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ABB Feather Duster Product Manual

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  • Page 1 Product manual Feather Duster...
  • Page 3 Product manual Feather Duster Document ID: 3HAW050027150 Revision: Revision: C...
  • 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, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    4.4.2 Start up of the Feather Duster motor ....... . .
  • Page 6 Table of Contents 5 Maintenance 5.1 Introduction ............... 65 5.2 Expected components lifetime .

  • Page 7: Overview Of This Manual

    • spare parts Usage This manual should be used when working during: • installation, from lifting the Feather Duster to its work site and securing it to the foundation, to making it ready for operation • maintenance work • repair work.
  • Page 8 References Reference - ABB documentation Document ID Operating manual - General safety information 3HAC031045-001 Product manual - IRC5 Robot Controller with FlexPendant 3HAC021313-001 Service Information System - IRC5 3HAC025709-001 Operating manual - IRC5 with FlexPendant 3HAC16590 Getting started, IRC5 and RobotStudio...

  • Page 9: Product Documentation, M2004

    The manipulator documentation 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. All documents listed can be ordered from ABB on a DVD. The documents listed are valid for M2004 manipulator systems. Product manuals...
  • Page 10 Operating manuals 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 trouble shooters. The group of manuals includes: • Emergency safety information •...

  • Page 11: How To Read The Product Manual

    0.0.3. How to read the product manual Reading the procedures The procedures contain references to figures, tools, material etc. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the robot/controller.
  • Page 12 3HAW050027150 Revision: C...

  • Page 13: Safety

    1 Safety 1.1. Introduction 1 Safety 1.1. Introduction Overview The safety information in this manual is divided in two categories: • general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in General safety information on page •...

  • Page 14: General Safety Information

    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. Related information...

  • Page 15: Safety Risks Related To The Robot

    Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 16 1 Safety 1.3.1. Safety risks during installation and service work on robot Complete robot Safety risk Description Hot components! Removed parts may result in collapse of robot! Caution signal Caution! Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Warning signal Warning!

  • Page 17: Safety Risks Related To Tools/Workpieces

    1 Safety 1.3.2. Safety risks related to tools/workpieces 1.3.2. Safety risks related to tools/workpieces Safe handling 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).

  • Page 18: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety 1.3.3. Safety risks related to pneumatic/hydraulic systems 1.3.3. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy may be present in these systems. After shutdown, particular care must be taken.

  • Page 19: Safety Risks During Operational Disturbances

    1 Safety 1.3.4. Safety risks during operational disturbances 1.3.4. Safety risks during operational disturbances General • The industrial robot is a flexible tool which can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 20: Risks Associated With Live Electric Parts

    1 Safety 1.3.5. Risks associated with live electric parts 1.3.5. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

  • Page 21: Safety Actions Related To The Robot

    1 Safety 1.4.1. Safety fence dimensions 1.4 Safety actions related to the robot 1.4.1. Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.

  • Page 22: Fire Extinguishing

    1 Safety 1.4.2. Fire extinguishing 1.4.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator or controller)! 3HAW050027150 Revision: C...

  • Page 23: Emergency Release Of The Robots/Manipulators Axes

    1 Safety 1.4.3. Emergency release of the robots/manipulators axes 1.4.3. Emergency release of the robots/manipulators axes Description In an emergency situation, any of the robot's/manipulators axes may be released manually by pushing the brake release buttons on the robot. How to release the brakes is detailed in the robot product manual. •...

  • Page 24: Brake Testing

    1 Safety 1.4.4. Brake testing 1.4.4. Brake testing When to test During operation the holding brakes of each axis motor wear normally. A test may be per- formed to determine whether the brake can still perform its function. How to test The function of each axis' motor holding brakes may be checked as detailed below: 1.

  • Page 25: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety 1.4.5. Risk of disabling function "Reduced speed 250 mm/s" 1.4.5. Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change Transm. gear ratio or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s. 3HAW050027150 Revision: C...

  • Page 26: Safe Use Of The Teach Pendant Unit

    1 Safety 1.4.6. Safe use of the Teach Pendant Unit 1.4.6. Safe use of the Teach Pendant Unit NOTE! The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

  • Page 27: Work Inside The Manipulator's Working Range

    1 Safety 1.4.7. Work inside the manipulator's working range 1.4.7. Work inside the manipulator's working range WARNING! If work must be carried out within the robot's work envelope, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

  • Page 28: Translate The Information On Safety And Information Labels

    Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

  • Page 29: Safety Stops

    1 Safety 1.5.1. What is an emergency stop? 1.5 Safety stops 1.5.1. What is an emergency stop? Definition of emergency stop An emergency stop is a state that overrides any other manipulator control, disconnects drive power from the manipulator motors, stops all moving parts, and disconnects power from any potentially dangerous functions controlled by the manipulator system.
  • Page 30 1 Safety 1.5.1. What is an emergency stop? Emergency stop devices In a manipulator system there are several emergency stop devices that can be operated in order to achieve an emergency stop. There are emergency stop buttons available on the Flex- Pendant and on the controller cabinet (on the Control Module on a Dual Cabinet Controller).There can also be other types of emergency stops on your manipulator, consult your plant or cell documentation to see how your manipulator system is configured.

