ABB Feather Duster V2 Product Manual Download

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ROBOTICS

Product manual

Feather Duster V2

Summary of Contents for Feather Duster V2

Page 1: ...ROBOTICS Product manual Feather Duster V2 ...

Page 2: ...Trace back information Workspace Systems version a4 Checked in 2018 11 29 Skribenta version 5 3 012 ...

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

Page 5: ...symbols on product labels 35 2 About Feather Duster V2 35 2 1 Feather Duster V2 system 35 2 1 1 Introduction 38 2 1 2 Process diagram 39 2 2 Main components 39 2 2 1 Component overview 40 2 2 2 Feather roller 42 2 2 3 Ionization unit 45 2 2 4 Exhaust system 46 2 2 5 Compressed air system 47 3 Installation and commissioning 47 3 1 Introduction 48 3 2 Technical specification 51 3 3 On site installat...

Page 6: ...he ionization unit 151 5 2 6 Replacing the safety edge sensor 155 5 2 7 Replacing the motor 169 6 Decommissioning 169 6 1 Introduction 170 6 2 Environmental information 171 6 3 Dismantle 173 7 Reference information 173 7 1 Introduction 174 7 2 Unit conversion 175 7 3 Screw joints 178 7 4 Standard toolkit 179 7 5 Special tools 181 8 Spare parts 181 8 1 Introduction 182 8 2 Spare part list and illus...

Page 7: ...edge of mechanical and electrical installation repair maintenance work Organization of chapters NOT MANDATORY The manual is organized in the following chapters Contents Chapter References Documentation of ABB products referred to in the manual is listed in the table below Document ID Document name of ABB products 3HAC047136 001 Product manual IRC5 3HAC031045 001 Operating manual General safety inf...

Page 8: ...ent ID Download from Document name of non ABB products http dj hstyq com Up load down 80WD 80WD M02410 24V 20Model pdf Product Manual of Motor 80WD M02410 24V https www slipring cn up Load product month_1710 201710181737252791 pdf LPT080 Series Slip Ring with Through Bore 80mm https www keyence com cn mykey ence ptn 001 dlLangType en GB dlLangId Ultra High Speed Sheath Sensing Ioniser SJ H Series ...

Page 9: ...oning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application m...

Page 10: ... The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 10 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved Product documentation Continued ...

Page 11: ...nclude specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 13 Illustrations The manipulator is illustrated with general figures that does not take painting or protection type in consideration Likewise certain work methods or general information that is valid for several robot models can be illustrated with illustrations that show a different...

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Page 13: ...duct Repairs carried out by in experienced or non qualified personnel Foreign objects Force majeure Nation region specific regulations To protect personnel the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the Product is installed To be observed by the supplier of the complete system The int...

Page 14: ...ng or malfunctioning rotating tool or other device fitted to the Product Safe handling Users shall not be exposed to hazards including slipping tripping and falling hazards It must be possible to safely turn off tools such as milling cutters etc Make sure that guards remain closed until the cutters stop rotating It should be possible to release parts by manual operation valves Safe design Emergenc...

Page 15: ...ew The protective stops and emergency stops are described in the product manual for the controller Product manual Feather Duster V2 15 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 16: ...guishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the Product or controller 16 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 17: ...rrest burn injuries or other severe injuries To avoid these personal injuries switch off the main power on the controller before proceeding work Note Switch off all main power switches in a MultiMove system Product manual Feather Duster V2 17 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 1 Safety 1 2 2 Make sure that the main power has been switched off ...

Page 18: ...ety lock Make sure that no one else can turn on the power to the controller and Product while you are working with the system A good method is to remove the power cable to the controller If the Product is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a Product standing directly on the floor Energy stored in the Product for t...

Page 19: ...active or passive safety operation ABB is not liable for damages caused by the use of non original spare parts and special equipment ABB is not liable for damages or injuries caused by unauthorized modifications to the Product Personal protective equipment Always use suitable personal protective equipment based on the risk assessment for the Product installation Allergenic material See Environment...

Page 20: ...ncy stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold ...

Page 21: ...y equipment installed to secure the position or restrict the Product motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the Product and is out of its reach behind safety fences or similar 6 Verify that all required covers or paddings ...

Page 22: ...vices mounted on the Product or inside the cell Keep away from rotating and moving parts to not get entangled with hair or clothing Keep clear of moving parts so that limbs hands or fingers do not get trapped or crushed by the Product To prevent anyone else from taking control of the Product always put a safety lock on the cell door and bring the three position enabling device with you when enteri...

Page 23: ...oduct switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the Product to move Anyone entering the working space of the Product must always hold the teach pendant This is to prev...

Page 24: ...anteed if the valid regulations are followed Voltage related risks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The main supply main switch The transformers The power unit The control powe...

Page 25: ...live even if the Product system is in the OFF position Power supply cables which are in motion during the working process may be damaged Product manual Feather Duster V2 25 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 26: ...our hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic 26 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 1 Safety 1 3 7 H...

Page 27: ...as described below 1 Run related part to a position where the combined weight of the part and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the part maintains its position If the part does not change position as the motors are switched off then the brake function is adequate Product manual Feather Duster V2 27 3HAX010000210 Revision A Copy...

Page 28: ... instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING Warns for electrical hazards which could result in severe personal injury or death...

Page 29: ...conditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP Product manual Feather Duster V2 29 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 30: ...sh German and French Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of cru...

Page 31: ... disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the parts of the Product can fall down Continues on next page Product manual Feather Duster V2 31 3HAX010000210 Revision A Copyright 2018 ABB All ri...

Page 32: ...burns Both signs are used 3HAC 4431 1 06 xx1300001087 Brake release buttons xx0900000820 xx1000001140 Lifting bolt xx0900000821 Continues on next page 32 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 33: ... energy xx0900000825 Warns that this part contains stored energy Used in combination with Do not disassemble symbol Pressure xx0900000826 Warns that this part is pressurized Usually contains additional text with the pressure level Continues on next page Product manual Feather Duster V2 33 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product label...

