ABB OmniCore V250XT Type A Product Manual
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ABB OmniCore V250XT Type A Product Manual

ABB OmniCore V250XT Type A Product Manual

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ROBOTICS
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OmniCore V250XT Type A

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Summary of Contents for ABB OmniCore V250XT Type A

  • Page 1 ROBOTICS Product manual OmniCore V250XT Type A...
  • Page 2 Trace back information: Workspace 23A version a19 Checked in 2023-03-24 Skribenta version 5.5.019...
  • Page 3 Product manual OmniCore V250XT Type A OmniCore Document ID: 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Controller description OmniCore V250XT Type A .................. Technical data for OmniCore V250XT Type A controller ........... Safety functions and safety related data for OmniCore V250XT Type A ....... The unit is sensitive to ESD ................. Handling of FlexPendant ..................Network security ....................
  • Page 6 5.2.10 Replacing the power supply ..............5.2.11 Replacing the drive unit ................5.2.12 Replacing the fieldbus master ..............5.2.13 Replacing the main computer battery ............Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 7 Standard toolkit for controller ................Screw joints ..................... Weight specifications ..................Lifting accessories and lifting instructions .............. Spare parts Controller parts ....................9.1.1 Controller system parts ................Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 8 Customer cables - CP/CS connectors (option) ..........9.3.3 Customer cables - Ethernet floor cables ............9.3.4 Customer cables - DeviceNet cables ............Index Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 9: Overview Of This Manual

    Product manual scope The manual covers all variants and designs of the OmniCore V250XT Type A. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
  • Page 10 Overview of this manual Continued References All documents can be found via myABB Business Portal, www.abb.com/myABB. Document name Document ID Product specification - OmniCore V line 3HAC074671-001 Circuit diagram - OmniCore V250XT 3HAC074000-008 Operating manual - RobotStudio 3HAC032104-001 Operating manual - OmniCore...

  • Page 11: Product Documentation

    Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
  • Page 12 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 13: Safety

    Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.

  • Page 14: Safety Data

    Extended Safety Functions. Performance level data The performance level data for the respective controller variant is presented in section Safety functions and safety related data for OmniCore V250XT Type A on page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B...

  • Page 15: Requirements On Personnel

    The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 16: Safety Signals And Symbols

    NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 17 Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 18: Safety Symbols On Controller Labels

    The descriptions in this section are generic, the labels can contain additional information such as values. Label Description Read the user manual before use. xx1400001152 CE label xx1800000835 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 19 High voltage inside the module even if the main switch is in the OFF position. xx1400001156 ESD sensitive components inside the controller. xx1400001162 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 20: Robot Stopping Functions

    Automatic Stop (AS) initiate the protective stop function in automatic mode only. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 21 Note For OmniCore, a safety input used to initiate a protective stop must remain active for at least 100 ms. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 22: About Emergency Stop

    1 Inspect the machinery in order to detect the reason for the emergency stop device actuation. 2 Locate and disengage the emergency stop device or devices that initiated the emergency stop function. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

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

    In case of hazard, release or compress the three-position enabling device. How to use the hold-to-run function for manual high speed mode is described in the operating manual for the controller. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 24: Robot Operating Modes

    Teach or tune programmed manipulator positions The mode manual high speed The mode manual high speed, is used for program verification only. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 25 Setting program pointer (to Main, to routine, to cursor, to service routine, etc.) • Starting and stopping program execution • Stepping program execution • Manually adjusting speed (0–100%) Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 26: About The Automatic Mode

    Automatic Stop, AS, or General Stop, GS.) Note Prior to allowing the robot to operate in automatic mode, ensure that any suspended safeguards, are returned to full functionality. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 27: Safety During Installation And Commissioning

    When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 28 Compressed air • Hydraulics End-effector hazards require particular attention for applications which involve close human collaboration with the robot. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 29 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 30: Safety During Operation

    Safety devices that are not connected to the robot or robot system cannot initiate a protective or emergency stop. These must be stored out of sight so that they cannot be mistaken for being in use. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 31: Safety During Maintenance And Repair

    See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Related information See also the safety information related to installation and operation. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 32: Safety During Troubleshooting

    The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.

  • Page 33: Safety During Decommissioning

    See section Decommissioning on page 335. If the robot is decommissioned for storage, take extra precaution to reset safety devices to delivery status. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 34 This page is intentionally left blank...

  • Page 35: Controller Description

    2.1 OmniCore V250XT Type A About OmniCore V250XT Type A The OmniCore V250XT Type A is one of the OmniCore V line controllers. OmniCore V line is a versatile and powerful controller with high degree of flexibility covering a wide range robot and applications. V line supports external axis and provides flexible configuration opportunities.

  • Page 36: Technical Data For Omnicore V250Xt Type A Controller

    2 Controller description 2.2 Technical data for OmniCore V250XT Type A controller 2.2 Technical data for OmniCore V250XT Type A controller Overview of the controller xx2300000064 OmniCore V250XT Type A, Baseline Reference to circuit diagram OmniCore V250XT Type A Drive unit...
  • Page 37 2 Controller description 2.2 Technical data for OmniCore V250XT Type A controller Continued OmniCore V250XT Type A, Options Reference to circuit diagram OmniCore V250XT Type A Scalable I/O K5.1 Option Additional I/O K5.2 Option K5.3 K5.4 Safety digital base I/O K3.1...
  • Page 38 2 Controller description 2.2 Technical data for OmniCore V250XT Type A controller Continued The robot controller shall only be stored indoors, in an environment that is dry and dust-free. In addition, wind, temperature fluctuations, and condensation shall be avoided. Operating conditions The table shows the allowed operating conditions for the controller.
  • Page 39 2 Controller description 2.2 Technical data for OmniCore V250XT Type A controller Continued Airborne noise level Data Description Note Airborne noise level The sound pressure level one Controller in Motors On Mode: meter away from each surface < 65 dB(A) Leq of the controller.
  • Page 40 2 Controller description 2.2 Technical data for OmniCore V250XT Type A controller Continued Robot Residual Current in controller (mA) IRB 660 < 30 mA IRB 2600 < 30 mA IRB 4600 < 30 mA IRB 5710 < 30 mA IRB 5720 <...

  • Page 41: Safety Functions And Safety Related Data For Omnicore V250Xt Type A

    2 Controller description 2.3 Safety functions and safety related data for OmniCore V250XT Type A 2.3 Safety functions and safety related data for OmniCore V250XT Type A Basic Safety Functions The OmniCore V250XT Type A provides safety with structure category 3 with performance level d according to EN ISO 13849-1.

