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1.6 Safety during operation

Automatic operation

Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.

Lock and change of operating mode

To prevent hazard, it is the responsibility of the integrator 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 cannot initiate
a protective or emergency stop. These must be stored out of sight so that they
cannot be mistaken for being in use.

Product manual - OmniCore V400XT

31

3HAC081697-001 Revision: A

© Copyright 2022-2023 ABB. All rights reserved.

1 Safety

1.6 Safety during operation

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Summary of Contents for OmniCore V400XT

Page 1: ...ROBOTICS Product manual OmniCore V400XT...

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

Page 3: ...Product manual OmniCore V400XT OmniCore Document ID 3HAC081697 001 Revision A Copyright 2022 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: ...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 inst...

Page 6: ...ent of air filter 171 4 5 Function tests 171 4 5 1 Function test of emergency stop 172 4 5 2 Function test of manual auto and manual full speed mode with FlexPendant 173 4 5 3 Function test of three p...

Page 7: ...n 343 7 Troubleshooting 343 7 1 Introduction to troubleshooting 345 7 2 Troubleshooting fault symptoms 346 7 2 1 No LEDs are lit on the controller 349 7 2 2 Start up failure 352 7 2 3 System update fa...

Page 8: ...onnection parts 437 9 1 3 Logic parts 440 9 1 4 Application parts 444 9 1 5 Cabinet parts 448 9 1 6 Miscellaneous parts 453 9 1 7 Cables 455 9 2 FlexPendant parts 456 9 3 Manipulator cables 456 9 3 1...

Page 9: ...or to provide 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 maintena...

Page 10: ...5041 001 Technical reference manual System parameters 3HAC066559 001 Application manual Functional safety and SafeMove 3HAC028879 001 Application manual Connected Services 3HAC066561 001 Application m...

Page 11: ...eshooting 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 Re...

Page 12: ...g of the products The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 12 Product manual OmniCore V40...

Page 13: ...en the safety devices are defective not in their intended location or in any other way not working When instructions for operation and maintenance are not followed as intended Non authorized design mo...

Page 14: ...d application 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 th...

Page 15: ...of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot The plant liable must make sure that the personnel is trained on the robot an...

Page 16: ...ll result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentiall...

Page 17: ...indicate where to find additional information or how to do an operation in an easier way TIP Product manual OmniCore V400XT 17 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 1...

Page 18: ...y only 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 a...

Page 19: ...ng cable 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 i...

Page 20: ...SRRC label for 3G only for Chinese market OmniCore XXX OmniCore XXX 3G LTD XXXXXXXXXXX xx2300001441 SRRC label for 4G only for Chinese market xx2300001824 20 Product manual OmniCore V400XT 3HAC081697...

Page 21: ...nitiate 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 se...

Page 22: ...safety 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 Visua...

Page 23: ...ly possible 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...

Page 24: ...ed The 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 cont...

Page 25: ...ing 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 th...

Page 26: ...pressed 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...

Page 27: ...ad start 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 configur...

Page 28: ...ct caused by a breaking or malfunctioning rotating tool or other device fitted to the robot The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in...

Page 29: ...isher 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...

Page 30: ...ions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level 30 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright...

Page 31: ...tor 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 syst...

Page 32: ...rated conditions the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside There is a hazard in case of abuse mechanical thermal electrical which leads...

Page 33: ...me DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers A risk assessment must be done to address both robot and robot syst...

Page 34: ...g on page 339 If the robot is decommissioned for storage take extra precaution to reset safety devices to delivery status 34 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 202...

Page 35: ...bility covering a wide range robot and applications V line supports external axis and provides flexible configuration opportunities The OmniCore V400XT controller offers a compact yet flexible solutio...

Page 36: ...ed in industrial environment T43 T42 T44 T41 T5 T6 A1 T4 T46 X1 X7 PE0 X8 X0 X2 X3 X81 X91 X92 T45 xx2300001955 Continues on next page 36 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyr...

Page 37: ...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 External fan Ba...

Page 38: ...5 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 Option T6 T9 ODVA power supply Option Air filter Option X0 I...

Page 39: ...41 F Minimum ambient temperature 45 C 113 F Maximum ambient temperature 2 000 m Maximum ambient altitude In accordance with ETSI EN 300 019 2 3 Environmental class 3 5 3M5 Shock and Vibration Random...

Page 40: ...ise level Note Description Data Controller in Motors On Mode 64 4 dB A Leq The sound pressure level one meter away from each surface of the controller Airborne noise level Controller in Standby Mode 5...

Page 41: ...0 VAC 3 phase IRB 6720 3x32 A 380 VAC 480 VAC 3 phase IRB 6730 3x32 A 380 VAC 480 VAC 3 phase IRB 6740 3x32 A 380 VAC 480 VAC 3 phase IRB 7600 Note For details about installations according to UL requ...

Page 42: ...7 The controller drive system shall only be used with specified manipulator variant The following table shows the mapping list Drive system type Controller Manipulator E4 OmniCore V400XT IRB 2600 E5 E...

Page 43: ...abling device on the FlexPendant 8 58E 08 Mirror emergency stop state of the robot through emergency status output of the controller 3 87E 07 Emergency stop function of the robot initiated by external...

Page 44: ...and still supervision Related information Safety data on page 14 The SISTEMA ABB FSDT libraries contain details for the safety functions 44 Product manual OmniCore V400XT 3HAC081697 001 Revision A Cop...

Page 45: ...one of the following alternatives Use a wrist strap The wrist strap button is located inside the controller Wrist straps must be tested frequently to ensure that they are not damaged and are operatin...

Page 46: ...ist strap button is shown in the following illustration xx2300001842 46 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 2 Controller description 2...

Page 47: ...r scrubbing sponges See the product manual for the robot controller section Cleaning the FlexPendant Always close the protective cap on the USB port when no USB device is connected The port can break...

Page 48: ...application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches...

Page 49: ...er 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...

Page 50: ...ata 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 A...

Page 51: ...ority 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...

Page 52: ...nts 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...

