ABB OmniCore V400XT Product Manual
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ABB OmniCore V400XT Product Manual

ABB OmniCore V400XT Product Manual

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OmniCore V400XT

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Summary of Contents for ABB OmniCore V400XT

  • Page 1 ROBOTICS Product manual OmniCore V400XT...
  • Page 2 Trace back information: Workspace 23D version a22 Checked in 2024-01-15 Skribenta version 5.5.019...
  • Page 3 Product manual OmniCore V400XT OmniCore Document ID: 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 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

    Safety during decommissioning ................Controller description OmniCore V400XT ..................... Technical data for OmniCore V400XT controller ............Safety functions and safety related data for OmniCore V400XT ........The unit is sensitive to ESD ................. Handling of FlexPendant ..................Network security ....................
  • Page 6 Replacing the main computer ..............5.2.9 Replacing the main computer battery ............5.2.10 Replacing the power unit ................5.2.11 Replacing the HVLP power unit (DSQC3072) ..........Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 7 7.3.10 Troubleshooting the Ethernet switch (DSQC1035) ......... 7.3.11 Troubleshooting the main computer ............7.3.12 Troubleshooting the process power supply ..........7.3.13 Troubleshooting the power supply, ODVA ............ Reference information Introduction ...................... Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 8 Manipulator cables .................. 9.3.2 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 V400XT 3HAC081697-001 Revision: A © 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 V400XT. 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 V400XT 3HAC082020-008 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 V400XT 3HAC081697-001 Revision: A © 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

    Performance level data The performance level data for the respective controller variant is presented in section Safety functions and safety related data for OmniCore V400XT on page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 15: Requirements On Personnel

    The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 17 1.2.1 Safety signals in the manual Continued Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © 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 V400XT 3HAC081697-001 Revision: A © 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 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 20 XXXXXXXXXXX xx2300001438 SRRC label for 3G (only for Chinese market) OmniCore XXX OmniCore XXX-3G-LTD XXXXXXXXXXX xx2300001441 SRRC label for 4G (only for Chinese market) xx2300001824 Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 21: Robot Stopping Functions

    AS / GS, a dedicated discrete protective stop input on the robot controller, will when the protective stop function is configured as Automatic Stop (AS) initiate the protective stop function in automatic mode only. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 22 For OmniCore, a safety input used to initiate a protective stop must remain active for at least 100 ms. Stop category configuration for OmniCore The stop category configuration is done in RobotStudio, in the tool Visual Safety. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 23: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 24: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 25: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 26 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 27: About The Automatic Mode

    GS, see actual controller) Note Prior to allowing the robot to operate in automatic mode, ensure that any suspended safeguards, are returned to full functionality. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 28: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 29 Water • Compressed air • Hydraulics End-effector hazards require particular attention for applications which involve close human collaboration with the robot. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 30 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 31: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 32: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 33: 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 34: Safety During Decommissioning

    1.9 Safety during decommissioning General See section Decommissioning on page 339. If the robot is decommissioned for storage, take extra precaution to reset safety devices to delivery status. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 35: Controller Description

    2.1 OmniCore V400XT About OmniCore V400XT The OmniCore V400XT 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 V400Xt Controller

    2 Controller description 2.2 Technical data for OmniCore V400XT controller 2.2 Technical data for OmniCore V400XT controller Overview of the controller OmniCore V400XT is intended to be used in industrial environment. X81, X91, xx2300001955 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A ©...
  • Page 37 2 Controller description 2.2 Technical data for OmniCore V400XT controller Continued K5.2 K5.1 K5.3 K3.1 K5.4 A2.K1 A2.K2 A2.K3 A2.K4 A2.K4 xx2300001956 OmniCore V400XT, Baseline Unit Reference to circuit diagram OmniCore V400XT Drive unit, High Voltage Baseline DSQC3062 Power unit HVHP DSQC3070...
  • Page 38 2 Controller description 2.2 Technical data for OmniCore V400XT controller Continued Unit Reference to circuit diagram OmniCore V400XT Power distribution board A2.K1 Baseline DSQC1085 Processor board DSQC1086 A2.K3 Baseline Ethernet switch DSQC1088 A2.K4 Baseline Safety board DSQC1087 A2.K5 Baseline Incoming mains switch...
  • Page 39 2 Controller description 2.2 Technical data for OmniCore V400XT controller Continued Transportation and storage conditions Parameter Value Minimum ambient temperature -40°C (-40°F) Maximum ambient temperature +55°C (+131°F) Maximum ambient temperature (less than 24 +70°C (+158°F) hrs) Shock and Vibration In accordance with ETSI EN 300 019-2-2 / Environmental class 2.3...
  • Page 40 2 Controller description 2.2 Technical data for OmniCore V400XT controller Continued Protection class (IEC 60529) Controller cabinet, compartment including IP23 cooling channel FlexPendant IP54 The cabinet must be closed and sealed when no internal access is required. If the cabinet is not properly closed and sealed (door and cable grommets), it does not comply with the protection class (IP54) and may affect the following: •...
  • Page 41 2 Controller description 2.2 Technical data for OmniCore V400XT controller Continued Line fusing As baseline there is no integrated fuse or circuit breaker. The option 3008-3 Mains connector/Fuse includes integrated circuit breaker. Robot Voltage (V) Current (A) IRB 460 380 VAC-480 VAC, 3-phase...
  • Page 42 2 Controller description 2.2 Technical data for OmniCore V400XT controller Continued Drive system The drive system provides motion power and absorbs excess braking energy when the robot is running. There is a label for the drive system on the controller. The label contains the specific drive system type information, so the label will vary according to the drive system type.

  • Page 43: Safety Functions And Safety Related Data For Omnicore V400Xt

    2.3 Safety functions and safety related data for OmniCore V400XT Overview The OmniCore V400XT provides safety with structure category 3 with performance level d according to EN ISO 13849-1. This fulfils the safety performance requirement as stated in the robot safety standard EN ISO 10218-1.
  • Page 44 2 Controller description 2.3 Safety functions and safety related data for OmniCore V400XT Continued Description [1/hour] Tool position supervision 3.87E-07 Tool speed supervision 3.87E-07 Tool orientation supervision 3.87E-07 Stand still supervision 3.87E-07 Related information Safety data on page 14 The SISTEMA/ABB FSDT libraries contain details for the safety functions.