  • Page 42: The Unit Is Sensitive To Esd

    The location of the wrist strap button is shown in the following illustration. xx2200001483 There is an additional wrist strap button on the main computer. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 43: Handling Of Flexpendant

    To reduce the risk of cuts if the glass chips or cracks, do not touch or attempt to remove the broken glass. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 44: Network Security

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

  • Page 45: Open Source And 3Rd Party Components

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

  • Page 46: Abb Ability

    ABB Ability™ OmniCore™ controller hardware has been turned on and has been connected. After the establishment of the connection there will be a data flow from the OmniCore™ controller hardware to the ABB Ability™ digital platform.
  • Page 47 Continued Data ABB will not acquire any right, title and interest in the data other than the rights granted by Customer to ABB, but ABB will have the right to collect, store, aggregate, analyze or otherwise use the data for (i) providing and maintaining the hardware, services and/or the ABB software to Customer;...
  • Page 48 This page is intentionally left blank...

  • Page 49: Installation And Commissioning

    Note Always connect the OmniCore V250XT Type A and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B ©...

  • Page 50: Installation Activities

    Note If the controller replaces another OmniCore controller, see Operating manual - Integrator's guide OmniCore for descriptions of how to transfer software configurations. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 51: Transporting And Handling

    Stacked cabinets must be lifted separately. Use a suitable lifting accessory to avoid injury to personnel! For more information about stacked cabinets, see Securing and stacking the controller cabinet on page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 52: Unpacking

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

  • Page 53: Storing

    3 Installation and commissioning 3.3.3 Storing 3.3.3 Storing Storing the controller For storing, see Transportation and storage conditions on page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 54: On-Site Installation

    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 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 55 For service activities such as cleaning and replacement of controller filters, a free space of 500 mm is required on one side of the controller. Min. 500 mm xx2200001742 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 56: Securing And Stacking The Controller Cabinet

    3.4.2 Securing and stacking the controller cabinet Securing the controller The controller can be secured to the ground. The figure below shows the bolt pattern for the OmniCore V250XT Type A controller. The diameter of the four bolt holes are 14 mm. xx2200001823...

  • Page 57: Mounting 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. xx2100000767 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 58 Secure with the screws. Screws: BN33 Phillips pan head tapping screw ST2.9x13 (3 pcs) Tightening torque: 6 Nm-7.8 Nm xx2100000766 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 59 Action Note/illustration Clean the surface and make sure it is dry. Remove the protective liner from the tape. xx2000002352 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 60 Hang the holder with the bracket to the desired place. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 61 Clean the surface and make sure it is dry. Remove the protective liner from the tape. xx2000002357 Press the holder onto the desired place. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 62 3 Installation and commissioning 3.4.3 Mounting the FlexPendant holder Continued Action Note/illustration Use two M5 screws to secure the holder. xx2000002358 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 63: Connecting The Connected Services Antenna

    Connect the antenna cable to the connec- ted services gateway by rotating the connector. xx1900001948 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 64: Electrical Connections

    3.5 Electrical connections 3.5.1 Connectors on the OmniCore V250XT Type A controller General The following section describes the connectors on the OmniCore V250XT Type A controller. CAUTION Always inspect the connector for dirt or damage before connecting it to the controller.
  • Page 65 3 Installation and commissioning 3.5.1 Connectors on the OmniCore V250XT Type A controller Continued Connectors The following details the connection interface on the OmniCore V250XT Type A controller. xx2000001277 Description Incoming mains switch Motors on lamp Ethernet outlet connector, MGMT (Management)
  • Page 66 3 Installation and commissioning 3.5.1 Connectors on the OmniCore V250XT Type A controller Continued Description Ethernet outlet connector, WAN Cable grommet for Connected Services antenna (3G/WiFi) Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 67: Connecting Cables To The Controller

    Ethernet, according to the standard specification of the respective bus. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 68 Multi wire 4 pair 1.0//17 Multi wire 6 pair 1.0//17 Multi wire 9 pair 1.0//17 0.75//18 three phase 1.0//17 three phase 10.3 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 69 All signals that are sensitive to interference should be routed and strapped along the right side of the controller cabinet according to the image. xx2200001825 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 70 The best connection is one in which the shielding is extended up to and makes a solid 360° connection (shown below) with the ground plane or chassis. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 71 The ground for the controller cabinet, robot manipulator and peripheral devices must be the same, preferably an equipotential ground grid (mesh). Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 72 The screens of the 2 cables must be connected as shown in the figure, but not connected to the chassis of the unit. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 73 V max voltage and 125 V nominal voltage. The resistor should be 100 Ω, and the capacitor should be 1W 0.1 - 1 µF (typically 0.47 µF). Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 74: Power Supply System Requirements

    In the following section the transformer configuration refers to the transformer secondary side. Configuration of the transformer primary side is not discussed in this context. Allowed power supply systems Only the following systems are allowed by ABB: TN−S system TN−C system PE and N are separate conductors that are A combined PEN conductor is used as both connected together only near the transformer.
  • Page 75 To some extent, isolation transformers will filter out harmonics, spikes and surges. For further information refer to regional power supply standards. Allowed isolation transformer types The following isolation transformer types are allowed by ABB: Delta-Wye isolation transformer (△/Y) Wye-Wye isolation transformer (Y /Y) xx1700001319...

  • Page 76: Connecting The Manipulator To The Controller

    Action Connect the manipulator cable to the connector X1. Lock the connector with the lever. Secure the cables to avoid tripping or wear. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 77: Fitting The Connector For Incoming Mains

    Cable gland O-ring Hood, EMC Locking lever (x2) Connector insert Specifications The following describes the cable requirements for the incoming mains connection to the OmniCore V250XT Type A controller. Component Description Cable type Flexible oil resistant rubber Cable area Protective earth Included parts The following parts are included in the delivery.
  • Page 78 Tighten the screws to secure the cables. Remove screw and washer on top of contact and insert the ground cable with cable lug. Secure with washer and screws. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 79: Connecting Incoming Mains And Protective Earth To The Controller

    There are two options to connect the cabinet to protective earth: • PE0 on front panel. • PE1 and PE2 on X0 (incoming mains connector). Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 80 ABB. Standard toolkit Standard toolkit for controller on page 392. Circuit diagram Circuit diagram - OmniCore V250XT, 3HAC074000-008 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 81 The full load current for the robot is marked on the controller name plate, and is also displayed in section Line fusing on page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 82: Detaching And Attaching A Flexpendant

