ABB OmniCore V250XT Product Manual Download

Page: 370 / 456

7.2.8 Reflashing firmware failure

Description

When reflashing firmware, the automatic process can fail which will stop the system.
A message is generated in the event log.

This fault usually occurs due to a lack of compatibility between hardware and
software.

Recommended working procedure

If the controller stops with a message about firmware failure, use this procedure
to troubleshoot what might cause the problem.

Note

Action

Read the message to see which unit has failed.

If the relevant unit has been replaced recently,
make sure that the versions of the old and the
new unit are identical.

Check the software versions.

If RobotWare has been updated recently, make
sure that the versions of the old and the new unit
are identical.

If the problem remains, contact your local ABB
for information about which firmware version is
compatible with your hardware.

370

Product manual - OmniCore V250XT

3HAC073447-001 Revision: B

7 Troubleshooting

7.2.8 Reflashing firmware failure

Summary of Contents for OmniCore V250XT

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

Page 2: ...Trace back information Workspace 22A version a10 Checked in 2022 03 02 Skribenta version 5 4 005 ...

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

Page 5: ... to ESD 45 2 5 Handling of FlexPendant 46 2 6 Network security 47 2 7 Open source and 3rd party components in RobotWare 48 2 8 ABB Ability 51 3 Installation and commissioning 51 3 1 Introduction to installation and commissioning 52 3 2 Installation activities 53 3 3 Transporting and handling 53 3 3 1 Lifting the controller cabinet 54 3 3 2 Unpacking 55 3 3 3 Storing 56 3 4 On site installation 56 ...

Page 6: ...ed mode with FlexPendant 168 4 5 3 Function test of three position enabling device 169 4 5 4 Function test of Automatic Stop 170 4 5 5 Function test of General Stop 171 4 5 6 Function test of external emergency stop 172 4 5 7 Function test of ESTOP_STATUS output 173 4 5 8 Function test of reduced speed control 175 5 Repair 175 5 1 Introduction to repair 176 5 2 Replacement of controller parts 176 ...

Page 7: ...he FlexPendant 368 7 2 6 Problem using the joystick 369 7 2 7 Controller fails to start 370 7 2 8 Reflashing firmware failure 371 7 2 9 Inconsistent path accuracy 373 7 2 10 Controller is overheated 374 7 3 Troubleshooting units 374 7 3 1 Troubleshooting LEDs in the controller 375 7 3 2 Troubleshooting the FlexPendant 376 7 3 3 Troubleshooting the drive unit 382 7 3 4 Troubleshooting the power uni...

Page 8: ...dant parts 447 9 3 Manipulator cables 447 9 3 1 Manipulator cables 448 9 3 2 Customer cables CP CS connectors option 449 9 3 3 Customer cables Ethernet floor cables 450 9 3 4 Customer cables DeviceNet cables 451 Index 8 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved Table of contents ...

Page 9: ... read this manual This manual is intended for installation personnel maintenance personnel repair personnel Prerequisites A maintenance repair installation craftsman working with an ABB robot must be trained by ABB and have the required knowledge of mechanical and electrical installation repair maintenance work be trained to respond to emergencies or abnormal situations Product manual scope The ma...

Page 10: ...es are made in this revision Added information on decoupling ES output and ES input see De scriptions for connectors on page92 and Configuring robot stopping functions on page 105 NOTE about protected earth harness removed from sections Residual current on page 40 and Connection of protective earth on page 78 Part numbers for mating connectors corrected in Robot signal ex change proxy mating conne...

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

Page 12: ...he manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 12 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved Product documentation Continued ...

Page 13: ...on of the robot when the safety devices are defective not in their intended location or in any other way not working When instructions for operation and maintenance are not followed Non authorized design modifications of the robot Repairs on the robot and its spare parts carried out by in experienced or non qualified personnel Foreign objects Force majeure Spare parts and equipment ABB supplies or...

Page 14: ...ed 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 the safety functions Note The safety functions are divided into two types called Basic Safety Functions and Extended Safety Functions Performance level data The performance level data for the respectiv...

Page 15: ...e of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot The plant liable must make sure that the personnel is trained on the robot and on responding to emergency or abnormal situations Personal protective equipment Use personal protective equipment as stated in the instructions Product manual OmniCore V250XT 15 3HAC073447 001 Revi...

Page 16: ...ill result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous situation which if not av...

Page 17: ...o indicate where to find additional information or how to do an operation in an easier way TIP Product manual OmniCore V250XT 17 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 18: ...ey 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 and information on labels Note The descriptions in this section are generic the labels can contain additional information such as values Description Label Read the user manual before use xx1400001152 ...

Page 19: ... disconnecting 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 inside the module even if the main switch is in the OFF position xx1400001156 ESD sensitive components inside the controller xx1400001162 Product manual OmniCore V250XT 19 3HAC073447 001 Re...

Page 20: ...e Y N Default stop category Description Inputs to initiate a stop function Y Stop category 0 Input to initiate the emergency stop func tion The Emergency Stop function is initi ated in both automatic and manual mode Emergency Stop ES For deviations see the product manual for the manipulator Y Stop category 1 Input to initiate the protective stop func tion The protective stop function can either be...

Page 21: ...te for safeguarding measures or safety functions Note A safety input used to initiate a protective stop must remain active for at least 100 ms Product manual OmniCore V250XT 21 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 1 Safety 1 3 1 Protective stop and emergency stop Continued ...

Page 22: ...nly 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 Note The emergency stop device on the FlexPendant is operational when the robot is powered Indicators to be used to verify that the robot is powered are the main switch on the cabinet or the LED indi...

Page 23: ...device must never be rendered inoperational in any way If there is a need to enter safeguarded space always bring the FlexPendant This is to enforce single point of control Hold to run function in manual high speed mode The hold to run function for manual high speed allows movement in conjunction with the three position enabling device when the button connected to the function is actuated manually...

Page 24: ...tasks In manual reduced speed mode the movement of the TCP is limited to 250 mm s In addition there is a limitation on the maximum allowed speed for each axis Manual control of the robot from inside the safeguarded space shall be performed through the FlexPendant WARNING Wherever possible the manual mode of operation shall be performed with all persons outside the safeguarded space Tasks normally ...

Page 25: ...mpressed 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 Tasks normally performed in mode manual high speed The following tasks are normally performed in manual high speed mode Program verification Setting program pointer to Main to routine to cursor to se...

Page 26: ...en robot is at stop Load start stop and modify RAPID programs through remote clients Safeguard mechanisms Protective stop through Automatic Stop AS See actual configuration for the protective stop function The protective stop function can be be configured to either Automatic Stop AS or General Stop GS Note Prior to allowing the robot control system to operate in automatic mode ensure that any susp...

Page 27: ...act caused by a breaking or malfunctioning rotating tool or other device fitted to the robot The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator Consider exposure to hazards such as slipping tripping and falling Hazards due to the working position and posture for a person working with ...

Page 28: ...t the safety devices necessary to protect people working with the robot system are designed and installed correctly When integrating the robot with external devices to a robot system The integrator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards The integrator of the robot system must ensure that safety functions are interlocked...

Page 29: ...tions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level Product manual OmniCore V250XT 29 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 1 Safety 1 5 Safety during installation and commissioning Continued ...

Page 30: ...ator 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 30 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyri...

Page 31: ...der rated conditions the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside There is a hazard in case of abuse mechanical thermal electrical which leads to the activation of safety valves and or the rupture of the battery container As a result under certain circumstances electrolyte leakage electrode materials reaction with moisture water or batte...

Page 32: ...g on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers CAUTION Risk of hot surfaces that can cause burns A risk assessment must be done to address both robot and robot system specific hazards Related information See also the safety information related to installation operation maintenance and repair 32 Product manual OmniCore V250XT 3HAC073447 ...

Page 33: ...1 9 Decommissioning General See section Decommissioning on page 345 Product manual OmniCore V250XT 33 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 1 Safety 1 9 Decommissioning ...

Page 34: ...This page is intentionally left blank ...

Page 35: ...xibility covering a wide range robot and applications V line supports external axis and provides flexible configuration opportunities The OmniCore V250XT controller offers a compact yet flexible solution for advanced applications and robots sizes up to IRB6700 Product manual OmniCore V250XT 35 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 2 Controller description 2 1 OmniCo...

Page 36: ...pply Scalable I O unit or Safe I O unit K5 1 K3 1 K5 2 K5 3 K5 4 Incoming mains switch Q0 FlexPendant connector X4 SMB connector X2 Motor connector X1 Incoming mains connector X0 Standard fan G1 G4 Air filter xx2100000665 OmniCore V250XT Baseline OmniCore V250XT Reference to circuit diagram Baseline T4 Drive unit Baseline A1 Power unit Continues on next page 36 Product manual OmniCore V250XT 3HAC0...

Page 37: ...50XT Options OmniCore V250XT Reference to circuit diagram Option K5 1 Scalable I O Option K5 2 Additional I O K5 3 K5 4 Option K3 1 Safety digital base I O Option B1 Conveyor tracking module Option K4 Ethernet switch Option T5 T8 Process power supply Option T6 T9 ODVA power supply Option Air filter Option X0 Incoming mains cable gland Dimensions Value Parameter 650 mm Width 480 mm Depth 960 mm Hei...

Page 38: ... the controller Value Parameter 5 C 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 vibration Note The humidity conditions shall apply with the environmental conditions EN 60721 3 3 climatic class 3K3 For temperatures 0 30 C the relative humidity mu...

Page 39: ...ings to the controller cabinet must be sealed This includes unconnected connectors which must be fitted with covers Noise emission 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 Noise emission Controller in Standby Mode 59 5 dB A Leq Power supply Value Mains 380 VAC 480 VAC 3 phase Voltage for OmniCore V2...

Page 40: ... A 380 VAC 480 VAC 3 phase IRB 6700 Note For details about installations according to UL requirements see Connecting incoming mains and protective earth to the controller chapter in Product manual OmniCore V250XT Residual current An external earth fault protection residual current device RCD is required based on the following data Residual Current in controller mA Robot 30 mA IRB 4600 30 mA IRB 57...

Page 41: ... 88E0 07 Protective stop function of the robot initiated by external protective stop device attached to protective stop inputs of the controller Extended Safety Functions The safety data is valid for the Extended safety functions for applicable ABB manipulators The supported manipulators are listed in Product specification OmniCore V line PFHD 1 hour Safety Function 1 88E0 07 Muting of emergency s...

Page 42: ...n Safety data on page 14 The SISTEMA ABB FSDT libraries contain details for the safety functions 42 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 2 Controller description 2 3 Safety functions and safety related data for OmniCore V250XT Continued ...

Page 43: ...he wrist strap button is located inside the controller Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly Use an ESD protective floor mat The mat must be grounded through a current limiting resistor Use a dissipative table mat The mat should provide a controlled discharge of static voltages and must be grounded Wrist strap button The location of ...

Page 44: ...tional wrist strap button on the main computer 44 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 2 Controller description 2 4 The unit is sensitive to ESD Continued ...

Page 45: ... use sharp objects such as screwdriver or pen for operating the touch screen This could damage the touch screen Instead use your finger or a stylus Never clean the FlexPendant with solvents scouring agent or scrubbing sponges See the product manual for the robot controller section Cleaning the FlexPendant Always close the protective cap on the USB port when no USB device is connected The port can ...

Page 46: ...s application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information ABB Ltd and its entities are not liable for damage and or loss related to such security breaches any unauthoriz...

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

Page 48: ...ommercially reasonable technical and organizational measures in order to protect the data against security breaches accidental or unlawful destruction loss alteration and unauthorized disclosure of or access to the data The cellular data connection is not required for the operation of the hardware and the connectivity settings can be adjusted and turned off at any given time Detailed information o...

Page 49: ...ity General Terms and Conditions ABB Ability Terms and Conditions https ability abb com terms Special Terms and Conditions for ABB Ability Connected Services https new abb com products robotics service robot registration Product manual OmniCore V250XT 49 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 2 Controller description 2 8 ABB Ability Continued ...

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

Page 51: ...tallation work is commenced all safety information must be observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page13 before performing any installation work Note Always connect the OmniCore V250XT and the robot to protective earth and res...

Page 52: ...roller on page 77 Install a residual current device RCD 7 Connecting incoming mains and protective earth to the controller on page 77 Connect incoming mains to the controller 8 Connector X14 on page 92 Connect safeguards to the controller 9 How to connect industrial networks for example PROFINET is described in the respective application manual Connect for example Ethernet PC and other connections...

Page 53: ...The following figure shows the maximum angle between the lifting straps when lifting the controller The weight of the controller module is detailed in section Weight on page 37 0 6 xx2100000343 Product manual OmniCore V250XT 53 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 3 1 Lifting the controller cabinet ...

Page 54: ...o 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 38 6 Make sure that the expected operating environment of the controller conforms to the specifications as described in Operating conditions on page 38 7 The controller can be taken to its installation site as described in section On si...

Page 55: ... controller For storing see Transportation and storage conditions on page 38 Product manual OmniCore V250XT 55 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 3 3 Storing ...

Page 56: ...oller Min 300 mm Min 150 mm xx2100001274 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 56 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 4 1 Required installation space ...

Page 57: ...ctivities 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 xx2100002646 Product manual OmniCore V250XT 57 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 4 1 Required installation space Continued ...

Page 58: ...T controller is designed so that a maximum of two controllers can be stacked on top of each other 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 controllers must not tilt more than 10 degrees 58 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rig...

Page 59: ...on page 414 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 Mounting the bracket for the emergency stop on the FlexPendant holder The FlexPendant holder is shipped without the bracket for the emergency stop assembled to the holder They are separated as two parts xx2...

Page 60: ...der 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 Continues on next page 60 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 4 3 Mounting the FlexPendant holder Continu...

Page 61: ...se 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 Remove the protective liner from the tape 2 Continues on next page Product manual OmniCore V250XT 61 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning ...

Page 62: ...ike the door of the equipment Tip The bracket is included when the FlexPendant is purchased Note illustration Action xx2000002354 Hang the FlexPendant holder to the bracket according to the screws on the bracket 1 Continues on next page 62 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 4 3 Mounting the FlexPen...

