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ABB OmniCore V250XT Type B, Product Manual


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ROBOTICS

Product manual

OmniCore V250XT Type B

Summary of Contents for OmniCore V250XT Type B

Page 1: ...ROBOTICS Product manual OmniCore V250XT Type B...

Page 2: ...Trace back information Workspace 23D version a22 Checked in 2024 01 15 Skribenta version 5 5 019...

Page 3: ...Product manual OmniCore V250XT Type B OmniCore Document ID 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved Specifications subject to change without notice...

Page 4: ...y 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...

Page 5: ...ve to ESD 47 2 5 Handling of FlexPendant 48 2 6 Network security 49 2 7 Open source and 3rd party components 50 2 8 ABB Connect ABB Ability 53 3 Installation and commissioning 53 3 1 Introduction to i...

Page 6: ...of air filter 173 4 5 Function tests 173 4 5 1 Function test of emergency stop 174 4 5 2 Function test of manual auto and manual full speed mode with FlexPendant 175 4 5 3 Function test of three posi...

Page 7: ...45 7 Troubleshooting 345 7 1 Introduction to troubleshooting 347 7 2 Troubleshooting fault symptoms 348 7 2 1 No LEDs are lit on the controller 351 7 2 2 Start up failure 354 7 2 3 System update failu...

Page 8: ...ection parts 440 9 1 3 Logic parts 443 9 1 4 Application parts 447 9 1 5 Cabinet parts 451 9 1 6 Miscellaneous parts 456 9 1 7 Cables 458 9 2 FlexPendant parts 459 9 3 Manipulator cables 459 9 3 1 Man...

Page 9: ...rovide safety and user guides for the robot system Who should read this manual This manual is intended for installation personnel maintenance personnel repair personnel Prerequisites A maintenance rep...

Page 10: ...e 3HAC065041 001 Technical reference manual System parameters 3HAC066559 001 Application manual Functional safety and SafeMove 3HAC028879 001 Application manual Connected Services 3HAC066561 001 Appli...

Page 11: ...ooting Decommissioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists Refer...

Page 12: ...the products The 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 V250XT...

Page 13: ...he 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 as intended Non authorized design modifi...

Page 14: ...ation may determine that a safety related control system performance other than that stated in ISO 10218 is warranted for the application The SISTEMA ABB FSDT libraries contains details for the safety...

Page 15: ...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 o...

Page 16: ...esult 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 ha...

Page 17: ...icate where to find additional information or how to do an operation in an easier way TIP Product manual OmniCore V250XT Type B 17 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved...

Page 18: ...ly use graphics The information labels contain information in text See Symbols and information on labels on page 18 Note The safety and information labels on the product must be observed Symbols and i...

Page 19: ...able Read operation manual before installation Enclosure environmental type rating is type 1 Inserting fingers or foreign objects into opening may cause personal injury xx1800000836 High voltage insid...

Page 20: ...RC label for 3G only for Chinese market OmniCore XXX OmniCore XXX 3G LTD XXXXXXXXXXX xx2300001441 SRRC label for 4G only for Chinese market xx2300001823 20 Product manual OmniCore V250XT Type B 3HAC08...

Page 21: ...ate a stop function Yes Stop category 0 Input to initiate the emergency stop function The Emergency Stop function is initiated in both automatic and manual mode Emergency Stop ES For deviations see th...

Page 22: ...ety input used to initiate a protective stop must remain active for at least 100 ms Stop category configuration for OmniCore The stop category configuration is done in RobotStudio in the tool Visual S...

Page 23: ...ossible by an intentional human action on the device where the command has been initiated The disengagement of the emergency stop device shall not restart the machinery but only permit restarting Note...

Page 24: ...he three position enabling device must never be rendered inoperational in any way If there is a need to enter safeguarded space always bring the FlexPendant This is to enforce single point of control...

Page 25: ...some maintenance tasks In manual reduced speed mode the movement of the TCP is limited to 250 mm s In addition there is a limitation on the maximum allowed speed for each axis Manual control of the ro...

Page 26: ...ssed the speed is reset to the initial speed that is not exceeding 250 mm s WARNING Wherever possible the manual mode of operation shall be performed with all persons outside the safeguarded space Tas...

Page 27: ...tart stop and modify RAPID programs through remote clients Safeguard mechanisms Protective stop function initiated by Automatic Stop AS the dedicated input AS or the dedicated input AS GS configured t...

Page 28: ...aused 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...

Page 29: ...r in the event of a fire in the robot Safety devices The integrator is responsible for that the safety devices necessary to protect people working with the robot system are designed and installed corr...

Page 30: ...are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level 30 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyri...

Page 31: ...to make sure that keys used to lock or change the operating mode are handled only by authorized personnel Safety devices not in use Safety devices that are not connected to the robot or robot system...

Page 32: ...ted 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...

Page 33: ...ANGER 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 s...

Page 34: ...page 341 If the robot is decommissioned for storage take extra precaution to reset safety devices to delivery status 34 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023...

Page 35: ...bility covering a wide range robot and applications V line supports external axis and provides flexible configuration opportunities The OmniCore V250XT Type B controller offers a compact yet flexible...

Page 36: ...o be used in industrial environment T43 T42 T41 T5 T6 A1 T4 X1 X7 PE0 X0 X2 X3 X81 X91 X92 xx2300001958 Continues on next page 36 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyri...

Page 37: ...ne A1 Power unit LVHP DSQC3069 Baseline A1 Power unit HVLP DSQC3072 Baseline X2 X3 Manipulator signal connector SMB Baseline X4 FlexPendant connector HMI Baseline X1 Motor connector Baseline G1 G2 Ext...

Page 38: ...t Option K5 1 Scalable I O Option K5 2 Additional I O K5 3 K5 4 Option K3 1 Safety digital base I O Option B1 Conveyor tracking module Option K4 Ethernet switch Option T5 T8 Process power supply Optio...

Page 39: ...ontroller see Operating conditions on page 39 The robot controller shall be stored according to its IP classification IP54 that is indoors in an environment that is dry and dust free In addition wind...

Page 40: ...d sealed door and cable grommets it does not comply with the protection class IP54 and may affect the following The electromagnetic compatibility EMC is affected Units inside the cabinet are exposed t...

Page 41: ...phase IRB 6650S 3x32 A 380 VAC 480 VAC 3 phase IRB 6660 3x32 A 380 VAC 480 VAC 3 phase IRB 6700 3x32 A 380 VAC 480 VAC 3 phase IRB 6710 3x32 A 380 VAC 480 VAC 3 phase IRB 6720 3x32 A 380 VAC 480 VAC...

Page 42: ...er drive system shall only be used with specified manipulator variant The following table shows the mapping list Drive system type Controller Manipulator E4 OmniCore V250XT Type B IRB 2600 E5 E8 OmniC...

Page 43: ...abling device on the FlexPendant 8 58E 08 Mirror emergency stop state of the robot through emergency status output of the controller 2 58E 07 Emergency stop function of the robot initiated by external...

Page 44: ...ll supervision Related information Safety data on page 14 The SISTEMA ABB FSDT libraries contain details for the safety functions 44 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Cop...

Page 45: ...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 co...

Page 46: ...strap button is shown in the following illustration xx2200001817 46 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 2 Controller descriptio...

Page 47: ...crubbing 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...

Page 48: ...plication 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 un...

Page 49: ...delivery of the product ABB software is licensed under the ABB end user license agreement which is provided separately RobotWare For RobotWare there is license information in the folder licenses in th...

Page 50: ...signal as provided by the telecommunications carrier on the location where the ABB Ability OmniCore hardware is installed The cellular data connection is to be used solely in connection with the ABB A...

Page 51: ...y to operate the equipment under FCC rules When the optional connectivity module is installed the operating conditions must be such that there is a minimum separation distance of 20 cm between the ded...

Page 52: ...and developments including all resulting intellectual property Rights are exclusively owned by us In addition we have the right to use the data for benchmarking purposes if and to the extent it is an...

Page 53: ...ller on page 36 Safety information Before any installation work is commenced all safety information must be observed There are general safety aspects that must be read through as well as more specific...

Page 54: ...tive earth to the controller on page 84 Connect incoming mains to the controller 8 Connector X14 Connect safeguards to the controller 9 How to connect industrial networks for example PROFINET is descr...

Page 55: ...ge 39 0 6 xx2100000343 WARNING When lifting and transporting the cabinet using a forklift the cabinet door must be closed to avoid tilting WARNING Stacked cabinets must be lifted separately Use a suit...

Page 56: ...ndle 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 operati...

Page 57: ...roller For storing see Transportation and storage conditions on page 39 Product manual OmniCore V250XT Type B 57 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 3 Installation an...

Page 58: ...ller Min 300 mm Min 150 mm xx2200001824 A free space of 300 mm on the back of the controller is required A free space of 150 mm on the sides of the controller is required Continues on next page 58 Pro...