    CAUTION The FlexPendant connector shall only be used to connect the FlexPendant. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 83 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 Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 84 A popup window with 30 seconds countdown timer is displayed. xx1900000404 5 When the countdown is progressing, detach the FlexPendant. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 85 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 Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 86: Ethernet Networks On Omnicore

    ABB Ability™ ABB Ability™ connection. work Public Net- Public/factory network. work I/O Network Secondary public/factory network. Isolated from WAN. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 87 Note The management port shall never be used for more than one client at a time. ABB Robot- ics assumes no responsibility for any er- rors/hazards that may appear when more than one client is used.
  • Page 88 The traffic for both industrial networks on the Public Network can share the ethernet medium with each other and with other non-industrial network traffic. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 89 On OmniCore E line controllers, the WAN2 port is equivalent to a wired Connected Services Gateway (DSQC1041). The IP address configuration is done either in RobotStudio or on the FlexPendant. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 90 Defining network settings in RobotStudio: 1 In the Configuration browser, right-click the controller and select Properties\Network Settings and then Public Network. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 91 Defining network settings on the FlexPendant: 1 On the start screen, tap Settings, and then select Network from the menu. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 92 Properties\Network Settings and then I/O Network. 2 In the I/O Network window, configure the network interface and click xx2200000389 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 93 Enable on Public Network, Enable on Private Network and Enable on I/O Network for pre-registered Network Services. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 94 The port forwarding is configured through system parameters. See Technical reference manual - System parameters for detailed information. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 95: Descriptions For Connectors

    0V_CH1_CH2 Reference ground towards 24 V. 24V_CH2 24 V power, provided by robot controller, for ES channel 2 only. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 96 Note The emergency stop and protective stop will activate when the voltage is between 11.4 V and 21.5 V. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 97 AS1+ / GS1+ AS1- / GS1- 0V_CH1_CH2 Customer_0V_CH1 24V_CH2 Customer_24V_CH2 AS2+ / GS2+ AS2- / GS2- 0V_CH1_CH2 Customer_0V_CH2 xx2100002264 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 98 0V_CH1_CH2 Customer_0V_CH2 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 Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 99 Negative side of emergency stop output, channel 1. ESOUT1+ Positive side of emergency stop output, channel 1. Reserved Reserved Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 100 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 - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 101 Connection Customer IO power supply Type Weidmüller BCF 3.81/08/180F BCF 3.81/08/180F SN BK BX 8 Pins Article number 3HAC064739-001 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 102 Maximum length 75 m Type of cable CAT5e SF/UTP I/O connectors - Scalable I/O (option) Scalable I/O output connectors Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 103 "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 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 104 The characteristics are shown in the following table. Parameter Value Voltage 24 V DC Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 105 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. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 106: Configuring Robot Stopping Functions

    Note It is not possible to configure both Automatic Stop and General Stop on the OmniCore V250XT Type A 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).
  • Page 107 Apply the configuration to the controller Action Note/illustration In the Visual SafeMove ribbon, click on Controller and then select Write to con- troller. xx1500000801 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 108 1 Log in as a user with the grant Lock Safety Controller Configuration. 2 In the Settings app, select the Safety Controller, and then Configuration. 3 Select the check box Locked. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 109 In RobotWare releases prior to 7.6, the ES input cannot be decoupled from the ES output. The LocalEmergencyStop was named InternalEmergencyStop prior to RobotWare 7.6. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 110: Programmable Stop Functions

    A restart will continue the program ted, e.g. after having been jogged execution. away. \AllMoveTasks: all robots will be stopped. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 111 At power fail, all execution will be stopped. After powerOn/motorsOn, it is possible to restart and continue the execution where it stopped. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 112 Stopping time and distance metric for stop category 0 and stop category 1 are detailed in Product specification Robot stopping distances according to ISO 10218-1. The data are valid for floor mounted manipulator, without any tilting. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 113: I/O System

    Fieldbus board (master) Available board The following master board is available. Description Article number Type designation DeviceNet Board 3HAC043383-001 DSQC1006 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 114 Application manual - DeviceNet Master/Slave 3HAC066562-001 Application manual - EtherNet/IP Scanner/Adapter 3HAC066565-001 Application manual - PROFINET Controller/Device 3HAC066558-001 Application manual - I/O Engineering 3HAC082346-001 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 115: Scalable I/O, Internal And External

    I/O base unit. Scalable I/O units The I/O unit DSQC1030 Digital Base belongs to the ABB Scalable I/O system, which is a modular, compact, and scalable I/O system that consists of a base device (minimum configuration), and add-on devices.

  • Page 116: Installing Options

    DSQC1031 Analog add-on [3034-2] 3HAC058665-001 DSQC1032 Connectors I/O Analog 3HAC060925-001 Relay add-on [3035-2] 3HAC058666-001 DSQC1033 Connectors I/O Relay 3HAC060926-001 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 117 ESD on page xx2200001483 Push the digital base into the bracket until you hear a clear clicking sound. xx1900002447 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 118 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 119: Installing The Safety Digital Base Device

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 120 ESD on page xx2200001483 Push the digital base into the bracket until you hear a clear clicking sound. xx2200001972 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 121 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 122: Installing The Ethernet Extension Switch

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 123 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 124: Concluding Procedure

    Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 125: Installing The Power Supply Optional Device

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 126 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 127 For DSQC 634: xx2200002012 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 128 T8.X2-24VTerminal block • T6.X2-24VTerminal block T9.X2-24VTerminal block Concluding procedure Action Note/Illustration Close the door. Closing the door on page 179. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 129 3.7.4 Installing the power supply optional device Continued Action Note/Illustration Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 130: Installing The Fieldbus Master

    Harness DeviceNet is an option of process connector. Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 131 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 132 When handling the computer outside of the controller, use the wrist strap button located on the side of the computer. xx2000000419 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 133 Insert the DeviceNet board into the card slots along the guide rail in the main computer. xx1800003417 Card slots Guide rail Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 134 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 135 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 136: Installing The Conveyor Tracking Module (Ctm)

    Required parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 137 The unit is sensitive to ESD on page xx2200001483 Open the door. Opening the door on page 178. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 138 Function tests on page 167. For more information about the option Conveyor Tracking, see Application manual - Conveyor tracking. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 139: Installing The Cable Grommet Assembly

    It is recommended to use icotek KT grommet. Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 140 Removing the slot cover (baseline) Action Note/Illustration Remove the attachment screws. xx2100001282 Take out the cover from the inside of the controller. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 141 Refit the cover strip onto the frame. xx1900002335 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 142 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 2 Nm - 3 Nm. xx1900002334 Route the cables through the cut-out. xx1900002333 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 143 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 144 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 145: Installing The Air Filter