  • Page 31: Safety Related Instructions

    1 Safety 1.6.1. Safety signals in the manual 1.6 Safety related instructions 1.6.1. Safety signals in the manual Introduction to safety signals This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: •...
  • Page 32 1 Safety 1.6.1. Safety signals in the manual Symbol Designation Signification ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE electrostatic hazards which could result in severe (ESD) damage to the product. Electrostatic discharge (ESD) MAGNETIC An intense and/or variable magnetic field can affect or FIELDS damage certain electrical devices like cardiac pacemakers.

  • Page 33: System Description

    2.1 System overview 2.1.1. System basics General The Feather Duster Robot system is a pre-paint finishing equipment mounted on a 6 axis manipulator. It is used to remove dust and dirt particles from car bodies and from surfaces to be painted.
  • Page 34 Two AC Ionization bars are 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 body surface after cleaning.

  • Page 35: Components Overview

    Suction slot with flexible lips Ionizing bar Anti-collision safe edge Ostrich roller The Feather Duster is equipped with an ostrich feather roller. The roller is made up of disks of feathers stacked on a stainless steel shaft. See Feather roller on page Ionization unit The ionization system consists in an ionizing air knife bar mounted on the trailing edge and a ionization bar mounted in the mechanical unit.
  • Page 36 It is also an interface to automats (e.g. PLC cabinet), providing the signal from the main sensors (e.g. anti-collision switch). Control cabinet The control cabinet is a standard ABB IRC5 controller, used to control robot motion. For more information, see Product Manual, Control Cabinet IRC5. 3HAW050027150 Revision: C...

  • Page 37: Process Diagram

    2 System description 2.1.3. Process diagram 2.1.3. Process diagram General The figure below shows the general process diagram: Figure 4: General process diagram 3HAW050027150 Revision: C...

  • Page 38: Feather Roller

    2.2. Feather roller General The Feather Duster is equipped with a roller which is an assembly of ostrich feathers disks stacked on a stainless steel shaft. The shaft is equipped with coupling hubs for quick change. An approach switch monitors the speed on the drive shaft of the rollers. The rotating speed of the feather rollers can therefore be optimally controlled and adjusted to the body and the conveyor speed, achieving a uniform relative speed between feathers and body.

  • Page 39: Ionization

    2.3. Ionization General The Feather Duster system is equipped with an ionization system which purpose is to reduce or eliminate static charge from the cleaned surface. The system includes a high voltage generator, an ionizing bars and an ionizing air knife.

  • Page 40: Exhaust System

    2.4. Exhaust system General The Feather Duster system requires an exhaust fan to suck the dust and dirt from the feathers. An adjustable 1016 mm (40”) long exhaust slot spans the full length of the feather shaft, where all of the dust and contaminants are collected from the feathers. The exhaust air from the ductwork is routed through flexible hose.

  • Page 41: Compressed Air System

    2 System description 2.5. Compressed air system 2.5. Compressed air system General The compressed air system is required to supply air to the ionization air knife. The system is supplied with a solenoid controlled air valve, mounted on the process cabinet. If the air pressure is lower than the setting value, a fault will be created.

  • Page 42: Technical Specification

    Deviation ≤ 25mm Conveyor System Robot specifications Feather Duster is designed to be integrated with ABB IRB6640-185 or IRB6700-175. Alternatively, it may also be used with IRB6700-200 and IRB6700-205. No particular option is required for the robot. See 3HAC028284-001, IRB6640 Product specification or 3HAC044265, IRB6700 Product specification.

  • Page 43: Feather Duster Dimensions

    3 Technical Specification 3.2. Feather Duster dimensions 3.2. Feather Duster dimensions Dimensions The following figure shows the Feather Duster dimensions: Figure 10: Dimensions 3HAW050027150 Revision: C...
  • Page 44 3 Technical Specification 3.2. Feather Duster dimensions 3HAW050027150 Revision: C...

  • Page 45: Installation And Commissioning

    4 Installation and commissioning 4.1. Introduction 4 Installation and commissioning 4.1. Introduction Safety information Before any service work is commenced, it is important that all safety information is observed! Read Safety on page 11 before performing any service work. Required equipment Equipment Note Standard toolkit...