Page 59: ...ties such as cleaning and replacement of controller filters a free space of 500 mm is required on one side of the controller Min 500 mm xx2200001742 Product manual OmniCore V250XT Type B 59 3HAC087112...

Page 60: ...um of two controllers can be stacked The controllers must be safely fixed to each other and it must be assured that the opened door on the upper controller does not cause imbalance CAUTION The stacked...

Page 61: ...page 426 Standard toolkit 3HAC079391 001 TPU Holder asm 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...

Page 62: ...xx2100000765 Insert the bracket into the FlexPendant holder 3 Screws BN33 Phillips pan head tapping screw ST2 9x13 3 pcs Secure with the screws 4 Tightening torque 6 Nm 7 8 Nm xx2100000766 Continues...

Page 63: ...is procedure to mount the FlexPendant holder onto a flat surface like the top of the controller or a desktop Note illustration Action Clean the surface and make sure it is dry 1 xx2000002352 Remove th...

Page 64: ...uipment Tip The bracket is included on delivery Note illustration Action xx2000002354 Hang the FlexPendant holder to the bracket according to the screws on the bracket 1 Hang the holder with the brack...

Page 65: ...ews 1 Separate the rear part from the FlexPend ant holder 2 Clean the surface and make sure it is dry 3 xx2000002357 Remove the protective liner from the tape 4 Press the holder onto the desired place...

Page 66: ...58 Use two M5 screws to secure the holder 6 66 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 3 Installation and commissioning 3 4 3 Mounti...

Page 67: ...Place the magnet part of the antenna on the outside of the cabinet 1 xx2200001973 Insert the antenna cable through the cable grommet 2 Apply cable ties and suitable cable pro tection to ensure that t...

Page 68: ...Connec ted Services gateway by rotating the connector 4 xx2300000672 68 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 3 Installation and c...

Page 69: ...B controller CAUTION Always inspect the connector for dirt or damage before connecting it to the controller Clean or replace any damaged parts Continues on next page Product manual OmniCore V250XT Typ...

Page 70: ...MT Management C FlexPendant connector HMI D Motor connector E Manipulator signal connector SMB F Cable grommet assembly G Incoming mains connector H Ethernet outlet connector LAN3 I Continues on next...

Page 71: ...ices antenna 3G 4G WiFi K ADU additional drive unit connector L Product manual OmniCore V250XT Type B 71 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 3 Installation and commis...

Page 72: ...d 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...

Page 73: ...lti wire 4 pair 0 2 24 1 8 2 1 2 3 2 6 Multi wire 6 pair 0 2 24 1 6 1 8 2 0 2 3 Multi wire 9 pair 0 2 24 5 6 6 5 7 2 7 9 Single wire 0 5 20 4 5 5 2 5 8 6 3 Multi wire 2 pair 0 5 20 3 6 4 2 4 7 5 1 Mul...

Page 74: ...f 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...

Page 75: ...ing 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...

Page 76: ...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...

Page 77: ...screens at both ends on all units Example 2 If the cable is terminated where a good earth connection is not available a noise suppression capacitor can be used The screens of the 2 cables must be con...

Page 78: ...hat 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...

Page 79: ...g systems are allowed by ABB TN C system TN S system A combined PEN conductor is used as both a PE and an N conductor PE and N are separate conductors that are connected together only near the transfo...

Page 80: ...n transformer types The following isolation transformer types are allowed by ABB Wye Wye isolation transformer Y Y Delta Wye isolation transformer Y xx1700001319 xx1700001318 A Primary input B Seconda...

Page 81: ...ment board Manipulator cable Handles supply to and feedback from any position switches Position switch cables option Handles communication with equipment fitted on the manipulator by the customer Cust...

Page 82: ...connection to the OmniCore V250XT Type B controller Description Component Flexible oil resistant rubber Cable type 3G x 6 mm2 or AWG10 Cable area PE1 and PE2 points on X0 incoming mains connector Prot...

Page 83: ...ve earth PE2 Connect the wires according to the illus tration 2 Tighten the screws to secure the cables 3 Remove screw and washer on top of contact and insert the ground cable with cable lug Secure wi...

Page 84: ...otection Branch circuit protection must be provided in accordance with the Manufacturer Instructions National Electrical Code and any additional local codes Prerequisites Before incoming mains is conn...

Page 85: ...et and protective earth must comply with the local electrical requirements Required equipment Note Equipment L1 L2 L3 PE1 PE2 Main connection cable three phase Details see Fitting the connector for in...

Page 86: ...ibes 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 any damaged parts Action xx21000012...

Page 87: ...FlexPendant grant CAUTION Before detaching the FlexPendant another emergency stop shall be available CAUTION With a detached FlexPendant there is no visual identification of the operating mode CAUTION...

Page 88: ...ch the FlexPendant in automatic mode 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 88 Product manu...

Page 89: ...imer is displayed xx1900000404 5 When the countdown is progressing detach the FlexPendant Continues on next page Product manual OmniCore V250XT Type B 89 3HAC087112 001 Revision A Copyright 2023 2023...

Page 90: ...endant CAUTION 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 xx19000...

Page 91: ...ABB Robotics assumes no responsibility for any errors hazards that may appear when more than one client is used MGMT Management FlexPendant connection TPU ABB Connect connection ABB Connect ABB Connec...

Page 92: ...in 0V A1 0V A2 0V A3 0V B1 0V B2 0V B3 24V_TRUNK C1 24V_TRUNK C2 24V_TRUNK C3 24V_TRUNK D1 24V_TRUNK D2 24V_TRUNK D3 Connector X19 Description Connector for 24V_IO_EXT output Connection SC 3 81 90F Ty...

Page 93: ...or X18 Description Connector for MS_ON OFF 24V digital output Connection Dynamic D 2100S Type Tyco Electronics 1376135 3 Article number Description Name Pin MS_ONOFF 1 0V 3 Connector X31 Description C...

Page 94: ...0V_CHASSI A2 PTC1 B1 PTC2 B2 PTC1 C1 PTC2 C2 Processor board front panel connectors xx2300000440 Connector X1 X2 X3 X4 X6 X9 Description Connectors for ECAT MGMT DEV TPU and DRV Motion Link Connectio...

Page 95: ...N1 WAN2 and LAN Connection RJ45 Type Article number ABB Connect X1 Label WAN1 X2 WAN2 X3 LAN X4 Description Name Pin BI_DA 1 BI_DA 2 BI_DB 3 BI_DC 4 BI_DC 5 BI_DB 6 BI_DD 7 BI_DD 8 Continues on next p...

Page 96: ...U B5 24V_TPU A5 24V_MON B6 MON_LAMP A6 24V_MON B7 MON_PB A7 B8 A8 B9 A9 B10 A10 Connector X14 Description Connector for Safety IO signals Connection S2L 3 50 90F Type Weidm ller 1728680000 Article num...

Page 97: ...N 11 GS_CH1_P 14 GS_CH1_N 13 24V_CH1_EXT 16 0V_IO_EXT 15 Note The following operating regions are defined according to IEC 61131 2 2017 clause 6 4 4 2 The emergency stop function is activated open loo...

Page 98: ...d from an external power supply Customer_24V_CH1 Customer_24V_CH2 Customer_0V_CH1 Customer_0V_CH2 Customer provided power 0V_IO_EXT 24V_CH1_EXT 0V_IO_EXT 24V_CH2_EXT A2 K5 X14 GS_CH1_P GS_CH1_N GS_CH2...

Page 99: ...input can be powered from an external power supply 6 8 5 7 2 1 4 3 Customer_24V_CH1 Customer_24V_CH2 Customer_0V_CH1 Customer_0V_CH2 Customer provided power 0V_IO_EXT 24V_CH1_EXT EXT_ESTOP_CH1_P EXT_E...

Page 100: ...ty IO signals Connection S2L 3 50 90F Type Weidm ller 1728690000 Article number 2 4 6 1 3 5 8 10 12 7 9 11 14 16 13 15 18 17 xx1800000555 Name Pin Name Pin 24V_MON 2 MON_PB1 1 24V_MON 4 MON_LAMP1 3 6...

Page 101: ...d from an external power supply Customer_24V_CH1 Customer_24V_CH2 Customer_0V_CH1 Customer_0V_CH2 Customer provided power 0V_IO_EXT 24V_CH1_EXT 0V_IO_EXT 24V_CH2_EXT AS_CH1_P AS_CH1_N AS_CH2_P AS_CH2_...

Page 102: ...e protected from external EM disturbance suggested to use separate multicore cables Note The ESOUT pins reflect the emergency status of the controller ESOUT can be decoupled from ES input to avoid dea...

Page 103: ...2 1 4 3 xx2300001000 Antenna connector The Connected Services Gateway unit has either an ABB Connect port or an antenna connector on the front See installation procedures in section On site installat...

Page 104: ...the grommet Incorrect use of grommets will affect ingress protection EMI EMC and temperature It is recommended to use icotek KT grommet Ethernet outlet connector MGMT Management The following type of...