    3.7.8 Installing the air filter Location The illustration shows the location of the air filter on the controller. xx2200001484 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 146 Continued Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 147 Fit the air filter unit to the cabinet. xx2200001772 Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 148: Installing The Mains Connections Cable

    3.7.9 Installing the mains connections cable Location The illustration shows the location of the incoming mains cable gland in the controller. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 149 Standard toolkit for controller on page 392. ESD protective wrist band Required documents Document Article number Note Circuit diagram - OmniCore 3HAC074000-008 V250XT Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 150 A Cable gland B Incoming mains switch C Cable pipe Remove protection from the incoming mains switch (B). Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 151 (B). Connect the wires to the incoming mains See circuit diagram. switch (B). Refit protection on the incoming mains switch (B). Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 152: Installing External Devices

    Available current supplied to or from this equipment must not exceed 8 A under any condition of load, including short circuit. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 153: Initial Test Before Commissioning

    Function tests Before commissioning, perform the function tests in section Function tests on page 167 to verify that the safety features work properly. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 154 This page is intentionally left blank...

  • Page 155: Maintenance

    Function test after replacement of component After replacing a component in the controller, the function tests should be performed. See Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 156: Inspection Activities

    4 Maintenance 4.2.1 Inspection of controller 4.2 Inspection activities 4.2.1 Inspection of controller Inspecting the OmniCore V250XT Type A controller Action Note/illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on...

  • Page 157: Cleaning Activities

    4.3 Cleaning activities 4.3.1 Cleaning air filter Location The air filter is located as shown in the illustration below. xx2200001484 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 158 Insert the polymeric filter element to the filter and secure with the metallic line. xx2200001827 Refit the air filter unit to the cabinet. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 159 Note/Illustration Remove the air filter unit. xx2200001773 Clean the metal mesh filter with compressed air. Refit the air filter unit to the cabinet. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 160: Cleaning Of The Controller Cabinet

    • Never use compressed air or spray with a high pressure cleaner. • Never leave the door open when cleaning the exterior. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 161: Cleaning The Flexpendant

    Check that all protective covers are fitted to the device before cleaning. • Make sure that no foreign objects or liquids can penetrate into the device. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 162 Do not spray with a high pressure cleaner. • Do not clean the device, operating panel and operating elements with compressed air, solvents, scouring agent or scrubbing sponges. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 163: Changing/Replacing Activities

    4.4.1 Replacement of air filter Location The air filter unit is located as shown in the illustration below. xx2200001484 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 164 For more information, see Electrical safety on page Removing the air filter Action Note/Illustration Remove the air filter unit. xx2200001773 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 165 For more information, see Electrical safety on page Refit the air filter unit to the cabinet. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 166 Continued Concluding procedure Action Note/Illustration Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 167: Function Tests

    The message 10013 Emergency stop state is also available in the event log. Release the emergency stop device to re- set the emergency stop state. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 168: Function Test Of Manual, Auto, And Manual Full Speed Mode With Flexpendant

    Note of the failure must be found. Manual full speed mode is not available in USA or Canada. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 169: Function Test Of Three-Position Enabling Device

    10012 Safety guard stop state does not appear • if the event message 90780 Two- channel fault in Safety Controller appears Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 170: Function Test Of Safety Switches

    If the event message 37101 Brake Failure appears in the event log, then the test has failed and the root cause of the failure must be found. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 171: Function Test Of Automatic Stop

    90523 Safety Controller Protective Stop triggered does not appear • if the event message 90780 Two- channel fault in Safety Controller appears Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 172: Function Test Of General Stop

    90523 Safety Controller Protective Stop triggered does not appear • if the event message 90780 Two- channel fault in Safety Controller appears Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 173: Function Test Of External Emergency Stop

    The event message 90518 Safety control- ler Emergency stop triggered appears by default. Release the external emergency stop device to reset the external emergency stop state. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 174: Function Test Of Estop_Status Output

    Make sure that the accessory device is not in emergence stop status any more and can be reset. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 175: Function Test Of Reduced Speed Control

    To get accurate results, use sensors or I/O signals to measure the time. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 176 This page is intentionally left blank...

  • Page 177: Repair

    During maintenance inside the controller, beware of sharp corners on the internal fan located on the door. Note When replacing a part on the OmniCore V250XT Type A, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.

  • Page 178: Replacement Of Controller Parts

    Pull out the door with the handle. Use the door stop to lock the door posi- tion before maintenance is started. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 179 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 180 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 181 Refitting the rear cover Action Info/illustration Refit the the rear cover. Secure it with the screws. xx2200001062 Refit the air filter cover plate. xx2200001773 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 182: Replacing The Fans

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...

  • Page 183: Replacing The External Fans

    5.2.2.1.1 Replacing the external fans Location The illustration shows the location of the external fan in the controller. xx2200001778 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 184 Disconnect the external fan: • G1.X1-K2.X17 G2.X1-K2.X17 Remove the fan bracket screws. xx2200001063 Take out the fan bracket and the fan. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 185 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 186 Make sure that the filter cover plate is correctly positioned. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 187: Replacing The Internal Fan

    For more information, see Electrical safety on page Open the door. Opening the door on page 178. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 188 • G5.X1-K2.X17 Remove the screws holding the fan as- sembly. xx2200001069 Remove the fan assembly from the mounting plate. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 189 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 190 ESD on page xx2200001483 Secure the internal fan attachment Screws: Torx pan head screw M4x8 (4 pcs) screws. xx2200001071 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 191 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 192: Replacing The Main Computer Fan

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 193 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 194 When handling the computer outside of the controller, use the wrist strap button located on the side of the computer. xx2000000419 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 195 Disconnect the main computer fan: • A2.X1 Lift the fan bracket off the hooks and re- move it. xx2100002179 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 196 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 197 Place the main computer fan in the bracket. xx2100002180 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 198 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 199 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 200: Replacing The Power Unit Fan

    5.2.2.4 Replacing the power unit fan Location The illustration shows the location of the power unit computer fan in the controller. xx2100002281 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 201 Continued Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 202 The unit is sensitive to ESD on page xx2200001483 Place the power unit fan in the bracket. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 203: Concluding Procedure

    Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 204: Replacing The Robot Signal Exchange Proxy