  • Page 46: Mechanical Installation

    Safety on page 11 before performing any service work. General The Feather Duster mechanical installation consists mainly in the installation of the steel structure frame and the mounting of the exhaust air and compressed air supply hoses. Refer to Assembly drawings on page 89 for details.

  • Page 47: Carbon Fiber Covers

    4 Installation and commissioning 4.2.2. Carbon fiber covers 4.2.2. Carbon fiber covers General The covers are interchangeable carbon fiber panels, fastened on the frame with 4 M8 screw bolts. Figure 13: Carbon fiber cover 3HAW050027150 Revision: C...

  • Page 48: Instructions For The Installation Of The Steel Structure Frame

    IRB6700, and the Feather Duster mechanical design was modified accordingly. In this chapter are described the procedures for mounting the Feather Duster to robots delivered before the design changes, and for mounting the Feather Duster to robots delivered after the design change.
  • Page 49 4 Installation and commissioning 4.2.3. Instructions for the installation of the steel structure frame Steps Action Info/IIIustration Insert the upper half interface plate into the gap. Tighten the 6 screws. Tightening torque: 35Nm. Once the upper interface plate is tight, install the lower interface plate the same way.
  • Page 50 Pay attention to the orientation of installation: there is a 3mm deep groove on the top of the Feather Duster steel column which must be aligned with the 0°calibration mark of the robot 6th axis. Pre-tighten 2x M12x35 hexagon socket head cap screws.
  • Page 51 4 Installation and commissioning 4.2.3. Instructions for the installation of the steel structure frame Procedure - robots delivered after 2016 (pendulum calibration or axis calibration) Steps Action Info/IIIustration Ensure that the robot is calibrated. Set Axis 5 in +90° position and axis 6 in 0°...
  • Page 52 4 Installation and commissioning 4.2.3. Instructions for the installation of the steel structure frame Steps Action Info/IIIustration Re-fit the turning disk, following the instructions in the robot manual (3HAC044266 - Product manual IRB 6700, Chapter “Replacing the turning disk”). Install the V-seal around the turning disk.
  • Page 53 Pay attention to the orientation of installation: there is a 3mm deep groove on the top of the Feather Duster steel column which must be aligned with the 0°calibration mark of the robot 6th axis. Pre-tighten 2x M12x35 hexagon socket head cap screws.

  • Page 54: Instructions For The Connection Of Flexible Hoses And Cables

    4 Installation and commissioning 4.2.4. Instructions for the connection of flexible hoses and cables 4.2.4. Instructions for the connection of flexible hoses and cables Pneumatic system overview The pneumatic system is described in the diagram below: Figure 14: pneumatic diagram 3HAW050027150 Revision: C...
  • Page 55 External routing The external routing of the exhaust hose, pneumatic tube and cables must be completed before the internal connection of the feather duster. 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.
  • Page 56 Once the exhaust hose and the flexible conduit (which contains the pneumatic tube and the harness) have been assembled onto the robot, connect them to the hose connector at the back of the Feather Duster. The electrical harness must be guided through the cover from the external connector to the internal connector.
  • Page 57 4 Installation and commissioning 4.2.4. Instructions for the connection of flexible hoses and cables Steps Action Info/IIIustration Before routing the internal cables and air pipe, use the Teach Pendant to jog the manipulator’s 6 axis to +360° Insert the pneumatic tube and the cable harness in the Ø29mm, 1.2m long internal flexible conduit.
  • Page 58 4 Installation and commissioning 4.2.4. Instructions for the connection of flexible hoses and cables Steps Action Info/IIIustration Run the robot in manual to make sure that the assembly allows for all axis to run a complete stroke. If necessary, adjust the distance of the flexible conduit and the exhaust hose between clamps.

  • Page 59: Electrical Installation

    4.3. Electrical installation 4.3. Electrical installation Introduction The electrical system of the feather duster consists mainly in the process cabinet, the deionization bars and the motor. The feather duster can be controlled by the PLC or the robot IRC5 controller.
  • Page 60 4 Installation and commissioning 4.3. Electrical installation Junction box All the electrical devices connect to the process cabinet through the junction box. The figure below shows the cable connection details in the junction box. Figure 19: Cable connection in the junction box For details, refer to the wiring diagram of the flexible harness 3HAW050024279 in the appendix Process cabinet...
  • Page 61 HAR.09 14 000 9950 Dummy module HAR.09 14 010 0303 Frame The table below lists the mating Harting connectors which may be ordered with the Feather Duster, as separate parts or assembled on an ABB harness: Qty. ABB N°- HAR. N° 3HAW050024361 HAR.19 30 016 1521 Hood...