Page 105: ...0 V for the outputs and 0 V for the inputs For connection details see Circuit diagram OmniCore V250XT rev 04 or later 3HAC074000 008 and Application manual Scalable I O 3HAC070208 001 Continues on nex...

Page 106: ...f the cables which need to go through the grommet Incorrect use of grommets will affect ingress protection EMI EMC and temperature It is recommended to use icotek KT grommet The cable layout is recomm...

Page 107: ...able for the customer connection The cables connected by customer to the 24 V terminal block should go through the cable grommet and fasten on the cabinet Note The diameter of the cables must match th...

Page 108: ...manual Functional safety and SafeMove Configure the robot stopping functions in Visual SafeMove WARNING The new settings must be verified by test before the robot is used Note Depending on the control...

Page 109: ...s required Tip See also the circuit diagram Circuit diagram OmniCore V250XT rev 04 or later Apply the configuration to the controller Note illustration Action xx1500000801 In the Visual SafeMove ribbo...

Page 110: ...then Configuration 3 Select the check box Validated Set the configuration to locked When the stop configuration is approved the status of the configuration should be changed to Locked on the FlexPend...

Page 111: ...hese stops are performed without using the brakes and the power is never disconnected The program execution can be continued directly for example by activating a start signal Stop with RAPID instructi...

Page 112: ...y slide off path fairly much Search instructions can be pro grammed with arguments to stop the robot movement close to the point where a search hit was no ticed The program execution will continue wit...

Page 113: ...obot might make a limited movement when restarted WARNING The revolution counters might need to be updated after a colli sion to ensure path accuracy Stopping time distance Stopping time and distance...

Page 114: ...le for installing a DeviceNet M S board on the main computer The software based fieldbuses are connected directly to one of the Ethernet ports xx2300001738 Available board The following master board i...

Page 115: ...anual Article number Manual title 3HAC066565 001 Application manual EtherNet IP Scanner Adapter 3HAC066558 001 Application manual PROFINET Controller Device 3HAC082346 001 Application manual I O Engin...

Page 116: ...e minimum configuration and add on devices The DSQC1042 Safety Digital Base is a device that can be used to control and monitor machine safety equipment The device can be used together with the scalab...

Page 117: ...Local 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 Ana...

Page 118: ...tion 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 45 2 xx2200001...

Page 119: ...its for external mounting as described in Application manual Scalable I O 3 Opening the door on page 184 Open the door 4 Connect the external base device to the internal base device X3 or the Ethernet...

Page 120: ...SQC1042 3HAC062908 001 DSQC1042 Extended safety 3HAC069538 001 Connectors Safety I O Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for contr...

Page 121: ...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 45 2 xx2200001817 xx2200001972 Push the digital base i...

Page 122: ...ctor K5 1 X5 K3 1 X5 to from A2 X4 K5 1 X4 A2 X3 The harness connected to I O unit by customer 4 Concluding procedure Note Illustration Action Closing the door on page 185 Close the door 1 Perform the...

Page 123: ...Portal www abb com myABB Note Article number Spare part DSQC1035 3HAC059187 001 Ethernet Extension switch 3014 1 Harness A2 X4 K4 X6 3HAC084152 001 Ethernet Harness Required tools and equipment Note A...

Page 124: ...n 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 45 3 xx2200001817...

Page 125: ...between the upper surface of the Ethernet extension switch and the lower surface of highest bracket on the main computer xx1800000972 3 Reconnect any connectors disconnected at removal 4 Concluding pr...

Page 126: ...d with integrated brake snubbers When integrating a motor not delivered by ABB it is of great importance that the motor has a snubber fitted across the brake terminals at the motor Failure to do so wi...

Page 127: ...itch is in the OFF position 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 V250XT Type B via myABB Business...

Page 128: ...ration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Opening the door on page 184 Open the door 2 Location o...

Page 129: ...inform ation in section The unit is sensitive to ESD on page 45 2 xx2200001817 Screws Torx pan head screw M4x8 4 pcs Fit the additional drive unit and secure with the screws 3 Tightening torque 2 Nm...

Page 130: ...m the function tests to verify that the safety features work properly see Function tests on page 173 2 130 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All r...

Page 131: ...tion of the power supply optional device in the controller xx2200001473 Continues on next page Product manual OmniCore V250XT Type B 131 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights re...

Page 132: ...nt is defined in section Standard toolkit for controller on page 426 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore...

Page 133: ...e 45 3 xx2200001817 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 n...

Page 134: ...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 xx2200002012 Cont...

Page 135: ...nal block T5 X2 24VTerminal block T8 X2 24VTerminal block T6 X2 24VTerminal block T9 X2 24VTerminal block 3 Concluding procedure Note Illustration Action Closing the door on page 185 Close the door 1...

Page 136: ...e safety features work properly see Function tests on page 173 2 136 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 3 Installation and comm...

Page 137: ...te The spare part numbers that are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT Type B via myABB Business Portal www abb com myABB Note Article number Spare...

Page 138: ...ER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is se...

Page 139: ...equired 6 Closing the door on page 185 Close the door 7 Perform the function tests to verify that the safety features work properly see Function tests on page 173 8 For more information about the opti...

Page 140: ...e The spare part numbers that are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT Type B via myABB Business Portal www abb com myABB Note Article number Spare...

Page 141: ...ctrical safety on page 29 1 Opening the door on page 184 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safet...

Page 142: ...t 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 142 Product man...

Page 143: ...est 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 Laf...

Page 144: ...00002332 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 29...

Page 145: ...grommet assembly into the cover of the cabinet 3 xx2100000845 Secure it with the screws Concluding procedure Note Illustration Action Closing the door on page 185 Close the door 1 Perform the function...

Page 146: ...the location of the air filter on the controller xx2200001484 Continues on next page 146 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 3...

Page 147: ...section Standard toolkit for controller on page 426 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT rev 04 or...

Page 148: ...the function tests to verify that the safety features work properly see Function tests on page 173 4 148 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rig...

Page 149: ...ation of the incoming mains cable gland in the controller xx2100002285 Continues on next page Product manual OmniCore V250XT Type B 149 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights res...

Page 150: ...rotective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT rev 04 or later Continues on next page 150 Product manual OmniCore V250XT Type B 3HA...

Page 151: ...move the dust protection lid from the cable gland A 1 A Cable gland B Incoming mains switch C Cable pipe Remove protection from the incoming mains switch B 2 Continues on next page Product manual Omni...

Page 152: ...002287 Connect protective earth to one of the two screws 6 Note Use cable lugs in the connection Tightening torque 5 Nm Route the phase wires through the pipe up to the incoming mains switch B 7 See c...

Page 153: ...V250XT Type B via myABB Business Portal www abb com myABB Note Article number Spare part DSQC1096 3HAC085254 001 DeviceNet M S 3029 1 Required tools and equipment Note Article number Equipment Content...

Page 154: ...p 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 45 3 xx2200001817 Installing the...

Page 155: ...ing the door on page 185 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 173 2 Product manual OmniCore V250XT Type B 155 3HAC087...

Page 156: ...or later Installing the motor connection box Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1...

Page 157: ...the connectors for ADU 1 3 A and ADU 4 6 B on the cabinet 5 Connect the SMB cable to the SMB con nector for ADU 1 6 C on the cabinet 6 Continues on next page Product manual OmniCore V250XT Type B 157...

Page 158: ...Connect motor cables and resolver cables to the motor connection box 9 Perform the function tests to verify that the safety features work properly see Function tests on page 173 10 158 Product manual...

Page 159: ...wed on the door of the controller Available current supplied to or from this equipment must not exceed 8 A under any condition of load including short circuit Product manual OmniCore V250XT Type B 159...

Page 160: ...ming mains and protective earth to the controller on page 84 Function tests Before commissioning perform the function tests in section Function tests on page 173 to verify that the safety features wor...

Page 161: ...est Manual auto and manual full speed mode with FlexPend ant Function test of three position en abling device on page 175 12 months Function test Enabling device Function test of Automatic Stop on pag...

Page 162: ...ing the unit read the safety inform ation in section The unit is sensitive to ESD on page 45 2 xx2200001817 Inspect connectors and cabling to make sure they are securely fastened and cabling not damag...

Page 163: ...tion The air filter is located as shown in the illustration below xx2200001484 Continues on next page Product manual OmniCore V250XT Type B 163 3HAC087112 001 Revision A Copyright 2023 2023 ABB All ri...

Page 164: ...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 d...

Page 165: ...annot be separated from the filter assembly Note Illustration Action xx2200001773 Remove the air filter unit 1 Clean the metal mesh filter with compressed air 2 Refit the air filter unit to the cabine...

Page 166: ...en 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 w...

Page 167: ...g 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 FlexPen...

Page 168: ...er Do not clean the device operating panel and operating elements with compressed air solvents scouring agent or scrubbing sponges 168 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A C...

Page 169: ...ocation The air filter unit is located as shown in the illustration below xx2200001484 Continues on next page Product manual OmniCore V250XT Type B 169 3HAC087112 001 Revision A Copyright 2023 2023 AB...