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 205 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 206 Pull the cable ties out from the locking holes. xx1900001495 Remove the screws and lift out the robot signal exchange proxy. xx1900001887 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 207 Fit the robot signal exchange proxy and Screws: Torx pan head screw M4x8 (4 pcs) secure the screws. xx1900001887 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 208 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 209: Replacing The Ethernet Switch

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 210 Removing the Ethernet extension switch (option) Action Note/Illustration Disconnect: • K2.X2 - K4.X8, A2.X1 • K4.X7 - K5.1.X5/K3.1.X5 • K4.X6 - A2.X4 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 211 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 212 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 213: Replacing The Connected Services Gateway

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 214 Note The connected services antenna is installed by the customer, and the cable routing can therefore differ. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 215 The connector K7.X2 is locked; grab the connector, push it in to release it and then remove the connector. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 216 The unit is sensitive to ESD. Before handling the unit read the safety inform- ation in section The unit is sensitive to ESD on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 217 Apply cable ties and suitable cable pro- tection to ensure that the cable may not be damaged by the door. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 218 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 219: Replacing The Scalable I/O Unit

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 220 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 221 The harness connected to I/O unit by customer. Push the buckle of the digital base slightly and take out the digital base. xx1900002446 xx1900002447 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 222 K5.1.X5/K3.1.X5 to/from A2.X4. • K5.1.X4 - K2.X3 • The harness connected to I/O unit by customer Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 223: Concluding Procedure

    Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 224: Replacing The Safety Digital Base Device

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 225 K5.1.X5/K3.1.X5 to/from A2.X4. • K5.1.X4 - K2.X3 • The harness connected to I/O unit by customer. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 226 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 227 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 228: Replacing The Main Computer

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 229 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 230 Carefully pull the side of the Ethernet extension switch and rotate it tightly to take it out from the bracket. xx1800000491 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 231 The unit is sensitive to ESD on page xx2000000419 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 232 The unit is sensitive to ESD on page xx2000000419 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 233 Screws: Torx pan head screw M4x8 (4 pcs) secure the screws. Insert the cable ties into the locking holes. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 234 Ethernet switch (option), connected services gateway, scalable I/O (option), and main computer. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 235 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 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 236 Pull the cable ties out from the locking holes. xx1900001886 Remove the screws and lift out the robot signal exchange proxy. xx1900001887 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 237 Carefully pull the side of the Ethernet extension switch and rotate it tightly to take it out from the bracket. xx1900001888 xx1800000491 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 238 Carefully pull the side of the connected services gateway and rotate it tightly to take it out from the bracket. xx1900001890 xx1800000495 TOP VIEW Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 239 When handling the computer outside of the controller, use the wrist strap button located on the side of the computer. xx1900001893 xx1900001894 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 240 The unit is sensitive to ESD on page xx2200001483 Fit the main computer to the mounting plate. xx1900001894 xx1900001893 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 241 The unit is sensitive to ESD. Before handling the unit read the safety inform- ation in section The unit is sensitive to ESD on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 242 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 243 Ethernet extension switch and the lower surface of highest bracket on the main computer. xx1900001888 xx1800000972 xx1800000491 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 244 Fit the robot signal exchange proxy and Screws: Torx pan head screw M4x8 (4 pcs) secure the screws. xx1900001887 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 245 (option), ABB ability™ connected services, scalable I/O digital base (op- tion), and main computer. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 246: Concluding Procedure

    Operating manual - Integrator's guide Omni- a local backup to restore the RobotWare Core, section Installing a new RobotWare system. system. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 247 Carefully read the information and then check all boxes to confirm that you agree with the ABB conditions. Tap Next to proceed. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 248 The restoration and the manually entered serial number to of the serial number is completed. ensure that there is a match. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 249: Replacing The Power Unit

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 250 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 251 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 252 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 253: Replacing The Power Supply

    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 Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 254 Continued Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 255 Removing the power supply Action Note/Illustration Remove the end clamp besides the power supply with a screwdriver. xx2200002009 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 256 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 257 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 258 Removing the power supply Action Note/Illustration Remove the end clamp besides the power supply with a screwdriver. xx2200002011 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 259 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 260 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 261: Replacing The Drive Unit

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B ©...
  • Page 262 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 263 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 264 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 265: Replacing The Fieldbus Master

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 266 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 267 When handling the computer outside of the controller, use the wrist strap button located on the side of the computer. xx2000000419 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 268 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 269 Insert the fieldbus master straight into the card slots along the guide rail. xx1900001911 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 270 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 271 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 272: Replacing The Main Computer Battery

    Note Standard toolkit Content is defined in section Standard toolkit for controller on page 392. ESD protective wrist band Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 273 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 274 When handling the computer outside of the controller, use the wrist strap button located on the side of the computer. xx2000000419 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 275 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 276 Insert the battery into the slot in the main computer. xx2100002582 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 277 Screws: Torx pan head screw M4x8 (4 pcs) secure the screws. Insert the cable ties into the locking holes. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 278 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 279: Replacing The Conveyor Tracking Module (Ctm)

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 280 The unit is sensitive to ESD on page xx2200001483 Removing the conveyor tracking module (option) Action Note/Illustration Disconnect: • B1.X7 - K4.X1-X5 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 281 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 282 Hang the conveyor tracking module into the bracket and push the lower of it until you hear a clear clicking sound. xx1900001913 xx2200001844 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 283: Concluding Procedure

    Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 284: Replacing The Air Filter

    5.2.15 Replacing the air filter Location The illustration shows the location of the air filter on the controller. xx2200001484 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 285 Continued Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 286 The procedure below details how to remove the polymeric filter element (option 3005-2 Moist dust filter). Action Note/Illustration Take out the polymeric filter element from the filter. xx2200001827 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 287 Refit the air filter unit to the cabinet. Concluding procedure Action Note/Illustration Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 288: Replacing The Break Resistor Bleeder

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B ©...
  • Page 289 Removing the break resistor bleeder Action Note/Illustration Remove the cable ties and disconnect the break resistor bleeder: • A1.R1-A1.X10 • Earth cable. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 290 Remove the screws holding the break resistor bleeder. xx2200001074 Remove the break resistor bleeder and pull the cables through the opening. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 291 The unit is sensitive to ESD on page xx2200001483 Refit the break resistor bleeder and se- cure the screws. xx2200001074 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 292 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 293: Replacing Parts On The Front Panel And Door

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 294 Remove cable ties and cable supports. Remove nuts and attachment screws. xx2200001981 Push the manipulator signal connector out through the front panel. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 295 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 296: Replacing The Motor Connector

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...

