ATI Technologies Speedeburr 9150-AC-90 User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
Axial Compliant
Robotic Deburring Tool
Installation and Operation Manual
9150-AC-90
Document #: 9610-50-1000-06
October 2009

Hiac Installation and Operation Manual
Document: 9610-50-1000-06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
2
Information contained in this document is the property of ATI Industrial Automation, Inc. (ATI) and
shall not be reproduced in whole or in part without prior written approval of ATI. The information
herein is subject to change without notice. This manual is periodically revised to reflect and
incorporate changes made to the product.
The information contained herein is confidential and reserved exclusively for the customers and authorized agents of
ATI Industrial Automation and may not be divulged to any third party without prior written consent from ATI. No
warranty including implied warranties is made with regard to accuracy of this document or fitness of this device for a
particular application. ATI Industrial Automation shall not be liable for any errors contained in this document or for any
incidental or consequential damages caused thereby. ATI Industrial Automation also reserves the right to make changes
to this manual at any time without prior notice.
ATI assumes no responsibility for any errors or omissions in this document. Users’ critical evaluation
of this document is welcomed.
©Copyright by ATI Industrial Automation. All rights reserved.
How to Reach Us
Sales, Service and Information about ATI products:
ATI Industrial Automation
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati-ia.com
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Technical support and questions:
Application Engineering
Tel: [phone], Option 2, option 2
Fax: [phone]
E-mail: [email protected]
CAUTION: This manual describes the function, application and safety
considerations of this product. This manual must be read and understood
before any attempt is made to install or operate this product, otherwise damage
to this product or unsafe conditions may occur.
!

Hiac Installation and Operation Manual
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3
Table of Contents
1. Safety Precautions..........................................................................................................................4
2. Tool Information ..............................................................................................................................5
3. General Data...................................................................................................................................6
3.1 Environmental Limitations...................................................................................................6
3.2 Extent of Warranties and Warranty Conditions ..................................................................6
4. Handling, Installation, Storage and Transportation.........................................................................7
4.1 Inspection of Condition when Delivered.............................................................................7
4.2 Unpacking and Handling.....................................................................................................7
4.3 Installation...........................................................................................................................7
4.3.1 Mounting, Adapter, and Interface Plate ...............................................................7
4.3.2 Pneumatics...........................................................................................................9
4.4 Transportation and Protection during Transportation.......................................................10
4.5 Storage and Preventive Maintenance during storage ......................................................10
5. Technical Description....................................................................................................................11
5.1 Technical Specifications ...................................................................................................11
6. Operating Instructions...................................................................................................................14
6.1 General Precautions.........................................................................................................14
6.2 Hiac Working Environment...............................................................................................15
6.3 Tool Center Point (TCP) Position .....................................................................................15
6.4 Operational Considerations..............................................................................................15
6.5 Programming ....................................................................................................................17
7. Maintenance Instructions ..............................................................................................................18
7.1 Regular Operational Maintenance....................................................................................18
7.2 Lubrication ........................................................................................................................20
7.3 Replacement of Burrs.......................................................................................................20
7.4 Replacement of Other Hiac Parts.....................................................................................21
7.5 Overhaul ...........................................................................................................................21
7.6 Repairs and Spare Parts ..................................................................................................21
8. Drawings........................................................................................................................................22
9. Terms and Conditions...................................................................................................................23

Hiac Installation and Operation Manual
Document: 9610-50-1000-06
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4
1. Safety Precautions
Please consult Section 6.2—Hiac Working Environment in this User Manual.
•Never use or start the unit without first reading and understanding this Installation
and Operation Manual
•Make sure that the unit is mounted into the installation position as described in
Section 3.1—Environmental Limitations of this document.
•Never use the unit for other purposes than those explicitly described in this document.
•Never use the unit in any other way than that described.
•Make sure that the pneumatic control equipment is mounted as described in Section
4.3.2—Pneumatics of this document.
•Only original spare parts and files/burrs delivered from ATI must be used (see
Section 7.6—Repairs and Spare Parts).
•Never be near the unit while it is started or running. If it is necessary to approach the
unit while in motion, stand behind appropriate Plexiglass®windows.
•Beware of rotating parts.
•Use eye-protection (e.g., safety glasses).
•The installation must be protected by a barrier to prohibit people from approaching
the unit while in operation.
•Beware of high sound levels.Always use hearing protection while working in the
neighborhood of the unit.
ATI is not liable for damages if the above instructions and instructions found elsewhere in
this manual are not followed.