Page 34: ...ng on these parts can cause damage to the parts Must wear safety helmet xx1800002608 No entering xx1800002609 Warns that entering the working areas can cause injuries or damages 34 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 35: ...r Duster V2 is installed and the robot controller a complete Feather Duster V2 system mainly consists of a feather roller ionization unit exhaust system compressed air system and process cabinet Structure The following figure shows the complete Feather Duster V2 system A C B D F E G xx1800001263 Note Description Item See Feather roller on page 40 Feather roller A See Ionization unit on page 42 Ion...

Page 36: ...is mounted on the Feather Duster to deliver an ionized air stream both to remove any static charge from the feather brushes just prior to the exhaust slot and to neutralize the surfaces after cleaning Removable carbon fiber covers allow easy access to the inner mechanical and electrical components which are based on a modular design principle Benefits As a pre paint finishing equipment using ostri...

Page 37: ...cal parts Low air consumption thanks to optimized air gaps and reduced amount of required rollers Easy programming high flexibility large working area and accessibility Common graphic user interface for both cleaning and painting robots Modularity electrical circle structure ensures the convenience during disconnection and reassembly Product manual Feather Duster V2 37 3HAX010000210 Revision A Cop...

Page 38: ...eNet Compressed Air 24V DeviceNet Compressed Air 24V DeviceNet Compressed Air Feather Duster Air curtain DSQC651 BLDC Motor Ionizing Bar Rotate Sensor An collision sensor Air speed sensor 5V AO 24V 24V DO DI DO xx1800000876 38 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 2 About Feather Duster V2 2 1 2 Process diagram ...

Page 39: ...ster V2 are shown as follows xx1800001264 Suction slot with flexible lips A Ionizing bar B Safety edge sensor C Feather roller D Ionizing air knife E Product manual Feather Duster V2 39 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 2 About Feather Duster V2 2 2 1 Component overview ...

Page 40: ...sensor monitors the speed of the roller shaft The rotation speed of the feather roller can therefore be optimally controlled and adjusted to the car body and the conveyor speed achieving a uniform relative speed between feathers and car body xx1800001265 Continues on next page 40 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 2 About Feather Duster...

Page 41: ...positively and negatively as well are consolidated by the relatively opposite charge potential and then absorbed by the feathers The rotating feather roller transfers the feathers that are full of dust particles to the area of the ionizing bar installed inside the roller covers The ionizing bar neutralizes the electrostatic charges on the feathers The suction slot then sucks the neutralized dust p...

Page 42: ...ge The generation speed of positive ions is improved as the increasing setting voltages from 0V to 1000V Electrostatic elimination time sec Voltage V 1000 0 100 200 300 400 500 600 700 800 900 0 0 5 1 1 5 2 3 3 5 4 4 5 5 5 5 6 6 5 7 7 5 8 8 5 9 9 5 2 5 10 xx1800000877 During the first half of the cycle the discharge begins when the potential reaches up to setting voltage During the second half of ...

Page 43: ...Hz to 68Hz generate ions generate ions xx1800000871 Ionizing air knife and ionizing bar Each Feather Duster V2 has an ionizing air knife and an ionizing bar xx1800001266 Ionizing bar A Continues on next page Product manual Feather Duster V2 43 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 2 About Feather Duster V2 2 2 3 Ionization unit Continued ...

Page 44: ...bar neutralizes the dust particles on feathers The ionizing bar bracket of the ionizing air knife could be adjusted so that the air stream can properly blow onto the car body surface This is critical for achieving better dust elimination effects xx1800001267 44 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 2 About Feather Duster V2 2 2 3 Ionizatio...

Page 45: ... collects dusts and contaminants from the feathers and then the dusts and contaminants are exhausted through the exhaust manifold and exhaust hose The exhaust air volume vary depending on the exhaust fan location fan power and ductwork arrangement The Feather Duster V2 requires an air flow of at least 15 m3 min at 1 500 Pa A pressure sensor connected to the ductwork ensures that the exhaust is run...

Page 46: ...id controlled air valve mounted on the process cabinet If the air pressure is lower than the setting value a fault will be generated xx1600000668 Value Item 3 5 6 bar Pressure 5 μm Filter accuracy 3 m3 min Volume 46 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 2 About Feather Duster V2 2 2 5 Compressed air system ...

Page 47: ... general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read chapter Safety on page 13 before performing any installation work Product manual Feather Duster V2 47 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 1 Introduction ...

Page 48: ...000 rpm Roller speed 15 m3 min at 1 500 Pa dynamic Exhaust air flow 1 5 m3 min at 3 5 bar per robot Compressed air supply 0 3 m s 0 05 Downdraft air velocity 60 70 Humidity requirement 20 C to 25 C Temperature requirement 25 mm Conveyor system deviation Continues on next page 48 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and comm...

Page 49: ...13 1293 98 270 xx1800000955 Continues on next page Product manual Feather Duster V2 49 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 2 Technical specification Continued ...

Page 50: ...85 2 8 No particular option is required for the robot For detailed robot specifications see Product specification IRB 6700 and Product specification IRB 6640 For compatibility with other robot variants please contact ABB 50 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 2 Technical specification Continued ...

Page 51: ...positioned as shown in the following figure The flange surface of axis 6 must be horizontal xx1800001268 Continues on next page Product manual Feather Duster V2 51 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 1 Pre installation procedure ...

Page 52: ...e travel Note that the curve of the feathers follows the vehicle travel In this case the feathers will not bent backward while spinning xx1800001347 52 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 1 Pre installation procedure Continued ...

Page 53: ...not installed Make sure they are carefully secured or moved aside before lifting the Feather Duster V2 Required equipment Note Article number Equipment Overhead crane Continues on next page Product manual Feather Duster V2 53 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 2 Lifting Feather Duster V2 with lifting accessories ...