  • Page 297: Replacing 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 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 298 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 299: Concluding Procedure

    Use the same position as from removing the motor connector. Concluding procedure Action Note/Illustration Close the door. Closing the door on page 179. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 300 5.3.2.1 Replacing the motor connector Continued Action Note/Illustration Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 301: Replacing The Hmi Signal (Flexpendant) Connector

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 302 Make records about the sequence that cables are removed. The cables need to be installed in the same position. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 303 Action Note/Illustration Disconnect: • TPU (X4) - K2.X9 & X13 Remove the screws. xx2100000830 Remove the cover plate. xx2100000831 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 304 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 305 Use the same position as from removing the HMI signal connector. Refit the cover plate. xx2100000831 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 306 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 307: Replacing The Cable Grommet Assembly

    It is recommended to use icotek KT grommet. Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 308 Make records about the sequence that cables are removed. The cables need to be installed in the same position. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 309 Releasing the cables from the cable grommet assembly Action Note/Illustration Unscrew the cable entry frame from the enclosure wall. xx1900002332 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 310 Remove the attachment screws on the frame and cover strip together. xx1900002334 Remove the cover strip from the frame. xx1900002335 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 311 Remove the grommets in the upper row first and then the second row. xx1900002336 Remove the cable form the correspond- ing KT grommet. xx1900002337 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 312 Refit the cover strip onto the frame. xx1900002335 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 313 12.9 Lafre 2C2B/FC6.9 (3 pcs) Tightening torque: 2 Nm - 3 Nm. xx1900002334 Route the cables through the cut-out. xx1900002333 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 314 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 315: Concluding Procedure

    Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 316: Replacing The Ethernet Outlet Connector With Cable

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 317 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 318 Continued Removing the Ethernet outlet connector with cable Action Note/Illustration Remove the screws. xx2100000830 Remove the cover plate. xx2100000831 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 319 The cables need to be installed in the same position. Take the Ethernet outlet connector with cable out from the upper side. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 320 ETH outlet with cable. Concluding procedure Action Note/Illustration Close the door. Closing the door on page 179. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 321 5.3.5 Replacing the Ethernet outlet connector with cable Continued Action Note/Illustration Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 322: Replacing The Led Indicator

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 323 The unit is sensitive to ESD on page xx2200001483 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 324 Insert the LED indicator into the cover from outer side of the door and the screw from inner side and screw them up. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 325 Closing the door on page 179. Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 326: Replacing Parts On The Flexpendant

    Power cable Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 327 Disconnect the FlexPendant from the controller. Remove the attachment screws for the power cable cover. xx1800001189 Remove the power cable cover. xx1800001190 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 328 The unit is sensitive to ESD. Before handling the unit read the safety inform- ation in section The unit is sensitive to ESD on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 329 Screws: Torx pan head screw M4x8 (3 pcs) the screws. xx1800001196 Perform the function tests to verify that the safety features work properly, see Function tests on page 167. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 330: Replacing The Joystick Protection

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 331 The unit is sensitive to ESD. Before handling the unit read the safety inform- ation in section The unit is sensitive to ESD on page Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 332 5.4.2 Replacing the joystick protection Continued Action Note/Illustration Refit the joystick protection. xx1800001200 Secure the screws. xx1800001206 Countersunk head screw: ST2.9 X 10 (6 pcs) Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 333: Replacing The Fasten Strip

    Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V250XT Type A via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 334 This page is intentionally left blank...

  • Page 335: Decommissioning

    (part of Delete RobotWare system function) in RobotWare. See Operating manual - Integrator's guide OmniCore. Transportation Prepare the robot or parts before transport, this to avoid hazards. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 336: Environmental Information

    6.2 Environmental information 6.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
  • Page 337 China RoHS symbol The following symbol shows the information to hazardous substances and the environmental protection use period of OmniCore V250XT Type A according to "Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products (SJ/T 11364-2014) ".
  • Page 338 This page is intentionally left blank...

  • Page 339: Troubleshooting

    Make a historical fault log to keep track of problems over time. • Consult those working with the robot when the problem occurred. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 340 The robot has recently Check: been moved from one site • connections to another (an already • software versions working robot) Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 341: Troubleshooting Fault Symptoms

    Reflashing firmware failure on page 354 • Inconsistent path accuracy on page 355 • Controller is overheated on page 357 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 342: No Leds Are Lit On The Controller

    Check the FlexPendant for errors and warnings. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. Recommended working procedure If no LEDs are lit on the controller during start-up, use this procedure to troubleshoot what might cause the problem.
  • Page 343 366. • If abnormal, troubleshoot Check the LED status. the LEDs. See Troubleshooting LEDs in the controller on page 358. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 344: Start-Up Failure

    Check the FlexPendant for errors and warnings. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. Recommended working procedure If there seems to be a power failure during start-up, use this procedure to troubleshoot what might cause the problem.
  • Page 345 Troubleshooting the drive unit on page 360. If the problem remains, contact ABB. For more details, see Circuit diagram - OmniCore V250XT. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 346: System Update Failure

    2 Perform a complete re-installation of the RobotWare system using RobotWare Installation Utilities, start the RobotWare system and then reload the previous backup. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 347: Problem Releasing The Robot Brakes

    DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. Recommended working procedure If the brakes do not release, no robot movement is possible and a number of error log messages can occur.
  • Page 348 For more details on how to release the brakes, see the robot's product manual. • If it is not ok, contact your local ABB. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 349: Problem Starting Or Connecting The Flexpendant

    Make sure that the controller is switched on. Wait 30 s - 1 min to enable start-up sequence. Check the FlexPendant for errors and warnings. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 350 Action DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. Recommended working procedure If the FlexPendant starts but does not display the main interface during the start-up, use this procedure to troubleshoot what might cause the problem.
  • Page 351 Check that the FlexPendant works normally. If it is not ok, contact your local ABB. This is detailed in section Troubleshooting the FlexPendant on page 359. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 352: Problem Using The Joystick

    FlexPendant. replace the FlexPendant. Note The reset button only resets the FlexPendant, not the system on the controller. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 353: Controller Fails To Start

    See also Troubleshooting the main computer on page 380. How to install systems is described in Operating manual - Integrator's guide OmniCore. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 354: Reflashing Firmware Failure

    If RobotWare has been updated recently, make sure that the versions of the old and the new unit are identical. If the problem remains, contact your local ABB for information about which firmware version is compatible with your hardware. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B ©...