  • Page 45: The Unit Is Sensitive To Esd

    The mat must be grounded through a current-limiting resistor. • Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 46 2.4 The unit is sensitive to ESD Continued Wrist strap button The location of the wrist strap button is shown in the following illustration. xx2300001842 Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 47: Handling Of Flexpendant

    FCC statement Changes or modification to the FlexPendant not expressly approved by ABB will void the user’s authority to operate the equipment. This device complies with Part 15 of the FCC Rules. Operation is subject to the...

  • Page 48: 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 49: 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 50: Abb Connect (Abb Ability)

    The content of this section is only available in English. Note ABB Connect is the new name for previously known ABB Ability. During a period of time, both ABB Connect and ABB Ability will appear on our products. The OmniCore™ controller hardware is delivered with a standard mobile connection (Cellular data connection), or WIFI modem and/or Ethernet connection.
  • Page 51 Changes or modifications not expressly approved by ABB could void the user’s authority to operate the equipment under FCC rules. When the optional connectivity module is installed, the operating conditions must be such that there is a minimum separation distance of 20 cm between the dedicated antenna and nearby persons or other antennas.
  • Page 52 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 53: Installation And Commissioning

    Safety on page 13 before performing any installation work. Note Always connect the OmniCore V400XT and the robot to protective earth and residual current device (RCD) before connecting to power and starting any installation work. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A ©...

  • Page 54: Installation Activities

    158. 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 55: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 56: 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 57: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 58: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 59 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 60: 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 V400XT controller. The diameter of the four bolt holes are 14 mm. xx2200001823...

  • Page 61: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 62 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 63 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 64 Hang the FlexPendant holder to the bracket according to the screws on the bracket. xx2000002354 Hang the holder with the bracket to the desired place. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 65 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 66 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 67: Connecting The Connected Services Antenna

    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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 68 3.4.4 Connecting the Connected Services antenna Continued Action Note/Illustration Connect the antenna cable to the Connec- ted Services gateway by rotating the connector. xx2300001642 xx2300000672 Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 69: Electrical Connections

    3.5 Electrical connections 3.5.1 Connectors on the OmniCore V400XT controller General The following section describes the connectors on the OmniCore V400XT controller. CAUTION Always inspect the connector for dirt or damage before connecting it to the controller. Clean or replace any damaged parts.
  • Page 70 3 Installation and commissioning 3.5.1 Connectors on the OmniCore V400XT controller Continued Description Incoming mains switch Motors on lamp Ethernet outlet connector, MGMT (Management) FlexPendant connector (HMI) Motor connector Manipulator signal connector (SMB) Cable grommet assembly Incoming mains connector Ethernet outlet connector, LAN3...

  • Page 71: Connecting Cables To The Controller

    Shielded cable with twisted pair conductors. A specific cable signals should be used for field bus connections and Ethernet, according to the standard specification of the respective bus. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 72 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 73 • Cables carrying analog low-level signals is another exception where the shield should be grounded at only one end. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 74 Shield pigtail termination, as shown below, shall be avoided. If a pigtail connection cannot be avoided, make it as short as possible. xx1700001321 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 75 Connecting incoming mains and protective earth to the controller on page For information on how to connect protective earth for the manipulator, see the corresponding product manual. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 76 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 77 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 78: 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 79 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 80: Connecting The Manipulator To The Controller

    Connecting the cables from the manipulator to the controller Action Connect the manipulator cable to the connector X1. Lock the connector with the lever. Secure the cables to avoid tripping or wear. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 81: Fitting The Connector For Incoming Mains

    PE1 and PE2 points on X0 (incoming mains connector). Included parts The following parts are included in the delivery. Part Order number Quantity Connector kit 3HAC075871-001 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 82 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 83: Connecting Incoming Mains And Protective Earth To The Controller

    The cabinet must be connected to protective earth. See Connection of protective earth on page • A residual current device (RCD) must be installed. See Residual current on page Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 84 Equipment Note Main connection cable (three-phase) L1, L2, L3, PE1, PE2 Details see Fitting the connector for incoming mains on page Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 85 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 86: Detaching And Attaching A Flexpendant

    CAUTION The FlexPendant connector shall only be used to connect the FlexPendant. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 87 Detaching the FlexPendant in automatic mode Use the following procedure to detach the FlexPendant in automatic mode: 1 On the status bar, tap the QuickSet button. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 88 4 Tap Detach. 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 89 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 90: Ethernet Networks On Omnicore

    Note The management port shall never be used for more than one client at a time. ABB Robotics assumes no responsibility for any errors/hazards that may appear when more than one client is used.