Page 54: ... Duster V2 Removing the PDCPD cover Note Action xx1800001270 Remove the 6 screws on the covers 1 xx1800001321 Separate and remove the 2 covers re spectively in proper order 2 xx1800001322 Continues on next page 54 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 2 Lifting Feather Duster V2 with lifting accessories...

Page 55: ...ling to the lifting eye nut and to the overhead crane 2 CAUTION The Feather Duster V2 weighs 120 kg All lifting accessories used must be sized accordingly 3 WARNING Personnel must not under any circum stances be present under the suspen ded load 4 Continues on next page Product manual Feather Duster V2 55 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commission...

Page 56: ...00001769 Lift the Feather Duster V2 down onto the feather roller support 6 56 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 2 Lifting Feather Duster V2 with lifting accessories Continued ...

Page 57: ...o the robots Preparations on the robot Note Action Make sure the robot is calibrated 1 xx1800001328 Jog axes 5 and 6 of the robot to 90 and 0 respectively 2 For details see Product manu al Product ProductName Remove the turning disk of the robot 3 Continues on next page Product manual Feather Duster V2 57 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commission...

Page 58: ...s 12 9 DIN912 8 pcs Replacement screws M6x40 class 12 9 DIN912 8 pcs Tightening torque 14 Nm Secure the convert adapters with screws and washers Note For IRB 6700 the replacement screws are 10 mm longer than the removed screws from the robot 5 For details see Product manu al Product ProductName Refit the turning disk of the robot 6 Sealing V ring 3HAX010000446 xx1800001327 Install the V ring to th...

Page 59: ...cs xx1800001270 Release the 6 screws 1 xx1800001321 Remove the PDCPD cover 2 xx1800001322 Continues on next page Product manual Feather Duster V2 59 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 3 Installing the Feather Duster V2 Continued ...

Page 60: ...over 3 xx1800001334 Screw M6x12 4 pcs xx1800001335 Remove the cable socket 4 Continues on next page 60 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 3 Installing the Feather Duster V2 Continued ...

Page 61: ...e moved Prevent damages or injuries due to sudden dropping 5 xx1800001337 Lifting the Feather Duster V2 to the robot Note Action M8 DIN580 2 pcs xx1800001333 Fit the lifting screws to the steel structure frame CAUTION The lifting eye nuts must be fitted to the pos itions shown in the figure to balance the Feather Duster V2 while lifting 1 Continues on next page Product manual Feather Duster V2 61 ...

Page 62: ...CAUTION The Feather Duster V2 weighs 120 kg All lifting accessories used must be sized accordingly 3 WARNING Personnel must not under any circum stances be present under the suspended load 4 Raise the overhead crane to lift the Feather Duster V2 5 Continues on next page 62 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commission...

Page 63: ... to the robot Note Action xx1800001332 Adjust the installation orientation by aligning the 3 mm deep groove on the column with the 0 calibration mark of axis 6 1 xx1800001342 Fit the screws and washers but not tighten yet 2 Continues on next page Product manual Feather Duster V2 63 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 3 Installing the...

Page 64: ...convert adaptors with screws and washers CAUTION When fitting the exhaust pipe covers make sure the inner edge of the covers must press on the lip of the V ring on the axis 6 xx1800001345 5 Screw M8x20 4 pcs Tightening torque 43 Nm Continues on next page 64 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 3 Instal...

Page 65: ...ure the two halves of the exhaust pipe covers with screws 7 xx1800001334 Screw M4x16 14 pcs Tightening torque 3 Nm Continues on next page Product manual Feather Duster V2 65 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 3 Installing the Feather Duster V2 Continued ...

Page 66: ...rew with emboss ing 6 pcs xx1800001270 Refit the PDCPD covers 1 xx1800001323 66 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 3 Installing the Feather Duster V2 Continued ...

Page 67: ...fe Internal Duster hood D12 Process Cabinet xx1800001348 The components in the air valve are from left to right quick fitting reducer regulator valve silencer reducer and quick fitting Continues on next page Product manual Feather Duster V2 67 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 4 Connecting exhaust hose and cables ...

Page 68: ... page 103 The electrical cables are combined with the air tube within a protection flexible conduit Exhaust hose and conduit are fixed at different locations on the robot to minimize wearing during operation xx1800001591 Exhaust hose A Hose holder B Cabling C Cable clamp D Fixing plate E Support frame F Continues on next page 68 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2...

Page 69: ...uction on page 68 for the installation posi tions of the fixing plates Install fixing plates 2 Routing and connecting the exhaust hose Note Action xx1800001350 Remove the screws on a hose holder 1 Continues on next page Product manual Feather Duster V2 69 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 3 4 Connecting exhaust hose and cables Contin...

Page 70: ... routed through all the hose holders CAUTION The exhaust hose sections between every two hose holders must not be straightened When the robot axis turns or bents the exhaust hose must be flexible to move together 5 xx1800001544 Secure the exhaust hose to the exhaust hose connector with an adjustable hoop 6 Continues on next page 70 Product manual Feather Duster V2 3HAX010000210 Revision A Copyrigh...

Page 71: ...gh the robot arms and final to the Feather Duster V2 3 xx1800001768 Secure the cabling with cable clamps CAUTION The cable sections between every two clamps must not be straightened When the robot axis turns or bents the cabling must be flexible to move together 4 xx1800001574 Insert the connectors to the cable plug 5 Product manual Feather Duster V2 71 3HAX010000210 Revision A Copyright 2018 ABB ...

Page 72: ...or An collision sensor Air speed sensor 5V AO 24V 24V DO DI DO xx1800000876 Process cabinet There are five Harting connectors on the process cabinet For details refer the circuit diagram Art No 3HAX010000300 of the process cabinet FD1 FD3 FD4 FD2 FD4 FD3 FD2 FD1 2xCover 32 2xCover 25 Cover 2x 3HAW050059700 Adaptor Plate 3x3HAW050059705 xx1800001349 Function Connector Main power supply input FD1 Si...