Page 63: ...the FlexPendant holder to the desired place Note illustration Action xx2000002356 Remove the four screws 1 Separate the rear part from the FlexPend ant holder 2 Clean the surface and make sure it is dry 3 Continues on next page Product manual OmniCore V250XT 63 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 4 3 Mounting the FlexPendant hold...

Page 64: ...4 Press the holder onto the desired place 5 xx2000002358 Use two M5 screws to secure the holder 6 64 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 4 3 Mounting the FlexPendant holder Continued ...

Page 65: ...damage before connecting it to the controller Clean or replace any damaged parts Connectors The following details the connection interface on the OmniCore V250XT controller H E G F J I K D C B A xx2000001277 Continues on next page Product manual OmniCore V250XT 65 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 5 1 Connectors on the OmniCore...

Page 66: ...or SMB F Cable grommet assembly G Incoming mains connector H Ethernet outlet connector LAN3 I Ethernet outlet connector WAN J Connected Services antenna connector 3G WiFi K 66 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 5 1 Connectors on the OmniCore V250XT controller Continued ...

Page 67: ...r and analog I O Measurement signals This class covers ordinary analogue signals such as analogue sig nals 4 20 mA 0 10V or signals below 1 MHz low speed digital signals RS232 RS485 digital on off signals limit switches en coders etc Class 2 slightly sens itive Gateway fieldbus connection computer link Data communication signals Applies to cables carrying very sensitive signals Signals with a full...

Page 68: ...9 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 Multi wire 4 pair 0 5 20 3 2 3 7 4 1 4 5 Multi wire 6 pair 0 5 20 2 8 3 2 3 6 4 0 Multi wire 9 pair 0 5 20 6 7 7 8 8 6 9 5 Single wire 0 75 18 5 4 6 2 6 9 7 6 Multi wire 2 pair 0 75 18 4 4 5 1 5 6 6 ...

Page 69: ...es All external cables that are to be connected inside the controller must be shielded in the chassis before entering the cabinet Separation distances can be reduced if e g dividers are used between cables classes Manufacturers of cable duct systems can provide information on how reduced separation distances can be achieved using their specific products All signals that are sensitive to interferen...

Page 70: ...hey pass through Shielding cable requirements The best method for shielding is to ground the shield at both ends of the cable provided the ends grounding are at the same potential If the grounding points have different electric potentials grounding both ends will create a ground loop allowing unwanted current to flow in the shield In such cases one end grounding may be used The grounding point sho...

Page 71: ...01321 Ground and screen connections The task of the grounding system is twofold protective and functional The primary task is to serve as protective earth PE for personal and equipment safety The secondary task is to serve as a return path for common mode current For further information refer to EN 60204 1 and UL 1740 Grounding requirements The controller cabinet ground must come from the mains po...

Page 72: ...ct protective earth for the manipulator see the corresponding product manual Examples The following figure shows 2 examples on how protective earth and the signal cable screens can be connected Control cabinet External unit Example 1 Example 2 xx1200000960 Example 1 Where a good earth connection is available on all units the best shielding is obtained by grounding all screens at both ends on all u...

Page 73: ...s that control them 0 V 24 V DC 1 2 3 0 V 24 V AC DC xx1200000961 1 The diode should be dimensioned for the same current as the relay coil and a voltage of twice the supply voltage 2 The varistor should be dimensioned for the same energy as the relay coil and a voltage of twice the supply voltage 3 When AC voltage is used the components needs to be dimensioned for 500 V max voltage and 125 V nomin...

Page 74: ...surement 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 Customer cables option Handles power supply to and control of the external axes motors as well as feedback from the servo system Additional axes cables option These categories above are divided into s...

Page 75: ... to the controller Detailed view xx2100001257 Description Cable gland A O ring B Hood EMC C Locking lever x2 D Connector insert E Continues on next page Product manual OmniCore V250XT 75 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 5 4 Fitting the connector for incoming mains ...

Page 76: ...e the following procedure to fit the connectors Note illustration Action Cut the cable to desired length 1 2 1 3 4 4 PE1 3 PE2 1 2 xx2100001258 Description L1 1 L2 2 L3 3 Not used 4 Protective earth PE1 Protective 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 lu...

Page 77: ...tection must be provided in accordance with the Manufacturer Instructions National Electrical Code and any additional local codes Introduction Before incoming mains is connected to the controller the following prerequisites must be fulfilled An external circuit breaker or fuse must be installed See Line fusing on page 79 The cabinet must be connected to protective earth See Connection of protectiv...

Page 78: ... mA earth fault protec tion can be used if it is Hager CDH440R CDH440D or ABB F204 B 40 0 03 External earth fault protection residual current circuit breaker Class B for frequency converters 300mA 32 A Class K Note For installations according to UL requirements use Circuit Breaker Type SU203M K32 manufactured by ABB External fuse or circuit breaker See Standard toolkit for controller on page 414 S...

Page 79: ...ing levers Tip When you hear a clear clicking sound it is locked 1 xx2100001259 Line fusing An external circuit breaker class K or fuse must be added to prevent short circuit and overload The full load current for the robot is marked on the controller name plate and is also displayed in section Load current on page 40 Product manual OmniCore V250XT 79 3HAC073447 001 Revision B Copyright 2020 2022 ...

Page 80: ...the FlexPendant grant CAUTION Before detaching the FlexPendant another emergency stop shall be available CAUTION With a detached FlexPendant there is no visual identification of the operating mode CAUTION A FlexPendant that is not connected to the robot must be stored out of sight so that it cannot be mistaken for being in use CAUTION The FlexPendant connector shall only be used to connect the Fle...

Page 81: ... detach the FlexPendant in automatic mode 1 On the status bar tap the QuickSet button 2 Tap the Logout Restart tab 3 In the FlexPendant section tap Detach FlexPendant Continues on next page Product manual OmniCore V250XT 81 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 5 6 Detaching and attaching a FlexPendant Continued ...

Page 82: ...own timer is displayed 5 When the countdown is progressing detach the FlexPendant Continues on next page 82 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 5 6 Detaching and attaching a FlexPendant Continued ...

Page 83: ...lexPendant 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 xx1900000975 CAUTION Make sure that the emergency stop device is not pressed in before attaching the FlexPendant Product manual OmniCore V250XT 83 3HAC073447 001 Revision B Copyright 2020 2022 ABB All ri...

Page 84: ...local to this specific ro bot I O Scalable I O ETHERNET SWITCH Private Net work ABB service personnel MGMT Management FlexPendant connection HMI FlexPendant ABB Ability connection ABB Ability Ability Net work Public factory network WAN Public Net work Secondary public factory network Isolated from WAN LAN I O Network Continues on next page 84 Product manual OmniCore V250XT 3HAC073447 001 Revision ...

Page 85: ...industrial network WAN 4 Connected to the controller s I O Network Intended for connecting the robot controller to a factory wide industrial network isolated from WAN LAN 5 Connected to the controller s Private Net work The MGMT port shall be used by ser vice personnel in close proximity to the con troller with a single client connected to the controller MGMT Management 6 Note The management port ...

Page 86: ...ork as well as master on the Private Network ABB Ability TM MGMT LAN WAN Robot Controller A ETHERNET SWITCH I O FlexPendant ABB Ability TM MGMT LAN WAN Robot Controller B ETHERNET SWITCH I O FlexPendant PLC I O I O Ethernet medium Industrial network with PLC as master Industrial network with Robot Controller A as master xx2100002085 This can be implemented by setting up an EtherNet IP adapter on t...

Page 87: ...has a static configuration with IP address 192 168 125 1 24 and hosts a DHCP server The purpose of the Private Network is to connect the computers within the robot controller as well as I O networks and process equipment local to the robot Many IP addresses are reserved on this network so it is recommended that new units get their IP address from the DHCP server Note Never connect another DHCP ser...

Page 88: ... administrator The Public Network segment can be used for Connecting a PC running RobotStudio For more information see Operating manual RobotStudio Mounting FTP or NFS disks from the controller Running Industrial Ethernet protocols Most protocols are disabled by default in the controller firewall See Firewall settings on page 91 for information about how to enable these protocols The Public Networ...

Page 89: ... settings on the FlexPendant 1 On the start screen tap Settings and then select Network from the menu Continues on next page Product manual OmniCore V250XT 89 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 5 7 Ethernet networks on OmniCore Continued ...

Page 90: ...Pendant Defining network settings in RobotStudio 1 In the Configuration browser right click the controller and select Properties Network Settings and then I O Network 2 In the I O Network window configure the network interface and click OK xx2200000389 Continues on next page 90 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and c...

Page 91: ...900000352 Note Only pre registered Network Services can be configured in the Firewall Manager settings The user cannot add new Network Services in the Firewall Manager and can only change the parameters Enable on Public Network Enable on Private Network and Enable on I O Network for pre registered Network Services Note Only users with UAS grant Modify network security properties can modify the fir...

Page 92: ...both manual mode and automatic mode See Protective stop and emergency stop on page 20 The default configuration for the protective stop function is Automatic Stop AS That is active in automatic mode only Changes to the default configuration for the protective stop function that is from Automatic Stop automatic mode to General Stop both manual and automatic mode are made in the tool RobotStudio See...

Page 93: ...und towards 24 V 0V_CH1_CH2 9 24 V power provided by robot controller for AS GS channel 2 only 24V_CH2 10 Negative side of AS GS input channel 2 AS2 GS2 11 Customer needs to connect these pins to the reference ground of 24 V power Positive side of AS GS input channel 2 AS2 GS2 12 Customer needs to connect these pins to a 24 V power Negative side of AS GS input channel 1 AS1 GS1 13 Customer needs t...

Page 94: ...owered from an external power supply Customer_24V_CH1 Customer_24V_CH2 Customer_0V_CH1 Customer_0V_CH2 Customer provided power 0V_CH1_CH2 24V_CH1 0V_CH1_CH2 24V_CH2 K2 X14 AS1 GS1 AS1 GS1 AS2 GS2 AS2 GS2 14 13 15 10 12 11 9 16 Customer provided protec ve stop device xx2100002264 Continues on next page 94 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights re...

Page 95: ...1 4 3 Customer_24V_CH1 Customer_24V_CH2 Customer_0V_CH1 Customer_0V_CH2 Customer provided power 0V_CH1_CH2 24V_CH1 ES1 ES1 0V_CH1_CH2 24V_CH2 ES2 ES2 Customer provided emergency stop device K2 X14 xx2100002263 For more connections other than those illustrated above carefully assess the risk before use and contact your local ABB for support Continues on next page Product manual OmniCore V250XT 95 3...

Page 96: ...n lamp output interface The max sink current is 50mA MON_LAMP 3 24 V power supplied by robot controller for motors on lamp and motors on push button use only It must not be used for any other functions 24V_MON 4 Reserved NC 5 Reserved NC 6 Reserved NC 7 Reserved NC 8 Reserved NC 9 Reserved NC 10 Negative side of emergency stop output channel 2 ESOUT2 11 Positive side of emergency stop output chann...

Page 97: ...Output for Safety Input of Next Stage ESOUT2 ESOUT2 Safety PLC or Relay Relay Output for Safety Input of Next Stage Isola on Isola on K2 X15 Customer provided device 14 13 12 11 xx2000001763 Note State 0 of Emergency stop output shall be recognized as Emergency stop triggered Note The maximum length of the cable connected to the ESOUT pins shall be 10 m Continues on next page Product manual OmniCo...

Page 98: ... another OmniCore controller See Configuring robot stopping functions on page 105 Although the Motors On function is available on the FlexPendant an interface is provided in X15 for an optional Motors On push button and an indication lamp K2 X15 Customer provided device 24V_MON MON_PB 24V_MON MON_LAMP Lamp Push bu on 2 1 4 3 xx1900000598 Connector X19 Description Customer IO power supply Connectio...

Page 99: ... characteristics are shown in the following table Value Parameter 24V DC Voltage 3 10 Voltage tolerance 3 A Max output current Connector X20 Description Customer optional power input Not available Connection Weidmüller BCF 3 81 06 180F Type BCF 3 81 06 180F SN BK BX 6 Pins 3HAC064738 001 Article number Continues on next page Product manual OmniCore V250XT 99 3HAC073447 001 Revision B Copyright 202...

Page 100: ...es 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 Ethernet outlet connector MGMT Management The following type of Ethernet cable is recommended for connection to the Ethernet outlet connector MGMT port Value Ethernet cable 75 m Maximum length CAT5e SF UTP Type of cable Continues on nex...

Page 101: ...vice If the process power supply is supplied by the logical power supply connector X19 a surge protector must be installed to protect the device For connection details see Circuit diagram OmniCore V250XT 3HAC074000 008 and Application manual Scalable I O 3HAC070208 001 Recommended surge protector IN OUT 10 9 4 3 8 7 12 11 xx1800002551 The protect voltage for the surge protector should be 24 V DC C...

Page 102: ...ive power 24 V DC red V 5 Tip The DeviceNet network needs to be powered by a separate 24 V power supply or the DeviceNet function will not work See Application manual DeviceNet Master Slave 3HAC066562 001 section Hardware overview for more information on how to connect 24 V to the DeviceNet network For connection details see Circuit diagram OmniCore V250XT 3HAC074000 008 Continues on next page 102...

Page 103: ...ter 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 recommended as the following illustration 24V terminal block option This connector is internally connected with the optional power supply It is a 24 V power supply for the customer The characteristics ...

Page 104: ...e 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 diameter of the grommet Incorrect installation will affect the ingress protection It is recommended to use icotek KT grommet 104 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 ...

Page 105: ...e only Note It is not possible to configure both Automatic Stop and General Stop on the OmniCore V250XT without the use of a safe fieldbus Note The dedicated discrete safety input to activate the protective stop function can be configured as either Automatic Stop AS or General Stop GS For simultaneous use of AS and GS support for a safety protocol is required See option SafeMove For more informati...