  • Page 91: Descriptions For Connectors

    24V_TRUNK 24V_TRUNK 24V_TRUNK 24V_TRUNK 24V_TRUNK Connector X19 Description Connection Connector for 24V_IO_EXT output Type SC 3.81 90F Weidmüller Article number 1793380000 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 92 Name Description MS_ONOFF Connector X31 Description Connection Connector for system power mode control Type Dynamic D-1200D Tyco Electronics Article number 2-1827876-2 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 93 Connection Connectors for ECAT, MGMT, DEV, TPU and DRV (Motion Link) Type RJ45 Article number Label ECAT1, IN ECAT2, OUT MGMT Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 94 Name Description BI_DA+ BI_DA- BI_DB+ BI_DB- Ethernet switch front panel connectors xx2300001768 Connector X1, X2, X3, X4 Description Connection Connectors for ABB Connect, WAN1, WAN2 and LAN. Type RJ45 Article number Label ABB Connect WAN1 WAN2 Name Description BI_DA+ BI_DA-...
  • Page 95 The connector X14 allows for connecting general stop and emergency stop devices. General Stop is operational in both manual mode and automatic mode. See Protective stop and emergency stop on page Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 96 The emergency stop function is not activated (closed loop) when the voltage is above 15 V. The protective stop function is not activated (closed loop) when the voltage is above 15 V. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 97 Customer provided power protec ve stop device A2.K5.X14 Customer_24V_CH1 24V_CH1_EXT GS_CH1_P GS_CH1_N 0V_IO_EXT Customer_0V_CH1 24V_CH2_EXT Customer_24V_CH2 GS_CH2_P GS_CH2_N 0V_IO_EXT Customer_0V_CH2 xx2300000996 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 98 Customer provided Customer provided power emergency stop device A2.K5.X14 Customer_24V_CH1 24V_CH1_EXT EXT_ESTOP_CH1_P EXT_ESTOP_CH1_N 0V_IO_EXT Customer_0V_CH1 24V_CH2_EXT Customer_24V_CH2 EXT_ESTOP_CH2_P EXT_ESTOP_CH2_N 0V_IO_EXT Customer_0V_CH2 xx2300000998 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 99 If separate power supplies are used for each channel (Ch1, Ch2) they must have common ground. For more connections other than those illustrated above, carefully assess the risk before use and contact your local ABB for support. Connector X15 Description...
  • Page 100 Customer provided power protec ve stop device A2.K5.X15 Customer_24V_CH1 24V_CH1_EXT AS_CH1_P AS_CH1_N 0V_IO_EXT Customer_0V_CH1 24V_CH2_EXT Customer_24V_CH2 AS_CH2_P AS_CH2_N 0V_IO_EXT Customer_0V_CH2 xx2300000994 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 101 To increase diagnostic cover on Emergency Stop output suitable diagnostics measures on the relay interfacing device could be added, such as antivalence or pulse testing by external interfacing safety device. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 102 MON_PB1 Lamp 24V_MON(+) MON_LAMP(-) xx2300001000 Antenna connector The Connected Services Gateway unit has either an ABB Connect port or an antenna connector on the front. See installation procedures in section On-site installation on page xx1900002450 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A ©...
  • Page 103 The following type of Ethernet cable is recommended for connection to the Ethernet outlet connector (MGMT port): Ethernet cable Value Maximum length 75 m Type of cable CAT5e SF/UTP Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 104 The connectors contain 16 digital input signals, 16 digital output signals, 24 V and 0 V for the outputs, and 0 V for the inputs. For connection details, see Circuit diagram - OmniCore V400XT, 3HAC082020-008 and Application manual - Scalable I/O, 3HAC070208-001.
  • Page 105 This connector is internally connected with the optional power supply. It is a 24 V power supply for the customer. The characteristics are shown in the following table. Parameter Value Voltage 24 V DC Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 106 The 24 V terminal block power supply is isolated from the internal logical circuit of the controller. For connection details, see Circuit diagram - OmniCore V400XT, 3HAC082020-008. Customer cable layout It is recommended to use multicore cable for the customer connection.

  • Page 107: Configuring Robot Stopping Functions

    3 For user-created stop configurations, select the signal that should trigger the stop in the Trigger signal dropdown menu. • 0 = activate stop • 1 = deactivate stop Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 108 7 After the configuration is done, the safety configuration must be transferred to the controller and then a restart of the controller is required. See also the circuit diagram, Circuit diagram - OmniCore V400XT. Apply the configuration to the controller...
  • Page 109 Always read the RobotWare release notes and verify the robot stopping functions by test after an upgrade. Contact your local ABB office for guidance. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © 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 V400XT 3HAC081697-001 Revision: A © 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 V400XT 3HAC081697-001 Revision: A © 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 the product specification for the respective manipulator. The data is valid for floor mounted manipulators, without any tilting. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 113: I/O System

    The software based fieldbuses are connected directly to one of the Ethernet ports. xx2300001738 Available board The following master board is available. Description Article number Type designation DeviceNet M/S 3HAC085254-001 DSQC1096 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 114 Application manual - EtherNet/IP Scanner/Adapter 3HAC066565-001 Application manual - PROFINET Controller/Device 3HAC066558-001 Application manual - I/O Engineering 3HAC082346-001 Application manual - CC-Link IE Field Basic 3HAC082295-001 Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © 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

    Local I/O Digital base [3032-1] 3HAC058663-001 DSQC1030 Connectors digital base/add on 3HAC060919-001 Digital add-on [3033-2] 3HAC058664-001 DSQC1031 Analog add-on [3034-2] 3HAC058665-001 DSQC1032 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 117 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 118 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 119: Installing The Safety Digital Base Device

    The illustration shows the location of the safety digital base device in the controller. xx2300001792 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 120 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 121 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 122: Installing The Ethernet Extension Switch

    3.7.3 Installing the Ethernet extension switch Location The illustration shows the location of the Ethernet extension switch in the controller. xx2200001091 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 123 3.7.3 Installing the Ethernet extension switch 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 124 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 125 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 126: Installing Additional Drive Units

    ABB products such as Track Motion, Positioners, Motor Units, Gear Units are equipped with integrated brake snubbers. When integrating a motor not delivered by ABB, it is of great importance that the motor has a snubber fitted across the brake terminals, at the motor. Failure to do so will void warranty and may result in drive unit failure.
  • Page 127 Do not touch the drive unit when the DC-BUS High Voltage LED is on. There is residual voltage in the drive unit even if the main switch is in the OFF position. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 128 3.7.4 Installing additional drive units 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 129 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 130 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 131: 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 V400XT via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A ©...
  • Page 132 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 133 For DSQC 634: Hang the power supply to the bracket and push the lower part until you hear a clear clicking sound. xx1900001908 For DSQC 634: xx1900001950 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 134 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 135: 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 136 The unit is sensitive to ESD on page xx2300001842 Open the door. Opening the door on page 182. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 137 Function tests on page 171. For more information about the option Conveyor Tracking, see Application manual - Conveyor tracking. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 138: 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 139 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 140 Refit the cover strip onto the frame. xx1900002335 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 141 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 142 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 143 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 144: Installing The Air Filter

    3.7.8 Installing the air filter 3.7.8 Installing the air filter Location The illustration shows the location of the air filter on the controller. xx2300001800 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 145 3.7.8 Installing the air filter 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 146 Fit the air filter unit to the cabinet. xx2300001802 Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 147: 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. xx2100002285 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 148 Standard toolkit for controller on page 424. ESD protective wrist band Required documents Document Article number Note Circuit diagram - OmniCore 3HAC082020-008 V400XT Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 149 (A). xx2100002286 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 150 (B). Connect the wires to the incoming mains See circuit diagram. switch (B). Refit protection on the incoming mains switch (B). Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 151: Installing The Devicenet Board

    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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 152 Remove the cover plate from the main computer assembly. Insert the DeviceNet board into the slot in the main computer assembly. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 153 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 154: Installing The Motor Connection Box