Page 170: ...parations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Removing the air filter Note Illus...

Page 171: ...ption 3005 2 Moist dust filter Note Illustration Action xx2200001827 Insert the polymeric filter element to the filter and secure with the metallic line 1 Refitting the air filter Note Illustration Ac...

Page 172: ...ction tests to verify that the safety features work properly see Function tests on page 173 1 172 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights res...

Page 173: ...ent log or the event message 10013 Emergency stop state and 90518 Safety controller Emer gency stop triggered for robots prepared for collaborative applications does not appear then the test has faile...

Page 174: ...und 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 r...

Page 175: ...he event message 90780 Two channel fault in Safety Controller appears This test is passed if the event message 10012 Safety guard stop state appears in the event log While still holding the three posi...

Page 176: ...ake 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 posit...

Page 177: ...pening the connected robot cell door which has interlock connection with Auto matic Stop 2 If either of the following happens then the test is failed and the root cause must be found if the event mess...

Page 178: ...General Stop 2 If either of the following happens then the test is failed and the root cause must be found if the event message 90523 Safety Controller Protective Stop triggered does not appear if the...

Page 179: ...ton make sure to verify that it is not activated 2 Start the robot system 3 The test is passed if the event message 10013 Emergency stop state appears in the event log Press the emergency stop device...

Page 180: ...est is passed if the event message 10013 Emergency stop state appears in the event log Press the emergency stop device 4 If the event message 90780 Two channel fault in Safety Controller appears in th...

Page 181: ...eed 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 man...

Page 182: ...This page is intentionally left blank...

Page 183: ...a specific repair activity are listed in the respective procedures Safety information Read chapter Safety on page 13 before commencing any service work WARNING Wait at least three minutes after power...

Page 184: ...llustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Opening the door Info illustration Action Insert t...

Page 185: ...ction DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The...

Page 186: ...ntroller covers Preparations Info illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Continues on ne...

Page 187: ...section The unit is sensitive to ESD on page 45 2 xx2200001817 Refitting the rear cover Info illustration Action Refit the the rear cover 1 xx2200001062 Secure it with the screws 2 Continues on next p...

Page 188: ...ction xx2200001773 Refit the air filter cover plate 3 188 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 5 Repair 5 2 1 Opening the robot c...

Page 189: ...part External fan 3HAC082805 001 Fan unit Internal fan 3HAC083027 001 Fan unit Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller...

Page 190: ...cation The illustration shows the location of the external fan in the controller xx2200001778 Continues on next page 190 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023...

Page 191: ...tion in section The unit is sensitive to ESD on page 45 2 xx2200001817 Removing the rear cover on page 186 Remove the rear cover of the controller 3 Removing the external fans Note Illustration Action...

Page 192: ...power For more information see Electrical safety on page 29 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform a...

Page 193: ...ding procedure Note Illustration Action Refitting the rear cover on page 187 Refit the rear cover of the controller 1 Make sure that the filter cover plate is correctly positioned 2 Perform the functi...

Page 194: ...Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Opening the door on page 184 Open the door 2 Cont...

Page 195: ...tion Action Disconnect all connectors from the unit to be replaced 1 xx2200001069 Remove the screws holding the fan as sembly 2 Remove the fan assembly from the mounting plate 3 xx2200001070 Remove th...

Page 196: ...information see Electrical safety on page 29 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...

Page 197: ...mbly 5 Reconnect any connectors disconnected at removal 6 Concluding procedure Note Illustration Action Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safe...

Page 198: ...Type B via myABB Business Portal www abb com myABB Note Article number Spare part Main computer fan 3HAC084390 001 Fan w contact Required tools and equipment Note Article number Equipment Content is d...

Page 199: ...page 184 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...

Page 200: ...0 Remove the fan from the bracket 4 Refitting the main computer fan Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more informatio...

Page 201: ...ews 3 Screws Torx T10 6 pcs Tightening torque 0 7 Nm Concluding procedure Note Illustration Action Refitting the Connected Services gateway on page 214 If necessary refit the Connected Ser vices gatew...

Page 202: ...listed in the table can be out of date See the latest spare parts of the OmniCore V250XT Type B via myABB Business Portal www abb com myABB Note Article number Spare part Power unit fan 3HAC081496 00...

Page 203: ...lectrical safety on page 29 1 Opening the door on page 184 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the saf...

Page 204: ...power For more information see Electrical safety on page 29 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform a...

Page 205: ...ted at removal 5 Concluding procedure Note Illustration Action Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safety features work properly see Function te...

Page 206: ...siness Portal www abb com myABB Note Article number Spare part DSQC1035 3HAC059187 001 Ethernet Extension switch 3014 1 Harness A2 X4 K4 X6 3HAC084152 001 Ethernet Harness Required tools and equipment...

Page 207: ...Opening the door on page 184 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 T...

Page 208: ...e the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling...

Page 209: ...bracket on the main computer xx1800000972 3 Reconnect any connectors disconnected at removal 4 Concluding procedure Note Illustration Action Closing the door on page 185 Close the door 1 Perform the...

Page 210: ...the OmniCore V250XT Type B 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 DSQC1...

Page 211: ...re doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Opening the door on page 184 Open the door 2 Location of wrist strap button ELEC...

Page 212: ...ay by rotating the connector 2 Remove any cable ties and protection 3 xx2200001973 Pull the cable out through the cable grommet 4 Remove the magnet part of the antenna from the cabinet 5 Removing the...

Page 213: ...tration Action xx1900000971 Remove the attachment screws and pull out the front cover of the Connected Services 3G 1 xx1900000972 Carefully pull out the sim card from its holder 2 Continues on next pa...

Page 214: ...DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before hand...

Page 215: ...on the outside of the cabinet 1 Note The Connected Services antenna is installed by the customer and the cable routing can therefore differ Follow the cable routing recorded during the disassembly whe...

Page 216: ...llustration Action Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 173 2 216 Product manual OmniCor...

Page 217: ...sted in the table can be out of date See the latest spare parts of the OmniCore V250XT Type B via myABB Business Portal www abb com myABB Continues on next page Product manual OmniCore V250XT Type B 2...

Page 218: ...page 426 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT rev 04 or later Removing the Connected Services gate...

Page 219: ...onnecting the antenna Note Illustration Action Note The Connected Services antenna is installed by the customer and the cable routing can therefore differ Record the cable routing when you re move the...

Page 220: ...ugh the cable grommet 4 Remove the magnet part of the antenna from the cabinet 5 Removing the Connected Services gateway Note Illustration Action Disconnect all connectors from the unit to be replaced...

Page 221: ...lift the Connected Services gateway slightly and then pull it out from the bracket 3 Refitting the Connected Services gateway Refitting the Connected Services gateway Note Illustration Action DANGER...

Page 222: ...he unit is sensitive to ESD on page 45 2 xx2300000673 Hook up the Connected Services gate way to the bracket and push carefully into position 3 Continues on next page 222 Product manual OmniCore V250X...

Page 223: ...that there is a minimum separation distance of 20 cm between the dedicated antenna and nearby persons Place the magnet part of the antenna on the outside of the cabinet 1 Note The Connected Services a...

Page 224: ...he Connec ted Services gateway by rotating the connector 5 Concluding procedure Note Illustration Action Closing the door on page 185 Close the door 1 Perform the function tests to verify that the saf...

Page 225: ...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...

Page 226: ...Opening the door on page 184 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 Th...

Page 227: ...the digital base option Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Continues on next pa...

Page 228: ...the bracket until you hear a clear clicking sound 3 Reconnect any connectors disconnected at removal 4 Concluding procedure Note Illustration Action Closing the door on page 185 Close the door 1 Perfo...

Page 229: ...Spare part DSQC1042 3HAC062908 001 DSQC1042 Extended safety 3HAC069538 001 Connectors Safety I O Required tools and equipment Note Article number Equipment Content is defined in section Standard toolk...

Page 230: ...ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 45 3 xx2200001817 Removing the safety digital base device Note Illustration Action Disconnect...

Page 231: ...the unit read the safety inform ation in section The unit is sensitive to ESD on page 45 2 xx2200001817 xx2200001972 Push the digital base into the bracket until you hear a clear clicking sound 3 Rec...

Page 232: ...erify that the safety features work properly see Function tests on page 173 2 232 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 5 Repair 5...

Page 233: ...ote The spare part numbers that are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT Type B via myABB Business Portal www abb com myABB Continues on next page P...

Page 234: ...arations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Opening the door on page 184 Open t...

Page 235: ...embly Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 ELECTROSTATIC DISCHARGE ESD The unit m...

Page 236: ...ences can be imported Note When replacing the computer and logic unit both the serial number and licences are lost The serial number must be restored as described below Licences however can either be...

Page 237: ...serial number is found on the silver label 6 The system compares the downloaded file and the manually entered serial number to ensure that there is a match Tap Browse to open the hardware inform atio...

Page 238: ...te Article number Spare part CR2032 N A Standard Coin Cell Battery Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 426...