Page 73: ...14 000 9950 1 Female contact Harting 09 15 000 6205 6 Frame for modules Harting 09 14 010 0303 1 Bulkhead mounting housing Harting 09 30 010 0301 1 FD4 Module for female contacts 1 Harting 09 14 012 3101 1 Female contact Harting 09 15 000 6205 9 D Sub 9 Shield female Harting 09 14 009 3101 1 D SUB FE turned contact_AWG 22 26_PL1 Harting 09 67 000 5476 5 Dummy module Harting 09 14 000 9950 1 Frame ...

Page 74: ...NG 09 14 012 3001 1 Dummy module HARTING 09 14 000 9950 1 Hood HARTING 19 30 010 1521 1 FD4 Frame HARTING 09 14 010 0313 1 Connector Mod HARTING 09 14 012 3001 1 Male Pin 0 5mm HARTING 09 15 000 6103 2 Serial Bus module 9 shield Male HARTING 09 14 009 3001 1 D SUB MA turned contact_AWG 22 26_PL1 HARTING 09 67 000 5576 5 Dummy module HARTING 09 14 000 9950 1 Note Recommended tools Crimp HARTING 09 ...

Page 75: ...om the robot for example out of its reach behind safety fences and so on 3 Pay special attention to the function of the part previously serviced 4 Setting the robot TCP Use this procedure to set the TCP Action Use the FTP software to connect the robot 1 Download HOME robdata robdata sys and backup the current file before any modification 2 Use the shopfloor editor or UE editor to open the file rob...

Page 76: ... information about the Feather Duster V2 roller speed alarm status and air status will be displayed as shown in the following figure CAUTION The green light means the connection is in good condition If the light shows red warning the connection of the device must has problems Please check the connect condition Continues on next page 76 Product manual Feather Duster V2 3HAX010000210 Revision A Copy...

Page 77: ... speed as the figure illustrated below xx1800001600 Continues on next page Product manual Feather Duster V2 77 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 5 System start up Continued ...

Page 78: ... sub page is showed after starting the set signal application in which the Select All and Cancel All button will be enabled xx1800001752 78 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 3 Installation and commissioning 3 5 System start up Continued ...

Page 79: ...erform the activity including required tools and materials The procedures are gathered in different sections and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when perfo...

Page 80: ...he working conditions of the Feather Duster V2 Calendar time specified in months regardless of whether the system is running or not Operating time specified in operating hours More frequent running means more frequent maintenance activities 80 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 4 Maintenance 4 2 1 Specification of maintenance intervals ...

Page 81: ... activities Cleaning activities Cleaning activities on page 83 x Cleaning the Feather Duster V2 Inspection activities x Inspecting for faults Check for abnormal wear or contamination x Inspecting the Feather Duster V2 Inspecting feathers on page 86 x Inspecting feathers Inspecting the ionization unit on page 87 x Inspecting the ionization unit Inspecting the cabling and ex haust hose on page 89 x ...

Page 82: ...ly Maintenance activities Replacing the bearing housing on page 126 Replacing the bearing housing Overhaul x Overhaul of complete product 82 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 4 Maintenance 4 2 2 Maintenance schedule Continued ...

Page 83: ...ded to clean and inspect the whole Feather Duster every week Cleaning procedure Preparations before the removal Note Action Jog the robot a proper height for easily access the Feather Duster V2 1 Removing the PDCPD cover Note Action xx1800001270 Remove the 6 screws on the covers 1 Continues on next page Product manual Feather Duster V2 83 3HAX010000210 Revision A Copyright 2018 ABB All rights rese...

Page 84: ...per order 2 xx1800001322 Cleaning surfaces Note Action xx1800001592 Clean the surface of motor 1 Continues on next page 84 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 4 Maintenance 4 3 1 Cleaning the Feather Duster V2 Continued ...

Page 85: ...itting the PDCPD cover Note Action Screw Round head screw with emboss ing 6 pcs xx1800001270 Refit the PDCPD covers 1 xx1800001323 Alcohol may be used but with care Strong alcohol for example acetone must be avoided High pressure cleaning equipment may be used but spraying directly on the Feather Duster V2 must be avoided Product manual Feather Duster V2 85 3HAX010000210 Revision A Copyright 2018 ...

Page 86: ...allation Reseal packages if they have been opened for inspection Do not put feathers on the floor directly Always use the ABB provided feather roller support Art No 3HAX010000450 to support the feather roller Inspection feathers Visual inspection no tools are required Other tools and procedures are specified in the replacement procedure xx1600000678 Feather in good condition A Worn feather to be r...

Page 87: ...ing bar is located as shown in the figure xx1800001266 Ionizing bar A Ionizing air knife B Required tools and equipment Visual inspection no tools are required Continues on next page Product manual Feather Duster V2 87 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 4 Maintenance 4 4 2 Inspecting the ionization unit ...

Page 88: ...limination effects Use this procedure to adjust the ionizing air knife Note Action xx1800001546 Rotate the ionizing bar directly 1 xx1800001547 Rotate the ionizing bar bracket until a proper angle of the air knife is achieved 2 88 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 4 Maintenance 4 4 2 Inspecting the ionization unit Continued ...

Page 89: ...Duster V2 exhaust hose routes from the Feather Duster V2 to the exhaust fan xx1800001552 Required tools and equipment Visual inspection no tools are required Other tools and procedures may be required if the spare part needs to be replaced These are specified in the replacement procedure Continues on next page Product manual Feather Duster V2 89 3HAX010000210 Revision A Copyright 2018 ABB All righ...

Page 90: ...cabinet the exhaust hose from the Feather Duster V2 to the exhaust fan Look for abrasions cuts or crush damages Note To inspect the internal cabling remove the carbon fiber covers first 1 Replace the cabling or exhaust hose if wear or damage is detected 2 90 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 4 Maintenance 4 4 3 Inspecting the cabling a...

Page 91: ...48 Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 178 Standard toolkit Steel tape Continues on next page Product manual Feather Duster V2 91 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 4 Maintenance 4 4 4 Inspecting the timing belt ...