  • Page 62: System Start-Up

    4.4.1. Introduction Introduction This chapter contains the instructions for setting up the Feather Duster system once the physical installation has been completed, and the robot and robot controller have been started To start the robot system up, refer to the controller and robot documentation. See...

  • Page 63: Start Up Of The Feather Duster Motor

    4 Installation and commissioning 4.4.2. Start up of the Feather Duster motor 4.4.2. Start up of the Feather Duster motor Introduction The content of this chapter is an adapted extract from the SEW Operating Instructions 16837614-Movidrive MDX61B (See References on page Movidrive key pad The figure below shows the key pad main keys.
  • Page 64 Movidrive MDX61B (References on page Some settings depend on the local power supply type and the motor type (380VAC-50Hz or 480VAC-60 Hz). In case of doubt, refer to the nameplate on the motor or contact ABB. Steps Action Parameters BASIC VIEW...
  • Page 65 4 Installation and commissioning 4.4.2. Start up of the Feather Duster motor Steps Action Parameters C04* Hz Enter the rated frequency specified on the motor nameplate. MOT.RATED FREQ1 Press the key to select the next parameter. 50.000 C05* V RATED MAINS Enter the rated power supply voltage.
  • Page 66 4 Installation and commissioning 4.4.2. Start up of the Feather Duster motor 3HAW050027150 Revision: C...

  • Page 67: Maintenance

    CAUTION! • Before any intervention on the mechanical and electrical components, all power supplies to the Feather Duster as well as to other machines within the danger zone must be turned off. • If required, the main switch should be locked.

  • Page 68: Expected Components Lifetime

    5 Maintenance 5.2. Expected components lifetime 5.2. Expected components lifetime General The expected lifetime of the components can vary greatly depending on how intensively the feather duster is run. Item Maintenance Cables 1,000,000 cycles Belt Over 16,000h Roller Over 6 month...

  • Page 69: Maintenance Planning

    The feather duster must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below. Non-predictable situations may also give rise to inspections of the feather duster. Any damage must be attended immediately! Time interval Maintenance More info.

  • Page 70: Maintenance Activities

    Ensure that the ionization bars are properly aligned. Inspection • Check for oil leaks. • Check for excessive play in gears. • Check that cables and hoses between control cabinet, robot and feather duster are not damaged. 3HAW050027150 Revision: C...

  • Page 71: Feather Roller Care And Replacement

    Keep the feather roller in its package until it is ready to be installed on the machine • Reseal packages if they have been opened for inspection • Do not allow feathers to rest on the floor. If possible, use the ABB feather roller support 3HAW050024260 (See Special tools on page 3HAW050027150 Revision: C...
  • Page 72 Loosen the nuts on both ends of the roller shaft. Extract the screw bolts. Proceed on both sides simultaneously. Remove the roller shaft from the mechanical unit. If available, place it on the ABB feather roller support 3HAW050024260 (See Special tools on page 81).
  • Page 73 5 Maintenance 5.4.2. Feather roller care and replacement Steps Action Info/IIIustration Stack 20 feather disks on the shaft. Pay attention to the orientation of the disks (See Correct feather rotation in Introduction on page 44). Tighten the locknut previously removed at the shaft’s end 3HAW050027150 Revision: C...
  • Page 74 5 Maintenance 5.4.2. Feather roller care and replacement Steps Action Info/IIIustration Fasten the shaft back into the frame. Pay attention the shaft orientation: the end with a keyway must but put in the matching slotted hub. 3HAW050027150 Revision: C...

  • Page 75: Belt Replacement

    5 Maintenance 5.4.3. Belt replacement 5.4.3. Belt replacement Procedure Steps Action Info/IIIustration Remove the two carbon fiber covers. Remove the tunnel cover on the motor side. Loosen the 4 nuts of the motor fixing flange to release the belt tension. Remove the belt.

  • Page 76: Motor Replacement

    5 Maintenance 5.4.4. Motor replacement 5.4.4. Motor replacement Location Figure: Location of the motor Motor Procedure Steps Action Info/IIIustration Remove the two carbon fiber covers. Remove the motor cover. 3HAW050027150 Revision: C...
  • Page 77 5 Maintenance 5.4.4. Motor replacement Steps Action Info/IIIustration Open the junction box and disconnect the cables. Electrical installation on page Remove the tunnel cover on the motor side. Loosen the 4 nuts of the motor fixing flange to release the belt tension.
  • Page 78 5 Maintenance 5.4.4. Motor replacement Steps Action Info/IIIustration Remove the motor flange. Install the flange on the new motor, and fasten the 4 screws. Mount the top shaft spacer on the motor axis. Install the motor on the support frame, and pre-tighten the 4 screws.