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: ...tective earth to the controller on page 83 Connect incoming mains to the controller 8 Connector X14 Connect safeguards to the controller 9 How to connect industrial networks for example PROFINET is de...

Page 55: ...page 38 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 s...

Page 56: ...handle the weight of the controller 5 If the controller is not installed directly it must be stored as described in Transportation and storage conditions on page 39 6 Make sure that the expected oper...

Page 57: ...controller For storing see Transportation and storage conditions on page 39 Product manual OmniCore V400XT 57 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 3 Installation and c...

Page 58: ...ller Min 300 mm Min 150 mm xx2300001776 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: ...tivities 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 V400XT 59 3HAC081697 00...

Page 60: ...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 ca...

Page 61: ...n page 424 Standard toolkit 3HAC079278 001 Flexpendant Holder 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 Mountin...

Page 62: ...er 2 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 Contin...

Page 63: ...e this 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 Remov...

Page 64: ...equipment 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 br...

Page 65: ...screws 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 p...

Page 66: ...02358 Use two M5 screws to secure the holder 6 66 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 3 Installation and commissioning 3 4 3 Mounting t...

Page 67: ...ons 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 tha...

Page 68: ...the Connec ted Services gateway by rotating the connector 4 xx2300000672 68 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 3 Installation and comm...

Page 69: ...age before connecting it to the controller Clean or replace any damaged parts Connectors The following details the connection interface on the OmniCore V400XT controller H E G F J I L M K D C B A xx23...

Page 70: ...connector H Ethernet outlet connector LAN3 I Ethernet outlet connector WAN J Cable grommet for Connected Services antenna 3G 4G WiFi K ADU additional drive unit connector 1 3 L ADU additional drive u...

Page 71: ...and analog I O Measurement signals This class covers ordinary analogue signals such as analogue sig nals 4 20 mA 0 10V or signals below 1 MHz low speed digital signals RS232 RS485 digital on off sign...

Page 72: ...Multi 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...

Page 73: ...de of the controller cabinet Cables should not be wound up like coils This could cause an magnetic field disturbing the signals There will also be a risk of overheating depending on the load Power sig...

Page 74: ...ielding 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...

Page 75: ...ew 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...

Page 76: ...all 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...

Page 77: ...es that control them 0 V 24 V DC 1 2 3 0 V 24 V AC DC xx1200000961 1 The diode should be dimensioned for the same current as the relay coil and a voltage of twice the supply voltage 2 The varistor sho...

Page 78: ...owing 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 tra...

Page 79: ...tion 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 Seco...

Page 80: ...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 81: ...mains connection to the OmniCore V400XT 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 82: ...ctive 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...

Page 83: ...t protection 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...

Page 84: ...abinet 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 fo...

Page 85: ...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 xx2100001259 C...

Page 86: ...he 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 CAUT...

Page 87: ...tic mode Use the following procedure to detach the FlexPendant in automatic mode 1 On the status bar tap the QuickSet button Continues on next page Product manual OmniCore V400XT 87 3HAC081697 001 Rev...

Page 88: ...h A popup window with 30 seconds countdown timer is displayed xx1900000404 5 When the countdown is progressing detach the FlexPendant Continues on next page 88 Product manual OmniCore V400XT 3HAC08169...

Page 89: ...exPendant 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 xx19...

Page 90: ...ime 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 Co...

Page 91: ...me Pin 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 90...

Page 92: ...ector 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 Descriptio...

Page 93: ...I A1 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 Conne...

Page 94: ...t WAN1 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 ne...

Page 95: ..._TPU 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...

Page 96: ...CH2_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...

Page 97: ...wered 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...

Page 98: ...top 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 E...

Page 99: ...Safety 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...

Page 100: ...ered 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_C...

Page 101: ...l be 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...

Page 102: ...u on 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 insta...

Page 103: ...ough 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 typ...

Page 104: ...ls 24 V and 0 V for the outputs and 0 V for the inputs For connection details see Circuit diagram OmniCore V400XT 3HAC082020 008 and Application manual Scalable I O 3HAC070208 001 Continues on next pa...

Page 105: ...er of 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 re...

Page 106: ...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 the di...

Page 107: ...on 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 cont...

Page 108: ...ontroller is required Tip See also the circuit diagram Circuit diagram OmniCore V400XT Apply the configuration to the controller Note illustration Action xx1500000801 In the Visual SafeMove ribbon cli...

Page 109: ...and 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 Flex...

Page 110: ...f these 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 instru...

Page 111: ...may 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...

Page 112: ...e robot 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 distan...

Page 113: ...lable 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 boar...

Page 114: ...e manual 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 En...

Page 115: ...vice 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 sca...

Page 116: ...ling configuring and using the scalable I O units see Application manual Scalable I O Required parts Note Article number Part DSQC1030 3HAC058663 001 Local I O Digital base 3032 1 3HAC060919 001 Conne...

Page 117: ...ual Scalable I O Installing the scalable I O internal base device Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrica...

Page 118: ...ation in section The unit is sensitive to ESD on page 45 2 Prepare the scalable I O units for external mounting as described in Application manual Scalable I O 3 Opening the door on page 182 Open the...

Page 119: ...an be out of date See the latest spare parts of the OmniCore V400XT via myABB Business Portal www abb com myABB Note Article number Spare part DSQC1042 3HAC062908 001 DSQC1042 Extended safety 3HAC0695...

Page 120: ...on Action 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...

Page 121: ...s not installed connect and discon nect the connector 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...

Page 122: ...location of the Ethernet extension switch in the controller xx2200001091 Continues on next page 122 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserve...

Page 123: ...for controller on page 424 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC082020 008 Circuit diagram OmniCore V400XT Installing the Ethernet extension s...

Page 124: ...rk 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 sensitive to ESD Before...

Page 125: ...on the main computer xx1800000972 3 Reconnect any connectors disconnected at removal 4 Concluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function...

Page 126: ...pped 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...

Page 127: ...when the DC BUS High Voltage LED is on There is residual voltage in the drive unit even if the main switch is in the OFF position Continues on next page Product manual OmniCore V400XT 127 3HAC081697 0...