  • Page 355: Inconsistent Path Accuracy

    Replace the faulty parallel bar as specified (applies to robots fitted with parallel bars in the product manual for the robot. only). Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 356 If applicable: Check the setting for the The swivel has an in-built resistance that swivel. needs to be set in the system parameters. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 357: Controller Is Overheated

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

  • Page 358: Troubleshooting Units

    Troubleshooting the power supply, ODVA on page 384 Troubleshooting the process power supply on page 383 Robot signal exchange proxy Troubleshooting the robot signal exchange proxy on page 385 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 359: Troubleshooting The Flexpendant

    Read the error event log message and follow any instructions of references. For more information on the FlexPendant, see Operating manual - OmniCore. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 360: Troubleshooting The Drive Unit

    7.3.3 Troubleshooting the drive unit Location The illustration shows the location of the drive unit in the controller. xx2200001474 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 361 • Red, flashing (~1Hz): Firmware error or self-test failure. • Green, flashing (~1Hz): Communica- tion error to another module. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 362 Power the controller off. Wait one minute, power the controller on. Wait 30-60 seconds after power-on. Make sure that the control system power is in run-time mode. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 363: Troubleshooting Flowchart

    Replacing the drive unit on page 261. • Flashing green (~ 1Hz): Communication error to another module. Proceed with step 3. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 364 If the Link/Activity LED is off, the fault remains. Replace the drive unit, see placing the drive unit on page 261. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 365 Replace the safety cable: X17. been fixed. Proceed with step 1. • If the fault remains, see Troubleshooting the power unit on page 366. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 366: Troubleshooting The Power Unit

    7.3.4 Troubleshooting the power unit Location The illustration below shows the location of the power unit in the controller. xx2200001481 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 367 No color: Voltage between DC+ - DC- DC-BUS High Voltage LED < 60 VDC • Yellow: Voltage between DC+ - DC- > 60 VDC Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 368 Yellow steady: Link without activity. Required test equipment Equipment needed for troubleshooting: Equipment Note Multimeter Insulating gloves Circuit diagram - OmniCore V250XT 3HAC074000-008 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 369 Replacing the power unit on page 249. • If the measured voltage is abnormal, proceed with step 6. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 370 249. • If the measured voltage is abnormal, see Troubleshooting the robot signal ex- change proxy on page 385. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 371 Replace cables: If DC_OUT is not OK, the unit may be faulty, • DC_OUT (X4 and X8) Replacing the power unit on page 249. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 372: Troubleshooting Fieldbuses And I/O

    Information about how to troubleshoot the fieldbuses and I/O units can be found in the manual for the respective fieldbus or I/O unit. See References on page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 373: Troubleshooting The Connected Services Gateway

    STATUS LED LINK, 3G status or WiFi status LED RF, signal strength status LEDs Factory reset pin hole Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 374 Power the controller off. Wait one minute, power the controller on. Wait 30-60 seconds after power-on. Make sure that the control system power is in run-time mode. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 375 Reset the module to factory using the re- Proceed with step 3. set pin hole for more than 5s, and restart the controller. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 376 • If there is a problem with the con- nection, repair the connection and go back to step 7. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 377: Related Information

    213. Related information All documents can be found via myABB Business Portal, www.abb.com/myABB. The approval code CMIIT ID is finally displayed on the nameplate of the product. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B...

  • Page 378: Troubleshooting The Ethernet Switch

    The illustration shows the location of the Ethernet switch in the controller. xx2200001478 LEDs The illustration below shows the indication LEDs on the Ethernet switch. xx1800000584 Status LED Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 379 • Flashing: The Ethernet is active on link. • Solid: A LAN link is established. • Off: A LAN link is not established. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 380: Troubleshooting The Main Computer

    The illustration below shows the LEDs on the main computer: xx1800000585 Power status LED HDD status LED Status LED Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 381: Troubleshooting Procedure

    If the LEDs do not turn steady after LEDs on page 380. approximately 5 minutes then re- start the controller and check the LEDs again. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 382 The main computer may be faulty, Replacing the main computer on page 228. replace it and verify that the fault has been fixed. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 383: Troubleshooting The Process Power Supply

    GREEN: When all DC outputs are within the specified output voltage levels. OFF: When DC output voltage is outside the specified voltage levels or turned off due to short circuit or overload. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 384: Troubleshooting The Power Supply, Odva

    GREEN: When all DC outputs are within the specified output voltage levels. OFF: When DC output voltage is outside the specified voltage levels or turned off due to short circuit or overload. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 385: Troubleshooting The Robot Signal Exchange Proxy

    Red, solid: Internal error. • Red, flashing: Firmware error or self-test failure. • Green, flashing: Communication error to another module. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 386 No color: FlexPendant power out- put voltage is not in normal range. • Green, solid: FlexPendant power output voltage is in normal range. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 387 If the input voltage is abnormal, proceed with For more details, see Circuit step 4. diagram - OmniCore V250XT. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 388 Replacing the proxy may be faulty, replace robot signal exchange proxy on page 204. it and verify that the fault has been fixed. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 389: Reference Information

    8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 390: Applicable Standards

    ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems - Part 1: General principles for design, normative reference from ISO 10218-1 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 391: Unit Conversion

    2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 392: Standard Toolkit For Controller

    Box spanner 8 mm Toolkit recommended for troubleshooting Tool Note Normal shop tools Contents as specified above. Multimeter Camera To document problems or procedures Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 393: Screw Joints

    The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess heads. Dimension Tightening torque (Nm) Class 4.8, oil-lubricated M2.5 0.25 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 394: Weight Specifications

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

  • Page 395: Lifting Accessories And Lifting Instructions

    The instructions delivered with the lifting accessories should be stored for later reference. Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 396 This page is intentionally left blank...

  • Page 397: Spare Parts

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

  • Page 398: Controller Parts

    9 Spare parts 9.1 Controller parts 9.1 Controller parts Note Removed parts and spare parts must not be disassembled or opened. Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 399: Controller System Parts

    Drive units xx2100000707 Spare part num- Description Type Spare part level 3HAC064590-001 Drive unit, High Voltage MDU DSQC 3062 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 400 Spare part num- Description Type Spare part level 3HAC063632-001 Power unit DSQC3070 HV 3x380-480V 3HAC074011-001 Power unit DSQC3069 LV 3x380-480V Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 401 9.1.1 Controller system parts Continued Break resistor bleeder xx2200001092 Spare part num- Description Type Spare part level 3HAC081951-001 Break resistor bleeder assembly Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 402 Spare part num- Description Type Spare part level 3HAC079506-001 Harness ETH outlet with cable Harness TPU connection xx1900001943 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 403 Spare part level 3HAC071006-001 Harness TPU connection Harness motors power xx2100002496 Spare part num- Description Type Spare part level 3HAC081696-001 Harness HV Manipulator Motor Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 404: Mains Connection Parts