Page 106: ...lect the stop category For some manipulators only category 1 stop is available 4 After the configuration is done the safety configuration must be written to the controller and then a restart of the controller is required Tip See also the circuit diagram Circuit diagram OmniCore V250XT Apply the configuration to the controller Note illustration Action xx1500000801 In the Visual SafeMove ribbon clic...

Page 107: ...ill stop Set the signal configured to stop the robot in relev ant operating modes 3 Relevant operating modes are Auto Automatic mode General All modes EmergencyStop All modes Set the configuration to validated When the stop configuration is validated the configuration the status of the configuration shall be changed to Validated on the FlexPendant 1 Log in as a user with the grant Safety Services ...

Page 108: ... an upgrade Contact your local ABB office for guidance RobotWare prior to 7 6 In RobotWare releases prior to 7 6 the ES input cannot be decoupled from the ES output The LocalEmergencyStop was named InternalEmergencyStop prior to RobotWare 7 6 108 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 5 9 Configuring r...

Page 109: ...ops program execution after the current instruction is com pleted Stop at End of Instruction All of 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 Note Only safety rated input signals are allowed to be used for safety Stop with RAPID instructions There are several RAPID ...

Page 110: ...gram will be restarted EXITCYCLE Stop Stiff stop the robot will stop as fast as possible This stop is performed by ramping down motion in each motor separate from each other and as fast as possible Since it will be without any coordination the robot 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 ...

Page 111: ...upervision WARNING Special care must be taken when restarting a machine that is stopped due to a collision The 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 distance metric for stop category 0 and stop category 1 are detailed in Product specification Rob...

Page 112: ...are connected directly to one of the Ethernet ports B A xx2100000501 Slot for fieldbus PCI express card A Fieldbus board master B Available board The following master board is available Type designation Article number Description DSQC1006 3HAC043383 001 DeviceNet Board Available software based fieldbuses The following software based fieldbuses are available as RobotWare options EtherNet IP PROFINE...

Page 113: ... 001 Application manual DeviceNet Master Slave 3HAC066565 001 Application manual EtherNet IP Scanner Adapter 3HAC066558 001 Application manual PROFINET Controller Device Product manual OmniCore V250XT 113 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 6 1 Available fieldbuses Continued ...

Page 114: ...otWare options or hardware options are required to communicate with the robot controller When using the RobotWare option EtherNet IP Scanner Adapter more configuration possibilities are available For more information about installing configuring and using the scalable I O units see Application manual Scalable I O Safety digital base device The safety I O unit DSQC1042 Safety Digital Base is a devi...

Page 115: ...lication manual Scalable I O Required parts Note Article number 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 DSQC1032 3HAC058665 001 Analog add on 3034 2 3HAC060925 001 Connectors I O Analog DSQC1033 3HAC058666 001 Relay add on 3035 2 3HAC060926 001 Connectors I O Relay Continues on next page ...

Page 116: ...ork inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 xx1900002447 Push the digital base into the bracket until you hear a clear clicking so...

Page 117: ...n page 28 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 Prepare the scalable I O units for external mounting as described in Application manual Scalable I O 3 Opening the door on page 176 Open the door 4 Connect the external base device to the internal base device X3 or the Ether...

Page 118: ...Portal www abb com myABB Note Article number Spare part DSQC1042 3HAC062908 001 DSQC1042 Extended safety 3HAC069538 001 Connectors Safety I O Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Continues on next page 118 Product manual OmniCore V250XT 3HAC073447 001 Revision ...

Page 119: ...age 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 xx1900002447 Push the digital base into the bracket until you hear a clear clicking sound 3 Continues on next page Product manual OmniCore V250XT 119 3HAC073447 001 Revision B Copyrig...

Page 120: ...onnector K5 1 X5 K3 1 X5 to from A2 X4 K5 1 X4 K2 X3 The harness connected to I O unit by customer 4 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 120 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights re...

Page 121: ...bb com myABB Note Article number Spare part DSQC1035 3HAC059187 001 Ethernet Extension switch 3014 1 Harness A2 X4 K4 X6 3HAC076473 001 Ethernet Harness Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Continues on next page Product manual OmniCore V250XT 121 3HAC073447 00...

Page 122: ...e unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Refitting the Ethernet extension switch option Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Continues on next page 122 Product manual OmniCore...

Page 123: ...ere should be no gap between the upper surface of the Ethernet extension switch and the lower surface of highest bracket on the main computer xx1800000972 3 Reconnect K2 X2 K4 X8 A2 X1 K4 X7 K5 1 X5 K3 1 X5 K4 X6 A2 X4 4 Concluding procedure Note Illustration Action Perform the function tests to verify that the safety features work properly see Function tests on page 166 1 Product manual OmniCore ...

Page 124: ...s Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Continues on next page 124 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 7 4 Installing the power supply optional device ...

Page 125: ... Circuit diagram OmniCore V250XT 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 Electrical safety on page 28 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...

Page 126: ...ower 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 Cross recessed cheese head screw M4x8 1 pcs xx1900001908 For DSQC 634 xx1900001950 Continues on next page 126 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All right...

Page 127: ... 24VTerminal block T8 X2 24VTerminal block T6 X2 24VTerminal block T9 X2 24VTerminal block 3 Concluding procedure Note Illustration Action Perform the function tests to verify that the safety features work properly see Function tests on page 166 1 Product manual OmniCore V250XT 127 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 7 4 Installi...

Page 128: ...est spare parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Note Article number Spare part DSQC1006 3HAC043383 001 DeviceNet Board Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit Continues on next page 128 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 20...

Page 129: ...TIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Removing the main computer assembly Note Illustration Action Disconnect all the connectors on the as sembly group of the robot signal ex change proxy Ethernet switch option connected services gateway and main computer 1 Continues on ...

Page 130: ...Note The connector K7 X2 is locked grab the connector push it in to release it and then remove the connector For the main computer K2 X8 A2 X6 K2 X2 K4 X8 A2 X1 K2 X12 A2 K3 X6 A2 K3 X7 K6 X2 A2 X9 A2 X5 K7 X2 A2 X4 K4 X6 K5 1 X5 Note If the Ethernet extension switch is installed connect and disconnect the connector A2 X4 to from K4 X6 If the Ethernet extension switch is not installed connect and ...

Page 131: ...ed there is no power cable Removing the robot signal exchange proxy Note Illustration Action Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 Pull the cable ties out from the locking holes 2 Continues on next page Product manual OmniCore V250XT 131 3HAC073447...

Page 132: ...e wrist strap button located on the side of the computer 1 xx2000000419 xx1800003415 Remove the screws on top of the main computer and take the cover off 2 xx1800003414 Remove the attachment screw on the cover of the fieldbus master and take out the cover 3 Continues on next page 132 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation...

Page 133: ...cs xx1800003416 Secure the DeviceNet board with the screw 5 Screws Hexalobular socket pan head screw M3x6 4 pcs xx1800003418 Refit the cover on the main computer and secure the screws 6 Continues on next page Product manual OmniCore V250XT 133 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 7 5 Installing the fieldbus master Continued ...

Page 134: ...xy and secure the screws 3 Insert the cable ties into the locking holes 4 Refitting the main computer assembly to the cabinet Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use th...

Page 135: ...ices and main computer 5 For the robot signal exchange proxy K2 X8 A2 X6 option K2 X2 K4 X8 A2 X1 K2 X12 A2 K3 X6 A2 K3 X7 K2 X10 A1 X13 K2 X4 A1 X9 K2 X3 K6 X1 A2 K3 X1 K5 1 X4 K7 X1 K2 X1 T2 X2 K2 X6 K2 X11 A1 X2 K2 X7 K2 X22 Harn LV robot power X1 K2 X9 X13 FlexPendant X4 Continues on next page Product manual OmniCore V250XT 135 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reser...

Page 136: ...4 K4 X6 K5 1 X5 Note If the Ethernet extension switch is installed connect and disconnect the connector A2 X4 to from K4 X6 If the Ethernet extension switch is not installed connect and discon nect the connector A2 X4 to from K5 1 X5 Concluding procedure Note Illustration Action Perform the function tests to verify that the safety features work properly see Function tests on page 166 1 136 Product...

Page 137: ...parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT 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 Power cable of CTM 3HAC069618 001 Harness 24V_CTM Continues on next page Product manual OmniCore V2...

Page 138: ...Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Opening the door on page 176 Open the door 3 Continues on next page ...

Page 139: ...ectors as required 6 Closing the door on page 176 Close the door 7 Perform the function tests to verify that the safety features work properly see Function tests on page 166 8 For more information about the option Conveyor Tracking see Application manual Conveyor tracking Product manual OmniCore V250XT 139 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and com...

Page 140: ...d in the table can be out of date See the latest spare parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC066396 001 Cable grommet asm Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Required documents Note Article ...

Page 141: ...e to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Removing the slot cover baseline Note Illustration Action xx2100001282 Remove the attachment screws 1 Take out the cover from the inside of the controller 2 Continues on next page Product manual OmniCore V250XT 141 3HAC073447 001 Revision B Copyright 2020 2022 ABB All ri...

Page 142: ... to the open side of the frame half flat sides pointing upwards Note The fl at side of the grommets in the up per row have to point downwards so that all flat sides rest on each other When using single row frames the fl at side has to point towards the cover strip 2 xx1900002335 Refit the cover strip onto the frame 3 Continues on next page 142 Product manual OmniCore V250XT 3HAC073447 001 Revision...

Page 143: ... with the screws 4 Tightening torque 2 Nm 3 Nm xx1900002334 xx1900002333 Route the cables through the cut out 5 Continues on next page Product manual OmniCore V250XT 143 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 7 7 Installing the cable grommet assembly Continued ...

Page 144: ...nect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Continues on next page 144 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rig...

Page 145: ...procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 Product manual OmniCore V250XT 145 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 7 7 Installing the cable grommet assembly Continued ...

Page 146: ...parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Note Article number Spare part Option 3005 1 Moist particle filter 3HAC075739 001 Air filter coarse assembly Option 3005 2 Moist dust filter 3HAC075740 001 Air filter fine assembly Continues on next page 146 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and...

Page 147: ...cuit diagram OmniCore V250XT Installing the air filter Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 xx2100002583 For option 3005 2 Moist dust filter Insert the polymeric filter element to the filter and secure with the metallic line 2 Continues on next page Product manual OmniCore V250XT ...

Page 148: ...orm the function tests to verify that the safety features work properly see Function tests on page 166 4 148 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 7 8 Installing the air filter Continued ...

Page 149: ...ontent is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT Continues on next page Product manual OmniCore V250XT 149 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 7 9 Installing the mains c...

Page 150: ...d B Incoming mains switch C Cable pipe Remove protection from the incoming mains switch B 2 Connecting incoming mains and protective earth to the controller on page 77 Connect incoming mains from an external earth fault protection 3 Continues on next page 150 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 7 9 ...

Page 151: ... cable lugs in the connection Tightening torque 1 7 Nm Route the phase wires through the pipe up to the incoming mains switch B 7 See circuit diagram Connect the wires to the incoming mains switch B 8 Refit protection on the incoming mains switch B 9 Product manual OmniCore V250XT 151 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 7 9 Insta...

Page 152: ... 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 152 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 8 Installing external devices ...

Page 153: ... incoming mains and protective earth to the controller on page 77 Function tests Before commissioning perform the function tests in section Function tests on page 166 to verify that the safety features work properly Product manual OmniCore V250XT 153 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 9 Initial test before commissioning ...

Page 154: ... information about commissioning see Operating manual Integrator s guide OmniCore 154 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 3 Installation and commissioning 3 10 Commissioning ...

Page 155: ...t Manual auto and manual full speed mode with FlexPend ant Function test of three position en abling device on page 168 12 months Function test Enable device Function test of Automatic Stop on page 169 12 months Function test Auto stop tested if used Function test of General Stop on page 170 12 months Function test General stop tested if used Function test of external emergency stop on page 171 12...

Page 156: ...ling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Inspect connectors and cabling to make sure they are securely fastened and cabling not damaged 3 Inspect the fans and ventilation holes to make sure they are clean 4 After inspection Temporarily turn the power supply on Inspect the fans to make sure they function correctly Switch the power ...

Page 157: ...tration below xx2100000441 Required equipment Note Equipment Water 30 40 C with cleansing liquid or detergent Cleaning agent Compressed air Continues on next page Product manual OmniCore V250XT 157 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 4 Maintenance 4 3 1 Cleaning air filter ...

Page 158: ...rface Blow with compressed air in opposite direction of filter airflow 4 xx2100002583 Insert the polymeric filter element to the filter and secure with the metallic line 5 Refit the air filter unit to the cabinet 6 Cleaning the coarse filter metal mesh The procedure below details how to clean the coarse filter that is option 3005 1 Moist particle filter Note The coarse filter cannot be separated f...

Page 159: ...ter unit 1 Clean the metal mesh filter with compressed air 2 Refit the air filter unit to the cabinet 3 Product manual OmniCore V250XT 159 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 4 Maintenance 4 3 1 Cleaning air filter Continued ...

Page 160: ...horten the life of paint work rust inhibitors signs or labels Always make sure that all protective covers are fitted to the controller before cleaning Never remove any covers or other protective devices when cleaning the outside of the controller Never use compressed air or spray with a high pressure cleaner Never leave the door open when cleaning the exterior 160 Product manual OmniCore V250XT 3H...

Page 161: ...using a soft cloth and water or a mild cleaning agent 3 Unlock the screen by tapping the buttons 4 Cleaning considerations The section below specifies some special considerations when cleaning the FlexPendant Use ESD Protection Use cleaning equipment as specified above Any other cleaning equipment may shorten the life time of the touch screen Check that all protective covers are fitted to the devi...

Page 162: ...leaner Do not clean the device operating panel and operating elements with compressed air solvents scouring agent or scrubbing sponges 162 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 4 Maintenance 4 3 3 Cleaning the FlexPendant Continued ...

Page 163: ...Note Equipment Air filter These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual OmniCore V250XT 163 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 4 Maintenance 4 4 1 Replacement of air filter ...

Page 164: ...000442 Remove the air filter unit 1 Removing the polymeric filter element The procedure below details how to remove the fine filter that is option 3005 2 Moist dust filter Note Illustration Action xx2100002583 Take out the polymeric filter element from the filter 1 Continues on next page 164 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 4 Main...

