ABB OmniCore V250XT

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Table of Contents5
Overview of this Manual9
Product Documentation11
Safety13
Safety Information13
Limitation of Liability13
Safety Data14
Requirements on Personnel15
Safety Signals and Symbols16
Safety Signals in the Manual16
Safety Symbols on Controller Labels18
Robot Stopping Functions20
Protective Stop and Emergency Stop20
About Emergency Stop22
Enabling Device and Hold-To-Run Functionality23
Robot Operating Modes24
About the Manual Mode24
About the Automatic Mode26
Safety During Installation and Commissioning27
Safety During Operation30
Safety During Maintenance and Repair31
Safety During Troubleshooting32
Decommissioning33
Controller Description35
Omnicore V250XT35
Technical Data for Omnicore V250XT Controller36
Safety Functions and Safety Related Data for Omnicore V250XT41
The Unit Is Sensitive to ESD43
Handling of Flexpendant45
Network Security46
Open Source and 3Rd Party Components in Robotware47
ABB Ability48
Installation and Commissioning51
Introduction to Installation and Commissioning51
Installation Activities52
Transporting and Handling53
Lifting the Controller Cabinet53
Unpacking54
Storing55
On-Site Installation56
Required Installation Space56
Securing and Stacking the Controller58
Mounting the Flexpendant Holder59
Electrical Connections65
Connectors on the Omnicore V250XT Controller65
Connecting Cables to the Controller67
Connecting the Manipulator to the Controller74
Fitting the Connector for Incoming Mains75
Connecting Incoming Mains and Protective Earth to the Controller77
Detaching and Attaching a Flexpendant80
Ethernet Networks on Omnicore84
Descriptions for Connectors92
Configuring Robot Stopping Functions105
Programmable Stop Functions109
I/O System112
Available Fieldbuses112
Scalable I/O, Internal and External114
Installing Options115
Installing the Scalable I/O Devices115
Installing the Safety Digital Base Device118
Installing the Ethernet Extension Switch121
Installing the Power Supply Optional Device124
Installing the Fieldbus Master128
Installing the Conveyor Tracking Module (CTM)137
Installing the Cable Grommet Assembly140
Installing the Air Filter146
Installing the Mains Connections Cable149
Installing External Devices152
Initial Test before Commissioning153
Commissioning154
Maintenance155
Maintenance Schedule, Omnicore155
Inspection Activities156
Inspection of Controller156
Cleaning Activities157
Cleaning Air Filter157
Cleaning of the Controller Cabinet160
Cleaning the Flexpendant161
Changing/Replacing Activities163
Replacement of Air Filter163
Function Tests166
Function Test of Emergency Stop166
Function Test of Manual, Auto, and Manual Full Speed Mode with Flexpendant167
Function Test of Three-Position Enabling Device168
Function Test of Automatic Stop169
Function Test of General Stop170
Function Test of External Emergency Stop171
Function Test of ESTOP_STATUS Output172
Function Test of Reduced Speed Control173
Repair175
Introduction to Repair175
Replacement of Controller Parts176
Opening the Robot Controller176
Replacing the Fans180
Replacing the Standard Fans182
Replacing the Internal Fan186
Replacing the Main Computer Fan190
Replacing the Power Unit Fan198
Replacing the Robot Signal Exchange Proxy202
Replacing the Ethernet Switch207
Replacing the Connected Services Gateway211
Replacing the Scalable I/O Unit217
Replacing the Safety Digital Base Device222
Replacing the Main Computer226
Replacing the Power Unit250
Replacing the Power Supply255
Replacing the Drive Unit263
Replacing the Fieldbus Master268
Replacing the Safety Module279
Replacing the Main Computer Battery286
Replacing the Conveyor Tracking Module (CTM)293
Replacing the Air Filter298
Replacing the Break Resistor Bleeder302
Replacing Parts on the Front Panel and Door306
Replacing the Manipulator Signal Connector (SMB)306
Replacing the Motor Connector309
Replacing the Motor Connector310
Replacing the HMI Signal (Flexpendant) Connector314
Replacing the Cable Grommet Assembly320
Replacing the Ethernet Outlet Connector with Cable329
Replacing the LED Indicator333
Replacing Parts on the Flexpendant337
Replacing the Power Cable and Power Cable Cover337
Replacing the Joystick Protection341
Replacing the Fasten Strip344
Decommissioning345
Introduction345
Environmental Information346
Troubleshooting349
Introduction to Troubleshooting349
Troubleshooting Fault Symptoms351
No Leds Are Lit on the Controller352
Start-Up Failure356
System Update Failure360
Problem Releasing the Robot Brakes361
Problem Starting or Connecting the Flexpendant364
Problem Using the Joystick368
Controller Fails to Start369
Reflashing Firmware Failure370
Inconsistent Path Accuracy371
Controller Is Overheated373
Troubleshooting Units374
Troubleshooting Leds in the Controller374
Troubleshooting the Flexpendant375
Troubleshooting the Drive Unit376
Troubleshooting the Power Unit382
Troubleshooting Fieldbuses and I/O389
Troubleshooting the Connected Services Gateway390
Troubleshooting the Ethernet Switch396
Troubleshooting the Main Computer398
Troubleshooting the Process Power Supply401
Troubleshooting the Power Supply, ODVA403
Troubleshooting the Robot Signal Exchange Proxy405
Reference Information411
Introduction411
Applicable Standards412
Unit Conversion413
Standard Toolkit for Controller414
Screw Joints415
Weight Specifications416
Lifting Accessories and Lifting Instructions417
Spare Parts419
Controller Parts420
Controller System Parts421
Mains Connection Parts426
Logic Parts427
Application Parts431
Cabinet Parts436
Miscellaneous Parts442
Cables444
Flexpendant Parts446
Manipulator Cables447
Customer Cables - CP/CS Connectors (Option)448
Customer Cables - Ethernet Floor Cables449
Customer Cables - Devicenet Cables450
Index451

ABB OmniCore V250XT - Page 454

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