Hiac Installation and Operation Manual
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5
2. Tool Information
The following information is included in the Hiac shipping and storage crate:
Pinnacle Park, 1031 Goodworth Drive, Apex, NC 27502 USA
Tel: [phone] E-mail: [email protected]
Fax: [phone] www.ati-ia.com
Model: ______________
Serial no.: ______________
Weight: _________ Output power: _____________
Min/Max. file/burr diameter: ______ Air vane motor: ____________
Max. drive pressure: _______
WARNINGS:
•Never use or start the tool without first reading and understanding the Installation and
Operation Manual.
•Make sure that the tool is mounted as described in Section 3.1—Environmental Limitations
of this Installation and Operation Manual.
•Never use the tool for other purposes than those explicitly described in the Installation and
Operation Manual.
•Make sure that the pneumatic control equipment is mounted as described in the Installation
and Operation Manual in Section 4.3.2—Pneumatics.
•Only original spare parts and files/burrs delivered from the tool manufacturer must be used
(see Section 7.6—Repairs and Spare Parts).
•Never stand near the tool while it is started and running. If it is necessary to approach the
tool while in motion, stand behind appropriate Plexiglass®windows.
•Be aware of rotating parts.
•A barrier to prohibit people from approaching the tool while in operation must secure the
installation.
•Be aware of high sound levels. Always use earplugs while working near the tool.
If the above instructions and instructions found in the Installation and Operation Manual
are not followed, no claims may be raised against the manufacturer, or the supplier of the
tool.
The crate must be used whenever transporting or storing the tool.
Speedeburr
Deburring Tool

Hiac Installation and Operation Manual
Document: 9610-50-1000-06
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6
3. General Data
3.1 Environmental Limitations
General:
Area classification: None
Gas group/ignition group: None
Operation:
Installation position: Mounted to robot by means of the Speedeburr adapter
and flange. The flange is specific to each type of robot.
This flange is normally not supplied by ATI.
Mounted to a table or stand by means of the
Speedeburr adapter (the robot is carrying the
workpiece).
Temperature range: 5°C–35°C
41°F–95°F
Storage:
Temperature range: 0°C–45°C
32°F–113°F
Conditions: The tool should be stored in its crate and in a dry place.
The tool should be kept dry and full of pneumatic oil
when stored. Keep unit in crate if possible. Consult
Section 4.5—Storage and Preventative Maintenance
during Storage of this manual
3.2 Extent of Warranties and Warranty Conditions
ATI Industrial Automation warrants the Hiac deburring tool for manufacturing errors for
one (1) year from the delivery date, delivery date is defined to be the date the Hiac is
shipped from ATI’s facility.
The warranty is not valid if the Hiac is used for other purposes than deburring.
The warranty is not valid if handling, installation, storage, transportation, operation, or
maintenance of the Hiac does not comply with the instructions given in this Manual.
The warranty is not valid if the warnings given are not obeyed.
If the instructions in this Manual and other instructions given in writing that accompany
the Hiac are not followed, no claims can be raised against the manufacturer or the
supplier of the Hiac.

Hiac Installation and Operation Manual
Document: 9610-50-1000-06
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7
4. Handling, Installation, Storage and Transportation
4.1 Inspection of Condition when Delivered
Upon receipt, the following should be checked:
- Delivery in accordance with freight documents
- Damage to packaging
If there is damage to any of the packaging, or if any of the goods have been exposed to
abnormal handling, unpack those parts that may have been damaged for a closer
inspection. If necessary, notify ATI for assistance in evaluation of the product condition.
4.2 Unpacking and Handling
The Hiac tool, during transportation, storing, and handling, should always be placed
inside the accompanying box (crate).
4.3 Installation
4.3.1 Mounting, Adapter, and Interface Plate
Figure 4.1 is a drawing of the Speedeburr pneumatic adapter (ATI Part #
9150-H/T-3178). This adapter, or equivalent, should be used for mounting the
Hiac to the robot or to other equipment. The adapter facilitates the connection
of the pneumatics to the Hiac.
The Hiac can be mounted on the robot or on a stand in which case the robot
carries the part to be deburred to the Hiac.
Refer to the drawing in Section 8—Drawings. The Hiac is mounted to the
Speedeburr adapter by means of (8) M4 screws. Be sure the O-rings (Figure
7.1, Item No.10) are positioned correctly into the grooves on the Hiac bracket
before mounting the Hiac to the pneumatic adapter. Removable thread locker
should be used for all mounting bolts.
The Speedeburr adapter is mounted to the wrist of the robot, usually by means
of a robot-specific interface plate. In some cases, the Speedeburr adapter will
mount directly to the robot without an interface plate. The interface plate is
manufactured either by the robot supplier, the Hiac supplier, the system
integrator, or by the owner/user of the Hiac.
The Hiac, with the Speedeburr adapter, may be mounted to a table or stand
using an interface plate or directly using the Speedeburr pneumatic adapter.