Page 165: ...ote Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Refit the air filter unit to the cabinet 2 Concluding procedure Note Illustration Action Perform the function tests to verify that the safety features work properly see Function tests on page 166 1 Product manual OmniCore V250XT 165 3HAC073447 0...

Page 166: ...ears in the event log Note For collaborative robots the event mes sage 90518 Safety controller Emergency stop triggered appears by default The message 10013 Emergency stop state is also available in the event log Press the emergency stop device on the FlexPendant Note If the event message 20223 Emergency stop conflict appears in the event log or the event message 10013 Emergency stop state and 905...

Page 167: ...be found This test is passed if it is possible to run the robot program in manual mode Change to Manual operating mode and Motors ON state and then run the robot in manual mode 3 If it is not possible to run the robot pro gram this test is failed and the root cause of the failure must be found This test is passed if it is possible to run the robot program in manual full speed mode Change to Manual...

Page 168: ...g then the test has failed and the root cause of the failure must be found This test is passed if the event message 10012 safety guard stop state appears in the event log While still holding the three position en abling device pressed press the enabling device harder to the enable the device s third position 3 If the event message 10012 Safety guard stop state does not appear or if the event messa...

Page 169: ...ivate the Automatic Stop for example by opening the connected robot cell door which has interlock connection with Auto matic Stop 2 If the event message 90523 Safety Control ler Protective Stop triggered does not ap pear in the event log then the test has failed and the root cause of the failure must be found Product manual OmniCore V250XT 169 3HAC073447 001 Revision B Copyright 2020 2022 ABB All ...

Page 170: ...red appears in the event log Activate the General Stop 2 If the event message 90523 Safety Control ler Protective Stop triggered does not ap pear in the event log then the test has failed and the root cause of the failure must be found 170 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 4 Maintenance 4 5 5 Function test of General Stop ...

Page 171: ...test is passed if the event message 10013 Emergency stop state appears in the event log Note For collaborative robots the event mes sage 90518 Safety controller Emergency stop triggered appears by default The message 10013 Emergency stop state is also available in the event log Press the emergency stop device Note If the event message 20223 Emergency stop conflict appears in the event log or the e...

Page 172: ...nt log Note For collaborative robots the event mes sage 90518 Safety controller Emergency stop triggered appears by default The message 10013 Emergency stop state is also available in the event log Press the emergency stop device Note If the event message 20223 Emergency stop conflict appears in the event log or the event message 10013 Emergency stop state and 90518 Safety controller Emer gency st...

Page 173: ...d speed higher than 250 mm s 2 This test is passed if the speed of the robot does not exceed 250 mm s otherwise the test is failed and the root cause of the fail ure must be found Start the program in manual mode and measure the time it takes for the robot to travel the distance Tip To get accurate results use sensors or I O signals to measure the time 3 Product manual OmniCore V250XT 173 3HAC0734...

Page 174: ...This page is intentionally left blank ...

Page 175: ...pair activity are listed in the respective procedures Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sure to read through the chapter Safety on page 13 before commencing any service work WARNING Wait at least three minutes after powering...

Page 176: ...side the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door Info illustration Action Insert the key to the door and turn it anti clockwise 1 Pull out the handle and turn it anti clock wise 2 Pull out the door with the handle 3 Closing the door Closing the door Info illustration Action Push the door back 1 Turn the handle clockwise and push i...

Page 177: ... DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Removing the rear cover Info illustration Action xx2100000442 Lift off the air filter cover plate 1 Continues on next page Product manual OmniCore V250XT 177 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair...

Page 178: ...age 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Refitting the rear cover Info illustration Action Refit the the rear cover 1 Continues on next page 178 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 AB...

Page 179: ...14 Secure it with the screws 2 xx2100000442 Refit the air filter cover plate 3 Product manual OmniCore V250XT 179 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 1 Opening the robot controller Continued ...

Page 180: ...s Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Continues on next page 180 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 Replacing the fans ...

Page 181: ...t Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT Continues on next page Product manual OmniCore V250XT 181 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 Replacing the fans Continued ...

Page 182: ...The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Removing the rear cover on page 177 Remove the rear cover of the controller 3 Removing the standard fans Note Illustration Action Disconnect standard fan G1 X1 K2 X17 G2 X1 K2 X17 G3 X1 K2 X17 G4 X1 K2 X17 1 Continues on next page 182 Product manual O...

Page 183: ...e standard fans Refitting the standard fans Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Continues on next page Product manual OmniCore V250XT 183 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 1 1 Replacing the standard fans Continued ...

Page 184: ...ge 43 2 xx2100000318 xx2100000311 Place the standard fan in the bracket Position the fan bracket on the controller using the hooks 3 xx2100000310 Secure the screws 4 Reconnect G1 X1 K2 X17 G2 X1 K2 X17 G3 X1 K2 X17 G4 X1 K2 X17 5 Continues on next page 184 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 1 1 Replacing the standard ...

Page 185: ... sure that the filter cover plate is correctly positioned 2 Perform the function tests to verify that the safety features work properly see Function tests on page 166 3 Product manual OmniCore V250XT 185 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 1 1 Replacing the standard fans Continued ...

Page 186: ...lustration shows the location of the internal fan in the controller xx2100002525 Continues on next page 186 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 2 Replacing the internal fan ...

Page 187: ...itive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Removing the internal fan Note Illustration Action xx2100000342 Remove the screws holding the fan as sembly 1 Remove the fan assembly from the mounting plate 2 Disconnect the internal fan G5 X1 K2 X17 3 Continues on next page Product manual OmniCore V250XT 187 3HAC07...

Page 188: ...more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Continues on next page 188 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2...

Page 189: ...rews holding the fan as sembly 5 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 Product manual OmniCore V250XT 189 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 2 Replacing the internal fan Continued ...

Page 190: ...250XT via myABB Business Portal www abb com myABB Note Article number Spare part Main computer fan 3HAC060653 001 Fan with contact Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Continues on next page 190 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright...

Page 191: ...eparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on pag...

Page 192: ...es 2 Remove the screws and lift out the robot signal exchange proxy 3 Removing the main computer fan Note Illustration Action Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 Continues on next page 192 Product manual OmniCore V250XT 3HAC073447 001 Revision B ...

Page 193: ... Disconnect the main computer fan A2 X1 3 xx2100002179 Lift the fan bracket off the hooks and re move it 4 Continues on next page Product manual OmniCore V250XT 193 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 3 Replacing the main computer fan Continued ...

Page 194: ... For more information see Electrical safety on page 28 1 xx2100000318 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 Continues on next page 194 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 3 Replacing the main co...

Page 195: ...tside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 xx2100002180 Place the main computer fan in the bracket 2 Continues on next page Product manual OmniCore V250XT 195 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 3 Replacing the main computer fan Continued ...

Page 196: ...uter and secure the screws 5 xx1900001909 Refitting the robot signal exchange proxy Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Continues on next page 196 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 3 Replacing the m...

Page 197: ... Fit the robot signal exchange proxy and secure the screws 3 Insert the cable ties into the locking holes 4 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 Product manual OmniCore V250XT 197 3HAC073447 001 Revision B Copyright 2020 2022 ABB All ri...

Page 198: ...tion shows the location of the power unit computer fan in the controller xx2100002281 Continues on next page 198 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 4 Replacing the power unit fan ...

Page 199: ...ocument 3HAC074000 008 Circuit diagram OmniCore V250XT Removing the power unit fan Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling...

Page 200: ... Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Place the power unit fan in the bracket ...

Page 201: ...N 5 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 Product manual OmniCore V250XT 201 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 2 4 Replacing the power unit fan Continued ...

Page 202: ...siness Portal www abb com myABB Note Article number Spare part DSQC3037 3HAC064662 001 Robot signal exchange proxy Mating connector for robot signal exchange proxy 3HAC065107 001 Harness Short circuit connector Harness K2 X2 K4 X8 A2 X1 3HAC064091 001 Harness 24_PC Harness K2 X12 K3 X6 K3 X7 3HAC059273 001 Harness dual channel safety Continues on next page 202 Product manual OmniCore V250XT 3HAC07...

Page 203: ... robot signal exchange proxy Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The ...

Page 204: ...4 K2 X1 A1 X6 K2 X17 G1 X1 G2 X1 G3 X1 G4 X1 G5 X1 A1 X2 K2 X11 A1 X2 K2 X7 K2 X22 Harn LV robot power X1 K2 X9 X13 FlexPendant X4 1 xx1900001495 Pull the cable ties out from the locking holes 2 xx1900001887 Remove the screws and lift out the robot signal exchange proxy 3 Continues on next page 204 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved...

Page 205: ...ROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Screws Torx pan head screw M4x8 4 pcs Fit the robot signal exchange proxy and secure the screws 3 xx1900001887 Continues on next page Product manual OmniCore V250XT 205 3HAC073447 001 Revision B Copyright 2020 2022 ABB All right...

Page 206: ... X6 K2 X17 G1 X1 G2 X1 G3 X1 G4 X1 G5 X1 A1 X2 K2 X11 A1 X2 K2 X7 K2 X22 Harn LV robot power X1 K2 X9 X13 FlexPendant X4 5 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 206 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 ...

Page 207: ...l www abb com myABB Note Article number Spare part DSQC1035 3HAC059187 001 Ethernet Extension switch 3014 1 Harness A2 X4 K4 X6 3HAC076473 001 Ethernet Harness Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Continues on next page Product manual OmniCore V250XT 207 3HAC07...

Page 208: ...pen the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Removing the Ethernet extension switch option Note Illustration Action Disconnect K2 X2 K4 X8 A2 X1 K4 X7 K5 1 X5 K3 1 X5 K4 X6 A2 X4 1 Continues on next page 208 Product manual...

Page 209: ...switch option Refitting the Ethernet extension switch option Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Continues on next page Product manual OmniCore V250XT 209 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 4 Replacing the Ethernet switch Continued ...

Page 210: ...hould be no gap between the upper surface of the Ethernet extension switch and the lower surface of highest bracket on the main computer xx1800000972 3 Reconnect K2 X2 K4 X8 A2 X1 K4 X7 K5 1 X5 K3 1 X5 K4 X6 A2 X4 4 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tes...

Page 211: ... V250XT via myABB Business Portal www abb com myABB Note Article number Spare part DSQC1039 3HAC060960 001 Connected Services 3G 3013 3 3HAC028459 001 Magnetic roof antenna 3G DSQC1040 3HAC060962 001 Connected Services WiFi 3013 2 3HAC059424 001 Magnetic roof antenna WiFi DSQC1041 3HAC061701 001 Connected Services Wired 3013 1 Harness A2 X5 K7 X2 3HAC076539 001 Ethernet Harness Continues on next p...

Page 212: ... doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Continues on next page 212 Pr...

Page 213: ...ine when you re move the cable from the cabinet 2 xx2100001054 Take the cable out from the cable grom met 3 xx1900001949 Remove the magnet part of the antenna from the top the cabinet 4 Continues on next page Product manual OmniCore V250XT 213 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 5 Replacing the connected services gateway Continued ...

Page 214: ...nector 1 xx1900001500 Carefully pull the side of the connected services gateway and rotate it tightly to take it out from the bracket 2 xx1900002329 i For connected services gateway wired there is no power cable Continues on next page 214 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 5 Replacing the connected services gateway Cont...

Page 215: ...onnected services gateway to the bracket and push carefully into position Note During the installation the gap between the lower surface of the connected ser vices gateway and the upper surface of the main computer should be zero 3 Reconnect K7 X1 K2 X3i K7 X2 A2 X5 4 i For connected services gateway wired there is no power cable Reconnecting the antenna Note Illustration Action xx2100001054 Inser...

Page 216: ...tions must be such that there is a minimum separation distance of 20 cm between the dedicated antenna and nearby persons Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 216 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 20...

Page 217: ... 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 DSQC1032 3HAC058665 001 Analog add on 3034 2 3HAC060925 001 Connectors I O Analog DSQC1033 3HAC058666 001 Relay add on 3035 2 3HAC060926 001 Connectors I O Relay Continues on next page Product manual OmniCore V250XT ...

Page 218: ...ion Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Conti...

Page 219: ... switch is not installed connect and discon nect the connector K5 1 X5 K3 1 X5 to from A2 X4 K5 1 X4 K2 X3 The harness connected to I O unit by customer 1 xx1900002446 Push the buckle of the digital base slightly and take out the digital base 2 xx1900002447 Continues on next page Product manual OmniCore V250XT 219 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 6...

Page 220: ...n ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 xx1900002447 Push the digital base into the bracket until you hear a clear clicking sound 3 Continues on next page 220 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5...

Page 221: ...discon nect the connector K5 1 X5 K3 1 X5 to from A2 X4 K5 1 X4 K2 X3 The harness connected to I O unit by customer 4 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 Product manual OmniCore V250XT 221 3HAC073447 001 Revision B Copyright 2020 2022 ...

Page 222: ...BB Business Portal www abb com myABB Note Article number Spare part DSQC1042 3HAC062908 001 DSQC1042 Extended safety 3HAC069538 001 Connectors Safety I O Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Continues on next page 222 Product manual OmniCore V250XT 3HAC073447 0...

Page 223: ...ty inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Removing the safety digital base device Note Illustration Action Disconnect K5 1 X5 K3 1 X5 A2 X4 K4 X7 Note If the Ethernet extension switch is installed connect and disconnect the connector K5 1 X5 K3 1 X5 to from K4 X7 If the Ethernet extension switch is not installed connect and discon nect the connector K5 1 X5 ...

Page 224: ...disconnect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Continues on next page 224 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB A...

Page 225: ...nsion switch is not installed connect and discon nect the connector K5 1 X5 K3 1 X5 to from A2 X4 K5 1 X4 K2 X3 The harness connected to I O unit by customer 4 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 Product manual OmniCore V250XT 225 3HAC...

Page 226: ...V250XT via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC063061 001 Main computer module assembly Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Continues on next page 226 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 202...

Page 227: ... the main computer by parts on page 235 Removing the main computer by assembly group Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handli...