    330 on the left side and 180 on the right side. If third party motors are to be connected, install a quenching circuit. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 155 1-3 (A) and ADU 4-6 (B) on the cabinet. xx2300001919 Connect the SMB cable to the SMB con- nector for ADU 1-6 (C) on the cabinet. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 156 Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 157: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 158: Initial Test Before Commissioning

    Function tests Before commissioning, perform the function tests in section Function tests on page 171 to verify that the safety features work properly. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 159: 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 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 160: Inspection Activities

    After inspection: Temporarily turn the power supply on. Inspect the fans to make sure they function correctly. Switch the power off. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 161: Cleaning Activities

    4.3.1 Cleaning air filter 4.3 Cleaning activities 4.3.1 Cleaning air filter Location The air filter is located as shown in the illustration below. xx2300001800 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 162 Insert the polymeric filter element to the filter and secure with the metallic line. xx2100002583 Refit the air filter unit to the cabinet. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 163 The coarse filter cannot be separated from the filter assembly. Action Note/Illustration Remove the air filter unit. xx2300001802 Clean the metal mesh filter with compressed air. Refit the air filter unit to the cabinet. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 164: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 165: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 166 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 167: Changing/Replacing Activities

    4.4 Changing/replacing activities 4.4.1 Replacement of air filter Location The air filter unit is located as shown in the illustration below. xx2300001800 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 168 For more information, see Electrical safety on page Removing the air filter Action Note/Illustration Remove the air filter unit. xx2300001802 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 169 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Refit the air filter unit to the cabinet. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 170 4.4.1 Replacement of air filter Continued Concluding procedure Action Note/Illustration Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 171: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 172: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 173: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 174: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 175: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 176: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 177: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 178: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 179: Function Test Of Reduced Speed Control

    To get accurate results, use sensors or I/O signals to measure the time. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 180 This page is intentionally left blank...

  • Page 181: 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 V400XT, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.

  • Page 182: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 183 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 184 Info/illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 185 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 186: Replacing The Fans

    5.2.2 Replacing the fans 5.2.2 Replacing the fans Location The illustration shows the location of the fans in the controller. xx2200001086 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 187 5.2.2 Replacing the fans 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...

  • Page 188: Replacing The External Fans

    5.2.2.1 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. xx2200001086 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 189 Disconnect all connectors from the unit to be replaced. Remove the fan bracket screws. xx2200001063 Take out the fan bracket and the fan. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 190 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 191 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 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 192: Replacing The Internal Fan

    For more information, see Electrical safety on page Open the door. Opening the door on page 182. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 193 Remove the fan assembly from the mounting plate. Remove the screws holding the fan cov- xx2200001070 Remove any cable ties. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 194 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 195 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 196: Replacing The Main Computer Fan

    The illustration shows the location of the main computer fan in the controller. xx2300001552 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 197 The unit is sensitive to ESD on page xx2300001842 If necessary, remove the Connected Removing the Connected Services gateway Services gateway. on page 210. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 198 Note/Illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 199 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 200: Replacing The Power Unit Fan

    The illustration shows the location of the power unit computer fan in the controller. xx2100002281 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 201 LEDs on page 382. is not lit. Removing the power unit fan Action Note/Illustration Disconnect all connectors from the unit to be replaced. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 202 Insert the fan assembly in the slot on the power unit. xx2100002282 CAUTION Sharp edges. Make sure the cables are not damaged. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 203 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 204: Replacing The Ethernet Switch (Dsqc1035)

    5.2.3 Replacing the Ethernet switch (DSQC1035) 5.2.3 Replacing the Ethernet switch (DSQC1035) Location The illustration shows the location of the Ethernet switch in the controller. xx2200001091 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 205 5.2.3 Replacing the Ethernet switch (DSQC1035) 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 206 Carefully pull the side of the Ethernet extension switch and rotate it tightly to take it out from the bracket. xx2300001835 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 207 Ethernet extension switch and the lower surface of highest bracket on the main computer. xx2300001835 xx1800000972 Reconnect any connectors disconnected at removal. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 208 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 209: Replacing The 3G Connected Services Gateway

    The illustration shows the location of the Connected Services gateway in the controller. For the 3G variant, there is a sim card inside the unit. xx2300001641 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 210 5.2.4 Replacing the 3G Connected Services gateway 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 211 Connected Services gateway by rotating the connector. xx2300001642 Remove any cable ties and protection. Pull the cable out through the cable grommet. xx2200001973 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 212 Removing the sim card Action Note/Illustration Remove the attachment screws and pull out the front cover of the Connected Services-3G. xx1900000971 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 213 Note/Illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 214 Note antenna cable. The Connected Services antenna is installed by the customer, and the cable routing can therefore differ. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 215 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 216: Replacing The 4G Connected Services Gateway

    Location xx2300000248 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 217 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 218 Remove any cable ties and protection. Pull the cable out through the cable grommet. xx2200001973 Remove the magnet part of the antenna from the cabinet. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 219 Carefully lift the Connected Services gateway slightly and then pull it out from the bracket. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 220 The unit is sensitive to ESD on page Hook up the Connected Services gate- way to the bracket and push carefully into position. xx2300000673 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 221 Note antenna cable. The Connected Services antenna is installed by the customer, and the cable routing can therefore differ. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 222 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 223: Replacing The Scalable I/O Unit

    The illustration shows the location of the scalable I/O in the controller. xx2300001791 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 224 The unit is sensitive to ESD on page xx2300001842 Removing the digital base (option) Action Note/Illustration Disconnect all connectors from the unit to be replaced. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 225 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 226 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 227: Replacing The Safety Digital Base Device

    The illustration shows the location of the safety digital base device in the controller. xx2300001792 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 228 ESD on page xx2300001842 Removing the safety digital base device Action Note/Illustration Disconnect all connectors from the unit to be replaced. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 229 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 230 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 231: Replacing The Main Computer

    The illustration shows the location of the main computer in the controller. xx2200001088 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 232 Removing the main computer assembly Action Note/Illustration Remove any cable ties. Disconnect all connectors from the unit to be replaced. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 233 Apply cable ties and suitable cable pro- tection to ensure that the cables may not be damaged by the door. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 234 Follow the instructions and tap Next to proceed. Carefully read the information and then check all boxes to confirm that you agree with the ABB conditions. Tap Next to proceed. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A...
  • Page 235 The restoration and the manually entered serial number to of the serial number is completed. ensure that there is a match. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 236: Replacing The Main Computer Battery