Hiac Installation and Operation Manual
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8
C' bore 1.9695
1.9685
(50mm H7)
0.2367
, 0.236 deep
0.2362
(6mm H7)
B.C. 1.575 0.079 deep
(4) 0.242 thru
C' bored opposite
equally spaced
2.6
1/8 NPT
Motor Air supply
#10-32
(2) Exhaust
1/4 NPT
Axial force air supply
#10-32
(2) Optional ports
(8) M4-0.7, 0.59 deep
B.C. 1.732
equally spaced
0.238, 0.75 deep
(2) 0.157,
1.22 deep
0.157, 0.24 deep
for M6 screws
side, B.C. 1.575
1.063
0.250
0.394
0.250
C
Lof B.C.
C
of Hiac body
L
of C' bore
L
Cof Hiac body
C
L
& B.C.
Interface Facing HIAC
Interface Facing Robot
Pneumatic Connections
Figure 4.1—Speedeburr (Hiac) Adapter
Dimensions in inches.

Hiac Installation and Operation Manual
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9
4.3.2 Pneumatics
Connect the Hiac as shown in the drawing in Section 8—Drawings,
Pneumatic Diagram. Two connection methods are shown. Option 1 uses one
solenoid valve to control both motor drive air supply and axial force air
supply. Option 2 uses two solenoid valves to independently control the two air
supplies.
Conventional pneumatic components (not supplied with the Hiac tool) are
used to control the air supply to the Hiac. ATI recommends that the user
install a pneumatic pressure regulator in order to achieve a stable air supply
and to reduce the air supply to the maximum of 90 psi.
The solenoid-operated valve(s) are actuated from the robot controller by
means of a digital output signal.
The external pressure regulator is used to control the air supply to the axial
force compliance mechanism, thus enabling control of the axial force on the
rotary burr. If the complete workpiece can be deburred with equal axial force,
a conventional manual pressure regulator can be used. If the burrs to be
removed are varying from place to place on the workpiece, and this variation
is repeatable for all workpieces of the same type, it may be necessary to adjust
the axial force by using an analog pressure regulator controlled from the robot
controller. An analog output port in the robot controller will be needed.
Function Thread Type Pressure
Motor inlet 1/8 NPT 45–75 psi, maximum 90 psi
Axial (contact) force inlet #10-32/M5 0–45 psi, maximum 45 psi
Control functions #10-32/M5 Optional
Exhaust 1/4 NPT Not Applicable
Table 4.1—Pneumatic Connections
It is recommended that 3/8” plastic tube be used for the motor air supply inlet,
and 5/32” tube for the axial force air supply inlet. Note that a #10-32
connection is used for the axial force air supply inlet, and a 1/8 NPT
connection for the motor air supply inlet. Use two silencers directly mounted
on the two 1/4 NPT exhaust outlets. Information on the sound intensity is
given in Section 5.1—Technical Specifications. If more noise suppression in
desired, install silencers on the exhaust line further away from the Speedeburr
CAUTION: Pneumatic components used for the motor drive circuit must
be able to meet the air consumption requirements (see Section 5.1—
Technical Specifications). Poor performance will result if the correct
components are not used.
!