Page 228: ...p tion K2 X2 K4 X8 A2 X1 K4 X7 K5 1 X5 K4 X6 A2 X4 For the connected services gateway K7 X1 K2 X3i K7 X2 A2 X5 Note The connector K7 X2 is locked grab the connector push it in to release it and then remove the connector For the main computer K2 X8 A2 X6 K2 X2 K4 X8 A2 X1 K2 X12 A2 K3 X6 A2 K3 X7 K6 X2 A2 X9 A2 X5 K7 X2 A2 X4 K4 X6 K5 1 X5 Note If the Ethernet extension switch is installed connect ...

Page 229: ...s gateway wired there is no power cable Removing the robot signal exchange proxy Note Illustration Action Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 Pull the cable ties out from the locking holes 2 Continues on next page Product manual OmniCore V250XT 2...

Page 230: ...d rotate it tightly to take it out from the bracket 1 Removing the connected services gateway Note Illustration Action xx1800000495 TOP VIEW Carefully pull the side of the connected services gateway and rotate it tightly to take it out from the bracket 1 Continues on next page 230 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 8 Re...

Page 231: ...he unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2000000419 xx1800000497 TOP VIEW Hook up the connected services gateway to the bracket and push carefully into position Note During the installation the gap between the lower surface of the connected ser vices gateway and the upper surface of the main computer should be zero 3 Continues on next page Product...

Page 232: ...ion in section The unit is sensitive to ESD on page 43 2 xx2000000419 xx1800000493 Hook up the Ethernet extension switch to the bracket and then push the switch into position Note During the installation there should be no gap between the upper surface of the Ethernet extension switch and the lower surface of highest bracket on the main computer xx1800000972 3 Continues on next page 232 Product ma...

Page 233: ... exchange proxy and secure the screws 3 Insert the cable ties into the locking holes 4 Refitting the main computer assembly to the cabinet Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the cont...

Page 234: ...onnected services and main computer 5 For the robot signal exchange proxy K2 X8 A2 X6 option K2 X2 K4 X8 A2 X1 K2 X12 A2 K3 X6 A2 K3 X7 K2 X10 A1 X13 K2 X4 A1 X9 K2 X3 K6 X1 A2 K3 X1 K5 1 X4 K7 X1 K2 X1 T2 X2 K2 X6 K2 X11 A1 X2 K2 X7 K2 X22 Harn LV robot power X1 K2 X9 X13 FlexPendant X4 Continues on next page 234 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All...

Page 235: ...t extension switch is not installed connect and discon nect the connector A2 X4 to from K5 1 X5 Concluding procedure Note Illustration Action Restoring the hardware settings on page248 Restore the hardware settings 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 Removing the main computer by parts Preparations Note Illustration Action ...

Page 236: ...nected services gateway scalable I O option and main computer 1 For the robot signal exchange proxy K2 X8 A2 X6 option K2 X2 K4 X8 A2 X1 K2 X12 A2 K3 X6 A2 K3 X7 K2 X10 A1 X13 K2 X21 TempSensor G3 TEMP K2 X4 A1 X9 K2 X3 A2 K3 X1 K7 X1 option 3032 1 K2 X3 K5 1 X4 option 3037 1 K2 X3 K3 1 X4 K2 X1 A1 X6 K2 X17 G1 X1 G2 X1 G3 X1 G4 X1 G5 X1 A1 X2 K2 X11 A1 X2 K2 X7 K2 X22 Harn LV robot power X1 K2 X9...

Page 237: ...4 X6 If the Ethernet extension switch is not installed connect and discon nect the connector A2 X4 to from K5 1 X5 A2 X5 K7 X2 A2 X6 K2 X8 A2 X9 A1 X3 A2 K3 X1 K2 X3 A2 K3 X6 A2 K3 X7 K2 X12 i For Connected Services Gateway wired there is no power cable Removing the robot signal exchange proxy Note Illustration Action xx1900001886 Pull the cable ties out from the locking holes 1 Continues on next ...

Page 238: ...on Note Illustration Action xx1900001888 Carefully pull the side of the Ethernet extension switch and rotate it tightly to take it out from the bracket 1 xx1800000491 Continues on next page 238 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 239: ... side of the connected services gateway and rotate it tightly to take it out from the bracket 1 xx1800000495 TOP VIEW Continues on next page Product manual OmniCore V250XT 239 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 240: ...puter ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 2 xx1900001894 Continues on next page 240 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 241: ...trap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 xx1900001894 Fit the main computer to the mounting plate 3 xx1900001893 Continues on next page Product manual OmniCore V250XT 241 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 ...

Page 242: ...net disconnect the mains power For more information see Electrical safety on page 28 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 Continues on next page 242 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 8 Replac...

Page 243: ...e of the main computer should be zero 3 xx1800000495 TOP VIEW Refitting the Ethernet extension switch option Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Continues on next page Product manual OmniCore V250XT 243 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repai...

Page 244: ...thernet extension switch to the bracket and then push the switch into position Note During the installation there should be no gap between the upper surface of the Ethernet extension switch and the lower surface of highest bracket on the main computer xx1800000972 3 xx1800000491 Continues on next page 244 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights r...

Page 245: ...ARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Screws Torx pan head screw M4x8 4 pcs Fit the robot signal exchange proxy and secure the screws 3 xx1900001887 Continues on next page Product manual OmniCore V250XT 245 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 R...

Page 246: ...STATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 2 xx2100000318 Reconnect all the connectors on as sembly of the robot signal exchange proxy ethernet extension seven port switch option ABB ability connected services scalable I O digital base op tion and main computer 3 Continues on next page 246 Product manual ...

Page 247: ...2 X5 Note The connector K7 X2 is locked grab the connector push it in to release it and then remove the connector For the main computer A2 X1 K2 X2 A2 X3 X24 A2 X4 K4 X6 K5 1 X5 Note If the Ethernet extension switch is installed connect and disconnect the connector A2 X4 to from K4 X6 If the Ethernet extension switch is not installed connect and discon nect the connector A2 X4 to from K5 1 X5 A2 X...

Page 248: ...er 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 Utilities Note Illustration Action Download the hardware information file hwsettings rsf from MyABB or from a previous system backup 1 xx1900000110 Access the RobotWare Installation Utilit ies 2 Tap Advance...

Page 249: ...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 is completed 7 Product manual OmniCore V250XT 249 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 8 Replacing the main computer Continued ...

Page 250: ...NING 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 250 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 9 Replacing the power unit ...

Page 251: ...or controller on page 414 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT Removing the power unit Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door ...

Page 252: ...322 Remove the screws and pull the power unit out from the two guiding pins on the mounting plate CAUTION Only the sheet metal on the power unit can be used for holding Do not touch the connectors or the filter on the power unit CAUTION The weight of the power unit is 13 kg Use protective gloves when lifting this unit CAUTION The cabling is sensitive to mechanical damage Handle it with care to avo...

Page 253: ...g the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Screws Torx pan head screw M4x8 4 pcs Position the power unit on the lower guiding pin on the mounting plate and then tip the unit upwards against the up per guiding pin Secure the screws 3 Tightening torque 2 Nm xx2100000322 Continues on next page Product manual OmniCore V250XT 253 3HAC073447...

Page 254: ...Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 254 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 9 Replacing the power unit Continued ...

Page 255: ...99 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 OmniCore V250XT 255 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 10 Replacing the power supply ...

Page 256: ... equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT Removing the DSQC 609 power supply Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power...

Page 257: ...ply Note Illustration Action xx1900001907 Remove the end clamp besides the power supply with a screwdriver 1 xx1900001908 Disconnect T5 X1 A1 X7Terminal block T8 X1 A1 X15Terminal block T5 X2 24VTerminal block T8 X2 24VTerminal block 2 Remove the screw and the power supply 3 Continues on next page Product manual OmniCore V250XT 257 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reser...

Page 258: ...the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Screws Cross recessed cheese head screw M4x8 1 pcs Fit the power supply to the bracket and fasten it with screw 3 xx1900001908 Reconnect T5 X1 A1 X7Terminal block T8 X1 A1 X15Terminal block T5 X2 24VTerminal block T8 X2 24VTerminal block 4 Continues on next page 258 Product manual OmniCore V250X...

Page 259: ...NGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Continues on next page Product manual OmniCore V250XT 259 3HAC0...

Page 260: ...ess the lower buckle to release and remove the power supply 3 Refitting the DSQC 634 power supply Refitting the power supply Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Continues on next page 260 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights ...

Page 261: ...the power supply into the bracket and push the lower of it until you hear a clear clicking sound 3 Reconnect T6 X1 A1 X7Terminal block T9 X1 A1 X15Terminal block T6 X2 24VTerminal block T9 X2 24VTerminal block 4 xx1900002443 Refit the end clamp besides the power supply 5 Continues on next page Product manual OmniCore V250XT 261 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved ...

Page 262: ...he function tests to verify that the safety features work properly see Function tests on page 166 1 262 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 10 Replacing the power supply Continued ...

Page 263: ...NING 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 OmniCore V250XT 263 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 11 Replacing the drive unit ...

Page 264: ...74106 001 Harness CTRL_FB Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT Removing the drive unit Preparations Note Illustration Action DANGER Before doing any work inside the c...

Page 265: ...X11 T4 X5 A1 X4 T4 X3 A1 X12 T4 X1 A1 X5 1 Lengthened screwdriver Remove the screws and pull the drive unit out from the two guiding pins on the mounting plate CAUTION The weight of the drive unit is 11 kg Use protective gloves when lifting this unit 2 xx2100000338 CAUTION The cabling is sensitive to mechanical damage Handle it with care to avoid damage to the cabling or the connector avoid any ki...

Page 266: ...g the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Screws Torx pan head screw M4x8 4 pcs Position the drive unit on the lower guid ing pin on the mounting plate and then tip the unit upwards against the upper guiding pin Secure the screws 3 Tightening torque 2 Nm xx2100000338 Continues on next page 266 Product manual OmniCore V250XT 3HAC073447...

Page 267: ...re Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 Product manual OmniCore V250XT 267 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 11 Replacing the drive unit Continued ...

Page 268: ...re V250XT via myABB Business Portal www abb com myABB Note Article number Spare part DSQC1006 3HAC043383 001 DeviceNet Board Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Continues on next page 268 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 ...

Page 269: ... more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Removing the main computer assembly Note Illustration Action Disconnect all the connectors on ...

Page 270: ...K7 X2 A2 X5 Note The connector K7 X2 is locked grab the connector push it in to release it and then remove the connector For the main computer K2 X8 A2 X6 K2 X2 K4 X8 A2 X1 K2 X12 A2 K3 X6 A2 K3 X7 K6 X2 A2 X9 A2 X5 K7 X2 A2 X4 K4 X6 K5 1 X5 Note If the Ethernet extension switch is installed connect and disconnect the connector A2 X4 to from K4 X6 If the Ethernet extension switch is not installed ...

Page 271: ... gateway wired there is no power cable Removing the robot signal exchange proxy Note Illustration Action Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 Pull the cable ties out from the locking holes 2 Continues on next page Product manual OmniCore V250XT 27...

Page 272: ...SCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 xx1900001909 Remove the attachment screws and take the cover off 2 Continues on next page 272 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 12 Replacing the fieldbus master Continued ...

Page 273: ...ny work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 xx2100000318 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 Continues on next page Product manual OmniCore V250XT 273 3HAC073447 001 Revision B Copyright 2020 2022 ABB All r...

Page 274: ...he side of the computer 1 xx2000000419 xx1900001911 Insert the fieldbus master straight into the card slots along the guide rail 2 Screws Screw with flange M3x6 1 pcs Secure the fieldbus adapter with the screw 3 xx1900001910 Continues on next page 274 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 12 Replacing the fieldbus master C...

Page 275: ...e 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2000000419 Screws Torx pan head screw M4x8 4 pcs Fit the robot signal exchange proxy and secure the screws 3 Insert the cable ties into the locking holes 4 Continues on next page Product manual Om...

Page 276: ... strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 2 xx2100000318 xx1900001885 Refit the assembly onto the mounting plate 3 xx1900001878 Continues on next page 276 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 12 Replacing th...

Page 277: ...ion K2 X2 K4 X8 A2 X1 K4 X7 K5 1 X5 K4 X6 A2 X4 For the connected services gateway K7 X2 A2 X5 Note The connector K7 X2 is locked grab the connector push it in to release it and then remove the connector For the main computer K2 X8 A2 X6 K2 X2 K4 X8 A2 X1 K2 X12 A2 K3 X6 A2 K3 X7 K6 X2 A2 X9 A2 X5 K7 X2 A2 X4 K4 X6 K5 1 X5 Note If the Ethernet extension switch is installed connect and disconnect t...

Page 278: ... the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 278 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 12 Replacing the fieldbus master Continued ...

Page 279: ...re V250XT via myABB Business Portal www abb com myABB Note Article number Spare part DSQC1015 3HAC048858 001 Safety Module Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Continues on next page Product manual OmniCore V250XT 279 3HAC073447 001 Revision B Copyright 2020 20...

Page 280: ...ns Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 x...

Page 281: ... holes 2 Remove the screws and lift out the robot signal exchange proxy 3 Removing the safety module Note Illustration Action Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 Continues on next page Product manual OmniCore V250XT 281 3HAC073447 001 Revision B ...

Page 282: ...pull it out from the card slot 3 Refitting the safety module Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Continues on next page 282 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 13 Replacing the safety modul...

Page 283: ...TIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 Insert the safety module straight into the card slots along the guide rail 2 Screws Screw with flange M3x6 1 pcs Secure the safety module with the screw 3 xx2100002176 Continues on next page Product manual OmniCore V250XT 283 3HAC073447 001 Revision B...

Page 284: ...ge 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2000000419 Screws Torx pan head screw M4x8 4 pcs Fit the robot signal exchange proxy and secure the screws 3 Insert the cable ties into the locking holes 4 Continues on next page 284 Product manu...

Page 285: ...e the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 Product manual OmniCore V250XT 285 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 13 Replacing the safety module Continued ...

Page 286: ...t 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 414 Standard toolkit ESD protective wrist band Continues on next page 286 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 14 Replacing...

Page 287: ...ns Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 x...