Page 239: ...e Electrical safety on page 29 1 Opening the door on page 184 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the...

Page 240: ...ro cessor board unit DSQC1086 1 Remove the processor board unit from the slot in the main computer assembly 2 Continues on next page 240 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A...

Page 241: ...nformation see Electrical safety on page 29 1 xx2200001817 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensiti...

Page 242: ...essor board unit 1 xx2300000941 Insert the processor board unit into the slot in the main computer assembly 2 Continues on next page 242 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A...

Page 243: ...Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 173 2 Product manual OmniCore V250XT Type B 243 3HA...

Page 244: ...ration shows the location of the power unit in the controller xx2300001838 Continues on next page 244 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights...

Page 245: ...tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 426 Standard toolkit ESD protective wrist band Required documents Note Article n...

Page 246: ...he two guiding pins on the mounting plate CAUTION Only the sheet metal on the power unit can be used for holding Do not touch the connectors or the filter on the power unit CAUTION The weight of the p...

Page 247: ...unit read the safety inform ation in section The unit is sensitive to ESD on page 45 2 xx2200001817 Screws Torx pan head screw M4x8 4 pcs Position the power unit on the lower guiding pin on the mount...

Page 248: ...n Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 173 2 248 Product manual OmniCore V250XT Type B 3...

Page 249: ...ration shows the location of the power unit in the controller xx2300001991 Continues on next page Product manual OmniCore V250XT Type B 249 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights...

Page 250: ...426 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT rev 04 or later Removing the power unit Preparations Note...

Page 251: ...ect all connectors from the unit to be replaced 1 xx2300001492 Remove the screws and pull the power unit out from the two guiding pins on the mounting plate CAUTION Only the sheet metal on the power u...

Page 252: ...ead the safety inform ation in section The unit is sensitive to ESD on page 45 2 xx2200001817 Screws Torx pan head screw M4x8 4 pcs Position the power unit on the lower guiding pin on the mounting pla...

Page 253: ...ng the door on page 185 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 173 2 Product manual OmniCore V250XT Type B 253 3HAC0871...

Page 254: ...ation shows the location of the power supply in the controller xx2200001473 Continues on next page 254 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All right...

Page 255: ...1 Harness PSU 3HAB7983 1 End clamp Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 426 Standard toolkit ESD protective...

Page 256: ...n The unit is sensitive to ESD on page 45 3 xx2200001817 Removing the power supply Note Illustration Action xx2200002009 Remove the end clamp besides the power supply with a screwdriver 1 Continues on...

Page 257: ...onnect the mains power For more information see Electrical safety on page 29 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the...

Page 258: ...009 Refit the end clamp besides the power supply 5 Concluding procedure Note Illustration Action Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safety feat...

Page 259: ...TATIC 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 45 3 xx2200001817 Removing the power supply Note...

Page 260: ...cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the u...

Page 261: ...it the end clamp besides the power supply 5 Concluding procedure Note Illustration Action Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safety features wo...

Page 262: ...ration shows the location of the drive unit in the controller xx2300001839 Continues on next page 262 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights...

Page 263: ...A1 X11 T4 X13 3HAC081731 001 Harness 24_BRAKE Harness A1 X2 T4 X17 3HAC082738 001 Harness CTRL_FB Required tools and equipment Note Article number Equipment Content is defined in section Standard tool...

Page 264: ...screwdriver Remove the screws and pull the drive unit out from the two guiding pins on the mounting plate CAUTION The weight of the drive unit is 11 kg Use protective gloves when lifting this unit 2 x...

Page 265: ...unit read the safety inform ation in section The unit is sensitive to ESD on page 45 2 xx2200001817 Screws Torx pan head screw M4x8 4 pcs Position the drive unit on the lower guid ing pin on the moun...

Page 266: ...n Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 173 2 266 Product manual OmniCore V250XT Type B 3...

Page 267: ...in the drive unit even if the main switch is in the OFF position 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 Omni...

Page 268: ...te Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Opening the door on page 184 Open the door 2 L...

Page 269: ...e CAUTION The cabling is sensitive to mechanical damage Handle it with care to avoid damage to the cabling or the connector avoid any kind of tilt or skew 3 xx2200001375 Refitting the additional drive...

Page 270: ...unit and secure with the screws 3 Tightening torque 2 Nm xx2200001375 Reconnect any connectors disconnected at removal 4 Concluding procedure Note Illustration Action Closing the door on page 185 Clo...

Page 271: ...he OmniCore V250XT Type B via myABB Business Portal www abb com myABB Note Article number Spare part DSQC1096 3HAC085254 001 DeviceNet M S 3029 1 Required tools and equipment Note Article number Equip...

Page 272: ...ower For more information see Electrical safety on page 29 1 Opening the door on page 184 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before...

Page 273: ...iceNet board Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Opening the door o...

Page 274: ...DeviceNet board into the slot in the main computer assembly 1 xx2300000921 Secure the screws that hold the Devi ceNet board unit 2 Concluding procedure Note Illustration Action Closing the door on pag...

Page 275: ...5 001 CONNECTOR KIT DSQC2000 Power cable of CTM 3HAC084173 001 Harness 24V_CTM 3HAC084195 001 Ethernet harness for CTM Required tools and equipment Note Article number Equipment Content is defined in...

Page 276: ...ATIC 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 45 3 xx2200001817 Removing the conveyor tracking m...

Page 277: ...mbling 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 disconne...

Page 278: ...sensitive to ESD on page 45 2 xx2200001817 xx1900001913 Hang the conveyor tracking module into the bracket and push the lower of it until you hear a clear clicking sound 3 xx2200001844 Continues on n...

Page 279: ...ng procedure Note Illustration Action Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 173 2 Product...

Page 280: ...ration shows the location of the air filter on the controller xx2200001484 Continues on next page 280 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights...

Page 281: ...d tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 426 Standard toolkit ESD protective wrist band Required documents Note Article...

Page 282: ...how to remove the polymeric filter element option 3005 2 Moist dust filter Note Illustration Action xx2200001827 Take out the polymeric filter element from the filter 1 Continues on next page 282 Pro...

Page 283: ...ote Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Refit the air filter unit to the cabinet 2 Co...

Page 284: ...ts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT Type B via myABB Business Portal www abb com myABB Continues on next pa...

Page 285: ...ore doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitiv...

Page 286: ...the break resistor bleeder bracket 3 xx2200001074 Remove the screws holding the break resistor bleeder 4 Remove the break resistor bleeder and pull the cables through the opening 5 Continues on next...

Page 287: ...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 45 2 xx2200001817 xx2200001074 Re...

Page 288: ...ting the rear cover on page 187 Refit the rear cover of the controller 1 Closing the door on page 185 Close the door 2 Perform the function tests to verify that the safety features work properly see F...

Page 289: ...81735 001 Harness SMB connection Harness 1xSMB 3HAC077440 001 Harness SMB link Harness 2xSMB 3HAC077388 001 Harness SMB link LV 3HAC083231 001 Harness SMB link Required tools and equipment Note Articl...

Page 290: ...he safety inform ation in section The unit is sensitive to ESD on page 45 3 xx2200001817 Removing the manipulator signal connector Note Illustration Action Disconnect all connectors from the unit to b...

Page 291: ...pulator signal connector into the cover plate in the front panel 3 Screws Torx pan head screw M4x8 4 pcs Secure it with the attachment screws 4 Tightening torque 2 7 Nm 10 xx2200001981 Reconnect any c...

Page 292: ...Article number Spare part 3HAC081696 001 Harness HV Manipulator Motor Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page...

Page 293: ...f 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 45 3 xx2200001817 Re...

Page 294: ...be installed in the same position 4 Take out the motor connector 5 Refitting the motor connector Refitting the motor connector Note Illustration Action DANGER Before doing any work inside the cabinet...

Page 295: ...the front panel from inner side of the cabinet and fasten it with the screws 3 Tightening torque 2 7 Nm 10 xx2200001982 Reconnect any connectors disconnected at removal 4 Secure the motor connector c...

Page 296: ...door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 173 2 296 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2...

Page 297: ...isted in the table can be out of date See the latest spare parts of the OmniCore V250XT Type B via myABB Business Portal www abb com myABB Note Article number Spare part Harness TPU 3HAC071006 001 Har...

Page 298: ...ing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Opening the door on page 184 Open the door 2 Location of wrist strap button ELECTROST...

Page 299: ...removed The cables need to be installed in the same position 1 Disconnect all connectors from the unit to be replaced 2 xx2100000830 Remove the screws 3 xx2100000831 Remove the cover plate 4 Continues...

Page 300: ...binet disconnect the mains power For more information see Electrical safety on page 29 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the uni...

Page 301: ...any connectors disconnected at removal 4 Secure the cables on HMI signal connect or with new cable ties Tip Use the same position as from removing the HMI signal connector 5 xx2100000831 Refit the cov...

Page 302: ...Illustration Action Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 173 2 302 Product manual OmniCo...