Hiac Installation and Operation Manual
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adapter. An oil recovery unit may be installed on the exhaust line to avoid the
mist lubrication droplets from entering the atmosphere around the robot
installation. Additionally, to reduce the sound in neighboring working areas, a
barrier (consult Section 6.2—Hiac Working Environment) surrounding the
installation may be installed (Plexiglas or Lexan is preferred).
The axial force air supply pressure regulator should have a 0–45 psi range.
When testing for the proper contact force start with a very low pressure and
increase slowly until the desired chamfer is achieved (typically 3 psi for
aluminum and more for steel workpieces).
Before start-up make sure the air lubrication system is filled with oil. See
Section 7.2—Lubrication for proper lubricants and lubricating systems.
4.4 Transportation and Protection during Transportation
The Hiac is packaged in a wooden crate designed to secure and protect it during
transportation. Always use the crate when transporting the Hiac in order to minimize the
risk of damage.
When taking the Hiac out of the crate and carrying, or performing maintenance, try to
always grab and hold it around the motor housing (please refer to the drawing in Section
8—Drawings).
4.5 Storage and Preventive Maintenance during storage
The Hiac should be stored in the wooden crate when it is not in use. The Hiac should
also be stored in a dry place.
For short-term storage (limited to a few weeks), no preventive maintenance is needed,
except for cleaning.
For long-term storage, the Hiac should be thoroughly cleaned of any burrs or debris. It
should not be disassembled. After cleaning, the Hiac should be "filled" with oil of the
same type used as lubrication during operation. The oil should be poured into the Hiac
through the adapter or through the Hiac bracket. Place the Hiac inside a sealed plastic
bag and place the Hiac inside the crate. This is necessary in order to keep the blades in
the air-vane motor from drying out and for preventing the risk of corrosion.
CAUTION: Lack of lubrication will cause destruction of the motor within a
relatively short time. If the lubrication is not working properly, you can hear the
motor running slower than normal, and the speed may be varying. Install the
lubrication equipment near the robot base (maximum 16 feet away from the
Hiac) for proper operation. See Section 7.2—Lubrication for more about
lubrication.
!

Hiac Installation and Operation Manual
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11
5. Technical Description
5.1 Technical Specifications
Main specifications for the Hiac:
Motor: Air motor, vane type
Speed: Idle 30,000 RPM, while deburring 18,000–25,000 RPM
Torque: 0.295 ft-lbs. at lower speeds
Power: 250 W at 20,000 RPM
Weight total: 1.124 lbs.
Weight, FFP with burr: 0.11 lbs.
Compensation (burr float): Max. ± 4 mm axial and lateral, ±2 mm recommended
Axial force: 0.23–5.6 lbs., @ supply pressure of 0–45 psi
Burr surface speed: 24.6–34.4 ft/sec, measured at 8mm dia. (halfway between
center tip and outer rim)
Air consumption: Approx. 14.1 CFM at 75 psi line pressure
Sound pressure level: 75 dB(A)
Sound pressure value: 87 dB(C)
Rotary burrs: 1) 90°coned shape, straight fluting.
2) 90°coned shape, spiraled fluting.
3) C2, C5 Carbide
Other rotary burr/file qualities on request.
Special tools: Burr changing tool.
All noise emission measurements were taken at a distance of 3 feet from the Hiac and at
a height of 5 feet from the floor. The Hiac was mounted on a laboratory test-bench. No
barriers or noise-reduction facilities were used except for exhaust return to an oil-
recovery-unit located beneath the test-bench. A drive pressure of 75 psi was applied (full
Hiac drive pressure). No axial force pressure was applied. The Hiac was running at full
idle speed. Because the working environment is not known, this method was considered
the best method for measurements.
The equivalent continuous A-weighted sound pressure level was measured as 75 dB (A).
The peak C-weighted instantaneous sound pressure value was measured as 87 dB(C).
Each Hiac goes through a thorough test procedure before it is shipped.
Below are theoretical and measured forces relative to applied axial air pressure. Please
note that theoretical calculations are not necessarily identical to actual data.
Measurements may vary from one product to another, and should only be treated as
nominal.

Hiac Installation and Operation Manual
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Axial contact force
0
1.1
2.25
3.4
4.5
5.6
0 2.9 5.8 8.7 11.6 14.5 17.4 20.3 23.2 26.1 29 31.9 34.8
Control pressure, psi
Axial force,lbs
F
Figure 5.1—Axial Contact Force (measured with rotary burr pointing downwards)
Due to pressure losses between the pressure regulator and the Free Flying Piston (FFP),
the axial force is lower than theoretical calculations will predict. The actual force
characteristics will change from installation to installation due to different types of
pneumatic components used.
0
50
100
150
200
250
300
350
400
0 5000 10000 15000 20000 25000 30000
Rotor velocity, in rpm
Rotor torque M, in Nmm
Output power P, in W
Torque
Pow er
Figure 5.2—Theoretical Calculations, Hiac Output Torque and Power