Page 92: ...00001270 Remove the 6 screws on the covers 1 xx1800001321 Separate and remove the 2 covers re spectively in proper order 2 xx1800001322 Continues on next page 92 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 4 Maintenance 4 4 4 Inspecting the timing belt Continued ...

Page 93: ...nel cover 1 xx1800001550 Check the timing belt for damage or wear 2 xx1800001551 Check the timing belt pulley for damage 3 Continues on next page Product manual Feather Duster V2 93 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 4 Maintenance 4 4 4 Inspecting the timing belt Continued ...

Page 94: ... for tension Wen you pinch the timing belt the distance between two sides should be approximately 50 55 mm If the belt tension is not correct adjust it 5 94 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 4 Maintenance 4 4 4 Inspecting the timing belt Continued ...

Page 95: ...er Duster V2 Required equipment The details of the equipment required to perform a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 173 Safety information There are general safety information and specific safety information The specific safety information describes the danger...

Page 96: ...0 pieces per pack One pack of brushes are stacked on the shaft 3HAX010000293 Feather brush 3HAX010000275 Roller shaft 3HAX010000281 Shaft bearing with housing 3HAX010000362 Shaft guide Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 178 Standard toolkit Continues on next page 96 Product manual Feather Duster V2 3HAX010000210 Revisio...

Page 97: ...roper height for easily access the Feather Duster V2 1 Removing the PDCPD cover Note Action xx1800001270 Remove the 6 screws on the covers 1 xx1800001321 Separate and remove the 2 covers re spectively in proper order 2 xx1800001322 Continues on next page Product manual Feather Duster V2 97 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 1 Replacing the feather roller C...

Page 98: ...001554 Push the feather roller along its axial direc tion to move one side of the roller out from the groove 2 Continues on next page 98 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 1 Replacing the feather roller Continued ...

Page 99: ...0001556 Uplift the feather roller a little to remove it CAUTION Pay attention not to collide with the ionizing air knife or safety edge sensor 4 xx1600000734 Put the feather roller on the feather roller support 5 Continues on next page Product manual Feather Duster V2 99 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 1 Replacing the feather roller Continued ...

Page 100: ...tation on page52 for correct feather orientation Stack feather brushes one by one to the roller shaft Make sure the feathers are in correct orient ation 1 xx1600000920 Secure with the locknut CAUTION Do not press the locknut too tight other wise the brushes may be distorted 2 Continues on next page 100 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved...

Page 101: ...llation of the feather roller 1 xx1800001555 Insert one side of the feather roller and rotate it to make the plate for spring out from the groove of the connected shaft 2 xx1800001554 Refit the other side of the feather roller in the suitable position 3 xx1800001553 Insert the setting screw into the correct position 4 Continues on next page Product manual Feather Duster V2 101 3HAX010000210 Revisi...

Page 102: ... Round head screw with emboss ing 6 pcs xx1800001270 Refit the PDCPD covers 1 xx1800001323 102 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 1 Replacing the feather roller Continued ...

Page 103: ...ally the cable chain While the connection between the controller box and the feather duster has to be replaced either The cable chain is located as shown in the figure xx1800001572 Required spare parts Note Article number Spare part PDCPD cover 3HAX010000247 front cover PDCPD cover 3HAX010000248 back cover 3HAX010000301 Controller box Slip ring 3HAX010000411 LPT080 0220 05S 01A Continues on next p...

Page 104: ...reparations before the removal Note Action Jog the robot a proper height for easily access the Feather Duster V2 1 Preparations on the Feather Duster V2 Note Action Screw Round head screw with emboss ing 6 pcs xx1800001270 Release the 6 screws 1 Continues on next page 104 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the c...

Page 105: ...001321 Remove the PDCPD cover 2 xx1800001322 Continues on next page Product manual Feather Duster V2 105 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 106: ... exhaust pipe cover 3 xx1800001334 Screw M6x12 4 pcs xx1800001335 Remove the cable socket 4 Continues on next page 106 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 107: ...rcement supports and upper cable chain cover installed on it may drop a little distance after screws are re moved Prevent damages or injuries due to sudden dropping 5 xx1800001337 Removing the cable chain Note Action xx1800001574 Plug off the external connectors 1 Continues on next page Product manual Feather Duster V2 107 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 ...

Page 108: ...Remove the plug and internal cable chain 4 Removing the tunnel covers Note Action xx1800001573 Remove the screws 1 Remove the tunnel covers on both side of the feather duster 2 Continues on next page 108 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 109: ...internal plugs 1 xx1800001754 xx1800001755 Remove the 5 connector bases from the tunnel frame 2 Continues on next page Product manual Feather Duster V2 109 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 110: ...ctor base and remove the cable from the back of tunnel frame 3 xx1800001757 Continues on next page 110 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 111: ...e screws on the controller box 4 xx1800001759 xx1800001760 Remove the controller box and its cable chain 5 Continues on next page Product manual Feather Duster V2 111 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 112: ...er box 1 Screw M6x10 4 pcs Tightening torque 15 Nm xx1800001758 Insert the cable harness of the controller box back to tunnel frame 2 xx1800001755 Refit the 5 connector bases to the tunnel frame 3 Continues on next page 112 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 113: ... cable base 4 xx1800001756 xx1800001754 Insert the 2 internal plugs 5 Continues on next page Product manual Feather Duster V2 113 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 114: ...s Tightening torque 2 Nm Screw Round head screw with embossing 2 pcs Refitting the cable chain Note Action xx1800001575 Refit the internal connectors next to the connector box 1 Continues on next page 114 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 115: ...ider and the plug 2 xx1800001576 xx1800001574 Connect the external connectors 3 Continues on next page Product manual Feather Duster V2 115 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 116: ...800001335 xx1800001329 Secure the two halves of the exhaust pipe covers with screws 2 xx1800001334 Screw M4x16 14 pcs Tightening torque 3 Nm Continues on next page 116 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 117: ...xx1800001349 Install the Harting connector plate to the process cabinet 2 Route the cabling up though the robot arms and final to the Feather Duster V2 3 xx1800001768 Secure the cabling with cable clamps CAUTION The cable sections between every two clamps must not be straightened When the robot axis turns or bents the cabling must be flexible to move together 4 Continues on next page Product manua...