Page 303: ...d 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 V250XT Type B via myABB Business Portal www abb com myABB Note Arti...

Page 304: ...ore doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Opening the door on page 184 Open the door 2 Location of wrist strap button ELE...

Page 305: ...ttachment 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 x...

Page 306: ...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 306 Product manual OmniCore V250XT Type B 3HAC087112 0...

Page 307: ...e 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 V250XT Type B 307 3HAC0871...

Page 308: ...oint 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 usi...

Page 309: ...er 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 V250XT Type B 309 3HAC087112 001...

Page 310: ...t disconnect the mains power For more information see Electrical safety on page 29 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit re...

Page 311: ...cluding procedure Note Illustration Action Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 173 2 Pr...

Page 312: ...at are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT Type B via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC084151 001 Etherne...

Page 313: ...ore doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Opening the door on page 184 Open the door 2 Location of wrist strap button ELE...

Page 314: ...100000830 Remove the screws 1 xx2100000831 Remove the cover plate 2 Continues on next page 314 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserv...

Page 315: ...placed 6 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 7 Take the Ethe...

Page 316: ...net outlet connector with cable into the cover from inner side of the cabinet 3 xx2100000852 Secure it with the locking ring 4 Reconnect any connectors disconnected at removal 5 Secure the Ethernet ou...

Page 317: ...that the safety features work properly see Function tests on page 173 2 Product manual OmniCore V250XT Type B 317 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 5 Repair 5 3 5...

Page 318: ...ted in the table can be out of date See the latest spare parts of the OmniCore V250XT Type B via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC065549 001 LED indicator Con...

Page 319: ...ore doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 Opening the door on page 184 Open the door 2 Location of wrist strap button ELE...

Page 320: ...nside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety i...

Page 321: ...e Illustration Action Closing the door on page 185 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 173 2 Product manual OmniCore...

Page 322: ...an be out of date See the latest spare parts of the OmniCore V250XT Type B via myABB Business Portal www abb com myABB Note Article number Spare part Harness TPU 3HAC071006 001 Harness TPU connection...

Page 323: ...e to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 45 1 Disconnect the FlexPendant from the controller 2 xx1800001189 Remove the attachment...

Page 324: ...ation 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 45 1 Continues on next page...

Page 325: ...Refit the power cable cover and tighten the screws 4 xx1800001196 Perform the function tests to verify that the safety features work properly see Function tests on page 173 5 Product manual OmniCore...

Page 326: ...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...

Page 327: ...e 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 handl...

Page 328: ...protection 2 xx1800001206 Secure the screws 3 Countersunk head screw ST2 9 X 10 6 pcs 328 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 5...

Page 329: ...ia 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...

Page 330: ...Note Article number Equipment Content is defined in section Standard toolkit for controller on page 426 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC0...

Page 331: ...lectrical safety on page 29 1 Reconnect any connectors disconnected at removal 2 Perform the function tests to verify that the safety features work properly see Function tests on page 173 3 Product ma...

Page 332: ...V250XT Type B via myABB Business Portal www abb com myABB Note Article number Spare part DSQC633C 3HAC043904 001 Measurement Unit Required tools and equipment Note Article number Equipment Content is...

Page 333: ...ge 45 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 2 DANGER Before doing any work inside the cabinet di...

Page 334: ...o be replaced 6 xx2300001705 Remove the screws at the front of the box 7 Push the measurement unit inwards and lift out of the box 8 xx2300001706 Remove the attachment screws from the mounting plate 9...

Page 335: ...e measurement unit and mounting plate in the box 2 xx2300001705 Refit the screws at the front of the box 3 Reconnect any connectors disconnected at removal 4 Continues on next page Product manual Omni...

Page 336: ...e function tests to verify that the safety features work properly see Function tests on page 173 6 336 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All right...

Page 337: ...Core V250XT Type B via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC044075 001 Battery Unit Required tools and equipment Note Article number Equipment Content is defined...

Page 338: ...3 Remove the screws holding the cover 2 Remove cable ties from battery 3 Disconnect all connectors from the unit to be replaced 4 Remove the battery 5 Refitting the motor connection box battery Note I...

Page 339: ...tion tests to verify that the safety features work properly see Function tests on page 173 4 Product manual OmniCore V250XT Type B 339 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights rese...

Page 340: ...This page is intentionally left blank...

Page 341: ...ature 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...

Page 342: ...e table below xx1800000058 Materials used in the product The table specifies some of the materials in the product and their respective use throughout the product Dispose components properly according...

Page 343: ...ns certain hazardous substances and can be used safely during its environmental protection use period as indicated by the number in the center which should enter into the recycling system after its en...

Page 344: ...This page is intentionally left blank...

Page 345: ...e the fault chain in two 3 Check communication parameters and cables 4 Check that the software version is compatible with the hardware Work systematically 1 Take a look around to make sure that all sc...

Page 346: ...eck software versions compatibilities between hardware and software options and their configuration The robot recently had a software upgrade Check connections software versions The robot has recently...

Page 347: ...s on page 355 Problem starting or connecting the FlexPendant on page 358 Problem using the joystick on page 362 Controller fails to start on page 363 Reflashing firmware failure on page 364 Inconsiste...

Page 348: ...k 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 engineers Recommended working proced...

Page 349: ...0 Repair connection Connection not ok Check AC input cable Connection ok Replace cable Broken cable Cable ok Ok Ok Check fuse F1 Check A1 X1 Abnormal Replace Q0 Abnormal Replace fuse F1 Abnormal Troub...

Page 350: ...ee Circuit diagram OmniCore V250XT rev 04 or later 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 c...

Page 351: ...am OmniCore V250XT rev 04 or later 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...

Page 352: ...Module status should be green If not see Troubleshooting the power unit on page 383 If the power unit is ok check that incoming mains is well connected and that the in coming mains switch is turned o...

Page 353: ...t green troubleshoot the main computer See Troubleshooting the main computer on page 416 Check LEDs PC Power distribution board DSQC1085 and HMI Safety board DSQC1087 5 If the drive unit status LED is...

Page 354: ...s in the system on page 354 New system configuration 1 Reset the RobotWare system The RAPID program and system parameters will be removed and the system will be set to default state but without system...

Page 355: ...roller 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...

Page 356: ...ec on not ok Repair connec on Repair connec on Connec on not ok Measure power on T4 X13 X14 Power is ok No power Connec on is ok Test the brake Test the brake release Brake is ok Brake not ok Brake re...

Page 357: ...see Circuit diagram OmniCore V250XT rev 04 or later 4 If it is not repair the connec tion and go to step 8 If it is ok go to the next step Check that the connection from the main drive unit to the mot...

Page 358: ...rface xx1900000917 Required test equipment Equipment needed for troubleshooting Note Equipment Multimeter Insulating gloves 3HAC074000 008 Circuit diagram OmniCore V250XT rev 04 or later Preparations...

Page 359: ...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 Continues on next page Product manual OmniCore V2...

Page 360: ...ion not ok Connections ok Start FlexPendant Problem solved Ok Not starting Replace FlexPendant Replace FlexPendant cable Reset the FlexPendant xx2300001760 Location of LEDs Information about LEDs not...

Page 361: ...for any damage 3 If possible test by connecting another FlexPend ant This is to eliminate the FlexPendant and cable as error sources Test the FlexPendant with a different controller to eliminate the c...

Page 362: ...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 replac...

Page 363: ...this situation the controller can be forced to start in RobotWare Installation Utilities mode Forcing startup of the RobotWare Installation Utilities mode Repeat the following action two times in a r...

Page 364: ...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...

Page 365: ...move 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 ven...

Page 366: ...section Problem re leasing the robot brakes on page 355 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 Ch...

Page 367: ...lace malfunctioning fans see Replacing the external fans on page 190 Check that the external fans are working 1 Replace malfunctioning fans see Replacing the internal fan on page 194 Check that the in...

Page 368: ...onal drive unit Troubleshooting the power unit on page 383 Power unit Troubleshooting fieldbuses and I O on page 396 Scalable I O Troubleshooting the 3G Connected Services gateway on page 397 3G Conne...

Page 369: ...ng the FlexPend ant If the FlexPendant is not responding or does not operate correctly see Problem starting or con necting the FlexPendant on page 358 2 Check the cable for connections and integrity 3...

Page 370: ...on shows the location of the drive unit in the controller xx2300001839 Continues on next page 370 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights res...

Page 371: ...r communication Green steady Drive unit is operation al 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 th...

Page 372: ...ing Link and activity Yellow steady Link without activity LA Link Activity 1 LED D No color Voltage between DC DC 60 VDC Yellow Voltage between DC DC 60 VDC DC BUS High Voltage LED E Required test equ...

Page 373: ...not ok Still flashing red Measure 24_BRAKE X13 X14 Abnormal Normal Red xx2100001982 Troubleshooting procedure The troubleshooting table is supposed to be used as a detailed instruction together with t...