Hiac Installation and Operation Manual
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We recommend a working speed of 15,000 to 25,000 RPM for maximum possible
output. A speed lower than 15,000 RPM is not recommended, as it increases the risk of
stalling the motor, due to the higher torque at lower speeds.
0
5000
10000
15000
20000
25000
30000
0 14.5 29 43.5 58 72.5 87
Drive pressure, in psi
Rotary speed
in RPM
Speed
Figure 5.3—Idle Speed as Function of Applied Drive Pressure

Hiac Installation and Operation Manual
Document: 9610-50-1000-06
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14
6. Operating Instructions
These operating instructions are intended to help system integrators program, start up, and
complete a robotic deburring cell containing a Hiac deburring tool. The system integrator
should be familiar with the task of deburring in general and should have extensive
knowledge relating to robots and automation incorporating robots.
The system integrator is responsible for providing user documentation for the complete
deburring installation. This document is not intended to cover all aspects of such an
installation, although it contains some information vital for the system user, such as
maintenance instructions for the Hiac and instructions related to safety.
6.1 General Precautions
It is important that all personnel involved in operation of the Hiac have a thorough
understanding of the operating procedures. Failure to follow these or neglecting safety
precautions can create hazardous situations, which may, in the worst case, injure
personnel or damage the deburring installation and the Hiac.
The Hiac must only be used for robotic deburring applications. The Hiac is a deburring
tool only.
Grinding, countersinking, or other metal-forming processes should not be performed by
the Hiac. It may be dangerous to operate the Hiac for these purposes. If a failure occurs
due to forces caused by improper use hazardous situations for both personnel and
equipment could be created. The Hiac is intended to perform deburring only.
The Hiac should not be used to deburr materials that are prone to fracture. A fracturing
workpiece may result in pieces of material damaging surrounding working environment
and personnel. Material removed correctly should be in the form of chips.
Reduce the robot velocity when the workpiece and the Hiac are making initial contact.
Making the contact movement between the Hiac and the workpiece too fast may in some
situations result in a collision. Collisions may create hazardous situations for both
personnel and equipment.
When performing maintenance, always remember to tighten nuts and bolts thoroughly
and use a removable thread lock adhesive. When replacing burrs, always attach the
burr correctly. Please consult Section 7.3—Replacement of Burrs.
DANGER: Never use the Hiac for purposes other than robotic deburring.
DANGER: Never use the Hiac as a hand-held machine.

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In order to increase the life of the Hiac motor and bearings, always use proper
lubrication. Please consult Section 7.2—Lubrication.
6.2 Hiac Working Environment
As described in previous sections, the Hiac should only be used in conjunction with a
robot in a secured work cell/chamber.
The work cell must be secured by means of barriers to prohibit personnel from entering
the cell. A lockable door should be included as a part of the barrier in order to facilitate
access to the cell for authorized personnel only. The barrier could consist partly or fully
of Plexiglas to facilitate observation of the deburring operations.
During system or Hiac maintenance, make sure the Hiac and robot are stopped before
entering the robot cell. When installing and testing, never be present in the cell when the
Hiac is running.
Be aware of rotating parts. Use eye-protection while working around the Hiac.
Be aware of high sound levels. Always use hearing protection while working in the
neighborhood of the deburring cell.
6.3 Tool Center Point (TCP) Position
Figure 6.1 shows the TCP position and Hiac dimensions. When setting the TCP position
in the robot controller, use the mid-position of the 0.31-inch axial stroke of the FFP.
Also remember to take into account the depth of the Speedeburr adapter (please consult
Section 4.3.1—Mounting, Adapter and Interface Plate). In case an additional interface
plate is used in order to fit the adapter to the robot, this depth must be considered as
well.
TCP: Without Speedeburr adapter: Dx = 2.95 in., Dy = 0 in., Dz = -2.75 in.
With Speedeburr adapter: Dx = 4.33 in., Dy = 0 in., Dz = -2.75 in.
6.4 Operational Considerations
To obtain best results, it is important for the FFP to be running with low friction in the
cylinder. Please consult Section 7.1—Regular and Operational Maintenance.
The Hiac should not be operated for extensive periods of time with the cutting tip
pointing up. This orientation will increase the amount of debris entering the cylinder and
cause premature wear of the cylinder and piston, possibly preventing the piston from
floating altogether. If the Hiac must be mounted in this orientation then a continuous or
regular burst of high velocity air should be used to blow debris away from the piston and
cylinder to insure low friction between the FFP and the cylinder.
For instructions on how to replace the burr, please consult Section 7.3—Replacement of
Burrs.

