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The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. 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, damages to persons or property, fitness for a specific purpose or the like.
Organization of chapters - NOT MANDATORY The manual is organized in the following chapters: Chapter Contents References Documentation of ABB products, referred to in the manual, is listed in the table below. Document name of ABB products Document ID Product manual - IRC5...
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3HAC050992-001 This manual contains all safety instructions from the product manuals for the manipulators and the controllers. Documentation of non-ABB products, be referred to while using the Feather Duster V2, is listed in the table below. Document name of non-ABB Download from...
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.
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the Feather Duster V2 (hereinafter, the Product) will not cause injury or damage even if all safety instructions are complied with.
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Unauthorized modifications of the originally delivered product/system are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected.
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Product and as a result of that affect the 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.
It replaces the tack-off machine with more flexibility and high efficiency. Besides the robot on which the Feather 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.
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2.1.1 Introduction Continued Item Description Note Controller ABB IRC5, used to control the robot motion. For more information, see Product manual - IRC5. Process cabinet Used to control the Feather Duster. It is also an interface to automats (for ex-...
2 About Feather Duster V2 2.2.1 Component overview 2.2 Main components 2.2.1 Component overview General Components on the main body of the Feather Duster V2 are shown as follows. xx1800001264 Suction slot with flexible lips Ionizing bar Safety edge sensor...
2.2.2 Feather roller 2.2.2 Feather roller General The Feather Duster V2 is equipped with a roller which is an assembly of ostrich feathers disks stacked on an aluminum shaft. The shaft is equipped with coupling hubs for quick change. An approach sensor monitors the speed of the roller shaft. The rotation speed of...
2.2.3 Ionization unit General The Feather Duster V2 is equipped with an ionizer unit whose purpose is to reduce or eliminate static charge from the cleaned surface. The ionizer unit includes an ionizing bar and an ionizing air air knife.
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1Hz to 68Hz xx1800000871 Ionizing air knife and ionizing bar Each Feather Duster V2 has an ionizing air knife and an ionizing bar. xx1800001266 Ionizing bar Continues on next page Product manual - Feather Duster V2 3HAX010000210 Revision: A...
2.2.4 Exhaust system General The Feather Duster V2 works with an exhaust fan to suck and exhaust dust particles from the feathers. The exhaust system of the Feather Duster V2 mainly includes a suction slot with two flexible lips, an exhaust manifold, and an exhaust hose.
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3 Installation and commissioning 3.2 Technical specification Continued 765.8 xx1800000956 Robot The following ABB robots are applicable to the installation of the Feather Duster. • IRB 6700-175/3.05 (recommended) • IRB 6700-200/2.60 • IRB 6700-205/2.80 • IRB 6640-185/2.8 No particular option is required for the robot. For detailed robot specifications, see Product specification - IRB 6700 and Product specification - IRB 6640.
3 Installation and commissioning 3.3.2 Lifting Feather Duster V2 with lifting accessories 3.3.2 Lifting Feather Duster V2 with lifting accessories Introduction xx1800001269 CAUTION The exhaust pipe covers and cable guide covers may packed around the steel column, but not installed. Make sure they are carefully secured or moved aside before lifting the Feather Duster V2.
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1 pcs, lifting capacity: > 120 kg Lifting eye nut M12, DIN580 (2 pcs) Feather roller support 3HAX010000450 Lifting the Feather Duster V2 Use this procedure to lift the Feather Duster V2. Removing the PDCPD cover Action Note Remove the 6 screws on the covers. xx1800001270 Separate and remove the 2 covers re- spectively in proper order.
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3 Installation and commissioning 3.3.2 Lifting Feather Duster V2 with lifting accessories Continued Fit the lifting accessories Action Note Fit the lifting screws (2 pcs) to the steel structure frame. CAUTION The lifting eye nuts must be fitted to the positions shown in the figure to balance the Feather Duster V2 while lifting.
3 Installation and commissioning 3.3.3 Installing the Feather Duster V2 3.3.3 Installing the Feather Duster V2 Required equipment Equipment Article number Note Overhead crane Roundsling 2 pcs, lifting capacity: > 120 kg Lifting screw M8, DIN580 (2 pcs) Procedure Use this procedure to install the steel structure frame to the robots.
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3 Installation and commissioning 3.3.3 Installing the Feather Duster V2 Continued Action Note • Convert adapter for IRB Install the convert adapters, starting from the 6700-175/3.05 and IRB one shown in the figure. 6700-205/2.80: 3HAX010000448 • Convert adapter for IRB CAUTION 6700-200/2.60: 3HAX010000445...
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3 Installation and commissioning 3.3.3 Installing the Feather Duster V2 Continued Preparations on the Feather Duster V2 Action Note Release the 6 screws. Screw: Round head screw with emboss- ing (6 pcs) xx1800001270 Remove the PDCPD cover. xx1800001321 xx1800001322 Continues on next page...