Page 128: ...ard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC082020 008 Circuit diagram OmniCore V400XT Installing the additional drive unit Preparations Note Illustration...

Page 129: ...k 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 sensitive to ESD Before h...

Page 130: ...X4 T4 X3 A1 X12 T4 X1 A1 X5 4 Concluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly se...

Page 131: ...Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the OmniCore V400XT via myABB Business Portal www abb com myABB Continues on next page Produc...

Page 132: ...OmniCore V400XT Installing the optional power supply Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrica...

Page 133: ...wer supply to the bracket and secure the power supply with the attached screw For DSQC 634 Hang the power supply to the bracket and push the lower part until you hear a clear clicking sound 1 Screws C...

Page 134: ...24VTerminal block T6 X2 24VTerminal block T9 X2 24VTerminal block 3 Concluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify th...

Page 135: ...arts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the OmniCore V400XT via myABB Business Portal www abb com myABB Note Article number Spare...

Page 136: ...efore 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 sensit...

Page 137: ...as required 6 Closing the door on page 183 Close the door 7 Perform the function tests to verify that the safety features work properly see Function tests on page 171 8 For more information about the...

Page 138: ...in the table can be out of date See the latest spare parts of the OmniCore V400XT via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC066396 001 Cable grommet asm Required...

Page 139: ...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 xx2300001842 Removing the slot cover baseline Note Illustration...

Page 140: ...to the open side of the frame half flat sides pointing upwards Note The fl at side of the grommets in the up per row have to point downwards so that all flat sides rest on each other When using single...

Page 141: ...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 V400XT 141 3HAC081697 001 Revision A Copyr...

Page 142: ...ect 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 sa...

Page 143: ...rocedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2 Product man...

Page 144: ...hows the location of the air filter on the controller xx2300001800 Continues on next page 144 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 3 Ins...

Page 145: ...ined in section Standard toolkit for controller on page 424 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC082020 008 Circuit diagram OmniCore V400XT In...

Page 146: ...rm the function tests to verify that the safety features work properly see Function tests on page 171 4 146 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights...

Page 147: ...location of the incoming mains cable gland in the controller xx2100002285 Continues on next page Product manual OmniCore V400XT 147 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserv...

Page 148: ...oolkit ESD protective wrist band Required documents Note Article number Document 3HAC082020 008 Circuit diagram OmniCore V400XT Continues on next page 148 Product manual OmniCore V400XT 3HAC081697 001...

Page 149: ...6 Remove 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...

Page 150: ...2100002287 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 S...

Page 151: ...niCore V400XT 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 152: ...tton 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 xx2300001842 Installing the Dev...

Page 153: ...Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2 Product manual OmniCore V400XT 153 3HAC081697...

Page 154: ...0XT 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 Note...

Page 155: ...x to 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 V400XT 155 3H...

Page 156: ...850 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 171 10 156 Product man...

Page 157: ...allowed 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 V400XT 157 3H...

Page 158: ...incoming mains and protective earth to the controller on page 83 Function tests Before commissioning perform the function tests in section Function tests on page 171 to verify that the safety features...

Page 159: ...Manual auto and manual full speed mode with FlexPend ant Function test of three position en abling device on page 173 12 months Function test Enabling device Function test of Automatic Stop on page 17...

Page 160: ...ing the unit read the safety inform ation in section The unit is sensitive to ESD on page 45 2 xx2300001842 Inspect connectors and cabling to make sure they are securely fastened and cabling not damag...

Page 161: ...Location The air filter is located as shown in the illustration below xx2300001800 Continues on next page Product manual OmniCore V400XT 161 3HAC081697 001 Revision A Copyright 2022 2023 ABB All right...

Page 162: ...nt 2 Clean the filter three or four times 3 Note Do not wring the filter to press out water Allow the filter to dry in one of these ways Lying flat on a flat surface Blow with compressed air in opposi...

Page 163: ...r cannot be separated from the filter assembly Note Illustration Action xx2300001802 Remove the air filter unit 1 Clean the metal mesh filter with compressed air 2 Refit the air filter unit to the cab...

Page 164: ...orten 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 device...

Page 165: ...sing 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 Flex...

Page 166: ...eaner Do not clean the device operating panel and operating elements with compressed air solvents scouring agent or scrubbing sponges 166 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyr...

Page 167: ...r Location The air filter unit is located as shown in the illustration below xx2300001800 Continues on next page Product manual OmniCore V400XT 167 3HAC081697 001 Revision A Copyright 2022 2023 ABB Al...

Page 168: ...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 Removing the air filter Note Il...

Page 169: ...nt option 3005 2 Moist dust filter Note Illustration Action xx2100002583 Insert the polymeric filter element to the filter and secure with the metallic line 1 Refitting the air filter Note Illustratio...

Page 170: ...function tests to verify that the safety features work properly see Function tests on page 171 1 170 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserve...

Page 171: ...e event 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 f...

Page 172: ...e found This test is passed if it is possible to run the robot program in manual mode Change to Manual operating mode and Motors ON state and then run the robot in manual mode 3 If it is not possible...

Page 173: ...if the 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...

Page 174: ...brake function test Note Action Start the robot system and change the op erating mode to manual 1 This test is passed if the brakes are disen gaged and the manipulator can be moved Press the three po...

Page 175: ...y opening 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 m...

Page 176: ...the 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...

Page 177: ...button 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 dev...

Page 178: ...e test 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...

Page 179: ...speed higher than 250 mm s 2 This test is passed if the speed of the robot does not exceed 250 mm s otherwise the test is failed and the root cause of the fail ure must be found Start the program in...

Page 180: ...This page is intentionally left blank...

Page 181: ...form 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 p...

Page 182: ...tration 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 the k...

Page 183: ...n Action 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 T...

Page 184: ...controller 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...

Page 185: ...he unit is sensitive to ESD on page 45 2 xx2300001842 Refitting the rear cover Info illustration Action Refit the the rear cover 1 xx2200001062 Secure it with the screws 2 xx2200001773 Refit the air f...

Page 186: ...illustration shows the location of the fans in the controller xx2200001086 Continues on next page 186 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reser...