Hiac Installation and Operation Manual
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Under normal conditions, no cooling or lubrication of the rotary burr is necessary. The Hiac
is used in most robot deburring installations with aluminum and steel workpieces without
any coolants.
2.126 3.583
2.953
Max
3.858
M
in
3.54
0.630
1.260
Figure 6.1—Hiac and Tool Center Point (TCP) Dimensions
CAUTION: The Hiac should not be operated for extensive periods of time with the
cutting tip pointing up. This orientation will increase the amount of debris entering
the cylinder and cause premature wear of the cylinder and piston, possibly
preventing the piston from floating altogether.
!

Hiac Installation and Operation Manual
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17
6.5 Programming
The Hiac must never be running while programming the robot.
There are various techniques that may be used to program the robot path. In any case,
the burr should be nominally at the mid-point of its stroke while deburring the part. It
will move up and down with part and path variation.
One programming method is to teach the path using the point of the burr as a guide,
following the edge of the part, then manually or automatically adding offsets to the path
points to achieve the final correct burr path. Another method is to program the actual
points, making sure that at each point the burr is at its nominal mid-point when in
contact with the part, and that there are no radial forces. The method used will depend
on the robot’s capabilities and programmer preferences.
If you are deburring sharp inner corners, it may be required to use the area of the burr
closer to its tip. Note that, in this case, some of the compensation ability of the Hiac, as
well as the cutting surface speed, is reduced.
When running the robot program the first time, observe the path with the axial supply
turned off. When increasing the path speed, it is important to notice that path deviation
may increase with speed. Verify that at operational robot path speed the Hiac burr
remains near the mid-point of its axial travel.
The axial force of the burr should be adjusted as described in Section 4.3.2—Pneumatics
in order to achieve a correct sized and even chamfer.
To change the drive speed, adjust the main supply pressure; the greater the pressure, the
greater the speed and vice versa. It is also possible to adjust the speed by using a small
flat-blade screwdriver to turn the adjustment screw on the side of the 90-degree bracket
(see Figures 7.1 and the drawing in Section 8—Drawings). This adjustment varies the
flow rate, clockwise to decrease, counter-clockwise to increase the flow rate (and
speed). In most applications, it is best to adjust the regulator to a maximum pressure
(75–90 psi) with the adjustment screw in the full out position, approximately flush with
the surface.
DANGER: The Hiac must never run without proper lubrication. Damage to the unit
will occur. Please consult Section 7.2—Lubrication.
CAUTION: The brass Cylinder (Figure 7.1, Item No. 5) that encloses the Free
Flying Piston must be protected from collisions. If struck, it may be damaged and
need replacement.
!

Hiac Installation and Operation Manual
Document: 9610-50-1000-06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
18
7. Maintenance Instructions
7.1 Regular Operational Maintenance
To obtain best results, it is important for the piston to be running with low friction in the
cylinder. This should be checked at regular intervals. Some debris will always enter the
cylinder and regular cleaning is recommended. The Hiac should not be operated for
extensive periods of time with the cutting tip pointing up. This orientation will increase
the amount of debris entering the cylinder and cause premature wear of the cylinder and
piston, possibly preventing the piston from floating altogether. If the Hiac must be
operated in this orientation, then a continuous or regular burst of high velocity air should
be used to blow debris away from the piston and cylinder to insure low friction between
the FFP and the cylinder.
Additionally, the outside of the Hiac should be kept clean to ensure proper cooling.
Recommended Inspection and Cleaning Procedure (Refer to Figure 7.1.)
•Remove the Lock Ring (Item No. 3) from the Hiac Motor Housing (Item No. 7)
using the hook spanner wrench (not shown).
•Gently pull the Cylinder (Item No. 5) and Free Flying Piston (FFP) (Item No. 4)
assembly from the Hiac Motor Housing.
•Thoroughly clean the Male Spline, the interior of the Motor Housing, and the Lock
Ring with a mild solvent.
•Spin the burr by holding the Free Flying Piston and assure it spins freely. If it
does not spin freely, replace the Free Flying Piston.
•Separate the FFP from the Cylinder and clean thoroughly.
•Inspect the FFP and Cylinder for scratches. Deep scratches may require
replacement of the part(s).
•Check the Burr (Item No. 6) condition and replace as necessary.
•Lightly lubricate the outside diameter of the Free Flying Piston and the inside
diameter of the Cylinder with the same oil used for operational air lubrication.
•Assemble the Free Flying Piston in the Cylinder and assure the Piston moves
freely without excessive play. The fit between the Free Flying Piston and the
Cylinder provides the seal for the axial down force air pressure, therefore the fit
must be consistent and without excessive play. If the play is excessive, replace the
Cylinder.
•Install the Cylinder and the Free Flying Piston assembly on the Motor Housing and
replace the Lock Ring. Do not over tighten the Lock Ring.
•Assure the axial down force and the drive are working properly