Page 118: ...ion xx1800001574 Insert the connectors to the cable plug 5 118 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 2 Replacing the cable chain Continued ...

Page 119: ...47 front cover PDCPD cover 3HAX010000248 back cover 3HAX010000268 High torque timing belt Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 178 Standard toolkit Steel tape Continues on next page Product manual Feather Duster V2 119 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 3 Replacing the timing belt...

Page 120: ...eather Duster V2 1 Removing the PDCPD cover Note Action xx1800001270 Remove the 6 screws on the covers 1 xx1800001321 Separate and remove the 2 covers re spectively in proper order 2 xx1800001322 Continues on next page 120 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 3 Replacing the timing belt Continued ...

Page 121: ...on xx1800001557 Loosen but not remove the screws on the adjustable plate 1 xx1800001767 Loosen the screw above the motor 2 Slightly adjust the motor to release the belt tension 3 Continues on next page Product manual Feather Duster V2 121 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 3 Replacing the timing belt Continued ...

Page 122: ... procedures to refit the timing belt Refitting the timing belt Note Action xx1800001559 Refit the timing belt 1 Continues on next page 122 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 3 Replacing the timing belt Continued ...

Page 123: ...ime measure the belt tension using a steel tape 2 Screws M8x25 4 pcs Tighten the screws on the adjustable plate when a proper timing belt is achieved 3 Tightening torque 43 Nm xx1800001557 Continues on next page Product manual Feather Duster V2 123 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 3 Replacing the timing belt Continued ...

Page 124: ... Refitting the tunnel covers at the motor side Note Action xx1800001549 Refit the tunnel covers 1 Refit the screws 2 Screw M4x8 6 pcs Tightening torque 2 Nm Continues on next page 124 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 3 Replacing the timing belt Continued ...

Page 125: ...w Round head screw with emboss ing 6 pcs xx1800001270 Refit the PDCPD covers 1 xx1800001323 Product manual Feather Duster V2 125 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 3 Replacing the timing belt Continued ...

Page 126: ...PDCPD cover 3HAX010000248 back cover 3HAX010000281 Shaft bearing with housing 3HAX010000268 High torque timing belt Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 178 Standard toolkit Steel tape Continues on next page 126 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4...

Page 127: ...e Feather Duster V2 1 Removing the PDCPD cover Note Action xx1800001270 Remove the 6 screws on the covers 1 xx1800001321 Separate and remove the 2 covers re spectively in proper order 2 xx1800001322 Continues on next page Product manual Feather Duster V2 127 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 128: ...Note Action xx1800001553 Remove the setting screw 1 xx1800001554 Push the feather roller along its axial direc tion to move one side of the roller out from the groove 2 Continues on next page 128 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 129: ...001556 Uplift the feather roller a little to remove it CAUTION Pay attention not to collide with the ionizing air knife or safety edge sensor 4 xx1600000734 Put the feather roller on the feather roller support 5 Continues on next page Product manual Feather Duster V2 129 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 130: ...0001767 Loosen the screw above the motor 2 Slightly adjust the motor to release the belt tension 3 xx1800001558 Remove the timing belt 4 Continues on next page 130 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 131: ...e screws 1 xx1800001562 Remove the shaft end slice 2 xx1800001563 Remove the lower timing belt pulley 3 Continues on next page Product manual Feather Duster V2 131 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 132: ...x1800001566 Key A Shaft sleeve B Bearing housing C Connected shaft D Remove the key and shaft sleeve to detach the connected shaft from the bearing housing 6 Continues on next page 132 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 133: ...xx1800001567 Remove the screws and washers 1 xx1800001568 Remove the tentacle on the back side 2 xx1800001569 Continues on next page Product manual Feather Duster V2 133 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 134: ...1800001571 Remove the bearing housing together with the fixed connected shaft 4 Continues on next page 134 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 135: ...t the connected shaft to the bearing housing 1 Refit the shaft sleeve and the key to key slot on the connected shaft 2 xx1800001565 Refit the bearing housing together with the connected shaft 3 xx1800001564 Secure with screws and washers 4 Continues on next page Product manual Feather Duster V2 135 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing...

Page 136: ...ey 5 xx1800001562 Refit the shaft end slice 6 xx1800001561 Secure with screws 7 Continues on next page 136 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 137: ...xx1800001571 Refit the fixed connected shaft to the bearing housing 1 xx1800001570 Refit the shaft end slice 2 Continues on next page Product manual Feather Duster V2 137 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 138: ... xx1800001568 xx1800001567 Refit the bearing housing together with the fixed connected shaft 4 Continues on next page 138 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 139: ...djust the motor at the same time measure the belt tension using a steel tape 2 Screws M8x25 4 pcs Tighten the screws on the adjustable plate when a proper timing belt is achieved 3 Tightening torque 43 Nm xx1800001557 Continues on next page Product manual Feather Duster V2 139 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 140: ...e end The boss must be aligned with the key slot on the support shaft This ensures the correct in stallation of the feather roller 1 xx1800001555 Insert one side of the feather roller and rotate it to make the plate for spring out from the groove of the connected shaft 2 Continues on next page 140 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Re...

Page 141: ...ct position 4 Refitting the tunnel covers at the motor side Note Action xx1800001549 Refit the tunnel covers 1 Refit the screws 2 Screw M4x8 6 pcs Tightening torque 2 Nm Continues on next page Product manual Feather Duster V2 141 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 142: ...Round head screw with emboss ing 6 pcs xx1800001270 Refit the PDCPD covers 1 xx1800001323 142 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 4 Replacing the bearing housing Continued ...