Page 187: ...an 3HAC083027 001 Fan unit Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 424 Standard toolkit ESD protective wrist ba...

Page 188: ...s Location The illustration shows the location of the external fan in the controller xx2200001086 Continues on next page 188 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 202...

Page 189: ...m ation in section The unit is sensitive to ESD on page 45 2 xx2300001842 Removing the rear cover on page 184 Remove the rear cover of the controller 3 Removing the external fans Note Illustration Act...

Page 190: ...ains 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 info...

Page 191: ...ncluding procedure Note Illustration Action Refitting the rear cover on page 185 Refit the rear cover of the controller 1 Make sure that the filter cover plate is correctly positioned 2 Perform the fu...

Page 192: ...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 Opening the door on page 182 Open the door 2...

Page 193: ...tration 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...

Page 194: ...ore 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 sect...

Page 195: ...s sembly 5 Reconnect any connectors disconnected at removal 6 Concluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the...

Page 196: ...V400XT 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 197: ...182 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ES...

Page 198: ...01090 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 inform...

Page 199: ...screws 3 Screws Torx T10 6 pcs Tightening torque 0 7 Nm Concluding procedure Note Illustration Action Refitting the Connected Services gateway on page 213 If necessary refit the Connected Ser vices ga...

Page 200: ...hat are listed in the table can be out of date See the latest spare parts of the OmniCore V400XT via myABB Business Portal www abb com myABB Note Article number Spare part Power unit fan 3HAC081496 00...

Page 201: ...ical safety on page 29 1 Opening the door on page 182 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 i...

Page 202: ...1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 45 2 xx...

Page 203: ...on Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2 Product manual OmniCore V400XT 203 3HAC081...

Page 204: ...tration shows the location of the Ethernet switch in the controller xx2200001091 Continues on next page 204 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights...

Page 205: ...d toolkit for controller on page 424 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC082020 008 Circuit diagram OmniCore V400XT Removing the Ethernet ext...

Page 206: ...ng the Ethernet extension switch option Note Illustration Action Disconnect all connectors from the unit to be replaced 1 xx2300001835 Carefully pull the side of the Ethernet extension switch and rota...

Page 207: ...ction The unit is sensitive to ESD on page 45 2 xx2300001842 xx2300001835 Hook up the Ethernet extension switch to the bracket and then push the switch into position Note During the installation there...

Page 208: ...door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2 208 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB...

Page 209: ...Connected Services gateway in the controller For the 3G variant there is a sim card inside the unit xx2300001641 Continues on next page Product manual OmniCore V400XT 209 3HAC081697 001 Revision A Co...

Page 210: ...t Note Article number Equipment Content is defined in section Standard toolkit for controller on page 424 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HA...

Page 211: ...the customer and the cable routing can therefore differ Record the cable routing when you re move the antenna cable from the cabinet 1 xx2300001642 Disconnect the antenna cable from the Connected Serv...

Page 212: ...de of the Connected Services gateway and rotate it tightly to take it out from the bracket 2 Removing the sim card Note Illustration Action xx1900000971 Remove the attachment screws and pull out the f...

Page 213: ...front cover of the Connected Services 3G and secure the screws 2 Refitting the Connected Services gateway Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains...

Page 214: ...erating conditions must be such 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...

Page 215: ...o the Connec ted Services gateway by rotating the connector 5 Concluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the...

Page 216: ...T via myABB Business Portal www abb com myABB Note Article number Spare part DSQC1093 3HAC086677 001 Connected Services 4G EU 3013 5 DSQC1093A 3HAC086678 001 Connected Services 4G US 3013 6 3HAC086604...

Page 217: ...d Services gateway 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...

Page 218: ...72 Disconnect the antenna cable from the Connected Services gateway by rotating the connector 2 Remove any cable ties and protection 3 xx2200001973 Pull the cable out through the cable grommet 4 Remov...

Page 219: ...gateway Wire K7 W202 from the 0V V connection on the Connected Services gateway 2 Note Press down the white button with a sharp object while pulling out the wire Carefully lift the Connected Services...

Page 220: ...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 xx2300000673 Hook up the Connected Services gate...

Page 221: ...uch 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 Servic...

Page 222: ...o the Connec ted Services gateway by rotating the connector 5 Concluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the...

Page 223: ...ortal www abb com myABB Note Article number Spare part DSQC1030 3HAC058663 001 Local I O Digital base 3032 1 3HAC060919 001 Connectors digital base add on DSQC1031 3HAC058664 001 Digital add on 3033 2...

Page 224: ...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 182 Open the door 2 Location of wrist strap button ELECTRO...

Page 225: ...connect 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 th...

Page 226: ...4 Concluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 17...

Page 227: ...the table can be out of date See the latest spare parts of the OmniCore V400XT via myABB Business Portal www abb com myABB Note Article number Spare part DSQC1042 3HAC062908 001 DSQC1042 Extended saf...

Page 228: ...For more information see Electrical safety on page 29 1 Opening the door on page 182 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before hand...

Page 229: ...ect 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 sa...

Page 230: ...ncluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2 2...

Page 231: ...are listed in the table can be out of date See the latest spare parts of the OmniCore V400XT via myABB Business Portal www abb com myABB Note Article number Spare part DSQC1095 3HAC085504 001 Main com...

Page 232: ...re information see Electrical safety on page 29 1 Opening the door on page 182 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling t...

Page 233: ...r more information see Electrical safety on page 29 1 ELECTROSTATIC DISCHARGE ESD The unit must be maintained in an ESD safe environment 2 xx2200001089 Refit the assembly onto the mounting plate and t...

Page 234: ...number must be restored as described below Licences however can either be restored automatically when the RobotWare system is installed or manually through Manage Licences in RobotWare Installation Ut...

Page 235: ...ares the downloaded file and the manually entered serial number to ensure that there is a match Tap Browse to open the hardware inform ation file from its location The restoration of the serial number...

Page 236: ...Note 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 4...

Page 237: ...ectrical safety on page 29 1 Opening the door on page 182 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safe...