  • Page 79: Reference Information

    6 Reference information 6.1. Introduction 6 Reference information 6.1. Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAW050027150 Revision: C...

  • Page 80: Unit Conversion

    6 Reference information 6.2. Unit conversion 6.2. Unit conversion Converter table Use the following table to convert units used in this manual. Quantity Unit Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...

  • Page 81: Bolt, Screws, Tightening Torques

    • Maximum allowed total deviation from the specified value is 10%! NOTE! Unless indicated otherwise, the bolts used on (or provided with) the Feather Duster are of class 8.8. NOTE! Unless indicated otherwise, all bolts must be clean of oil or grease and tightened with a mild thread-locker such as Loctite 243.

  • Page 82: Standard Toolkit

    6 Reference information 6.4. Standard toolkit 6.4. Standard toolkit General All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the standard toolkit and defined in the table below.

  • Page 83: Special Tools

    Multimeter Wire strippers Cable cutters Special tools available from ABB The following table specifies the special tools required during several of the service procedures. The tools may be ordered separately and are also specified directly in concerned instructions in the Product manual.
  • Page 84 6 Reference information 6.5. Special tools 3HAW050027150 Revision: C...

  • Page 85: Spare Parts

    Mechanical spare parts • Electrical parts and cables Some parts are available in several types, depending on the Feather Duster configuration. If you do not know what type of material is required for your Feather Duster, contact ABB. 3HAW050027150 Revision: C...

  • Page 86: Mechanical Spare Parts

    List of spare parts Item Qty ABB part no. Description Note 3HAW050024263 Carbon fiber covers Symetrical part - 2 covers per Feather Duster 3HAW050024318 Safe edge sensor Item Qty ABB part no. Description Note 3HAW050024255 Shaft assembly The shaft assembly includes the...
  • Page 87 7 Spare parts 7.2. Mechanical spare parts Item Qty ABB part no. Description Note 3HAW050024273 Feather Brush To form a complete brush, 20 pieces are stacked on the shaft 3HAW050024230 Shaft bearing with housing Item Qty ABB part no. Description...
  • Page 88 Description Note 3HAW050024238-010 Exhaust hose 10m 3HAW050024207-004 Outer protection Used from robot base to flexible conduit Ø wrist (Feather Duster 36mm Dresspack) 3HAW050024240-001 Inner protection Used from the robot wrist to flexible conduit Ø the electrical junction box in 29mm the Feather Duster.

  • Page 89: Electrical Spare Parts

    7 Spare parts 7.3. Electrical spare parts 7.3. Electrical spare parts List of spare parts Item Quantity ABB part reference no. Note 3HAW050024312 Safety edge sensor relay 3HAW050024313 General relay 3HAW050024317 Safe edge controller 3HAW050024325 Brake resistor 3HAW050024294-010 Control cable (from process...
  • Page 90 7 Spare parts 7.3. Electrical spare parts 3HAW050027150 Revision: C...

  • Page 91: Appendix

    • 3HAW050046230 Exhaust manifold assembly: for robots delivered after 2016 • 3HAW050024255 Shaft assembly • 3HAW050024373 IRB 6640 Feather duster dresspack • 3HAW050024377 IRB 6700-175 and IRB6700-205 Feather duster dresspack • 3HAW050024378 IRB 6700-200 Feather duster dresspack 3HAW050027150 Revision: C...
  • Page 93 Chuangye Rd, Kangqiao Part Weight 201319 Nanhui District Shanghai, PRC Ce document est la propriété de ABB Body In White SA et ne peut être tel: +86 2161298980 reproduit ou communiqué à des tiers sans autorisation écrite préalable 136.36 fax: +86 2161056905...
  • Page 94 Chuangye Rd, Kangqiao Part Weight 201319 Nanhui District Shanghai, PRC Ce document est la propriété de ABB Body In White SA et ne peut être tel: +86 2161298980 9.79 reproduit ou communiqué à des tiers sans autorisation écrite préalable fax: +86 2161056905...
  • Page 95 Chuangye Rd, Kangqiao Part Weight 201319 Nanhui District Shanghai, PRC Ce document est la propriété de ABB Body In White SA et ne peut être tel: +86 2161298980 9.93 reproduit ou communiqué à des tiers sans autorisation écrite préalable fax: +86 2161056905...
  • Page 96 Chuangye Rd, Kangqiao 201319 Nanhui District Part Weight Shanghai, PRC Ce document est la propriété de ABB Body In White SA et ne peut être tel: +86 2161298980 reproduit ou communiqué à des tiers sans autorisation écrite préalable 5.23 kg...
  • Page 97 Chuangye Rd, Kangqiao Part Weight 201319 Nanhui District Shanghai, PRC Ce document est la propriété de ABB Body In White SA et ne peut être tel: +86 2161298980 reproduit ou communiqué à des tiers sans autorisation écrite préalable 538.76 kg...
  • Page 98 Chuangye Rd, Kangqiao Part Weight 201319 Nanhui District Shanghai, PRC Ce document est la propriété de ABB Body In White SA et ne peut être tel: +86 2161298980 reproduit ou communiqué à des tiers sans autorisation écrite préalable 192.12 kg...
  • Page 99 Chuangye Rd, Kangqiao Part Weight 201319 Nanhui District Shanghai, PRC Ce document est la propriété de ABB Body In White SA et ne peut être tel: +86 2161298980 reproduit ou communiqué à des tiers sans autorisation écrite préalable 602.16 kg...