Hiac Installation and Operation Manual
Document: 9610-50-1000-06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
19
The burr must be replaced at regular intervals. During initial production, the burr and the
workpiece should be examined often in order to determine at what interval the burr
should be replaced as described in Section 7.3—Replacement of Burrs.
At regular intervals (normally once every two years or more often depending on the
application), an overhaul of the Hiac should be performed in order to fully comply with
the technical specifications. Parts inside the Hiac, such as the blades in the air-vane
motor and bearings should be replaced as part of the overhaul. Please consult Section
7.5—Overhaul.
At regular intervals, the pneumatics used to control the Hiac should also be checked,
especially the air-filter and lubricator. Remember to fill the lubricator with oil.
Item No. Qty. Part No. Description
1 1 3500-1062012-11 Spine Lock Screw
2 1 3700-51-1002 Male Spline
3 1 3700-51-1012 Lock Ring
4 1 9005-51-1000 Free Flying Piston (FFP)
5 1 3700-51-1009 Cylinder
6 1 Call ATI for Information Hiac Rotary File (Burr)
7 1 3700-51-1000 Hiac Motor Housing
8 1 3700-51-1001 90 Degree Bracket
9 1 3700-51-1015 Adjustment Screw
10 1 9150-HIAC-4796 O-ring Set
Figure 7.1—User-Serviceable Parts
CAUTION: The Hiac should not be operated for extensive periods of time with the
cutting tip pointing up. This orientation will increase the amount of debris entering
the cylinder and cause premature wear of the cylinder and piston, possibly
preventing the piston from floating altogether.
!

Hiac Installation and Operation Manual
Document: 9610-50-1000-06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
20
7.2 Lubrication
Before start-up, be sure a lubricator is installed as described in the pneumatic diagram in
the drawing in Section 8—Drawings. Make sure the air lubrication system is filled with
oil. Use oil similar to machine oil #10, spindle oil #60, Shell/Exxon ATF DEXRON II
automatic transmission oil, or similar.
Oilfog air lubrication systems are not recommended as a means for providing lubricated
air for this product. Only microfog systems should be used. The system should be
adjusted to 10–15 drops per minute. Only part of the oil drop actually enters the air
stream. Fill the lubricator with the proper type of oil at regular intervals.
It is recommended that the exhaust containing lubrication be filtered through an oil-
recovery system before exhausting it to the atmosphere. Long-time exposure to air
containing oil could be dangerous for personnel.
7.3 Replacement of Burrs
Figure 7.2 shows the burr-changing tools, the Free Flying Piston (FFP), and burr (rotary
file). The FFP and Cylinder should be inspected whenever a burr is replaced. The Piston
should rotate freely (by hand) in the Cylinder with no binding. If binding is detected, the
FFP and/or Cylinder should be replaced as described in Section 7.1—Regular
Operational Maintenance.
To change the burr, unscrew it with the burr-changing tools and replace it with a new
one. Re-assemble the parts as described in Section 7.1—Regular Operational
Maintenance.
After the burr is changed and the unit re-assembled, check that the Free Flying Piston
(FFP) is rotating with the burr. If the FFP is not rotating, static friction may be
inspected for any visible scratches. If a burr with an imbalance is used, the FFP may also
stop rotating. All burrs are checked for imbalance before they are shipped.
Only original ATI burrs should be used.
CAUTION: When the system is first installed, use a higher than recommended
oil setting (~2 times) until the unit is receiving consistently oiled air. If possible,
run oil through the entire pneumatic tube between the oiler and the unit prior to
o
p
eration.
!
CAUTION: Lack of lubrication will cause untimely wear on the motor and failure
within a relatively short period. If the lubrication is not working properly, the
motor will run slower than normal, and may vary in speed. Install the lubrication
equipment near the robot base (maximum 16 feet from the Hiac) for best
results.
!