Page 238: ...he pro cessor board unit DSQC1086 1 Remove the processor board unit from the slot in the main computer assembly 2 Continues on next page 238 Product manual OmniCore V400XT 3HAC081697 001 Revision A Co...

Page 239: ...e information see Electrical safety on page 29 1 xx2300001842 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sens...

Page 240: ...o cessor board unit 1 xx2300000941 Insert the processor board unit into the slot in the main computer assembly 2 Continues on next page 240 Product manual OmniCore V400XT 3HAC081697 001 Revision A Cop...

Page 241: ...on Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2 Product manual OmniCore V400XT 241 3HAC081...

Page 242: ...ING Do not touch the power unit when the DC BUS High Voltage LED is on There is residual voltage in the power unit even if the main switch is in the OFF position Continues on next page 242 Product man...

Page 243: ...tion Standard toolkit for controller on page 424 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC082020 008 Circuit diagram OmniCore V400XT Removing the...

Page 244: ...m the 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 th...

Page 245: ...inform ation in section The unit is sensitive to ESD on page 45 2 xx2300001842 Screws Torx pan head screw M4x8 4 pcs Position the power unit on the lower guiding pin on the mounting plate and then tip...

Page 246: ...se the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2 246 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2...

Page 247: ...t are listed in the table can be out of date See the latest spare parts of the OmniCore V400XT via myABB Business Portal www abb com myABB Note Article number Spare part DSQC3072 HVLP 3HAC066498 001 P...

Page 248: ...For more information see Electrical safety on page 29 1 Opening the door on page 182 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before hand...

Page 249: ...ion 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 un...

Page 250: ...m xx2300001492 Reconnect any connectors disconnected at removal 4 Concluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that...

Page 251: ...8 WARNING Do not touch the power supply when the DC OK LED is on There is residual voltage in the power supply even if the main switch is in the OFF position Continues on next page Product manual Omni...

Page 252: ...rticle number Equipment Content is defined in section Standard toolkit for controller on page 424 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC082020...

Page 253: ...01842 Removing the power supply Note Illustration Action xx1900001907 Remove the end clamp besides the power supply with a screwdriver 1 xx1900001908 Disconnect all connectors from the unit to be repl...

Page 254: ...Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 45 2 xx2300001842 Screws Cross recessed cheese head screw M4x8 1 pcs Fit the power supply to the b...

Page 255: ...unction tests on page 171 2 Removing the DSQC 634 power supply Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see...

Page 256: ...ng the power supply Note Illustration Action xx1900002443 Remove the end clamp besides the power supply with a screwdriver 1 xx1900001950 Disconnect all connectors from the unit to be replaced 2 Press...

Page 257: ...s sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 45 2 xx2300001842 xx1900001950 Hang the power supply into the bracket and push...

Page 258: ...n Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2 258 Product manual OmniCore V400XT 3...

Page 259: ...ING Do not touch the drive unit when the DC BUS High Voltage LED is on There is residual voltage in the drive unit even if the main switch is in the OFF position Continues on next page Product manual...

Page 260: ...38 001 Harness CTRL_FB Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 424 Standard toolkit ESD protective wrist band R...

Page 261: ...ed 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...

Page 262: ...inform ation in section The unit is sensitive to ESD on page 45 2 xx2300001842 Screws Torx pan head screw M4x8 4 pcs Position the drive unit on the lower guid ing pin on the mounting plate and then ti...

Page 263: ...se the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2 Product manual OmniCore V400XT 263 3HAC081697 001 Revision A Copyright 2022 2...

Page 264: ...WARNING Do not touch the drive unit when the DC BUS High Voltage LED is on There is residual voltage in the drive unit even if the main switch is in the OFF position Continues on next page 264 Produc...

Page 265: ...ge 424 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC082020 008 Circuit diagram OmniCore V400XT Removing the additional drive unit Preparations Note Il...

Page 266: ...ng out to have as a reference when refitting the cable ties 1 Disconnect all connectors from the unit to be replaced 2 Lengthened screwdriver Remove the screws and pull the drive unit out from the two...

Page 267: ...nsitive to ESD on page 45 2 xx2300001842 Screws Torx pan head screw M4x8 4 pcs Refit the additional drive unit and secure with the screws 3 Tightening torque 2 Nm xx2200001375 Reconnect any connectors...

Page 268: ...ts of the OmniCore V400XT 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 269: ...For more information see Electrical safety on page 29 1 Opening the door on page 182 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before hand...

Page 270: ...isconnect the mains power For more information see Electrical safety on page 29 1 Opening the door on page 182 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is se...

Page 271: ...eNet board unit 2 Concluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly see Function t...

Page 272: ...parts of the OmniCore V400XT via myABB Business Portal www abb com myABB Note Article number Spare part DSQC2000 3HNA027579 001 Conveyor tracking module 3103 1 3HNA029345 001 CONNECTOR KIT DSQC2000 P...

Page 273: ...connect the mains power For more information see Electrical safety on page 29 1 Opening the door on page 182 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sens...

Page 274: ...s sembling work 2 xx1900001913 Refitting the conveyor tracking module option Refitting the conveyor tracking module option Note Illustration Action DANGER Before doing any work inside the cabinet disc...

Page 275: ...age 45 2 xx2300001842 xx1900001913 Hang the conveyor tracking module into the bracket and push the lower of it until you hear a clear clicking sound 3 xx2200001844 Reconnect any connectors disconnecte...

Page 276: ...stration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2 276 Product manual OmniCore V...

Page 277: ...lustration shows the location of the air filter on the controller xx2300001800 Continues on next page Product manual OmniCore V400XT 277 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights re...

Page 278: ...Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 424 Standard toolkit ESD protective wrist band Required documents Note...

Page 279: ...ails how to remove the polymeric filter element option 3005 2 Moist dust filter Note Illustration Action xx2100002583 Take out the polymeric filter element from the filter 1 Continues on next page Pro...

Page 280: ...er 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 Refit the air filter unit to the cabinet...

Page 281: ...are 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 V400XT via myABB Business Portal www abb com myABB Continues on next pa...

Page 282: ...t 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 safe...

Page 283: ...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 Product manual OmniCor...