  • Page 101: Wiring Diagrams

    8 Appendix 8.2. Wiring diagrams 8.2. Wiring diagrams List This section contains the following diagrams: • 3HAW050024279: Flexible control harness • 3HAW050024294: Floor control cable • 3HAW050024286: EMU process cabinet 3HAW050027150 Revision: C...
  • Page 102 8 Appendix 8.2. Wiring diagrams 3HAW050027150 Revision: C...
  • Page 103 F26_ABB_Cover Project Discription Feather Duster FD5 Harness Robot Base to Arm Document Number 3HAW050024279 Revision Number of pages Status: 2012/6/1 Approved Feather Duster FD5 Harness Robot Base to Arm Title page / cover sheet RS / BIW Document no. Rev.Ind...
  • Page 104 Peel Length=100mm Tube Length = 4M Tube Length = 1.2M Cable Length = 6.8M Cable Length = 1.8M Status: 2012/6/1 Approved Feather Duster FD5 Harness Robot Base to Arm Layout Harness RS / BIW Document no. Rev.Ind Respsonsible Department: Page 3HAW050024279...
  • Page 105 -XP1 1.8 m -MOT Feature Motor Ionization bar Anti-collision Rotation speed switch Status: 2012/6/1 Approved Feather Duster FD5 Harness Robot Base to Arm Connection RS / BIW Document no. Rev.Ind Respsonsible Department: Page 3HAW050024279 Prepare by, Date N,Cao 2013/9/18...
  • Page 106 /3.2 /3.2 -R1.FD5 -R2.FD5 /3.2 /3.1 -R1.FD5-a -R2.FD5-XP1 /3.1 Status: 2012/6/1 Approved Feather Duster FD5 Harness Robot Base to Arm Cable diagram =+-W1 RS / BIW Document no. Rev.Ind Respsonsible Department: Page 3HAW050024279 Prepare by, Date N,Cao 2013/9/18 Approve by,...
  • Page 107 /3.3 -R1.FD5-b -R2.FD5-XP1 /3.3 /3.3 -R1.FD5-b GNYE -R2.FD5-XP1 /3.3 Status: 2012/6/1 Approved Feather Duster FD5 Harness Robot Base to Arm Cable diagram =+-W2 RS / BIW Document no. Rev.Ind Respsonsible Department: Page 3HAW050024279 Prepare by, Date N,Cao 2013/9/18 Approve by,...
  • Page 108 /3.5 /3.5 -R1.FD5-c -R2.FD5-XP1 /3.5 /3.5 -R1.FD5 -R2.FD5 /3.5 Status: 2012/6/1 Approved Feather Duster FD5 Harness Robot Base to Arm Cable diagram =+-W3 RS / BIW Document no. Rev.Ind Respsonsible Department: Page 3HAW050024279 Prepare by, Date N,Cao 2013/9/18 Approve by,...
  • Page 109 /3.1 /3.2 -MOT -R2.FD5 /3.2 /3.1 -MOT -R2.FD5-XP1 /3.1 Status: 2012/6/1 Approved Feather Duster FD5 Harness Robot Base to Arm Cable diagram =+-W4 RS / BIW Document no. Rev.Ind Respsonsible Department: Page 3HAW050024279 Prepare by, Date N,Cao 2013/9/18 Approve by,...
  • Page 111 F26_ABB_Cover Project Discription Feather Duster FD5 Harness Cabinet to Robot Base Document Number 3HAW050024294-XXX Revision Number of pages Status: 2012/6/1 Approved Feather Duster FD5 Harness Cabinet to Robot Base Title page / cover sheet RS / BIW Document no. Rev.Ind...
  • Page 112 3HAB8053-1 Barcodes Barcodes R1.FD5 ADD SAP NUMBER SAP NUMBER Length 3HAW050024294-010 3HAW050024294-015 Status: 2012/6/1 Approved Feather Duster FD5 Harness Cabinet to Robot Base Layout RS / BIW Document no. Rev.Ind Respsonsible Department: Page 3HAW050024294-XXX Prepare by, Date N,Cao 2013/9/18 Approve by,...
  • Page 113 -TUBE GNYE R1.FD5 Feature Motor Ionization bar Anti-collision Rotation speed switch Robot Base Status: 2012/6/1 Approved Feather Duster FD5 Harness Cabinet to Robot Base Connection RS / BIW Document no. Rev.Ind Respsonsible Department: Page 3HAW050024294-XXX Prepare by, Date N,Cao 2013/9/18...
  • Page 114 /3.1 /3.2 -FD5 -R1.FD5 /3.2 /3.2 -FD5-a -R1.FD5-A /3.2 Status: 2012/6/1 Approved Feather Duster FD5 Harness Cabinet to Robot Base Cable diagram =+-W1 RS / BIW Document no. Rev.Ind Respsonsible Department: Page 3HAW050024294-XXX Prepare by, Date N,Cao 2013/9/18 Approve by,...
  • Page 115 /3.3 -FD5-b -R1.FD5-B /3.3 /3.3 -FD5-b GNYE -R1.FD5-B /3.3 Status: 2012/6/1 Approved Feather Duster FD5 Harness Cabinet to Robot Base Cable diagram =+-W2 RS / BIW Document no. Rev.Ind Respsonsible Department: Page 3HAW050024294-XXX Prepare by, Date N,Cao 2013/9/18 Approve by,...