    Article number Note Standard toolkit Content is defined in section Standard toolkit for controller on page 424. ESD protective wrist band Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 237 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 238 Loosen the screws that hold the pro- cessor board unit, DSQC1086. xx2300000941 Remove the processor board unit from the slot in the main computer assembly. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 239 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 240 Insert the battery into the slot in the pro- cessor board unit. xx2300000942 Insert the processor board unit into the slot in the main computer assembly. xx2300000941 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 241 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 242: Replacing The Power Unit

    Do not touch the power unit when the DC-BUS High Voltage LED is on. There is residual voltage in the power unit even if the main switch is in the OFF position. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 243 5.2.10 Replacing the power unit 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 244 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. xx2100000322 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 245 Secure the screws. xx2100000322 Reconnect any connectors disconnected at removal. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 246 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 247: Replacing The Hvlp Power Unit (Dsqc3072)

    The illustration shows the location of the power unit in the controller. xx2300001804 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 248 The unit is sensitive to ESD on page xx2300001842 Removing the power unit Action Note/Illustration Disconnect all connectors from the unit to be replaced. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 249 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 250 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 251: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 252 5.2.12 Replacing the power supply 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 253 Disconnect all connectors from the unit to be replaced. Remove the screw and the power supply. xx1900001908 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 254 Screws: Cross recessed cheese head screw fasten it with screw. M4x8 (1 pcs) Tightening torque: 1.7 Nm±10%. xx1900001908 Reconnect any connectors disconnected at removal. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 255 For more information, see Electrical safety on page Open the door. Opening the door on page 182. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 256 Disconnect all connectors from the unit to be replaced. Press the lower buckle to release and remove the power supply. xx1900001950 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 257 Hang the power supply into the bracket and push the lower of it until you hear a clear clicking sound. xx1900001950 Reconnect any connectors disconnected at removal. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 258 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 259: Replacing The Drive Unit

    Do not touch the drive unit when the DC-BUS High Voltage LED is on. There is residual voltage in the drive unit even if the main switch is in the OFF position. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 260 5.2.13 Replacing the drive unit 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 261 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. xx2100000338 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 262 Tightening torque: 2 Nm tip the unit upwards against the upper guiding pin. Secure the screws. xx2100000338 Reconnect any connectors disconnected at removal. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 263 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 264: Replacing The Additional Drive Unit

    Do not touch the drive unit when the DC-BUS High Voltage LED is on. There is residual voltage in the drive unit even if the main switch is in the OFF position. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 265 5.2.14 Replacing the additional drive unit 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 266 Handle it with care to avoid damage to the cabling or the connector, avoid any kind of tilt or skew. xx2200001375 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 267 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 268: Replacing The Devicenet Board

    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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 269 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 270 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 271 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 272: Replacing The Conveyor Tracking Module (Ctm)

    The illustration shows the location of the conveyor tracking module in the controller. xx2300001793 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 273 ESD on page xx2300001842 Removing the conveyor tracking module (option) Action Note/Illustration Disconnect all connectors from the unit to be replaced. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 274 Note/Illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 275 Reconnect any connectors disconnected at removal. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 276 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 277: Replacing The Air Filter

    5.2.17 Replacing the air filter 5.2.17 Replacing the air filter Location The illustration shows the location of the air filter on the controller. xx2300001800 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 278 5.2.17 Replacing the air filter 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 279 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. xx2100002583 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 280 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 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 281: 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 V400XT via myABB Business Portal, www.abb.com/myABB. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A ©...
  • Page 282 184. Open the door. Opening the door on page 182. Removing the break resistor bleeder Action Note/Illustration Remove the cable ties. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 283 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 284 The unit is sensitive to ESD on page xx2300001842 Refit the break resistor bleeder and se- cure the screws. xx2200001074 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 285 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 286: Replacing Parts On The Front Panel And Door

    The illustration shows the location of the manipulator signal connector. xx2100000826 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 287 Remove cable ties and cable supports. Remove nuts and attachment screws. xx2100000827 Push the manipulator signal connector out through the front panel. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 288 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 289: Replacing The Motor Connector

    The illustration shows the location of the motor connector in the controller. xx2100000739 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...

  • Page 290: Replacing The Motor Connector

    The unit is sensitive to ESD on page xx2300001842 Removing the motor connector Action Note/Illustration Disconnect all connectors from the unit to be replaced. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 291 Note/Illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 292 Use the same position as from removing the motor connector. Concluding procedure Action Note/Illustration Close the door. Closing the door on page 183. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 293 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 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 294: Replacing The Hmi Signal (Flexpendant) Connector

    5.3.3 Replacing the HMI signal (FlexPendant) connector Location The illustration shows the location of the HMI signal connector in the controller. xx2300001845 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 295 5.3.3 Replacing the HMI signal (FlexPendant) connector 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 296 The cables need to be installed in the same position. Disconnect all connectors from the unit to be replaced. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 297 5 Repair 5.3.3 Replacing the HMI signal (FlexPendant) connector Continued Action Note/Illustration Remove the screws. xx2300001846 Remove the cover plate. xx2300001847 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 298 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 299 Use the same position as from removing the HMI signal connector. Refit the cover plate. xx2300001847 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 300 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 301: 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 302 Note 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 303 Take the cable grommet assembly out. 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 304 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 305 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 306 Refit the cover strip onto the frame. xx1900002335 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 307 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 308 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 xx2300001842 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 309 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 310: Replacing The Ethernet Outlet Connector With Cable

    5.3.5 Replacing the Ethernet outlet connector with cable Location The illustration shows the location of the Ethernet outlet connector with cable. xx2300001848 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 311 5.3.5 Replacing the Ethernet outlet connector with cable 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 312 The unit is sensitive to ESD on page xx2300001842 Removing the Ethernet outlet connector with cable Action Note/Illustration Remove the screws. xx2100000850 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 313 Remove the cover plate. xx2100000851 Remove the attachment screws on the door. xx2100000852 Turn the locking ring anti-clockwise to remove the connector. xx2100000852 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 314 The unit is sensitive to ESD on page Insert the Ethernet outlet connector with cable into the cover from inner side of the cabinet. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 315 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 316: Replacing The Led Indicator

    5.3.6 Replacing the LED indicator 5.3.6 Replacing the LED indicator Location The illustration shows the location of the LED indicator. xx2300001849 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 317 5.3.6 Replacing the LED indicator 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 318 Remove the terminals (X1&X2) of the cable from the lamp. Turn the MON_LAMP screw anti-clock- wise to remove the screw. Take the LED indicator out. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 319 Close the door. Closing the door on page 183. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 320: 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 321 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 322 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 323 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 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 324: Replacing The Joystick Protection

    The illustration shows the location of the joystick protection on the FlexPendant. xx1800001197 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 325 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 326 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 327: Replacing The Fasten Strip

    The illustration shows the location of the fasten strip on the FlexPendant. xx1900000771 Required spare parts Note The spare part numbers that are listed in the table can be out of date. See the latest spare parts of the OmniCore V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...