Page 284: ...rap 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 xx2300001842 xx2200001074...

Page 285: ...efitting the rear cover on page 185 Refit the rear cover of the controller 1 Closing the door on page 183 Close the door 2 Perform the function tests to verify that the safety features work properly s...

Page 286: ...MB 3HAC081735 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 Not...

Page 287: ...d the safety inform ation in section The unit is sensitive to ESD on page 45 3 xx2300001842 Removing the manipulator signal connector Note Illustration Action Disconnect all connectors from the unit t...

Page 288: ...manipulator 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 xx2100000827 Reconnect a...

Page 289: ...ABB Note 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...

Page 290: ...on 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 xx230000184...

Page 291: ...d to 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 cab...

Page 292: ...inet and fasten it with the screws 3 Tightening torque 2 7 Nm 10 xx2100000813 Reconnect any connectors disconnected at removal 4 Secure the motor connector cables with the velcro on the frame of the c...

Page 293: ...sts to verify that the safety features work properly see Function tests on page 171 2 Product manual OmniCore V400XT 293 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 5 Repair...

Page 294: ...ation shows the location of the HMI signal connector in the controller xx2300001845 Continues on next page 294 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All righ...

Page 295: ...page 424 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC082020 008 Circuit diagram OmniCore V400XT Removing the HMI signal connector Preparations Note...

Page 296: ...ustration Action Cut the cable ties and 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 th...

Page 297: ...screws 3 xx2300001847 Remove the cover plate 4 Continues on next page Product manual OmniCore V400XT 297 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 5 Repair 5 3 3 Replacing...

Page 298: ...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...

Page 299: ...ct 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 xx2300001847 Refit the...

Page 300: ...te Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2 300 Product manual Omn...

Page 301: ...le can be out of date See the latest spare parts of the OmniCore V400XT via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC066396 001 Cable grommet asm 3HAC084125 001 Harne...

Page 302: ...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 xx2300001842 Removing t...

Page 303: ...t assembly out 4 Releasing the cables from the cable grommet assembly Note Illustration Action xx1900002332 Unscrew the cable entry frame from the enclosure wall 1 Continues on next page Product manua...

Page 304: ...2334 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 304 Product manual OmniCore V400XT 3HAC081697 001...

Page 305: ...e the grommets in the upper row first and then the second row 5 xx1900002337 Remove the cable form the correspond ing KT grommet 6 Continues on next page Product manual OmniCore V400XT 305 3HAC081697...

Page 306: ...e point ing to the open side of the frame half flat sides pointing upwards Note The fl at side of the grommets in the up per row have to point downwards so that all flat sides rest on each other When...

Page 307: ...cover strip with the screws 4 Tightening torque 2 Nm 3 Nm xx1900002334 xx1900002333 Route the cables through the cut out 5 Continues on next page Product manual OmniCore V400XT 307 3HAC081697 001 Revi...

Page 308: ...inet 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...

Page 309: ...Concluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 171 2...

Page 310: ...ration shows the location of the Ethernet outlet connector with cable xx2300001848 Continues on next page 310 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All right...

Page 311: ...toolkit ESD protective wrist band Required documents Note Article number Document 3HAC082020 008 Circuit diagram OmniCore V400XT Removing the Ethernet outlet connector with cable Preparations Note Ill...

Page 312: ...ction The unit is sensitive to ESD on page 45 3 xx2300001842 Removing the Ethernet outlet connector with cable Note Illustration Action xx2100000850 Remove the screws 1 Continues on next page 312 Prod...

Page 313: ...crews on the door 3 xx2100000852 Turn the locking ring anti clockwise to remove the connector 4 Continues on next page Product manual OmniCore V400XT 313 3HAC081697 001 Revision A Copyright 2022 2023...

Page 314: ...he Ethernet outlet connector with cable Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 29 1 ELEC...

Page 315: ...from removing the harness ETH outlet with cable 6 Concluding procedure Note Illustration Action Closing the door on page 183 Close the door 1 Perform the function tests to verify that the safety featu...

Page 316: ...The illustration shows the location of the LED indicator xx2300001849 Continues on next page 316 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 5...

Page 317: ...on page 424 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC082020 008 Circuit diagram OmniCore V400XT Removing the LED indicator Preparations Note Illus...

Page 318: ...ving the LED indicator Note Illustration Action xx1900001926 Loose the attachment screws locking the cable 1 Remove the terminals X1 X2 of the cable from the lamp 2 Turn the MON_LAMP screw anti clock...

Page 319: ...2 Insert the LED indicator into the cover from outer side of the door and the screw from inner side and screw them up 3 xx1900001926 Insert the terminals X1 X2 of cables into the lamp and secure with...

Page 320: ...table can be out of date See the latest spare parts of the OmniCore V400XT via myABB Business Portal www abb com myABB Note Article number Spare part Harness TPU 3HAC071006 001 Harness TPU connection...

Page 321: ...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 scre...

Page 322: ...stration 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 pa...

Page 323: ...pcs 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 171 5 Product manual OmniCo...

Page 324: ...Portal www abb com myABB Note Article number Spare part 3HAC065408 001 Joystick guard Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for con...

Page 325: ...emove 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 h...

Page 326: ...ick protection 2 xx1800001206 Secure the screws 3 Countersunk head screw ST2 9 X 10 6 pcs 326 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 5 Rep...

Page 327: ...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 328: ...uipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 424 Standard toolkit ESD protective wrist band Required documents Note Article number Docume...

Page 329: ...e Electrical 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 171 3 Product...

Page 330: ...niCore V400XT 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 331: ...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 disconn...

Page 332: ...it to 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 pla...

Page 333: ...t the 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...

Page 334: ...the function tests to verify that the safety features work properly see Function tests on page 171 6 334 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights re...

Page 335: ...he OmniCore V400XT 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 336: ...move 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 Illus...

Page 337: ...unction tests to verify that the safety features work properly see Function tests on page 171 4 Product manual OmniCore V400XT 337 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved...

Page 338: ...This page is intentionally left blank...

Page 339: ...r nature which is all iron together and all plastic together and disposed of accordingly These parts must also be disposed of in accordance with the current legislation of the country in which the rob...