Page 143: ...ver 3HAX010000247 front cover PDCPD cover 3HAX010000248 back cover Ionizing air knife 3HAX010000310 Lonization Sensor Cable 2 Ionizing bar 3HAX010000309 Lonization Sensor Cable 1 Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 178 Standard toolkit Continues on next page Product manual Feather Duster V2 143 3HAX010000210 Revision A C...

Page 144: ... the Feather Duster V2 1 Removing the PDCPD cover Note Action xx1800001270 Remove the 6 screws on the covers 1 xx1800001321 Separate and remove the 2 covers re spectively in proper order 2 xx1800001322 Continues on next page 144 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 5 Replacing the ionization unit Continued ...

Page 145: ... remov ing it otherwise it may drop suddenly after the screws at one end are removed 2 Refitting the ionizing air knife Note Action xx1800001580 Refit the ionizing air knife with its bracket 1 Screw M6x30 4 pcs Tightening torque 10 Nm Continues on next page Product manual Feather Duster V2 145 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 5 Replacing the ionization u...

Page 146: ...6 pcs xx1800001270 Refit the PDCPD covers 1 xx1800001323 Replacing the ionizing bar Use these procedures to replace the ionizing bar Preparations before the removal Note Action Jog the robot a proper height for easily access the Feather Duster V2 1 Continues on next page 146 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 5 Replacing th...

Page 147: ...covers 1 xx1800001321 Separate and remove the 2 covers re spectively in proper order 2 xx1800001322 Continues on next page Product manual Feather Duster V2 147 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 5 Replacing the ionization unit Continued ...

Page 148: ...ect the connector 1 xx1800001582 Remove the ionizing bar by removing the screws 2 Continues on next page 148 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 5 Replacing the ionization unit Continued ...

Page 149: ...bar 1 Screw M6x10 4 pcs Tightening torque 15 Nm xx1800001581 Secure the cable with the locking nut 2 Continues on next page Product manual Feather Duster V2 149 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 5 Replacing the ionization unit Continued ...

Page 150: ...Round head screw with emboss ing 6 pcs xx1800001270 Refit the PDCPD covers 1 xx1800001323 150 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 5 Replacing the ionization unit Continued ...

Page 151: ...308 Anti Collision Cable 2 Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 178 Standard toolkit Removing the safety edge sensors Use these procedures to remove the safety edge sensors Preparations before the removal Note Action Jog the robot a proper height for easily access the Feather Duster V2 1 Removing the PDCPD cover Note Acti...

Page 152: ...00001584 Disconnect the connector by loosening the locking nut Note Do not mix the connector with the one of standard safety edge sensor 1 Pull out the cables from the connector 2 Continues on next page 152 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 6 Replacing the safety edge sensor Continued ...

Page 153: ...ing the standard safety edge sensor Note Action xx1800001586 Refit the safety edge sensor 1 Screw M6x25 4 pcs Tightening torque 10 Nm Route the cabling 2 xx1800001584 Secure the cabling by fastening the cable gland 3 Continues on next page Product manual Feather Duster V2 153 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 6 Replacing the safety edge sensor Continued ...

Page 154: ...ound head screw with emboss ing 6 pcs xx1800001270 Refit the PDCPD covers 1 xx1800001323 154 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 6 Replacing the safety edge sensor Continued ...

Page 155: ...back cover 3HAX010000268 High torque timing belt 3HAX010000271 Timing belt pulley 3HAX010000272 Motor 80WD M02410 24V Required tools and equipment Note Article number Equipment Content is defined in section Standard toolkit on page 178 Standard toolkit Steel tape Continues on next page Product manual Feather Duster V2 155 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2...

Page 156: ...her Duster V2 1 Removing the PDCPD cover Note Action xx1800001270 Remove the 6 screws on the covers 1 xx1800001321 Separate and remove the 2 covers re spectively in proper order 2 xx1800001322 Continues on next page 156 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the motor Continued ...

Page 157: ...he tunnel covers 2 Disconnecting the motor connector Note Action xx1800001587 Disconnect the connector by loosing the cable gland 1 Continues on next page Product manual Feather Duster V2 157 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the motor Continued ...

Page 158: ...xx1800001767 Loosen the screw above the motor 2 Slightly adjust the motor to release the belt tension 3 xx1800001558 Remove the timing belt 4 Continues on next page 158 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the motor Continued ...

Page 159: ...the screws 1 xx1800001589 Remove the pulley cover 2 xx1800001590 Remove the upper timing belt pulley 3 Continues on next page Product manual Feather Duster V2 159 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the motor Continued ...

Page 160: ... xx1800001594 Move the motor a little backward and adjust its orientation to remove it 2 xx1800001595 Remove the screw and washer 3 Continues on next page 160 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the motor Continued ...

Page 161: ...or Refitting the motor Note Action Screw M6x12 4 pcs Refit the adjustable plate to the motor 1 Tightening torque 10 Nm xx1800001597 xx1800001596 Refit the pulley hub Make sure the key on the motor axis aligned with the key slot of the pulley hub 2 Continues on next page Product manual Feather Duster V2 161 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the...

Page 162: ...ening torque 10 Nm xx1800001595 Refit the motor with the motor connector pointing to the side of ionizing air knife 4 Continues on next page 162 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the motor Continued ...

Page 163: ...e but not tighten yet 5 Tightening torque 25 Nm xx1800001593 Screw M5x25 1 pcs Tightening torque 5 Nm xx1800001594 Continues on next page Product manual Feather Duster V2 163 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the motor Continued ...

Page 164: ...y hub aligned with the key slot of the pulley 1 xx1800001589 Refit the pulley cover 2 xx1800001588 Secure with screws 3 Screw M5x10 3 pcs Tightening torque 5 9 Nm Continues on next page 164 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the motor Continued ...

Page 165: ...tly adjust the motor at the same time measure the belt tension using a steel tape 2 Screws M8x25 4 pcs Tighten the screws on the adjustable plate when a proper timing belt is achieved 3 Tightening torque 43 Nm xx1800001557 Continues on next page Product manual Feather Duster V2 165 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the motor Continued ...