Page 374: ...connection pro ceed with step 7 Verify that the input to X1 X2 is 24 VDC 10 If the measured voltage is normal re place the drive unit See Replacing the drive unit on page 262 If the measured voltage i...

Page 375: ...roceed with step 1 If there is a problem with the connection replace the safety related cables See 12 Restore the communication of the safety cable between the modules by reconnecting the cable X17 11...

Page 376: ...on shows the location of the drive unit in the controller xx2200001056 Continues on next page 376 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights res...

Page 377: ...U2 ADU1 MDU Power Unit 1 2 3 4 5 xx2300000976 See also Application manual Additional axes for OmniCore 3HAC082287 001 Continues on next page Product manual OmniCore V250XT Type B 377 3HAC087112 001 Re...

Page 378: ...on the additional drive unit xx2200001052 Continues on next page 378 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 7 Troubleshooting 7 3...

Page 379: ...ity Yellow steady Link without activity LA Link Activity 0 LED B Shows the actual state of the device state machine Off Drive unit is in state INIT Green flashing slow Drive unit is in state PRE OPERA...

Page 380: ...d yellow Check EtherCAT SMB cables X3 X4 X16 X18 Connection ok Abnormal Troubleshoot power unit Troubleshoot power unit Not lit Not lit Reconnect 24V_power cable Replace additional drive unit Reconnec...

Page 381: ...is abnormal proceed with step 11 Measure the 24V_BRAKE input at connector X13 X14 2 Make sure that the drive unit is operational Check the two Link Activity LEDs B D These LEDs indicate the communicat...

Page 382: ...properly on both ends If the Link Activity LED is yellow the fault has been fixed Proceed with step 1 If the Link Activity LED is off the fault remains Proceed with step 10 Restore the communication b...

Page 383: ...below shows the location of the power unit in the controller xx2300001838 Continues on next page Product manual OmniCore V250XT Type B 383 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights...

Page 384: ...olor Voltage between DC DC 60 VDC Yellow Voltage between DC DC 60 VDC DC BUS High Voltage LED A Continues on next page 384 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 202...

Page 385: ...n flickering fast Power unit is in state BOOTSTRAP ECAT STATUS C Shows the network communication speed Green steady Speed is 100 Mbps Off Speed is 10 Mbps SPEED D Shows the Link activity of the EtherC...

Page 386: ...ndant Disconnect DC_OUT loads test start Not resolved Check DC_OUT Not OK Not OK OK Replace DC_OUT Check A1 X2 cable Replace A1 X2 cable Connection not ok Connection not ok Steady green DC BUS High Vo...

Page 387: ...ro ceed with step 5 If AC_IN is is abnormal there is an issue with A1 X1 Proceed with step 3 Verify AC_IN 2 If the connection seems OK proceed with step 5 Check the connector at A1 X1 AC input Make su...

Page 388: ...LED is green with the loads disconnected Proceed with step 9 If the fault remains the unit may be faulty see Replacing the power unit on page 244 If the connection and cables seem OK proceed with step...

Page 389: ...within specification and is not broken If DC_OUT is OK and DC BUS High Voltage is on with the loads disconnec ted proceed with step 17 If DC_OUT is not OK the unit may be faulty see Replacing the powe...

Page 390: ...below shows the location of the power unit in the controller xx2300001991 Continues on next page 390 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights...

Page 391: ...n the power unit xx2300001469 Continues on next page Product manual OmniCore V250XT Type B 391 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 7 Troubleshooting 7 3 6 Troubleshoo...

Page 392: ...mware error or self test failure Green flashing 1Hz Communication error to another module Green steady Unit is operational Module Status Required test equipment Equipment needed for troubleshooting No...

Page 393: ...ocedure The troubleshooting table is supposed to be used as a detailed instruction together with the troubleshooting flowchart Note Action Make sure that the power unit is operational Power on the con...

Page 394: ...that the input to 24V_BRAKE_PWR is 25 2 VDC 5 If the 24V_BRAKE_PWR voltage is in the range proceed with step 7 If the 24V_BRAKE_PWR voltage is abnor mal proceed with step 11 Measure the 24V_BRAKE_PWR...

Page 395: ...See Replacing the break resistor bleeder on page 284 Check the bleeder connection at X10 CAUTION Before measuring the bleeder res istance do the following Shut down the power and wait 1 minute Discon...

Page 396: ...ot the fieldbuses and I O units can be found in the manual for the respective fieldbus or I O unit See References on page 10 396 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyrig...

Page 397: ...the location of the Connected Services gateway in the controller xx2300001805 Continues on next page Product manual OmniCore V250XT Type B 397 3HAC087112 001 Revision A Copyright 2023 2023 ABB All ri...

Page 398: ...y the following issues STATUS LED red green Fault indication No color Power to the unit is missing Red solid or flashing for more than 120s Internal error Try a pin reset if problem persists replace t...

Page 399: ...ess than 5s The module will reboot to reinitiate communication Long press more than 5s The module will be reset to factory status before restarting Reset pin hole Required test equipment Equipment nee...

Page 400: ...th the troubleshooting flowchart Note Action If the LED is Red green flashing proceed with step 2 OFF the unit is faulty or it does not have sufficient input voltage or the connection of the connector...

Page 401: ...LEDs are ON the Connected Services Gate way is connected to network and works well OFF the Connected Services Gateway is faulty or the connection of the connector X3 is not ok Pro ceed with step 8 Che...

Page 402: ...2 How to replace the unit is described in Replacing the 3G Connected Services gateway on page 210 The Connected Services Gateway may be faulty replace it and verify that the problem is resolved 13 Rel...

Page 403: ...the location of the Connected Services gateway in the controller xx2300001806 Continues on next page Product manual OmniCore V250XT Type B 403 3HAC087112 001 Revision A Copyright 2023 2023 ABB All ri...

Page 404: ...en WAN logged in no signal or logged out Signal green SIG field strength see table below connected data traffic not connected Link activity green ETH 100 Mbit s 10 Mbit s data rate yellow Signal quali...

Page 405: ...reen solid Ok Check LED PWR Check LED ETH Check 24V harness adapter Check LED WAN Check antenna placement Check LED SIG Ok Not lit Ok Ok Ok Ok Not ok Replace the Connected Services Gateway Power ok No...

Page 406: ...cedures The troubleshooting table is supposed to be used as a detailed instruction together with the troubleshooting flowchart Note Action If the LED is Green solid proceed with step 4 OFF proceed wit...

Page 407: ...properly Tip Try moving the antenna to different loca tions if the SIG signal level is low 6 If the correct unit version is used proceed with step 8 If the correct unit version is not used replace wi...

Page 408: ...with https 192 168 125 85 4 The INSYS login page is displayed xx2300000638 Note Enter the following to access this page User status Password status Continues on next page 408 Product manual OmniCore V...

Page 409: ...page on page 410 The log view displays all current logs Log view Troubleshoot the unit using the log page on page 410 Download a package with all logs archives and current status The logs can be save...

Page 410: ...or ABB troubleshooting These logs can be saved as a file and be sent to ABB L3 L4 Support for analysis Log download xx2300000912 Support Packet xx2300000913 Checking the gateway status 1 Connect a PC...

Page 411: ...the following Verify that the WAN chain is online xx2300000640 Continues on next page Product manual OmniCore V250XT Type B 411 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 7...

Page 412: ...file displays the profile version xx2300000763 It is recommended to store the profile version for reference This can be used later to verify that the unit has not been reset or tampered with CAUTION C...

Page 413: ...e field Firmware displays the firmware version The minimal firmware required is FW 6 11 xx2300000763 Related information All documents can be found via myABB Business Portal www abb com myABB Product...

Page 414: ...shows the location of the Ethernet switch in the controller xx2300001820 Continues on next page 414 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights r...

Page 415: ...ssues 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...

Page 416: ...xx2200001088 LEDs The following sections display the LEDs on the main computer units Power distribution board DSQC1085 xx2300000434 Continues on next page 416 Product manual OmniCore V250XT Type B 3HA...

Page 417: ...iz ing Green uneven flashing 1Hz Installation Utility Application loaded and ready for recovery operation Green steady Application is ready and unit is operational STAT Status Red Green Shows the Sign...

Page 418: ...ame FlexPendant power output LED can be used to identify the following status No color FlexPendant power output voltage is not in normal range Green solid FlexPendant power out put voltage is in norma...

Page 419: ...channel 1 ES2 External emergency stop LED channel 2 ES1 ES2 Troubleshooting procedure Note Action Wait at least 1 min after power on Make sure the power has been off for more than 10 seconds 1 Power o...

Page 420: ...at connector A1 X6 8 If the UPS LED is Steady green Proceed with step 11 Off Proceed with step 10 Check the UPS LED on the power distribution board DSQC1085 9 If the error message is insufficient pro...

Page 421: ...t be separated with 3 pcs of exterior support LEDs The illustration below shows the LEDs on the process power supply module A en1000000037 DC OK A Significance Description GREEN When all DC outputs ar...