Page 340: ...see 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 accordi...

Page 341: ...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 342: ...This page is intentionally left blank...

Page 343: ...vide 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...

Page 344: ...Check 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 recen...

Page 345: ...rakes on page 353 Problem starting or connecting the FlexPendant on page 356 Problem using the joystick on page 360 Controller fails to start on page 361 Reflashing firmware failure on page 362 Incons...

Page 346: ...heck 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 pro...

Page 347: ...on X0 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 T...

Page 348: ...re details see Circuit diagram OmniCore V400XT 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 close...

Page 349: ...ircuit diagram OmniCore V400XT 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 Tro...

Page 350: ...LED Module status should be green If not see Troubleshooting the power unit on page 381 If the power unit is ok check that incoming mains is well connected and that the in coming mains switch is turn...

Page 351: ...D HMI are not green troubleshoot the main computer See Troubleshooting the main computer on page 414 Check LEDs PC Power distribution board DSQC1085 and HMI Safety board DSQC1087 5 If the drive unit s...

Page 352: ...nges in the system on page 352 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 sys...

Page 353: ...r 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 erro...

Page 354: ...onnec 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...

Page 355: ...ls see Circuit diagram OmniCore V400XT 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 motor connector...

Page 356: ...he main interface xx1900000917 Required test equipment Equipment needed for troubleshooting Note Equipment Multimeter Insulating gloves 3HAC082020 008 Circuit diagram OmniCore V400XT Preparations Acti...

Page 357: ...ure 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...

Page 358: ...ection 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 n...

Page 359: ...ble 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 t...

Page 360: ...at 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 rep...

Page 361: ...rom 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...

Page 362: ...lem 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 softwa...

Page 363: ...n Remove the obstacles Study the path of the robot in motion to find if an external force for example an external cable package is colliding with or restricting the movement of the robot 1 Improve the...

Page 364: ...in section Problem re leasing the robot brakes on page 353 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...

Page 365: ...malfunctioning fans see Replacing the external fans on page 188 Check that the external fans are working 1 Replace malfunctioning fans see Replacing the internal fan on page 192 Check that the intern...

Page 366: ...itional drive unit Troubleshooting the power unit on page 381 Power unit Troubleshooting fieldbuses and I O on page 394 Scalable I O Troubleshooting the 3G Connected Services gateway on page 395 3G Co...

Page 367: ...using the FlexPend ant If the FlexPendant is not responding or does not operate correctly see Problem starting or con necting the FlexPendant on page 356 2 Check the cable for connections and integri...

Page 368: ...ation shows the location of the drive unit in the controller xx2300001794 Continues on next page 368 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserve...

Page 369: ...for 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...

Page 370: ...ellow flashing 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 Requir...

Page 371: ...ion 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 wi...

Page 372: ...he 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 259 If the measured voltag...

Page 373: ...ed Proceed 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 X1...

Page 374: ...ation shows the location of the drive unit in the controller xx2300001799 Continues on next page 374 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserve...

Page 375: ...ADU3 ADU2 ADU1 MDU Power Unit 1 2 3 8 7 6 4 5 xx2200000702 See also Application manual Additional axes for OmniCore 3HAC082287 001 Continues on next page Product manual OmniCore V400XT 375 3HAC081697...

Page 376: ...EDs on the additional drive unit xx2200001052 Continues on next page 376 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 7 Troubleshooting 7 3 4 Tr...

Page 377: ...tivity 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 OP...

Page 378: ...low 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 Reconnect Eth...

Page 379: ...ge 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 communi...

Page 380: ...ed 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 communicatio...

Page 381: ...on below shows the location of the power unit in the controller xx2300001797 Continues on next page Product manual OmniCore V400XT 381 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights rese...

Page 382: ...o color Voltage between DC DC 60 VDC Yellow Voltage between DC DC 60 VDC DC BUS High Voltage LED A Continues on next page 382 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 20...

Page 383: ...TIONAL Green 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...

Page 384: ...xPendant 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...

Page 385: ...AC pro 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 Mak...

Page 386: ...US 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 242 If the connection and cables seem OK proceed with s...

Page 387: ...is 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...

Page 388: ...on below shows the location of the power unit in the controller xx2300001804 Continues on next page 388 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights rese...

Page 389: ...Ds on the power unit xx2300001469 Continues on next page Product manual OmniCore V400XT 389 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 7 Troubleshooting 7 3 6 Troubleshootin...

Page 390: ...hing 1Hz Firmware 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 troubl...

Page 391: ...g procedure 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...

Page 392: ...fy 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_P...

Page 393: ...eder See Replacing the break resistor bleeder on page 281 Check the bleeder connection at X10 CAUTION Before measuring the bleeder res istance do the following Shut down the power and wait 1 minute Di...

Page 394: ...eshoot the fieldbuses and I O units can be found in the manual for the respective fieldbus or I O unit See References on page 10 394 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright...

Page 395: ...ows the location of the Connected Services gateway in the controller xx2300001641 Continues on next page Product manual OmniCore V400XT 395 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights...

Page 396: ...tify 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 replac...

Page 397: ...ss less 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...

Page 398: ...r with 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 conne...

Page 399: ...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 Check th...

Page 400: ...ty 12 How to replace the unit is described in Replacing the 3G Connected Services gateway on page 209 The Connected Services Gateway may be faulty replace it and verify that the problem is resolved 13...

Page 401: ...ows the location of the Connected Services gateway in the controller xx2300000248 Continues on next page Product manual OmniCore V400XT 401 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights...

Page 402: ...green 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 q...

Page 403: ...ge Green 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 o...

Page 404: ...shooting procedures 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...

Page 405: ...cted 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 replac...

Page 406: ...ser 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 406 Product manual OmniCo...

Page 407: ...log page on page 408 The log view displays all current logs Log view Troubleshoot the unit using the log page on page 408 Download a package with all logs archives and current status The logs can be s...

Page 408: ...s for 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...

Page 409: ...rify the following Verify that the WAN chain is online xx2300000640 Continues on next page Product manual OmniCore V400XT 409 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 7 Tr...