  • Page 328: Replacing Other Parts

    The motor connection box location is decided by the customer. 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number...
  • Page 329 Reconnect any connectors disconnected at removal. Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 330: Replacing The Measurement 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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 331 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Remove the screws holding the cover. xx2300001703 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 332 Push the measurement unit inwards and lift out of the box. Remove the attachment screws from the mounting plate. xx2300001706 Pull out the measurement unit. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 333 Put the measurement unit and mounting plate in the box. Refit the screws at the front of the box. xx2300001705 Reconnect any connectors disconnected at removal. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 334 Continued Action Note/Illustration Refit the cover. xx2300001703 Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 335: Replacing The Motor Connection Box Battery

    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 V400XT via myABB Business Portal, www.abb.com/myABB. Spare part Article number Note...
  • Page 336 Refitting the motor connection box battery Action Note/Illustration Refit the battery and secure with cable ties. Reconnect any connectors disconnected at removal. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 337 Continued Action Note/Illustration Refit the cover. xx2300001703 Perform the function tests to verify that the safety features work properly, see Function tests on page 171. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 338 This page is intentionally left blank...

  • Page 339: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 340: 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 341 China RoHS symbol The following symbol shows the information to hazardous substances and the environmental protection use period of OmniCore V400XT according to "Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products (SJ/T 11364-2014) ".
  • Page 342 This page is intentionally left blank...

  • Page 343: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 344 The following block diagram illustrates the power supply distribution. Main computer A2 Power distribution board A2.K1 Power unit Power unit Main drive Additional unit T4 drive units T41-T46 24VDC_TRUNK 24V_SYS_DRV 24V_SYS_DRV 24V_SYS_DRV xx2300001930 Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 345: Troubleshooting Fault Symptoms

    • Reflashing firmware failure on page 362 • Inconsistent path accuracy on page 363 • Controller is overheated on page 365 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 346: 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 347 Replace fuse F1 Abnormal Troubleshoot Check A1.X1 power unit Not lit Troubleshoot Check LED status LEDs Not lit Problem solved xx2100001064 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 348 Troubleshooting the power unit on page 381. • If abnormal, troubleshoot Check the LED status. the LEDs. See Troubleshooting LEDs in the controller on page 366. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 349: 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. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A...
  • Page 350 See Troubleshooting the main computer on page 414. • If the measured voltage is abnormal, proceed with step Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 351 If the drive unit status LED is not lit, see Troubleshooting the drive unit on page 368. If the problem remains, contact ABB. For more details, see Circuit diagram - OmniCore V400XT. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 352: System Update Failure

    (backup copy) of the previous system state. This is the simplest way. 2 Perform a complete re-installation of the RobotWare system using RobotWare Installation Utilities, start the RobotWare system and then reload the previous backup. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 353: 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 354 Test the brake Brake is ok Not ok Test the brake release Contact ABB Brake release is ok Problem solved xx2300001758 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 355 Check that the brake release function is ok. For more details on how to release the brakes, see the robot's product manual. • If it is not ok, contact your local ABB. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 356: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 357 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 358 Action Note Try resetting the FlexPendant using the reset See Operating manual - OmniCore. button located next to the USB port. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 359 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 367. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 360: Problem Using The Joystick

    If the joystick is still not working, then port on the back of the FlexPendant. replace the FlexPendant. Note The reset button only resets the FlexPendant, not the system on the controller. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 361: Controller Fails To Start

    Force starting the RobotWare Installation Utilities mode will not affect the files in the directories belonging to the installed system. How to install systems is described in Operating manual - Integrator's guide OmniCore. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 362: 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 V400XT 3HAC081697-001 Revision: A ©...

  • Page 363: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 364 353. 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 365: 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 366: Troubleshooting Units

    Troubleshooting the main computer on page 414 Power supply Troubleshooting the power supply, ODVA on page 420 Troubleshooting the process power supply on page 419 Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 367: Troubleshooting The Flexpendant

    Check the 24 V power supply. Read the error event log message and follow any instructions of references. For more information on the FlexPendant, see Operating manual - OmniCore. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 368: Troubleshooting The Drive Unit

    7.3.3 Troubleshooting the drive unit 7.3.3 Troubleshooting the drive unit Location The illustration shows the location of the drive unit in the controller. xx2300001794 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 369 Red, steady: Internal error. • 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 370 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 371 Replacing the drive unit on page 259. • Flashing green (~ 1Hz): Communication error to another module. Proceed with step 3. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 372 If the Link/Activity LED is off, the fault remains. Replace the drive unit, see placing the drive unit on page 259. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 373 If the connection seems OK, the fault has Replace the safety cable: X17. been fixed. Proceed with step 1. • If the fault remains, see Troubleshooting the power unit on page 381. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 374: Troubleshooting The Additional Drive Unit

    7.3.4 Troubleshooting the additional drive unit 7.3.4 Troubleshooting the additional drive unit Location The illustration shows the location of the drive unit in the controller. xx2300001799 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 375 ADU4 ADU5 ADU6 ADU3 ADU2 ADU1 Power Unit xx2200000702 See also Application manual - Additional axes for OmniCore 3HAC082287-001. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 376 7.3.4 Troubleshooting the additional drive unit Continued LEDs The illustration below shows the indication LEDs on the additional drive unit. xx2200001052 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 377 Yellow: Voltage between DC+ - DC- > 60 VDC Required test equipment Equipment needed for troubleshooting: Equipment Note Multimeter Insulating gloves Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 378 Replace Replace Troubleshoot Troubleshoot additional drive unit additional drive unit power unit power unit xx2200001226 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 379 X3/X4/X16/X18. Make sure that the cables are connected properly at If there is a problem with the connection, pro- both ends. ceed with step 9. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 380 If the connection seems OK, the fault has Replace the 24V_BRAKE cables been fixed. Proceed with step 1. X13/X14. • If the fault remains, see Troubleshooting the power unit on page 381. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 381: Troubleshooting The Power Unit