Page 288: ... Remove the screws and lift out the robot signal exchange proxy 3 Removing the main computer battery Note Illustration Action Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 Continues on next page 288 Product manual OmniCore V250XT 3HAC073447 001 Revision B ...

Page 289: ...ry Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Continues on next page Product manual OmniCore V250XT 289 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 14 Replacing the main computer battery Continued ...

Page 290: ... Location of wrist strap button ELECTROSTATIC DISCHARGE ESD When handling the computer outside of the controller use the wrist strap button located on the side of the computer 1 xx2000000419 xx2100002582 Insert the battery into the slot in the main computer 2 Continues on next page 290 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2...

Page 291: ...8 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2000000419 Screws Torx pan head screw M4x8 4 pcs Fit the robot signal exchange proxy and secure the screws 3 Insert the cable ties into the locking holes 4 Continues on next page Product manual OmniC...

Page 292: ...e door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 292 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 14 Replacing the main computer battery Continued ...

Page 293: ...e parts of the OmniCore V250XT 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 Power cable of CTM 3HAC069618 001 Harness 24V_CTM 3HAC076594 001 Ethernet harness for CTM Continues on next page Product manual OmniCore V250XT 293 3HAC073447 001 Revision B Copyright 2020 2022 ABB Al...

Page 294: ...abinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Removing the conveyor tracking module option Note Illustr...

Page 295: ...as sembling work 2 xx1900001913 Refitting the conveyor tracking module option Refitting the conveyor tracking module option Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Continues on next page Product manual OmniCore V250XT 295 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights r...

Page 296: ...t is sensitive to ESD on page 43 2 xx2100000318 xx1900001913 Hang the conveyor tracking module into the bracket and push the lower of it until you hear a clear clicking sound 3 xx1900001912 Continues on next page 296 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 15 Replacing the conveyor tracking module CTM Continued ...

Page 297: ...hesive part 4 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 Product manual OmniCore V250XT 297 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 15 Replacing the conveyor tracking module CTM Continued ...

Page 298: ...atest spare parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Note Article number Spare part Option 3005 1 Moist particle filter 3HAC075739 001 Air filter coarse assembly Option 3005 2 Moist dust filter 3HAC075740 001 Air filter fine assembly Continues on next page 298 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repa...

Page 299: ... Document 3HAC074000 008 Circuit diagram OmniCore V250XT Removing the air filter Preparations Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Removing the air filter Note Illustration Action xx2100000442 Remove the air filter unit 1 Continues on next page Product manual OmniCore V250XT 299 3...

Page 300: ...r element to the filter and secure with the metallic line 1 Refitting the air filter The procedure below details how to refit the fine filter that is option 3005 2 Moist dust filter Note Illustration Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Refit the air filter unit to the cabinet 2 Continues on next p...

Page 301: ...the function tests to verify that the safety features work properly see Function tests on page 166 1 Product manual OmniCore V250XT 301 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 16 Replacing the air filter Continued ...

Page 302: ...pare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Continues on next page 302 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 17 Replacing the break resistor bleeder ...

Page 303: ...he cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Removing the rear cover on page 177 Remove the rear cover of the controller 3 Removing the break r...

Page 304: ... Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Refit the break resistor bleeder and its bracket 3 xx2100002198 Secure the screw holding the break res istor bleeder bracket 4 Remove any remaining old shrink tubes from the cables 5 Continue...

Page 305: ...over on page 178 Refit the rear cover of the controller 1 Make sure that the filter cover plate is correctly positioned 2 Perform the function tests to verify that the safety features work properly see Function tests on page 166 3 Product manual OmniCore V250XT 305 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 2 17 Replacing the break resistor bleeder Continued ...

Page 306: ...tal www abb com myABB Note Article number Spare part Harness 1xSMB 3HAC078210 001 Harness SMB connection Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT Continues on next page 3...

Page 307: ...the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Removing the manipulator signal connector Note Illustration Action Loosen the screw and disconnect SMB T4 X16 1 Remove cable ties and cable supports 2 xx2100000827 Remove nuts and attachment screws on the cover plate 3 Push the manipulator signal connector out through the front panel 4 Continues on next page ...

Page 308: ...ensitive to ESD on page 43 2 Insert the 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 xx2100000827 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 ...

Page 309: ...yABB Note Article number Spare part 3HAC064332 001 Harness HV Manipulator Motor Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit ESD protective wrist band Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT Continues on next page Product manual OmniCore V2...

Page 310: ...IC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Removing the motor connector Note Illustration Action Disconnect the following connectors for the motor connector T4 X7 T4 X8 T4 X9 T4 X10 T4 X11 T4 X12 T4 X15 X1 K2 X7 X22 PE 1 PE 2 1 Continues on next page 310 Product manual OmniCor...

Page 311: ...eed 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 cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Continues on next page Product manual OmniCore V250XT 311 3HAC073447 001 Revision B Copyright 2020 2022 ABB Al...

Page 312: ...inet and fasten it with the screws 3 xx2100000813 Reconnect T4 X7 T4 X8 T4 X9 T4 X10 T4 X11 T4 X12 T4 X15 X1 K2 X7 X22 PE 5 PE 6 4 Secure the motor connector cables with the velcro on the frame of the cabinet Tip Use the same position as from removing the motor connector 5 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Continues on next page 312 Product...

Page 313: ...ests to verify that the safety features work properly see Function tests on page 166 2 Product manual OmniCore V250XT 313 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 2 1 Replacing the motor connector Continued ...

Page 314: ...at are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Note Article number Spare part Harness TPU 3HAC071006 001 Harness TPU connection Continues on next page 314 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 3 Replacing the HMI signal FlexPendant...

Page 315: ...n page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Removing the HMI signal connector Note Illustration Action Cut the cable ties and remove the cables out from the clips in the cabinet carefully Note Make records abo...

Page 316: ...00830 Remove the screws 3 xx2100000831 Remove the cover plate 4 Continues on next page 316 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 3 Replacing the HMI signal FlexPendant connector Continued ...

Page 317: ...e cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Continues on next page Product manual OmniCore V250XT 317 3HAC073447 001 Revision B Copyright 2020 ...

Page 318: ...TPU X4 K2 X9 X13 4 Secure the cables on HMI signal connect or with new cable ties Tip Use the same position as from removing the HMI signal connector 5 xx2100000831 Refit the cover plate 6 Continues on next page 318 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 3 Replacing the HMI signal FlexPendant connector Continued ...

Page 319: ...on Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 Product manual OmniCore V250XT 319 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 3 Replacing the HMI signal FlexPendant connector Continued ...

Page 320: ...ble can be out of date See the latest spare parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC066396 001 Cable grommet asm 3HAC073333 001 Harness network connection 2xM12 3HAC074398 001 Harness network connection 1xM12 3HAC069954 001 Blind plate 3HAC070894 001 Harness Ethernet comm 5xM12 Required tools and equipment Note Article number Equi...

Page 321: ... strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Removing the cable grommet assembly Note Illustration Action Remove the cables out from the clips in the cabinet carefully Note Make records about the sequence that cables are removed The cables need to be ins...

Page 322: ...et 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 322 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 4 Replacing the cable grommet assembly Continued ...

Page 323: ...02334 Remove the attachment screws on the frame and cover strip together 3 xx1900002335 Remove the cover strip from the frame 4 Continues on next page Product manual OmniCore V250XT 323 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 4 Replacing the cable grommet assembly Continued ...

Page 324: ...ve the grommets in the upper row first and then the second row 5 xx1900002337 Remove the cable form the correspond ing KT grommet 6 Continues on next page 324 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 4 Replacing the cable grommet assembly Continued ...

Page 325: ...re point ing to the open side of the frame half flat sides pointing upwards Note The fl at side of the grommets in the up per row have to point downwards so that all flat sides rest on each other When using single row frames the fl at side has to point towards the cover strip 2 xx1900002335 Refit the cover strip onto the frame 3 Continues on next page Product manual OmniCore V250XT 325 3HAC073447 ...

Page 326: ... 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 326 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 4 Replacing the cable grommet assembly Continued ...

Page 327: ...binet disconnect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Continues on next page Product manual OmniCore V250XT 327 3HAC073447 001 Revision B Copyright 2020 2022...

Page 328: ... Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 328 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 4 Replacing the cable grommet assembly Continued ...

Page 329: ...hat are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC079506 001 Harness ETH outlet with cable Continues on next page Product manual OmniCore V250XT 329 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 5 Replacing the Ethernet outlet connector ...

Page 330: ... doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Opening the door on page 176 Open the door 2 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 3 xx2100000318 Continues on next page 330 Pr...

Page 331: ... cable out from the upper side 5 Refitting the Ethernet outlet connector with cable Refitting the 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 28 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform atio...

Page 332: ...net Tip Use the same position as from removing the harness ETH outlet with cable 6 Concluding procedure Note Illustration Action Closing the door on page 176 Close the door 1 Perform the function tests to verify that the safety features work properly see Function tests on page 166 2 332 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 ...

Page 333: ... are listed in the table can be out of date See the latest spare parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC065549 001 LED indicator Continues on next page Product manual OmniCore V250XT 333 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 6 Replacing the LED indicator ...

Page 334: ...n Action DANGER Before doing any work inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 Location of wrist strap button ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 xx2100000318 Continues on next page 334 Product manual OmniCore V...

Page 335: ...ork inside the cabinet disconnect the mains power For more information see Electrical safety on page 28 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 2 Insert the LED indicator into the cover from outer side of the door and the screw from inner side and screw them up 3 Continues on...

Page 336: ...s 4 Concluding procedure Note Illustration Action Perform the function tests to verify that the safety features work properly see Function tests on page 166 1 336 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 3 6 Replacing the LED indicator Continued ...

Page 337: ... table can be out of date See the latest spare parts of the OmniCore V250XT via myABB Business Portal www abb com myABB Note Article number Spare part Harness TPU 3HAC071006 001 Harness TPU connection Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit Continues on next page Product manual OmniCore V2...

Page 338: ...o ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 1 Disconnect the FlexPendant from the controller 2 xx1800001189 Remove the attachment screws for the power cable cover 3 xx1800001190 Remove the power cable cover 4 Continues on next page 338 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reser...

Page 339: ...ustration Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 1 Continues on next page Product manual OmniCore V250XT 339 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the power cable and power cable cover Continued ...

Page 340: ... pcs xx1800001196 Refit the power cable cover and tighten the screws 4 Perform the function tests to verify that the safety features work properly see Function tests on page 166 5 340 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 4 1 Replacing the power cable and power cable cover Continued ...

Page 341: ...s Portal www abb com myABB Note Article number Spare part 3HAC065408 001 Joystick guard Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit for controller on page 414 Standard toolkit Required documents Note Article number Document 3HAC074000 008 Circuit diagram OmniCore V250XT Continues on next page Product manual OmniCore V250XT 341 3HAC07344...

Page 342: ...Remove the attachment screws 3 xx1800001199 Remove the joystick protection 4 Refitting the joystick protection Note Illustration Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety inform ation in section The unit is sensitive to ESD on page 43 1 Continues on next page 342 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2...

Page 343: ...tick protection 2 xx1800001206 Secure the screws 3 Countersunk head screw ST2 9 X 10 6 pcs Product manual OmniCore V250XT 343 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 5 Repair 5 4 2 Replacing the joystick protection Continued ...

Page 344: ...via myABB Business Portal www abb com myABB Note Article number Spare part 3HAC065419 001 Fasten strip Replacing the fasten strip Note Illustration Action Open the velcro on the fasten strip 1 Take the fasten strip out from the holes 2 Insert the new fasten strip into the holes one by one 3 Secure the velcro in a suitable length 4 344 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyri...

Page 345: ...rding to their nature which is all iron together and all plastic together and disposed of accordingly These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed Disposal of storage media Before disposal of any storage equipment anything from an SD card to a complete controller make sure that all sensitive informa...

Page 346: ...t 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 according to local regulations to prevent health or environmental hazards Example application Material Heat sinks on power supplies and drive units Aluminium Main computer Batteries Lithium Electronics Brom...

Page 347: ... phenyl ethers Polybrom inated bi phenyls Hexa valent chromium Cadmium Mercury Lead Cabinet Drive unit Power unit Computer and logic unit x Small fan x Cable harness x Cable glands Accessories This table was developed according to the provisions of SJ T 11364 The content of such hazardous substance in all homogeneous materials of such com ponent is below the limit required by GB T 26572 x The cont...

Page 348: ...l are based on the regulation in China These are not necessary to be concerned in other countries 348 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 6 Decommissioning 6 2 Environmental information Continued ...

Page 349: ...correctly fitted 2 Replace one thing at a time 3 Do not replace units randomly 4 Make sure that there are no loose screws turnings or other unexpected parts remaining after work has been performed 5 When the work is completed verify that the safety functions are working as intended Keep a track of history Make a historical fault log to keep track of problems over time Consult those working with th...

Page 350: ...ies between hardware and software options and their configuration The robot recently had a software upgrade Check connections software versions The robot has recently been moved from one site to another an already working robot 350 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 1 Introduction to troubleshooting Continued ...

Page 351: ...leasing the robot brakes on page 361 Problem starting or connecting the FlexPendant on page 364 Problem using the joystick on page 368 Controller fails to start on page 369 Reflashing firmware failure on page 370 Inconsistent path accuracy on page 371 Continues on next page Product manual OmniCore V250XT 351 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 ...

Page 352: ...Check the FlexPendant for errors and warnings 2 DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers Recommended working procedure If no LEDs are lit on the controller during start up use this procedure to troubleshoot what might cause the problem Continues on next page 352 Product manual OmniCore V250XT 3HAC073447 001 Re...

Page 353: ...X1 Process power supply T5 T8 X1 24V TRUNK X1 X2 X3 PC PS X4 X13 HMI 24V SYS DRV LED MS LED Main computer A2 24V PC LED X1 24V HMI LED HMI connection X4 FlexPendant 24V HMI X9 Robot signal exchange proxy K2 X7 X15 AC LED Safety board K3 X1 24V SYS xx2100001063 Continues on next page Product manual OmniCore V250XT 353 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troublesh...