Page 422: ...100001077 Significance Description GREEN When all DC outputs are within the specified output voltage levels DC OK OFF When DC output voltage is outside the specified voltage levels or turned off due t...

Page 423: ...ludes general information complementing the more specific information in the different procedures in the manual Product manual OmniCore V250XT Type B 423 3HAC087112 001 Revision A Copyright 2023 2023...

Page 424: ...ting industrial robots Presentation of characteristics ISO 9946 Other standards used in design Description Standard Safety of machinery Electrical equipment of machines Part 1 General requirements nor...

Page 425: ...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 Product manual OmniCore V250XT Type...

Page 426: ...ctions 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...

Page 427: ...pecial 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...

Page 428: ...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...

Page 429: ...fting 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 st...

Page 430: ...This page is intentionally left blank...

Page 431: ...ns 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 m...

Page 432: ...ved parts and spare parts must not be disassembled or opened Continues on next page 432 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights reserved 9 Sp...

Page 433: ...l Type Description Spare part num ber L1 DSQC3062 Drive unit High Voltage 3HAC064590 001 A Continues on next page Product manual OmniCore V250XT Type B 433 3HAC087112 001 Revision A Copyright 2023 202...

Page 434: ...Description Spare part num ber L1 DSQC 3065 Drive unit 3HAC064983 001 Continues on next page 434 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All rights rese...

Page 435: ...3632 001 HV 3x380 480V L1 DSQC3069 Power unit 3HAC062699 001 LV 3x380 480V L1 DSQC3072 Power unit 3HAC066498 001 HVLP Continues on next page Product manual OmniCore V250XT Type B 435 3HAC087112 001 Re...

Page 436: ...tion Spare part num ber L1 Break resistor bleeder assembly 3HAC081951 001 A Continues on next page 436 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB All right...

Page 437: ...are part num ber L1 Ethernet Harness 3HAC084151 001 A Harness TPU connection xx1900001943 Continues on next page Product manual OmniCore V250XT Type B 437 3HAC087112 001 Revision A Copyright 2023 2023...

Page 438: ...ess HV Manipulator Motor 3HAC081696 001 Harness ADU motors Spare part level Type Description Spare part num ber L1 Harness ADU Motors 3HAC084159 001 L1 Harn 1xADU Motors 3HAC077969 001 L1 Harn ADU Mot...

Page 439: ...s 3HAC073561 001 C L1 For options 3008 2 Connector and 3008 3 Connector fuse Connector kit 3HAC075871 001 L1 For option 3008 3 Connect or fuse Circuit breaker 32A 3p 3HAC079544 001 L1 For option 3008...

Page 440: ...rt level Type Description Spare part num ber L1 Main computer Standard 3HAC085504 001 Continues on next page 440 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB...

Page 441: ...teway xx2300001645 Spare part level Type Description Spare part num ber L1 Connected Services 3G 3013 3 baseline 3HAC060960 001 A L1 Magnetic roof antenna 3G baseline 3HAC028459 001 B Continues on nex...

Page 442: ...d Services Wired 3013 1 option 3HAC061701 001 E L1 DSQC1093 Connected Services 4G EU 3013 5 option 3HAC086677 001 L1 DSQC1093A Connected Services 4G US 3013 6 option 3HAC086678 001 L1 Magnetic roof an...

Page 443: ...79 001 A L1 CONNECTOR KIT DSQC2000 3HNA029345 001 L1 Power cable of CTM Harness 24V_CTM 3HAC084173 001 L1 Ethernet harness for CTM 3HAC084195 001 Ethernet switches xx1900001935 Continues on next page...

Page 444: ...r supply device xx2100000740 Spare part level Type Description Spare part num ber L1 DSQC 609 DSQC 609 power supply 3HAC14178 1 A L1 DSQC 634 DSQC 634 power supply 3HAC13398 2 B Continues on next page...

Page 445: ...d 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 D L1 C...

Page 446: ...ption Spare part num ber L1 DSQC1042 Extended safety 3HAC062908 001 L1 Connectors Safety I O 3HAC069538 001 446 Product manual OmniCore V250XT Type B 3HAC087112 001 Revision A Copyright 2023 2023 ABB...

Page 447: ...ber L1 External fan Fan unit 3HAC082805 001 A L1 Internal fan Fan unit 3HAC083027 001 B Main computer fan xx2300000925 Continues on next page Product manual OmniCore V250XT Type B 447 3HAC087112 001 R...

Page 448: ...pare part level Type Description Spare part num ber L1 Power unit fan Fan with connector 3HAC081496 001 Process fieldbus and I O connectors xx1900001928 Continues on next page 448 Product manual OmniC...

Page 449: ...num ber L1 HMI panel 3HAC077425 001 Swing handle Spare part level Type Description Spare part num ber L1 Swinghandle with cam 3HAC083816 001 LED indicator xx1900002451 Spare part level Type Descripti...

Page 450: ...00001826 Spare part level Type Description Spare part num ber L1 Air filter coarse assembly 3HAC082548 001 A L1 Air filter fine assembly 3HAC082547 001 B 450 Product manual OmniCore V250XT Type B 3HAC...

Page 451: ...B link 3HAC077440 001 L1 Harness 2xSMB Harness SMB link 3HAC077388 001 L1 Harness 1xSMB Harness SMB link 3HAC086308 001 End clamp xx1900001940 Spare part level Type Description Spare part num ber L1 E...

Page 452: ...mm camera lens LFC 25F1 3HAC053944 004 L1 8 mm camera lens LMC ML M0822UR 3HAC087266 001 L1 12 5 mm camera lens LMC ML M1218UR 3HAC087267 001 L1 16 mm camera lens LMC ML M1616UR 3HAC087268 001 L1 25...

Page 453: ...ethernet cable 15 m 3HAC075443 003 Service port connector Spare part level Type Description Spare part number L1 Service port connector 3HAC064848 001 Motor connection box xx2300001671 Continues on ne...

Page 454: ...AC078370 002 L1 Ext axis power harn _22m 3HAC078370 007 Dust Cap M12 Spare part level Type Description Spare part number L1 Dust Cap M12 3HAC073531 001 Key Spare part level Type Description Spare part...

Page 455: ...cable jumpers 3HAC084243 001 Wrist band Spare part level Type Description Spare part number L1 Wrist band 3HAB2997 1 Product manual OmniCore V250XT Type B 455 3HAC087112 001 Revision A Copyright 2023...

Page 456: ...Ethernet harness 3HAC081970 001 L1 Harness A1 X11 T4 X13 Harness 24_BRAKE 3HAC081731 001 L1 Harness A1 X2 T4 X17 Harness CTRL_FB 3HAC082738 001 Cables on the additional drive unit Spare part level Typ...

Page 457: ...L1 DSQC 609 and DSQC 634 Harness PSU 3HAC082508 001 Cables on the mains power connection Spare part level Type Description Spare part num ber L1 Harn Mains connection 3HAC082081 001 L1 Harn Mains con...

Page 458: ...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...

Page 459: ...e number Cable length IRB 460 2600 4600 5710 5720 67X0 L1 3HAC2493 1 Control cable signal 7 m IRB 460 2600 4600 5710 5720 67X0 L1 3HAC2530 1 Control cable signal 15 m IRB 460 2600 4600 5710 5720 67X0...

Page 460: ...level Article number CP CS cable length L1 3HAC022957 001 Cable CP CS 7 m L1 3HAC022957 002 Cable CP CS 15 m L1 3HAC022957 003 Harness CP CS 30 m 460 Product manual OmniCore V250XT Type B 3HAC087112 0...

Page 461: ...icle number Ethernet floor cable length L1 3HAC079476 001 Ethernet floor cable 7 m L1 3HAC079476 002 Ethernet floor cable 15 m L1 3HAC079476 004 Ethernet floor cable 30 m Product manual OmniCore V250X...

Page 462: ...umber DeviceNet floor cable length L1 3HAC022978 001 Harness CP CS DeviceNet 7 m L1 3HAC022978 002 Cable CP CS DeviceNet 15 m L1 3HAC022978 003 Harness CP CS DeviceNet 30 m 462 Product manual OmniCore...

Page 463: ...2 D damaged bearings 365 damaged parallel bar 365 detaching FlexPendant 87 DeviceNet 271 installing 154 dimensions 39 disconnecting FlexPendant 87 disposal of storage media 341 drive unit LED 371 repl...

Page 464: ...al operation mode 363 O ODVA 422 ODVA power supply LED 422 open source software OSS 49 operating conditions 39 operating mode automatic mode 27 function test 174 manual full speed mode 25 manual mode...

Page 465: ...installing 117 replacing 225 scalable I O external 116 scalable I O internal 116 shipping 341 signals safety 16 sim card replacing 210 software licenses 49 standards 424 steel disposal 342 stop categ...

Page 466: ......

Page 467: ......

Page 468: ...22 87 2000 ABB Engineering Shanghai Ltd Robotics Discrete Automation No 4528 Kangxin Highway PuDong New District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics Discrete Automation 1...

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