    7.3.5 Troubleshooting the power unit 7.3.5 Troubleshooting the power unit Location The illustration below shows the location of the power unit in the controller. xx2300001797 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 382 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 383 Yellow steady: Link without activity. Required test equipment Equipment needed for troubleshooting: Equipment Note Multimeter Insulating gloves Circuit diagram - OmniCore V400XT 3HAC082020-008 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 384 Troubleshoot robot signal Replace power unit Contact your local ABB Troubleshoot drive unit Replace power unit exchange proxy exchange proxy xx2100001981 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 385 Replacing the power unit on page 242. • If the measured voltage is abnormal, proceed with step 6. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 386 Replacing the power unit on page 242. • If the measured voltage is abnormal, see Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 387 242. Replace cables: If DC_OUT is not OK, the unit may be faulty, • DC_OUT (X4 and X8) Replacing the power unit on page 242. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 388: Troubleshooting The Hvlp Power Unit (Dsqc3072)

    7.3.6 Troubleshooting the HVLP power unit (DSQC3072) Location The illustration below shows the location of the power unit in the controller. xx2300001804 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 389 7 Troubleshooting 7.3.6 Troubleshooting the HVLP power unit (DSQC3072) Continued LEDs The illustration below shows the LEDs on the power unit. xx2300001469 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 390 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 391 • If the LED is not lit, proceed with step 4. • If the LED is red, proceed with step 11. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 392 If the AC_OUT voltage is normal, troubleshoot other modules. • If the AC_OUT voltage is abnormal, pro- ceed with step 11. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 393 1 minute. resistor bleeder on page 281. • Disconnect X10. The unit may be faulty. Replace the Replacing the power unit on page 242. power unit. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 394: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 395: Troubleshooting The 3G Connected Services Gateway

    7.3.8 Troubleshooting the 3G Connected Services gateway Location The illustration shows the location of the Connected Services gateway in the controller. xx2300001641 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 396 3G connection. Orange: • ON, flashing: 3G modem on, searching network. • ON, solid: 3G modem on and connected to network. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 397 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 398 OFF, the unit is faulty, or it does not have sufficient input voltage, or the connection of the connector X2 is not ok. Proceed with step 5. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 399 Verify that the configuration is done cor- tion log in Backup and Restore. rectly. Verify that the mobile operator is detected (for 3G). Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 400 209. Related information All documents can be found via myABB Business Portal, www.abb.com/myABB. The approval code CMIIT ID is displayed on the nameplate of the product. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A...

  • Page 401: Troubleshooting The 4G Connected Services Gateway

    7.3.9 Troubleshooting the 4G Connected Services gateway Location The illustration shows the location of the Connected Services gateway in the controller. xx2300000248 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 402 Very good 200 ms on, 200 ms off Good 100 ms on, 900 ms off Poor No signal or logged out Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 403 Check SIM card Replace the Connected Services Gateway Not ok Check 4G Gateway Dashboard Check connection Contact ABB Customer Services xx2300000759 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 404 CAUTION The ABB 4G gateway has been preconfigured in factory. Resetting the gateway will make it unusable and warranty is lost. Contact ABB if reset is required. Troubleshooting procedures The troubleshooting table is supposed to be used as a detailed instruction together with the troubleshooting flowchart.
  • Page 405 Check 4G Gateway Dashboard and Con- Troubleshooting the unit by connect- tact ABB Customer Services. ing a PC on page 406. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 406 3 Open a browser with https://192.168.125.85/. 4 The INSYS login page is displayed: xx2300000638 Note Enter the following to access this page: User (status) Password (status) Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 407 408 and the complete configuration. The support packet can be saved as a file and be sent to ABB L3/L4 Sup- port for analysis. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A ©...
  • Page 408 3 The Log view displays all current logs: xx2300000911 4 The Log download and Support Packet pages allow saving logs for ABB troubleshooting. These logs can be saved as a file and be sent to ABB L3/L4 Support for analysis. •...
  • Page 409 2 Connect to the Dashboard of the 4G gateway. xx2300000639 3 On the Dashboard, verify the following: • Verify that the WAN chain is online. xx2300000640 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 410 It is recommended to store the profile version for reference. This can be used later to verify that the unit has not been reset or tampered with. CAUTION Contact ABB if the profile version has changed or if the box has been reset. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A ©...
  • Page 411 3 On the Dashboard, the field Firmware displays the firmware version. The minimal firmware required is FW 6.11. xx2300000763 Related information All documents can be found via myABB Business Portal, www.abb.com/myABB. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 412: Troubleshooting The Ethernet Switch (Dsqc1035)

    7.3.10 Troubleshooting the Ethernet switch (DSQC1035) 7.3.10 Troubleshooting the Ethernet switch (DSQC1035) Location The illustration shows the location of the Ethernet switch in the controller. xx2200001091 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 413 On:100/1000 Mbps data rate is selected. Yellow: • Flashing: The Ethernet is active on link. • Solid: A LAN link is established. • Off: A LAN link is not established. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 414: Troubleshooting The Main Computer

    The illustration shows the location of the main computer in the controller. xx2200001088 LEDs The following sections display the LEDs on the main computer units. Power distribution board, DSQC1085 xx2300000434 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 415 Green (pulsing ~1Hz): Communication error to Base Applica- tion Note PWR LED will continue flashing until STAT LED is solid green. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 416 No color: Motors_ON function is off. • White, solid: Motors_ON function is • White, flashing: safety loop is open, for example after an emergency stop. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 417 • Green (pulsing ~1Hz): Communication error to PS-side application. Proceed with step 12. • Off or red: Proceed with step 13. Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 418 Install/re-install RobotWare, if pos- sible. The main computer may be faulty, Replacing the main computer on page 231. replace it and verify that the fault has been fixed. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 419: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 420: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 421: Reference Information

    8.1 Introduction 8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 422: Applicable Standards

    – Emission standard for industrial environments 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 423: Unit Conversion

    1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 424: Standard Toolkit For Controller

    Phillips-1 Box spanner 8 mm Toolkit recommended for troubleshooting Tool Note Normal shop tools Contents as specified above. Multimeter Camera To document problems or procedures Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 425: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 426: 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 427: Lifting Accessories And Lifting Instructions

    The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. The instructions delivered with the lifting accessories should be stored for later reference. Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 428 This page is intentionally left blank...