  • Page 116 /3.5 /3.5 -FD5-c -R1.FD5-C /3.5 /3.6 -FD5 -R1.FD5 /3.6 Status: 2012/6/1 Approved Feather Duster FD5 Harness Cabinet to Robot Base Cable diagram =+-W3 RS / BIW Document no. Rev.Ind Respsonsible Department: Page 3HAW050024294-XXX Prepare by, Date N,Cao 2013/9/18 Approve by,...
  • Page 117 F26_ABB_Cover Project Discription Feather Duster EMU Process Cabinet Document Number 3HAW050024286-XXX Revision Number of pages Status: Approved Feather Duster EMU Process Cabinet Title page / cover sheet Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date...
  • Page 118 230VAC = white control voltage 24VDC = + blue control voltage 24VDC = - blue external voltage = orange Status: Approved Feather Duster EMU Process Cabinet SAP No and Wiring Specification Document no. Rev.Ind RS / BIW Respsonsible Department:...
  • Page 119 Vacuum Ventilator FD3 Air Treatment Control Feather Duster FD4 Floor Harness Vacuum Pressure Switch Compressed Air FD5 Floor Harness Status: Approved Feather Duster EMU Process Cabinet System Diagram Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by,...
  • Page 120 Cover 3HAW050059714 5xTag Adaptor Plate 3X 3HAW050059705 Dim.30x15 Plate ABB.3HAC024694-001 IRC5 Cabinet Feather Duster Connection Layout Detail Tag: size 30x15mm show as drawing Attention!!! FD1 Male Connector installed FD1: MainPower Supply Input (400/480VAC) FD2: FeatherDuster Signal Interface FD3: Compress Air Valve...
  • Page 121 Rail L=350 Back of Cabinet Current Meter ATTENTION transformer is only installed when main power voltage is 3x480V (US) Transformer Status: Approved Feather Duster EMU Process Cabinet Cabinet Inside Layout Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX...
  • Page 122 /13.1 /14.1 Main Power Input -XP1 380-480VAC +-M2 Roller motor (control way: fieldbus) Status: Approved Feather Duster EMU Process Cabinet Main Power Supply & Motor Driver Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015...
  • Page 123 230V "480V" & "IN" Connect Output "230V" and "0V" 11-1.E 11-1.H -F10 11-2.A 11-3.A Status: Approved Feather Duster EMU Process Cabinet Main Circuit & Transformer Option Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015...
  • Page 124 Ionization bar Ionization bar Cabinet DC Power for feather for car body Ventilate Fan 直流电源 Status: Approved Feather Duster EMU Process Cabinet Ionization & DC Power Supply Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date...
  • Page 125 -WK1 -WK2 14 /12.2 /14.6 44 /12.2 Rotation IRC5 or PLC Detection Controller Cabinet Status: Approved Feather Duster EMU Process Cabinet DC Control Circuit Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 126 -XP1 /13.5 /13.6 PRESSURE SWITCH COMPRESSED AIR ANTI-COLLISION SWITCH VACUUM SWITCH OF COMPRESSED AIR VALVE Status: Approved Feather Duster EMU Process Cabinet DC Control Circuit1 Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 127 Function text Target designation Target designation Page / column /10.2 /10.2 /10.1 /10.1 /10.1 Status: Approved Feather Duster EMU Process Cabinet Terminal diagram =+-PS Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 128 =+-X1 Function text Target designation Target designation Page / column Rotation Detection -FD5-C -FD2-S /13.1 Status: Approved Feather Duster EMU Process Cabinet Terminal diagram =+-X1 Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 129 Function text Target designation Target designation Page / column -XS-T1 /11.8 /11.8 -XS-T1 /11.8 /11.8 Status: Approved Feather Duster EMU Process Cabinet Terminal diagram =+-XAC Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 130 /12.7 /12.8 /12.8 -FD4-A -FD3-A -FD2-S -FD5-C /12.8 /12.8 /12.8 /12.8 Status: Approved Feather Duster EMU Process Cabinet Terminal diagram =+-XDC Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by, Date Replacement of...
  • Page 131 /10.3 /10.3 -FD1-P /10.3 /10.3 /10.4 /10.4 /10.4 /10.4 /10.4 /10.4 Status: Approved Feather Duster EMU Process Cabinet Terminal diagram =+-XMP Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by, Date Replacement of...