Page 410: ...profile 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 CAUTIO...

Page 411: ...d the 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 Prod...

Page 412: ...ion shows the location of the Ethernet switch in the controller xx2200001091 Continues on next page 412 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights rese...

Page 413: ...ng issues Status LED Fault indication No color If input voltage is within specified voltage limits and the LED is not lit then replace the switch Shows the status of Ethernet links Ethernet LEDs Green...

Page 414: ...er xx2200001088 LEDs The following sections display the LEDs on the main computer units Power distribution board DSQC1085 xx2300000434 Continues on next page 414 Product manual OmniCore V400XT 3HAC081...

Page 415: ...tializ 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...

Page 416: ...n Name 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 no...

Page 417: ...ED 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 Powe...

Page 418: ...NK 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 p...

Page 419: ...must 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 output...

Page 420: ...xx2100001077 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 d...

Page 421: ...includes general information complementing the more specific information in the different procedures in the manual Product manual OmniCore V400XT 421 3HAC081697 001 Revision A Copyright 2022 2023 ABB...

Page 422: ...pulating 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...

Page 423: ...in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume Product manual OmniCore V400XT 4...

Page 424: ...structions 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 Sc...

Page 425: ...y special torque specified overrides the standard value Use the correct tightening torque for each type of screw joint Only use correctly calibrated torque keys Always tighten the joint by hand and ne...

Page 426: ...ry 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 wei...

Page 427: ...lifting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories The instructions delivered with the lifting accessories should be...

Page 428: ...This page is intentionally left blank...

Page 429: ...ctions 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 a...

Page 430: ...emoved parts and spare parts must not be disassembled or opened Continues on next page 430 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rights reserved 9 Spare...

Page 431: ...level Type Description Spare part num ber L1 DSQC3062 Drive unit High Voltage 3HAC064590 001 A Continues on next page Product manual OmniCore V400XT 431 3HAC081697 001 Revision A Copyright 2022 2023 A...

Page 432: ...on Spare part num ber L1 DSQC3065 Drive unit 3HAC064983 001 Power units xx2300001784 Continues on next page 432 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 ABB All rig...

Page 433: ...SQC3072 Power unit 3HAC066498 001 HVLP Break resistor bleeder xx2200001092 Spare part level Type Description Spare part num ber L1 Break resistor bleeder assembly 3HAC081951 001 A Continues on next pa...

Page 434: ...n Spare part num ber L1 Ethernet Harness 3HAC084151 001 A Harness TPU connection xx1900001943 Continues on next page 434 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 2023 AB...

Page 435: ...arness 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...

Page 436: ...rouds 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 3...

Page 437: ...e part level Type Description Spare part num ber L1 Main computer Standard 3HAC085504 001 Continues on next page Product manual OmniCore V400XT 437 3HAC081697 001 Revision A Copyright 2022 2023 ABB Al...

Page 438: ...gateway 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...

Page 439: ...ected 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 roo...

Page 440: ...27579 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 pa...

Page 441: ...Power 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 442: ...l add on 3033 2 Add on 3HAC058664 001 B L1 DSQC1032 Analog add on 3034 2 Add on 3HAC058665 001 C L1 Connectors I O Analog Add on 3HAC060925 001 L1 DSQC1033 Relay add on 3035 2 Add on 3HAC058666 001 D...

Page 443: ...scription Spare part num ber L1 DSQC1042 Extended safety 3HAC062908 001 L1 Connectors Safety I O 3HAC069538 001 Product manual OmniCore V400XT 443 3HAC081697 001 Revision A Copyright 2022 2023 ABB All...

Page 444: ...um 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 444 Product manual OmniCore V400XT 3HAC081697 001 Revis...

Page 445: ...83 Spare 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 Product manual OmniC...

Page 446: ...art num ber L1 HMI panel 3HAC077425 001 Swing handle Spare part level Type Description Spare part num ber L1 Swinghandle with cam 3HAC078328 001 LED indicator xx1900002451 Spare part level Type Descri...

Page 447: ...x2200001826 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 Product manual OmniCore V400XT 447 3HAC0816...

Page 448: ...0 001 L1 Harness 2xSMB Harness SMB link 3HAC077388 001 L1 LV Harness SMB link 3HAC083231 001 L1 Harness 1xSMB Harness SMB link 3HAC086308 001 End clamp xx1900001940 Spare part level Type Description S...

Page 449: ...1 25 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...

Page 450: ...ion 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 o...

Page 451: ...3HAC078370 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 p...

Page 452: ...xtra cable jumpers 3HAC084243 001 Wrist band Spare part level Type Description Spare part number L1 Wrist band 3HAB2997 1 452 Product manual OmniCore V400XT 3HAC081697 001 Revision A Copyright 2022 20...

Page 453: ...X3 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...

Page 454: ...001 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...

Page 455: ...065401 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...

Page 456: ...20 6600 6700 6710 6720 6730 6740 L1 3HAC2493 1 Control cable signal 7 m IRB 460 660 760 2600 4600 5710 5720 6600 6700 6710 6720 6730 6740 L1 3HAC2530 1 Control cable signal 15 m IRB 460 660 760 2600 4...

Page 457: ...re part 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 Product manual OmniCore V400XT 457 3HAC081697...

Page 458: ...evel Article 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 458 Product manual Om...

Page 459: ...rticle number 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 Product manual Omni...

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Page 461: ...l 340 D damaged bearings 363 damaged parallel bar 363 detaching FlexPendant 86 DeviceNet 268 installing 152 dimensions 38 disconnecting FlexPendant 86 disposal of storage media 339 drive unit LED 369...

Page 462: ...ormal operation mode 361 O ODVA 420 ODVA power supply LED 420 open source software OSS 49 operating conditions 39 operating mode automatic mode 27 function test 172 manual full speed mode 25 manual mo...

Page 463: ...104 installing 116 replacing 223 scalable I O external 115 scalable I O internal 115 shipping 339 signals safety 16 sim card replacing 209 software licenses 49 standards 422 steel disposal 340 stop c...

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Page 466: ...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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