Error processing document with Intelligent OCR - Exception from HRESULT: 0x80040154

How do we troubleshoot "Unable to process documents in UiPath using Intelligent OCR scope - Exception from HRESULT: 0x80040154" error when using IntelligentOCR activities?

This error usually comes if UiPath is unable to reach Abbyy FlexiCapture Engine. It could be because of any  of the below reason

1. Abbyy FlexiCapture Engine is not installed
2. Right version is not installed 
3. 64 bit variant of Engine is installed 

Flexicapture activities such as Classify Document, Process document inside Intelligent OCR Scope Activity will get faulted with an error

System.Runtime.InteropServices.COMException: Retrieving the COM class factory for component with CLSID {C0003003-0000-48FF-9197-57B7554849BA} failed due to the following error: 80040154 Class not registered (Exception from HRESULT: 0x80040154 (REGDB_E_CLASSNOTREG)).”.

Starting from the Abbyy FlexiCapture 12.0.1.3068 version, both 64-bit and 32-bit variants of Engine are available. By default, 64-bit variant is installed unless it is explicitly mentioned to install 32 bit.

UiPath being a 32-bit application supports only 32-bit Abbyy FlexiCapture Engine.

To overcome this, we can follow 2 approaches.

#1 Approach:
Adding the below parameter to the existing installation command will install Abbyy FlexiCapture as a 32-bit application.
ARCH=x86

Complete command looks like,
setup.exe /qb /v INSTALLDIR=“C:\ProgramData\ABBYY\SDK\12\FlexiCapture Engine” FCE=Yes PDF=Yes SN=serialkey ARCH=x86

#2 Approach:
Installing Abbyy FlexiCapture through GUI.

Installing from GUI instead of command prompt will install the engine in developer mode instead of Runtime
This will not be compatible with UiPath and result in error
Failed to run non-developer licenses in developer library

In order to resolve the issue, please follow the below steps
          1. Browse to the < installation folder>\Bin.
          2. Delete/Rename the Protection.Developer.dll library file

  Abbyy Reference Article - https://knowledgebase.abbyy.com/article/650