Page 354: ...C 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 Troubleshoot power unit Ok Problem solved Check Q0 power out Not lit Troubleshoot LEDs xx2100001064 Continues on next page 354 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 2 ...

Page 355: ... details see Circuit diagram OmniCore V250XT 3 Check that the AC input cable is properly connec ted 4 Use a multimeter and insulating gloves Check the output voltage of Q0 Make sure that Q0 is closed 5 Replace if damaged Replace if damaged Check the fuse F1 6 If abnormal troubleshoot the power unit See Troubleshooting the power unit on page 382 Check connector A1 X1 7 If abnormal troubleshoot the ...

Page 356: ...Circuit diagram OmniCore V250XT Preparations Action Make sure that the controller is switched on 1 Wait 30 s 1 min to enable start up sequence Check the FlexPendant for errors and warnings 2 DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers Continues on next page 356 Product manual OmniCore V250XT 3HAC073447 001 Revisi...

Page 357: ... unit A1 X1 X6 PE1 PE2 L1 L2 L3 Fuse F1 L1 L2 L3 L1 L2 L3 Power supply ODVA T6 79 X1 Process power supply T5 T8 X1 24V TRUNK X1 X2 X3 PC PS X4 X13 HMI 24V SYS DRV LED MS LED Main computer A2 24V PC LED X1 24V HMI LED HMI connection X4 FlexPendant 24V HMI X9 Robot signal exchange proxy K2 X7 X15 AC LED Safety board K3 X1 24V SYS xx2100001063 Continues on next page Product manual OmniCore V250XT 357...

Page 358: ...unit T4 Not OK Check LEDs PC HMI OK Troubleshoot robot signal exchange proxy K2 Not lit Check Module Status LED on A1 Troubleshoot power unit A1 Troubleshoot power unit A1 xx2100001066 Location of LEDs LEDs on the robot signal exchange proxy MS AS1 GS1 AS2 GS2 ES1 ES2 ESOUT1 ESOUT2 MON AC PS PC HMI EP xx2100001067 Continues on next page 358 Product manual OmniCore V250XT 3HAC073447 001 Revision B ...

Page 359: ...ange proxy on page 405 Look at the LED PS 2 LED MS should be green If not see Troubleshooting the robot signal exchange proxy on page 405 Look at the LED MS 3 LED PC and LED HMI should be green If not see Troubleshooting the robot signal exchange proxy on page 405 Look at the LEDs PC and HMI 4 For more details about the LEDs see Troubleshooting the main computer on page 398 Look at the LEDs PC PWR...

Page 360: ...anges in the system on page 360 New system configuration 1 Reset the RobotWare system The RAPID program and system parameters will be removed and the system will be set to default state but without system failure 2 Re implement your programs or configuration changes or 3 Selectively load contents from the previous system backup and correct possible errors when loading Rollback all changes in the s...

Page 361: ...ler while powered on must be performed by personnel trained by ABB or by ABB field engineers Recommended working procedure If the brakes do not release no robot movement is possible and a number of error log messages can occur Use this procedure to troubleshoot what might cause the problem Look at the following block diagram to understand how power is connected from incoming and forward Block diag...

Page 362: ...nnec 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 release is ok Not ok Contact ABB Problem solved Troubleshoot brake release on manipulator main computer A2 robot signal exchange proxy K2 power unit A1 Troubleshoot power unit A1 xx2100001142 Continue...

Page 363: ...3 X14 Tip For more details see Circuit diagram OmniCore V250XT 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 is ok T4 X15 X1 5 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 power unit is o...

Page 364: ...the main interface xx1900000917 Required test equipment Equipment needed for troubleshooting Note Equipment Multimeter Insulating gloves 3HAC074000 008 Circuit diagram OmniCore V250XT 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 Continues on next page 364 Product manual OmniCore V250XT...

Page 365: ...g block diagram to understand how power is connected from incoming and forward Block diagram Robot signal exchange proxy K2 PC X9 X13 HMI Safety board A2 K3 ES EN MON 24V HMI LED Ethernet LED HMI connection X4 FlexPendant MS LED Dual channel safety X6 X7 Ethernet X12 X8 X6 X1 X1 X3 X2 24V PC 24V SYS Main computer A2 xx2100001143 Continues on next page Product manual OmniCore V250XT 365 3HAC073447 ...

Page 366: ...endant cable Cable damaged Cable ok Check connection K2 X13 to X4 Check connector X4 Connection not ok Connection not ok Connections ok Start FlexPendant Problem solved Ok Not starting Replace FlexPendant Replace FlexPendant cable Reset the FlexPendant xx2100001144 Continues on next page 366 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Trou...

Page 367: ...next step Check the FlexPendant cable for any damage 4 If it is not ok repair the con nection and go to step six If it is ok go to the next step Check that the connection from the robot signal exchange proxy to the HMI signal connector is ok K2 X13 X4 5 If any connection fails re pair the connection and go to step six If the connections are ok go to the next step Check that the connection from the...

Page 368: ...hat the joystick lock is not activated 1 Make sure the controller is in manual mode 2 Make sure the FlexPendant is connected cor rectly to the controller 3 If the joystick is still not working then replace the FlexPendant Press the reset button located next to the USB port on the back of the FlexPendant Note The reset button only resets the FlexPendant not the system on the controller 4 368 Produc...

Page 369: ... to start in RobotWare Installation Utilities mode Forcing startup of the RobotWare Installation Utilities mode Repeat the following action two times in a row 1 Turn on the main power switch 2 Wait for approximately 15 seconds Note The PC STAT LED should be in flashing red state 3 Turn off the main power switch The installed system is de selected and in the next startup the RobotWare Installation ...

Page 370: ...blem Note Action Read the message to see which unit has failed 1 If the relevant unit has been replaced recently make sure that the versions of the old and the new unit are identical 2 Check the software versions 3 If RobotWare has been updated recently make sure that the versions of the old and the new unit are identical 4 If the problem remains contact your local ABB for information about which ...

Page 371: ...on Remove the obstacles Study the path of the robot in motion to find if an external force for example an external cable package is colliding with or restricting the movement of the robot 1 Improve the ventilation around the robot In high temperature environments the material in the robot can expand thereby causing inconsistent path accuracy 2 How to define these are described in Oper ating manual...

Page 372: ... in section Problem re leasing the robot brakes on page 361 Make sure the robot brakes work prop erly 9 The swivel has an in built resistance that needs to be set in the system parameters If applicable Check the setting for the swivel 10 372 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 2 9 Inconsistent path accuracy Contin...

Page 373: ...e malfunctioning fans see Replacing the standard fans on page 182 Check that the standard fans are working 1 Replace malfunctioning fans see Replacing the internal fan on page 186 Check that the internal fan is working 2 Replace malfunctioning fans see Replacing the power unit fan on page 198 Check that the power unit fan is working 3 If air filters are not clean see Cleaning air filter on page 15...

Page 374: ...ting the power unit on page 382 Power unit Troubleshooting fieldbuses and I O on page 389 Scalable I O Troubleshooting the connected services gateway on page 390 ABB Ability Connected Ser vices Troubleshooting the Ethernet switch on page 396 Ethernet switch Troubleshooting the main computer on page 398 Main computer Troubleshooting the power supply ODVA on page 403 and Troubleshooting the process ...

Page 375: ...t to the USB port 1 Note If protective gloves are used these must be compatible with touch screens when using the FlexPend ant If the FlexPendant is not responding or does not operate correctly see Problem starting or con necting the FlexPendant on page 364 2 Check the cable for connections and integrity 3 Check the 24 V power supply 4 Read the error event log message and follow any instructions o...

Page 376: ...ration shows the location of the drive unit in the controller xx2100000337 Continues on next page 376 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 3 Troubleshooting the drive unit ...

Page 377: ...g 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 the drive unit is missing Red steady Internal error Red flashing 1Hz Firmware error or self test failure Green flashing 1Hz Communica tion error to another module MS Module Status LED A Continues on...

Page 378: ...Yellow 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 Required test equipment Equipment needed for troubleshooting Note Equipment Multimeter Insulating gloves 3HAC074000 008 Circuit diagram OmniCore V250XT Preparations Action Check the FlexPendant for errors ...

Page 379: ...tion not ok Still flashing red Measure 24_BRAKE X13 X14 Abnormal Normal Red xx2100001982 Troubleshooting procedure The troubleshooting table is supposed to be used as a detailed instruction together with the troubleshooting flowchart Note Action Make sure that the drive unit is operational Power on the controller Check the Module Status LED A on the drive unit E A B C D xx2100002221 1 Wait at leas...

Page 380: ...e is a problem with the 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 263 If the measured voltage is abnormal there is an issue with the 24 VDC supply from the power unit See Troubleshoot ing the power unit on page 382 Measure the 24VDC SYS DRV input at connector X1 X2 6 Mak...

Page 381: ...ixed 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 related cables between the modules by reconnecting the cables X15 X16 X17 11 If the connection seems OK the fault has been fixed Proceed with step 1 If the fault remains see Troubleshooting the power unit on page 382 Replace the safety related cables X...

Page 382: ...ion below shows the location of the power unit in the controller xx2100000321 Continues on next page 382 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 4 Troubleshooting the power unit ...

Page 383: ...No color Voltage between DC DC 60 VDC Yellow Voltage between DC DC 60 VDC DC BUS High Voltage LED A Continues on next page Product manual OmniCore V250XT 383 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 4 Troubleshooting the power unit Continued ...

Page 384: ...ATIONAL 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 the EtherCAT slave port 1 Off No link Yellow flashing Link and activity Yellow steady Link without activity LINK ACT E Shows the network communication speed Green steady Speed is 100 Mbps Off Speed ...

Page 385: ...exPendant 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 Voltage LED Not lit Flashing green Connection ok Abnormal Measure 24V_TRUNK A1 X6 Replace power unit Read error message FlexPendant Disconnect 24V_TRUNK and restart Normal Measure 24V_TRUNK Abnormal...

Page 386: ... 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 Make sure that the power cables are connected properly at both ends 3 If there is a problem with the connection pro ceed with step 4 If the connection seems OK proceed with step 5 Replace AC input cable...

Page 387: ...TUS 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 250 If the connection and cables seem OK proceed with step 11 Make sure that the cables are con nected properly at both ends DC_OUT X4 and X8 AC_OUT X7 and X15 24V_TRUNK X6 24V_BRAKE X11 and X14 9 If there is a problem with the connection pro ceed with s...

Page 388: ...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 power unit on page 250 Test starting with DC_OUT loads disconnected 14 If the connection and cables seem OK proceed with step 11 Make sure that the cables are con nected properly at both ends CTRL FB A1 X2 15 If there is a problem with the connection pro c...

Page 389: ...leshoot the fieldbuses and I O units can be found in the manual for the respective fieldbus or I O unit See References on page 9 Product manual OmniCore V250XT 389 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 5 Troubleshooting fieldbuses and I O ...

Page 390: ...hows the location of the connected services gateway in the controller xx2100000446 Continues on next page 390 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 6 Troubleshooting the connected services gateway ...

Page 391: ...ssing Red solid or flashing Internal error Replace the unit Green flashing continuously Communication error to another module view error messages For the connected services 3G an orange LED indicator externally visible on the front indicates the status of the 3G connection LINK Orange ON flashing 3G modem on searching network ON solid 3G modem on and connected to network For the connected services...

Page 392: ...Equipment Multimeter Insulating gloves Preparations Action Check the FlexPendant for errors and warnings 1 Power the controller off Wait one minute power the controller on 2 Wait 30 60 seconds after power on 3 Make sure that the control system power is in run time mode Continues on next page 392 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 ...

Page 393: ...nna sim card etc Not ok Ok Not lit or solid Ok Ok Ok Ok Not ok Not ok Repair connection Not ok Troubleshoot robot signal exchange proxy K2 Replace the Connected Services Gateway Troubleshoot connectivity of 3G sim card WiFi antenna xx1900000139 Continues on next page Product manual OmniCore V250XT 393 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 6 Tro...

Page 394: ...p 4 If the input voltage is abnormal Troubleshooting the robot signal exchange proxy on page 405 Tip For more details see Circuit dia gram OmniCore V250XT Make sure that connector X2 is connected properly on both ends If the connection is OK proceed with step 5 If there is a problem with the con nection repair the connection and go back to step 1 Check that the connector X2 is well con nected and ...

Page 395: ...ices Gateway configuration in Operating manual Integ rator s guide OmniCore For 3G use a cell phone to test that the sim card is working For WiFi use a cell phone to verify the WiFi access Note When testing with a cell phone use the same configuration on the cell phone 9 For 3G and WiFi check the antenna con nectivity 10 How to replace the unit is described in Replacing the connected services gate...

Page 396: ...tion shows the location of the Ethernet switch in the controller xx2100000443 Continues on next page 396 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 7 Troubleshooting the Ethernet switch ...

Page 397: ...ollowing issues Status LED Fault indication No color If input voltage is within specified voltage limits and the LED is not lit then replace the switch Shows the status of Ethernet links Ethernet LEDs Green Off 10 Mbps data rate is selected On 100 1000 Mbps data rate is selected Yellow Flashing The Ethernet is active on link Solid A LAN link is established Off A LAN link is not established Product...

Page 398: ...ation shows the location of the main computer in the controller xx2100000457 Continues on next page 398 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 8 Troubleshooting the main computer ...

Page 399: ...nks one second off This is repeated until power off Internal fail of power FPGA and or the COM Express module Replace the computer unit Power failure during runtime fast flashing between blinks One to five blinks 20 fast flashing blinks This is repeated until power off Temporary voltage drop cycle the power to the controller Check the power supply voltage to the computer unit Replace the computer ...

Page 400: ...r Replace the main computer if the problem remains Red flashing continuously Failed to load the operating system Restart the controller See Controller fails to start on page 369 Replace the main computer if the problem remains Green even flashing continuously 1Hz Failure during start up Check error messages on FlexPendant See Controller fails to start on page 369 Green uneven flashing RobotWare In...

Page 401: ...ounted in a row and too close to each other there will be a heating problem and the units can be damaged To avoid damaging the power supply units the units must be separated with 3 pcs of exterior support Continues on next page Product manual OmniCore V250XT 401 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 9 Troubleshooting the process power supply ...