  • Page 429: 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 430: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 431: Controller System Parts

    9.1.1 Controller system parts Drive units xx2100000707 Spare part num- Description Type Spare part level 3HAC064590-001 Drive unit, High Voltage DSQC3062 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 432 9.1.1 Controller system parts Continued Additional drive units xx2200001050 Spare part num- Description Type Spare part level 3HAC064983-001 Drive unit DSQC3065 Power units xx2300001784 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 433 Power unit DSQC3072 HVLP 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 434 Continued Harness ETH outlet connection xx2100002585 Spare part num- Description Type Spare part level 3HAC084151-001 Ethernet Harness Harness TPU connection xx1900001943 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 435 Harness HV Manipulator Motor Harness ADU motors Spare part num- Description Type Spare part level 3HAC084159-001 Harness ADU Motors 3HAC077969-001 Harn. 1xADU Motors 3HAC083184-001 Harn. ADU Motors 4-6 Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 436: Mains Connection Parts

    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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 437: Logic Parts

    9.1.3 Logic parts 9.1.3 Logic parts Main computer xx2300000669 Spare part num- Description Type Spare part level 3HAC085504-001 Main computer Standard Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 438 Connected Services gateway xx2300001645 Spare part num- Description Type Spare part level 3HAC060960-001 Connected Services-3G [3013-3] (baseline) 3HAC028459-001 Magnetic roof antenna, 3G (baseline) Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 439 Connected Services-Wired [3013-1] DSQC1041 (option) 3HAC086677-001 Connected Services 4G EU [3013-5] DSQC1093 (option) 3HAC086678-001 Connected Services 4G US [3013-6] DSQC1093A (option) 3HAC086604-001 Magnetic roof antenna 4G (option) Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 440: Application Parts

    Conveyor tracking module [3103-1] DSQC2000 3HNA029345-001 CONNECTOR KIT - DSQC2000 3HAC084173-001 Harness 24V_CTM Power cable of 3HAC084195-001 Ethernet harness for CTM Ethernet switches xx1900001935 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 441 Spare part num- 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 442 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 443 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 444: Cabinet Parts

    Spare part num- Description Type Spare part level 3HAC082805-001 Fan unit External fan 3HAC083027-001 Fan unit Internal fan Main computer fan xx2300000925 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 445 Spare part num- Description Type Spare part level 3HAC081496-001 Fan with connector Power unit fan Process, fieldbus and I/O connectors xx1900001928 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 446 3HAC078328-001 Swinghandle with cam LED indicator xx1900002451 Spare part num- Description Type Spare part level 3HAC065549-001 LED indicator TPU cover xx1900002452 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 447 3HAC067213-001 TPU cover Air filter xx2200001828 xx2200001826 Spare part num- Description Type Spare part level 3HAC082548-001 Air filter coarse assembly 3HAC082547-001 Air filter fine assembly Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 448: Miscellaneous Parts

    Harness SMB link 3HAC086308-001 Harness SMB link Harness 1xSMB End clamp xx1900001940 Spare part num- Description Type Spare part level 3HAB7983-1 End clamp Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 449 Integrated Vision camera high res DSQC1064 3HAC087074-001 Integrated vision camera 2MPx DSQC1098 3HAC087075-001 Integrated vision camera 5MPx DSQC1099 3HAC051753-003 Integr Vision power cable 10 m Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 450 Integr Vision ethernet cable 15 m Service port connector Spare part number Description Type Spare part level 3HAC064848-001 Service port connector Motor connection box xx2300001671 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 451 Spare part number Description Type Spare part level 3HAC074600-001 Door stop Spare part number Description Type Spare part level 3HAC083827-001 Door stop Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 452 Spare part number Description Type Spare part level 3HAC084243-001 Extra cable jumpers Wrist band Spare part number Description Type Spare part level 3HAB2997-1 Wrist band Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 453: Cables

    Cables on the Connected Services unit Spare part num- Description Type Spare part level 3HAC085903-001 Ethernet harness Harness A2.K4.X1 - K7.ETH2 Continues on next page Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 454 Cables on the mains power connection Spare part num- Description Type Spare part level 3HAC082081-001 Harn. Mains connection 3HAC081971-001 Harn. Mains connection 3HAC077980-001 Harn. with ferrites 3HAC082694-001 Harn. mains conn._fuse Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 455: 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 456: Manipulator Cables

    IRB 660, 6650S, 6660, 7600 Control cable signal 22 m 3HAC7998-3 IRB 660, 6650S, 6660, 7600 Control cable signal 30 m 3HAC7998-4 IRB 660, 6650S, 6660, 7600 Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 457: Customer Cables - Cp/Cs Connectors (Option)

    CP/CS cables, IRB 460, 660, 760, 2600, 4600, 5710, 5720, 6650S, 6660, 67X0, 7600 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 458: Customer Cables - Ethernet Floor Cables

    Ethernet floor cable length 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.

  • Page 459: Customer Cables - Devicenet Cables

    DeviceNet floor cables, IRB 460, 660, 760, 2600, 4600, 5710, 5720, 6650S, 67X0, 7600 (option) 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 V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 460 This page is intentionally left blank...

  • Page 461: Index

    171 symbols, 18 controller fails to start, 361 controller mode, 361 general stop, 107, 176 cooling fan replacing, 186 configuring, 107 copper Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 462 23 function test, 174 recycling, 340 MTTF , 14 reduced speed control function test, 179 reflashing firmware failure, 362 national regulations, 28 regional regulations, 28 Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 463 404 scalable I/O external, 115 weight, 38 scalable I/O internal, 115 wrist strap, 46 shipping, 339 signals safety, 16 X45 IP20, 105 sim card Product manual - OmniCore V400XT 3HAC081697-001 Revision: A © Copyright 2022-2023 ABB. All rights reserved.
  • Page 466 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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