    Mains power connection xx2100000742 Mains power connection xx2100000742 Spare part number Description Type Spare part level 3HAC022165-002 Mains switch Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 405 For options 3008-2 Connector and 3008-3 Connector/fuse 3HAC079544-001 Circuit breaker 32A For option 3008-3 Connect- or/fuse 3HAC083284-001 Circuit breaker 16A For option 3008-3 Connect- or/fuse Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 406: Logic Parts

    Robot signal exchange proxy DSQC3037 3HAC065107-001 Harness Short-circuit connector Mating connect- or for robot sig- nal exchange proxy. Main computer xx1900001933 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 407 Main computer module assembly DeviceNet board xx2100002629 Spare part num- Description Type Spare part level 3HAC043383-001 DeviceNet Board (option) DSQC1006 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 408 9.1.3 Logic parts Continued Safety module xx2100002177 Spare part num- Description Type Spare part level 3HAC048858-001 Safety Module DSQC1015 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 409 3HAC028459-001 Magnetic roof antenna, 3G (baseline) 3HAC060962-001 Connected Services-WiFi [3013-2] (option) 3HAC059424-001 Magnetic roof antenna, WiFi (option) 3HAC061701-001 Connected Services-Wired [3013-1] DSQC1041 (option) Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 410: Application Parts

    Conveyor tracking module [3103-1] DSQC2000 3HNA029345-001 CONNECTOR KIT - DSQC2000 3HAC069618-001 Harness 24V_CTM Power cable of Ethernet switches xx1900001935 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 411 Description Type Spare part level 3HAC14178-1 DSQC 609 power supply DSQC 609 3HAC13398-2 DSQC 634 power supply DSQC 634 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 412 Analog add-on [3034-2] (Add-on) DSQC1032 3HAC060925-001 Connectors I/O Analog (Add-on) 3HAC058666-001 Relay add-on [3035-2] (Add-on) DSQC1033 3HAC060926-001 Connectors I/O Relay (Add-on) Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 413 9.1.4 Application parts Continued Safety digital base device xx2100000990 Spare part num- Description Type Spare part level 3HAC062908-001 DSQC1042 Extended safety 3HAC069538-001 Connectors Safety I/O Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 414: Cabinet Parts

    Spare part num- Description Type Spare part level 3HAC082805-001 Fan unit External fan 3HAC083027-001 Fan unit Internal fan Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 415 Power unit fan xx2100002283 Spare part num- Description Type Spare part level 3HAC081496-001 Fan with connector Power unit fan Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 416 HMI panel Swing handle Spare part num- Description Type Spare part level 3HAC083816-001 Swinghandle with cam LED indicator xx1900002451 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 417 LED indicator TPU cover xx1900002452 Spare part num- Description Type Spare part level 3HAC067213-001 TPU cover Air filter xx2200001828 xx2200001826 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 418 9 Spare parts 9.1.5 Cabinet parts Continued Spare part num- Description Type Spare part level 3HAC082548-001 Air filter coarse assembly 3HAC082547-001 Air filter fine assembly Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 419: Miscellaneous Parts

    Manipulator signal connectors (SMB) xx2200001954 Spare part num- Description Type Spare part level 3HAC081735-001 3HAC077440-001 Harness SMB link Fieldbus adapter slaves xx1900001937 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 420 3HAC066396-001 Cable grommet asm 3HAC073333-001 Harness network connection 2xM12 3HAC074398-001 Harness network connection 1xM12 3HAC070894-001 Harness Ethernet comm. 5xM12 Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 421 Integr Vision power cable 15 m 3HAC075443-003 Integr Vision ethernet cable 15 m Service port connector Spare part num- Description Type Spare part level 3HAC064848-001 Service port connector Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 422: Cables

    Spare part level 3HAC082081-001 Harn. Mains connection 3HAC081971-001 Harn. Mains connection 3HAC077980-001 Harn. with ferrites 3HAC082694-001 Harn. mains conn._fuse Continues on next page Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 423 Harness 24_PC Harness K2.X2 - K4.X8, A2.X1 3HAC059273-001 Harness dual channel safety Harness K2.X12 - K3.X6, K3.X7 3HAC076497-001 Ethernet harness Harness K2.X8 - A2.X6 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 424: Flexpendant Parts

    FlexPendant power cable 30 m 3HAC065419-001 Fasten strip 3HAC068915-001 FlexPendant extension cable, 15 m 3HAC068915-002 FlexPendant extension cable, 22 m 3HAC068915-005 FlexPendant extension cable, 30 m Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 425: Manipulator Cables

    Control cable signal 7 m 3HAC7998-1 Control cable signal 15 m 3HAC7998-2 Control cable signal 22 m 3HAC7998-3 Control cable signal 30 m 3HAC7998-4 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 426: Customer Cables - Cp/Cs Connectors (Option)

    CP/CS cables, IRB 460, 660, 2600, 4600, 5710, 5720, 6700 CP/CS cable length Article number Spare part level Cable CP/CS, 7 m 3HAC022957-001 Cable CP/CS, 15 m 3HAC022957-002 Harness-CP/CS, 30 m 3HAC022957-003 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 427: Customer Cables - Ethernet Floor Cables

    Article number Spare part level Ethernet floor cable, 7 m 3HAC079476-001 Ethernet floor cable, 15 m 3HAC079476-002 Ethernet floor cable, 30 m 3HAC079476-004 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.

  • Page 428: Customer Cables - Devicenet Cables

    DeviceNet floor cable length Article number Spare part level Harness-CP/CS/DeviceNet, 7 m 3HAC022978-001 Cable CP/CS DeviceNet, 15 m 3HAC022978-002 Harness-CP/CS/DeviceNet, 30 m 3HAC022978-003 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 429 131 height dimensions, 37 installed at a height, 27 disconnecting FlexPendant, 82 hold-to-run, 23 disposal of storage media, 335 hot surfaces, 31 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 430 13 risk of burns, 31 robot ODVA, 384 protection class, 38 ODVA power supply protection types, 38 LED, 384 robot signal exchange proxy Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 431 13 signals safety, 16 sim card weight, 37 replacing, 213 wrist strap, 42 software licenses, 45 standards, 390 steel X45 IP20, 103–104 Product manual - OmniCore V250XT Type A 3HAC084692-001 Revision: B © Copyright 2022-2023 ABB. All rights reserved.
  • Page 434 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2022-2023 ABB. All rights reserved. Specifications subject to change without notice.

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