Page 402: ...uts are within the specified output voltage levels DC OK OFF When DC output voltage is outside the specified voltage levels or turned off due to short circuit or overload 402 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 9 Troubleshooting the process power supply Continued ...

Page 403: ...power supply DSQC 634 is located as shown in the figure below xx2100000499 Continues on next page Product manual OmniCore V250XT 403 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 10 Troubleshooting the power supply ODVA ...

Page 404: ...e within the specified output voltage levels DC OK OFF When DC output voltage is outside the specified voltage levels or turned off due to short circuit or overload 404 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 10 Troubleshooting the power supply ODVA Continued ...

Page 405: ...2100000348 LEDs The illustration below shows the LEDs on the robot signal exchange proxy MS AS1 GS1 AS2 GS2 ES1 ES2 ESOUT1 ESOUT2 MON AC PS PC HMI EP xx2100001067 Continues on next page Product manual OmniCore V250XT 405 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 7 Troubleshooting 7 3 11 Troubleshooting the robot signal exchange proxy ...

Page 406: ...loop is closed Automatic Stop General Stop LEDs green AS1 GS1 Automatic Stop General Stop LED channel 1 AS2 GS2 Automatic Stop General Stop LED channel 2 AS1 GS1 AS2 GS2 External emergency stop LED can be used to identify the following status No color not lit External emer gency stop input loop is open Green solid External emergency stop input loop is closed External emergency stop LEDs green ES1 ...

Page 407: ...o color FlexPendant power out put voltage is not in normal range Green solid FlexPendant power output voltage is in normal range FlexPendant power output LED green HMI External power input LED can be used to identify the following status No color External power input voltage is not in normal range Green solid External power input voltage is in normal range External power input LED green EP Require...

Page 408: ...power unit Repair connection No resistance 24V Resistance 0V xx2100001148 Troubleshooting procedure The troubleshooting table is supposed to be used as a detailed instruction together with the troubleshooting flowchart Action Test Turn off power until all LEDs except MS which is solid red are off Then turn on power and wait 1 minute 1 If the LED_MS is Green proceed with step 5 Flashing red green a...

Page 409: ...y or it does not have sufficient input voltage Proceed with step 7 If the customer interface connectors are not properly connected to X14 and X15 the signals to and from the robot signal exchange proxy will be interpreted incorrectly If the connection is OK proceed with step 8 If there is a problem with the connection re pair the connection and go to step 6 Check that the customer inter face conne...

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Page 411: ...r includes general information complementing the more specific information in the different procedures in the manual Product manual OmniCore V250XT 411 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 8 Reference information 8 1 Introduction ...

Page 412: ...nipulating 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 normative reference from ISO 10218 1 IEC 60204 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity standard for industrial environments IEC 61000 6 2 Electromagnetic compatibility...

Page 413: ...7 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 V250XT 413 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 8 Reference information 8 3 Unit conversion ...

Page 414: ...nstructions Standard toolkit for controller Description Tool Tx10 Screw driver Torx Tx20 Screw driver Torx Tx25 Screw driver Torx Tx25 Ball tipped screw driver Torx 4 mm Screw driver flat blade 8 mm Screw driver flat blade 12 mm Screw driver flat blade Phillips 1 Screw driver 8 mm Box spanner Toolkit recommended for troubleshooting Note Tool Contents as specified above Normal shop tools Multimeter...

Page 415: ...ny special torque specified overrides the standard value Use the correct tightening torque for each type of screw joint Only use correctly calibrated torque keys Always tighten the joint by hand and never use pneumatical tools Use the correct tightening technique i e do not jerk Tighten the screw in a slow flowing motion Maximum allowed total deviation from the specified value is 10 The table belo...

Page 416: ...ury ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg Example Below is an example of how a weight specification is presented CAUTION The transformer weighs 55 kg All lifting equipment used must be sized accordingly 416 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 8 Reference information 8 6 Wei...

Page 417: ...f lifting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories The instructions delivered with the lifting accessories should be stored for later reference Product manual OmniCore V250XT 417 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 8 Reference information 8 7 Lifting accessories and lifting instru...

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Page 419: ...uctions given in the related product manuals must be strictly followed If there are any problems contact your local ABB for support L2 spare parts To replace the L2 parts require specialized training and might need special tools Only ABB field service personnel or qualified personnel trained by ABB can replace L2 parts Continues on next page Product manual OmniCore V250XT 419 3HAC073447 001 Revisi...

Page 420: ...Removed parts and spare parts must not be disassembled or opened Continues on next page 420 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 Controller parts ...

Page 421: ...ller system parts Drive units xx2100000707 Continues on next page Product manual OmniCore V250XT 421 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 1 Controller system parts ...

Page 422: ... Power units xx2100001171 Spare part level Type Description Spare part num ber L1 DSQC3070 Power unit 3HAC063632 001 HV 3x380 480V Continues on next page 422 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 1 Controller system parts Continued ...

Page 423: ...sistor bleeder xx2100002199 Continues on next page Product manual OmniCore V250XT 423 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 1 Controller system parts Continued ...

Page 424: ...H outlet connection xx2100002585 Spare part level Type Description Spare part num ber L1 Harness ETH outlet with cable 3HAC079506 001 A Continues on next page 424 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 1 Controller system parts Continued ...

Page 425: ...on 3HAC071006 001 A Harness motors power xx2100002496 Spare part level Type Description Spare part num ber L1 Harness HV Manipulator Motor 3HAC064332 001 A Product manual OmniCore V250XT 425 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 1 Controller system parts Continued ...

Page 426: ...switch 3HAC026222 003 B L1 Terminal shrouds 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 001 426 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 2 Mains connection parts ...

Page 427: ...t signal exchange proxy 3HAC064662 001 A L1 Mating connect or for robot sig nal exchange proxy Harness Short circuit connector 3HAC065107 001 B Main computer xx1900001933 Continues on next page Product manual OmniCore V250XT 427 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 3 Logic parts ...

Page 428: ... DeviceNet board xx2100002629 Spare part level Type Description Spare part num ber L1 DSQC1006 DeviceNet Board option 3HAC043383 001 A Continues on next page 428 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 3 Logic parts Continued ...

Page 429: ...ype Description Spare part num ber L2 DSQC1015 Safety Module 3HAC048858 001 A Continues on next page Product manual OmniCore V250XT 429 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 3 Logic parts Continued ...

Page 430: ...of antenna 3G baseline 3HAC028459 001 B L1 Connected Services WiFi 3013 2 option 3HAC060962 001 C L1 Magnetic roof antenna WiFi option 3HAC059424 001 D L1 DSQC1041 Connected Services Wired 3013 1 option 3HAC061701 001 E 430 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 3 Logic parts Continued ...

Page 431: ...ing module 3103 1 3HNA027579 001 A L1 CONNECTOR KIT DSQC2000 3HNA029345 001 L1 Power cable of CTM Harness 24V_CTM 3HAC069618 001 Ethernet switches xx1900001935 Continues on next page Product manual OmniCore V250XT 431 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 4 Application parts ...

Page 432: ...ce 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 432 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 4 Application parts Continued ...

Page 433: ...tal add on 3033 2 Add on 3HAC058664 001 B L1 DSQC1032 Analog add on 3034 2 Add on 3HAC058665 001 C L1 Connectors I O Analog Add on 3HAC060925 001 L1 DSQC1033 Relay add on 3035 2 Add on 3HAC058666 001 L1 Connectors I O Relay 3HAC060926 001 Add on Continues on next page Product manual OmniCore V250XT 433 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 4 Applic...

Page 434: ...Safety digital base device Continues on next page 434 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 4 Application parts Continued ...

Page 435: ...re part num ber L1 DSQC1042 Extended safety 3HAC062908 001 L1 Connectors Safety I O 3HAC069538 001 Product manual OmniCore V250XT 435 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 4 Application parts Continued ...

Page 436: ...9 1 5 Cabinet parts Fans xx2100000315 Continues on next page 436 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 5 Cabinet parts ...

Page 437: ...xx2100002180 Continues on next page Product manual OmniCore V250XT 437 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 5 Cabinet parts Continued ...

Page 438: ...nternal fan 3HAC075466 001 B L1 Main computer fan Fan with contact 3HAC060653 001 L1 Power unit fan Fan with connector 3HAC081496 001 Continues on next page 438 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 5 Cabinet parts Continued ...

Page 439: ...s DeviceNet 3HAC070918 001 D HMI panel Spare part level Type Description Spare part 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 Continues on next page Product manual OmniCore V250XT 439 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 5 ...

Page 440: ...ver xx1900002452 Spare part level Type Description Spare part num ber L1 TPU cover 3HAC067213 001 Air filter xx2100000741 Continues on next page 440 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 5 Cabinet parts Continued ...

Page 441: ... part num ber L1 Air filter coarse assembly 3HAC075739 001 A L1 Air filter fine assembly 3HAC075740 001 B Product manual OmniCore V250XT 441 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 5 Cabinet parts Continued ...

Page 442: ...num ber L1 Harness SMB connection 3HAC078210 001 A End clamp xx1900001940 Spare part level Type Description Spare part num ber L1 End clamp 3HAB7983 1 A Continues on next page 442 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 6 Miscellaneous parts ...

Page 443: ... part num ber L1 8 mm camera lens LTC 08F 3HAC053944 001 L1 12 5 mm camera lens LFC 12 5F 3HAC053944 002 L1 16 mm camera lens LFC 16F1 3HAC053944 003 L1 25 mm camera lens LFC 25F1 3HAC053944 004 L1 DSQC1063 Integrated Vision camera medium res 3HAC075182 001 L1 DSQC1064 Integrated Vision camera high res 3HAC075207 001 L1 Integr Vision power cable 3HAC051753 003 L1 Integr Vision ethernet cable 3HAC0...

Page 444: ... L1 Harness A1 X11 T4 X13 Harness 24_BRAKE 3HAC065532 001 L1 Harness A1 X2 T4 X17 Harness CTRL_FB 3HAC074106 001 Cables on the ABB Ability Connected Services unit Spare part level Type Description Spare part num ber L1 Ethernet Harness 3HAC076539 001 Cables on the power supply Spare part level Type Description Spare part num ber L1 DSQC 609 Harness PSU 24V 3HAC071467 001 L1 DSQC 634 Harness PSU 24...

Page 445: ...scription Spare part num ber L1 Harness K2 X8 A2 X6 Ethernet harness 3HAC076497 001 Product manual OmniCore V250XT 445 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 1 7 Cables Continued ...

Page 446: ...cover 3HAC065401 001 C L1 Joystick guard 3HAC065408 001 D L1 FlexPendant power cable 3 m 3HAC064448 002 E L1 FlexPendant power cable 10 m 3HAC064448 001 L1 FlexPendant power cable 30 m 3HAC064448 003 L1 Fasten strip 3HAC065419 001 F L1 FlexPendant extension cable 15 m 3HAC068915 001 L1 FlexPendant extension cable 22 m 3HAC068915 002 L1 FlexPendant extension cable 30 m 3HAC068915 005 446 Product ma...

Page 447: ...7 003 Power cable 22 m L1 3HAC026787 004 Power cable 30 m Signal cables IRB 4600 5710 5720 6700 Signal cable level Article number Signal cable length L1 3HAC2493 1 Signal cable 7 m L1 3HAC2530 1 Signal cable 15 m L1 3HAC2540 1 Signal cable 22 m L1 3HAC2566 1 Signal cable 30 m Product manual OmniCore V250XT 447 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 3 ...

Page 448: ... CS cable length L1 3HAC022957 001 Cable CP CS 7m L1 3HAC022957 002 Cable CP CS 15m L1 3HAC022957 006 Harness CP CS 22m L1 3HAC022957 003 Harness CP CS 30m 448 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 3 2 Customer cables CP CS connectors option ...

Page 449: ...or cable length L1 3HAC079476 001 Ethernet floor cable 7 m L1 3HAC079476 002 Ethernet floor cable 15 m L1 3HAC079476 003 Ethernet floor cable 22 m L1 3HAC079476 004 Ethernet floor cable 30 m Product manual OmniCore V250XT 449 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 3 3 Customer cables Ethernet floor cables ...

Page 450: ... cable length L1 3HAC022978 001 Harness CP CS DeviceNet 7m L1 3HAC022978 002 Cable CP CS DeviceNet 15m L1 3HAC022978 006 Harness CP CS DeviceNet 22m L1 3HAC022978 003 Harness CP CS DeviceNet 30m 450 Product manual OmniCore V250XT 3HAC073447 001 Revision B Copyright 2020 2022 ABB All rights reserved 9 Spare parts 9 3 4 Customer cables DeviceNet cables ...

Page 451: ...al of storage media 345 drive unit LED 377 replacing 263 troubleshooting flowchart 379 E earth fault protection 77 emergency stop 20 function test 166 emergency stops 22 enabling device 23 function test 168 EN ISO 13849 1 14 environmental information 346 ESD damage elimination 43 sensitive equipment 43 esd elimination 43 Ethernet installing 121 Ethernet extension switch installing 121 Ethernet swi...

Page 452: ...ode 24 manual reduced speed 24 optional power supply installing 124 original spare parts 13 P path accuracy 371 pedestal installed on pedestal 27 performance level PL 14 personnel requirements 15 PFHD 14 41 42 PL performance level 14 plastic disposal 346 power failure during start up 356 power supply 401 403 replacing 255 power supply optional installing 124 power unit LED 383 replacing 250 test e...

Page 453: ... I O internal 114 signals safety 16 sim card replacing 211 software licenses 47 standards 412 steel disposal 346 stop category 0 20 stop category 1 20 stops overview 20 storage conditions 38 switch Ethernet Extension 121 symbols safety 16 system integrator requirements 27 system update failure 360 T teach pendant detach attach 80 temperatures operation 38 storage 38 three position enabling device ...

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Page 456: ... 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics Discrete Automation No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics Discrete Automation 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC073447 001 Rev B en Copyright 2020 2022 ABB All rights reserved Specifications subject to change without notice ...

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