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Prevent damages or injuries due to sudden dropping. xx1800001336 xx1800001337 Lifting the Feather Duster V2 to the robot Action Note Fit the lifting screws to the steel structure M8, DIN580 (2 pcs) frame.
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The lifting eye nuts must be fitted to the pos- itions shown in the figure to balance the Feather Duster V2 while lifting. xx1800001341 CAUTION The Feather Duster V2 weighs 120 kg. All lifting accessories used must be sized accordingly! WARNING Personnel must not, under any circum-...
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3.3.3 Installing the Feather Duster V2 Continued Action Note Move the Feather Duster V2 under the axis 5 of the robot, with the flange of the steel structure frame vertically aligned with the axis 6 but not pressed to each other.
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3 Installation and commissioning 3.3.3 Installing the Feather Duster V2 Continued Action Note Insert the locating pin to locate the steel structure frame xx1800001343 Tighten all the screws. Screw: M12x25 (11 pcs) Tightening torque: 145 Nm xx1800001344 Fit the exhaust pipe covers and secure them to the convert adaptors with screws and washers.
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3 Installation and commissioning 3.3.3 Installing the Feather Duster V2 Continued Action Note Refit the socket and cable chain. Screw: M6x12 (4 pcs) Tightening torque: 10 Nm xx1800001335 Secure the two halves of the exhaust pipe covers with screws. xx1800001329...
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3 Installation and commissioning 3.3.3 Installing the Feather Duster V2 Continued Refitting the PDCPD cover Action Note Refit the PDCPD covers. Screw: Round head screw with emboss- ing (6 pcs) xx1800001270 xx1800001323 Product manual - Feather Duster V2 3HAX010000210 Revision: A...
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Continued Routing introduction After the Feather Duster V2 is correctly installed on the robot, connect external exhaust hose and electrical cables to make the Feather Duster V2 ready for operation. The Feather Duster V2 is delivered with internal cabling fitted. To replace...
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Adaptor Plate: 3x3HAW050059705 xx1800001349 Route the cabling up though the robot arms and final to the Feather Duster V2. 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.
3 Installation and commissioning 3.4 Electrical connection 3.4 Electrical connection Electrical system The electrical system of the Feather Duster V2 mainly exists in the process cabinet, the ionization unit and the motor. The Feather Duster V2 can be controlled by DeviceNet. Feather Duster...
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Dummy module Harting.09 14 010 0303 Frame for modules, Han-Modular The following table lists the mating Harting connectors to the previous ones. You can order them with the Feather Duster as separate parts or assembled on an ABB harness. Connector Quantity...
3.5 System start-up Introduction General This chapter contains the instructions for setting up the Feather Duster V2 system once the physical installation has been completed, and the robot and robot controller have been started up. To start up the robot system, refer to the controller and robot documentation. See...
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3.5 System start-up Continued Start-up of the Feather Duster V2 motor Startup procedure The following figure shows the home page of Feather Duster V2 FlexPendant application, which is a navigation page with the add-in version displayed at the lower right corner. xx1800001598...
Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the Feather Duster V2: • Calendar time: specified in months regardless of whether the system is running or not.
4.2.2 Maintenance schedule 4.2.2 Maintenance schedule Scheduled and non-predictable maintenance The Feather Duster V2 must be maintained regularly to ensure proper function. Non-predictable situations also give rise to inspections of the Feather Duster. Any damages must be attended to immediately!
General The Feather Duster V2 is used to remove dust particles and contaminants from car body and to-be-painted surfaces. It is important to keep the Feather Duster V2 clean first. It is recommended to clean and inspect the whole Feather Duster every week.
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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 3HAX010000210 Revision: A...
• 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.
The Feather Duster V2 cabling comprises the cabling from the Feather Duster V2 to the robot base, both internal and external, as well as the cabling to the process cabinet. The Feather 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.
The procedures are gathered in sections, divided according to the component location on the Feather Duster V2. Required equipment The details of the equipment required to perform a specific repair activity are listed in the respective procedures.
5.2.2 Replacing the cable chain Location of the cable chain The Feather Duster V2 cabling comprises the cabling from the Feather Duster V2 to the robot base, both internal and external, as well as the cabling to the controller box.
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Preparations before the removal Action Note Jog the robot a proper height for easily access the Feather Duster V2. Preparations on the Feather Duster V2 Action Note Release the 6 screws. Screw: Round head screw with emboss- ing (6 pcs)
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Adaptor Plate: 3x3HAW050059705 xx1800001349 Route the cabling up though the robot arms and final to the Feather Duster V2. 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.
5.2.6 Replacing the safety edge sensor Location of the safety edge sensor The Feather Duster V2 have two safety edge sensors, one of which is optional. The safety edge sensors are located as shown in the figure. Required spare parts...
6.3 Dismantle 6.3 Dismantle Disassembly of the Feather Duster V2 Note Use the safety pins to secure each parts of the Feather Duster V2 to prevent uncontrolled movement. Note Shut off the electrical and air supplies before removing all the connections.
UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.