  • Page 132 /14.2 ANTI-COLLISION SWITCH -R1_FD5 /14.2 Rotation Detection -R1_FD5 /13.1 -R1_FD5 /13.1 -R1_FD5 /13.1 Status: Approved Feather Duster EMU Process Cabinet Terminal diagram =+-XP1 Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by, Date...
  • Page 133 Function text Target designation Target designation Page / column /10.1 /10.1 /10.1 /10.2 -XMP /10.2 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD1-P Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 134 Function text Target designation Target designation Page / column /10.1 /10.1 /10.1 /10.2 /10.2 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD1-S Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 135 DO - Ionizion Bar Power ON R1.1_D257Q_EN -IRC_FD2 /13.7 -IRC_FD2 /13.7 DO - Compress Air On -IRC_FD2 /13.8 -IRC_FD2 /13.8 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD2-P Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 136 DO - Ionizion Bar Power ON R1.1_D257Q_EN -XDC /13.7 /13.7 DO - Compress Air On -XDC /13.8 /13.8 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD2-S Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date...
  • Page 137 Function text Target designation Target designation Page / column COMPRESSED AIR VALVE /14.6 -XDC /14.6 /14.6 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD3-A Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015...
  • Page 138 Target designation Target designation Page / column PRESSURE SWITCH OF COMPRESSED AIR -XDC /14.5 /14.5 /14.5 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD3-B Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015...
  • Page 139 Target designation Target designation Page / column COMPRESSED AIR VALVE -S4-Y1 /14.6 -S4-Y1 /14.6 /14.6 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD3-a Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 140 Target designation Target designation Page / column PRESSURE SWITCH OF COMPRESSED AIR -S4-PS /14.5 -S4-PS /14.5 /14.5 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD3-b Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015...
  • Page 141 =+-FD4-a Function text Target designation Target designation Page / column VACUUM SWITCH /14.8 /14.8 /14.8 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD4-a Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 142 Strip designation =+-FD5-B Function text Target designation Target designation Page / column /12.2 /12.2 /12.3 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD5-B Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 143 A3(+) /14.1 A4(-) /14.2 /14.2 Rotation Detection -XDC /13.1 -XDC /13.1 /13.1 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD5-C Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by, Date Replacement of...
  • Page 144 Page / column Roller motor (control way: fieldbus) -R1_FD5 /10.6 -R1_FD5 /10.6 -R1_FD5 /10.6 -R1_FD5 /10.7 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD5-a Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 145 Function text Target designation Target designation Page / column -R1_FD5 /12.2 -R1_FD5 /12.2 -R1_FD5 /12.3 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD5-b Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by,...
  • Page 146 -R1_FD5 /14.2 -R1_FD5 /14.2 Rotation Detection -R1_FD5 /13.1 -R1_FD5 /13.1 -R1_FD5 /13.1 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-FD5-c Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date 12/17/2015 Approve by, Date Replacement of...
  • Page 147 /13.6 DO - Ionizion Bar Power ON R1.1_D257Q_EN /13.7 /13.7 DO - Compress Air On /13.8 /13.8 Status: Approved Feather Duster EMU Process Cabinet Plug diagram =+-IRC_FD2 Document no. Rev.Ind RS / BIW Respsonsible Department: Page 3HAW050024286-XXX Prepare by, Date...
  • Page 150 Contact us ABB Engineering (Shanghai) Ltd. N°4528, Kangxin Highway, Pudong New District, Shanghai 201319 P.R.CHINA Telephone +86 (0) 21 6105 6666 www.abb.com...

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