Page 166: ... torque 5 Nm xx1800001767 Connecting the motor connector Note Action xx1800001587 Connect the connector and secure with the cable gland 1 Continues on next page 166 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the motor Continued ...

Page 167: ...crew M4x8 6 pcs Tightening torque 2 Nm Refitting the PDCPD cover Note Action Screw Round head screw with emboss ing 6 pcs xx1800001270 Refit the PDCPD covers 1 xx1800001323 Product manual Feather Duster V2 167 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 5 Repair 5 2 7 Replacing the motor Continued ...

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Page 169: ...tially or completely disposed of the various parts must be grouped together according to their nature which is all iron together and all plastic together and disposed of accordingly These parts must also be disposed of in accordance with the current legislation of the country in which the product is installed Safety information Before any service work is commenced it is extremely important that al...

Page 170: ...tion Hazardous material There are no hazardous materials used in this product 170 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 6 Decommissioning 6 2 Environmental information ...

Page 171: ...trical and air supplies before removing all the connections Note When disassemble the elevator make sure that the pressure block has been placed in the fetal membrane Disassemble each parts of the Feather Duster V2 from the foundation base plate Product manual Feather Duster V2 171 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 6 Decommissioning 6 3 Dismantle ...

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Page 173: ...ter includes general information complementing the more specific information in the different procedures in the manual Product manual Feather Duster V2 173 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 174: ... 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 174 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 7 Reference information 7 2 Unit conversion ...

Page 175: ...hould be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensio...

Page 176: ...ir maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The f...

Page 177: ...ing torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual Feather Duster V2 177 3HAX010000...

Page 178: ...llowing table This way the tools required are the sum of the standard toolkit and any tools listed in the instruction Contents standard toolkit Rem Tool Qty Socket head cap 2 17 mm 1 Torque wrench 0 3 45 Nm 1 Ratchet head for torque wrench 1 2 1 Hex socket head cap no 2 5 socket 1 2 bit L 110 mm 1 Small screwdriver 1 T handle with ball head 1 Small cutting plier 1 Plastic mallet 1 178 Product manu...

Page 179: ...ed in the section Standard toolkit on page 178 and of special tools listed directly in the instructions and also gathered in this section Contents special toolkit Rem Tool Qty 3HAX010000450 Feather roller support 1 Steel tape 1 Product manual Feather Duster V2 179 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 7 Reference information 7 5 Special tools ...

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Page 181: ...s Mechanical spare parts Electrical parts and cables Some parts are available in several types depending on the Feather Duster V2 configuration To acquire the type of material required for your Feather Duster V2 contact ABB Product manual Feather Duster V2 181 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 8 Spare parts 8 1 Introduction ...

Page 182: ...01761 Description Spare part number Convert adapter for IRB 6640 185 2 8 3HAX010000443 E Convert adapter for IRB 6700 175 3 05 and IRB 6700 205 2 80 3HAX010000448 Convert adapter for IRB 6700 200 2 60 3HAX010000445 Sealing V ring 3HAX010000446 F Continues on next page 182 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 8 Spare parts 8 2 Spare part l...

Page 183: ...G Motor 80WD M02410 24V 3HAX010000272 H High torque timing belt 3HAX010000268 J xx1800001763 Continues on next page Product manual Feather Duster V2 183 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 8 Spare parts 8 2 Spare part list and illustration Continued ...

Page 184: ...ber Lonization Sensor Cable 1 3HAX010000309 M Shaft bearing with housing 3HAX010000281 N Anti Collision Cable 1 3HAX010000307 P Anti Collision Cable 2 3HAX010000308 Q Lonization Sensor Cable 2 3HAX010000310 R Continues on next page 184 Product manual Feather Duster V2 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 8 Spare parts 8 2 Spare part list and illustration Continued ...

Page 185: ... 3HAX010000305 003 Harness Cabinet to Robot Base 3M 3HAX010000303 003 Harness Cabinet to Robot Base 5M 3HAX010000303 005 Harness Cabinet to Robot Base 10M 3HAX010000303 010 Harness Cabinet to Robot Base 15M 3HAX010000303 015 Continues on next page Product manual Feather Duster V2 185 3HAX010000210 Revision A Copyright 2018 ABB All rights reserved 8 Spare parts 8 2 Spare part list and illustration ...

Page 186: ...Cabinet Power Supply 10M 3HAX010000302 010 Harness Cabinet Power Supply 15M 3HAX010000302 015 Harness Cabinet Power Supply 30M 3HAX010000302 030 Rotation Sensor Cable 3HAX010000306 LPT080 0220 05S 01A 3HAX010000411 Side Anti collision Cable 1 3HAX010000311 Side Anti collision Cable 1 adaptor 3HAX010000312 Side Anti collision Cable 2 3HAX010000313 186 Product manual Feather Duster V2 3HAX010000210 ...

Page 187: ...000305 FD4 Harness 3HAX010000306 Feather Duster Rotation Sensor Cable 3HAX010000307 Feather Duster Anti Collision Cable 1 3HAX010000308 Feather Duster Anti Collision Cable 2 3HAX010000309 Feather Duster Ionization Sensor Cable 1 3HAX010000310 Feather Duster Ionization Sensor Cable 2 3HAX010000311 Feather Duster Side Anti collision Cable 1 3HAX010000312 Feather Duster Side Anti collision Cable 1 ad...

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Page 189: ...ls 30 symbols 30 protective equipment 19 protective wear 19 R region specific regulations 13 replacing 119 bearing housing 126 cable harness 103 ionization unit 143 motor 155 safety edge sensor 151 responsibility and validity 13 S safety brake testing 27 fire extinguishing 16 moving equipment 20 signals 28 signals in manual 28 symbols 28 symbols on product 30 test run 21 working range 22 safety ed...

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Page 192: ...ay Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAX010000210 Rev A en Copyright 2018 ABB All rights reserved Specifications subject to change without notice ...

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