of the fasten strip on the FlexPendant. xx1900000771 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 E10 via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...

  • Page 165: Troubleshooting

    Check: been installed • the configuration files • connectors • options and their configuration • changes in the robot working space/movements. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 166 The robot has recently Check: been moved from one site • connections to another (an already • software versions working robot) Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 167: Troubleshooting Fault Symptoms

    Controller fails to start on page 181 • Reflashing firmware failure on page 182 • Inconsistent path accuracy on page 183 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 168: No Leds Are Lit On The Controller

    Check the FlexPendant for errors and warnings. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. Recommended working procedure If no LEDs are lit on the controller during start-up, use this procedure to troubleshoot what might cause the problem.
  • Page 169 Measure incoming mains voltage and make problem is not in the robot control- sure the voltage is within the normal range. ler. Troubleshoot incoming mains. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 170 Check that the AC input cable is properly connec- tion. ted. • If normal, replace the power inlet. See Replacing the in- coming mains connector on page 153. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 171: Start-Up Failure

    For more details about the LEDs, Troubleshooting the drive unit on page 188. If the problem remains, contact ABB. For more details, see Circuit diagram - OmniCore E10. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 172: System Update Failure

    (backup copy) of the previous system state. This is the simplest way. 2 Perform a complete re-installation of the RobotWare system using RobotWare Installation Utilities, start the RobotWare system and then reload the previous backup. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 173: Problem Releasing The Robot Brakes

    DANGER Troubleshooting on the controller while powered 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.
  • Page 174 - computer and logic Brake is OK unit A2 Not OK Test the brake release Contact ABB Brake release is OK Problem solved xx2100001558 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 175 Check that the brake release function is ok. For more details on how to release the brakes, see the robot's product manual. • If it is not ok, contact your local ABB. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 176: Problem Starting Or Connecting The Flexpendant

    Make sure that the controller is switched on. Wait 30 s - 1 min to enable start-up sequence. Check the FlexPendant for errors and warnings. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 177 Action DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. Recommended working procedure If the FlexPendant starts but does not display the main interface during the start-up, use this procedure to troubleshoot what might cause the problem.
  • Page 178 Check the pins in the connector. If it is ok, go to the next step. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 179 Check that the FlexPendant works normally. If it is not ok, contact your local ABB. This is detailed in section Troubleshooting the FlexPendant on page 187. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 180: Problem Using The Joystick

    If the joystick is still not working, then port on the back of the FlexPendant. replace the FlexPendant. Note The reset button only resets the FlexPendant, not the system on the controller. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 181: Controller Fails To Start

    See also Troubleshooting the computer and logic unit on page 193. How to install systems is described in Operating manual - Integrator's guide OmniCore. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 182: Reflashing Firmware Failure

    If RobotWare has been updated recently, make sure that the versions of the old and the new unit are identical. If the problem remains, contact your local ABB for information about which firmware version is compatible with your hardware. Product manual - OmniCore E10 3HAC079399-001 Revision: C ©...

  • Page 183: Inconsistent Path Accuracy

    Replace the faulty parallel bar as specified (applies to robots fitted with parallel bars in the product manual for the robot. only). Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 184 173. If applicable: Check the setting for the The swivel has an in-built resistance that swivel. needs to be set in the system parameters. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 185: Controller Is Overheated

    Check the FlexPendant for errors and warnings. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. Recommended working procedure If the controller seems to be overheated, use this procedure to troubleshoot what might cause the problem.

  • Page 186: Troubleshooting Units

    Troubleshooting the drive unit on page 188 Power unit Troubleshooting the power unit on page 191 Computer and logic unit Troubleshooting the computer and logic unit on page 193 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 187: Troubleshooting The Flexpendant

    Check the 24 V power supply. Read the error event log message and follow any instructions of references. For more information on the FlexPendant, see Operating manual - OmniCore. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 188: Troubleshooting The Drive Unit

    6.3.3 Troubleshooting the drive unit 6.3.3 Troubleshooting the drive unit Location The illustration shows the location of the drive unit in the controller. xx2100001323 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 189 Flashing: The two units are communicating on the Ethernet channel. • Steady: A LAN link is established. • Off: A LAN link is not established. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 190 No color: Power to the drive unit is missing. • Red, steady: Internal error. • Red, flashing: Firmware error or self-test failure. • Green, flashing: Communication error to another module. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 191: Troubleshooting The Power Unit

    The illustration below shows the location of the power unit in the controller. xx2100001324 LEDs The illustration below shows the LEDs on the power unit. xx2100001561 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 192 Red, flashing: Firmware error or self-test failure. • No color: Voltage between DC+ - DC- ≤ 60 VDC High voltage warn- • Red: Voltage between DC+ - DC- > 60 VDC Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 193: Troubleshooting The Computer And Logic Unit

    The illustration shows the location of the computer and logic unit in the controller. xx2100001325 LEDs The illustration below shows the LEDs on the computer and logic unit: xx2100001559 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 194 The Ready/Executing LED indicates that the robot is in Motor on status (white) or not. • On: Robot is motor on. • Off: Robot is motor off. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 195: Decommissioning

    To remove all data from the OmniCore controller, use the Delete user data function (part of Delete RobotWare system function) in RobotWare. See Operating manual - Integrator's guide OmniCore. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 196: Environmental Information

    7.2 Environmental information 7.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
  • Page 197 China RoHS symbol The following symbol shows the information to hazardous substances and the environmental protection use period of OmniCore E10 according to "Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products (SJ/T 11364-2014) ".
  • Page 198 This page is intentionally left blank...

  • Page 199: Reference Information

    8.1 Introduction 8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 200: Applicable Standards

    Industrial robots and robot Systems - General safety require- ments EN ISO 10218-1 Robots and robotic devices — Safety requirements for indus- trial robots — Part 1: Robots Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 201: Unit Conversion

    1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 202: Standard Toolkit For Controller

    Phillips-1 Box spanner 8 mm Toolkit recommended for troubleshooting Tool Note Normal shop tools Contents as specified above. Multimeter Camera To document problems or procedures Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 203: Screw Joints

    The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess heads. Dimension Tightening torque (Nm) Class 4.8, oil-lubricated M2.5 0.25 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 204: Weight Specifications

    In all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. Example...

  • Page 205: Lifting Accessories And Lifting Instructions

    The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. The instructions delivered with the lifting accessories should be stored for later reference. Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 206 This page is intentionally left blank...

  • Page 207: Spare Parts

    9 Spare parts 9 Spare parts Spare part level ABB spare parts are categorized into two levels, L1 and L2. Always check the part level before conducting a service work on a spare part. • L1 spare parts The L1 parts can be replaced in the field. The maintenance and replacement instructions given in the related product manuals must be strictly followed.

  • Page 208: Controller Parts

    9 Spare parts 9.1 Controller parts 9.1 Controller parts Note Removed parts and spare parts must not be disassembled or opened. Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 209: Controller System Parts

    9.1.1 Controller system parts 9.1.1 Controller system parts Drive units xx2100001316 Spare part num- Description Type Spare part level 3HAC074966-001 Drive unit DSQC3084 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 210 9 Spare parts 9.1.1 Controller system parts Continued Power units xx2100001317 Spare part num- Description Type Spare part level 3HAC074985-001 Power unit DSQC3087 Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 211 9 Spare parts 9.1.1 Controller system parts Continued Harness TPU connection xx2100001319 Spare part num- Description Type Spare part level 3HAC077870-001 Harness TPU adapter Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 212: Mains Connection Parts

    Spare part num- Description Type Spare part level 3HAC075416-001 Harness AC input with SW Harness-Mains connection 3HAC077706-001 Connector AC power inlet Mating connect- or for Power in- Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 213: Logic Parts

    9 Spare parts 9.1.3 Logic parts 9.1.3 Logic parts Computer and logic unit xx2100001321 Spare part num- Description Type Spare part level 3HAC074970-001 Computer and logic unit Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 214: Cabinet Parts

    9.1.4 Cabinet parts 9.1.4 Cabinet parts Fan bracket assembly xx2100001312 Spare part num- Description Type Spare part level 3HAC078981-001 Fan bracket assembly Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 215 3HAC078983-001 Fan pressure bracket assembly Connector computer interface xx2100001315 Spare part num- Description Type Spare part level 3HAC076187-001 Connector computer interface Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 216 9 Spare parts 9.1.4 Cabinet parts Continued Fans xx2100001320 Spare part num- Description Type Spare part level 3HAC078273-001 Small fan Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 217: Miscellaneous Parts

    Integr Vision camera med. Res DSQC1020 3HAC053954-001 Integr Vision camera high res DSQC1021 3HAC051753-003 Integr Vision power cable 3HAC051736-003 Integr Vision ethernet cable Continues on next page Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 218 9 Spare parts 9.1.5 Miscellaneous parts Continued Mounting kit Spare part num- Description Type Spare part level 3HAC077631-001 Rack mounting kit Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 219: Cables

    Harness DC-BUS 3HAC075387-001 Harness EtherCAT 3HAC075386-001 Harness 24_SYS Harness signal cable asm xx2100001314 Spare part num- Description Type Spare part level 3HAC078253-001 Harness Signal cable assembly Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 220: Flexpendant Parts

    FlexPendant Holder w/t E-stop cover 3HAC065401-001 Power cable cover 3HAC065408-001 Joystick guard 3HAC064448-002 FlexPendant power cable 3 m 3HAC064448-001 FlexPendant power cable 10 m 3HAC065419-001 Fasten strip Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 221: Manipulator Cables

    Signal cable, shielded: 7 m 3HAC067446-002 Signal cable, shielded: 15 m 3HAC067446-003 Signal cables, IRB 1200 Singal cable length Article number Singal cable level 3HAC080671-001 3HAC080671-002 15 m 3HAC080671-003 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 222: Customer Cables - Cp/Cs Connectors (Option)

    9.3.2 Customer cables - CP/CS connectors (option) CP/CS cables, IRB 1100, 1300, 910INV, 920 CP/CS cable length Article number CP/CS cable level 3HAC067449-001 3HAC067449-002 15 m 3HAC067449-003 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.

  • Page 223: Customer Cables - Ethernet Floor Cables

    One end is RJ45, one end is X-code. Ethernet floor cable length Article number Ethernet floor cable level Eth.RJ45_X floor cable, 7 m 3HAC067447-002 Eth.RJ45_X floor cable, 15 m 3HAC067447-003 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 224 This page is intentionally left blank...

  • Page 225: Index

    36 joystick not working, 180 disconnecting FlexPendant, 75 disposal of storage media, 195 drive unit key of the mode switch, 30 LED, 189 replacing, 135 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 226 20 PPE, 15 storage conditions, 37 problem releasing the robot brakes, 173 symbols product standards, 200 safety, 16 protection classes, 38 system integrator requirements, 27 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 227 23 validity and responsibility, 13 function test, 112 tightening torque, 203 weight, 37 connecting, disconnecting, 75 wrist strap, 41 transportation conditions, 37 Product manual - OmniCore E10 3HAC079399-001 Revision: C © Copyright 2019-2022 ABB. All rights reserved.
  • Page 230 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2019-2022 ABB. All rights reserved. Specifications subject to change without notice.

Table of Contents