Atlas Copco R9 User manual

Unity Controller
R9 Variants
Issue 13
Original instructions for operation
and maintenance of self pierce rivet
equipment controller. Patents granted
and pending.

Copyright © 2022 Atlas Copco IAS
Intellectual property of
Atlas Copco Industrial Assembly Solutions
part of Atlas Copco Group.
All rights reserved.
No part of this publication may be reproduced,
distributed, or transmitted without the express
written permission of the publisher, except in the
case of work instruction documents.

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Unity Controller R9 Variants, Issue 13
Contents
1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Certication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. 1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. 2 Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. 3 Intended Use of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3. 4 Retention of Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3. 5 Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. 1 HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6. 2 Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6. 3 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7. 1 Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7. 2 Siting of Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8. 1 System Start-up Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8. 2 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8. 3 Modes of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9. 1 Controller Performance / Specication . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9. 2 HMI Performance / Specication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9. 3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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Unity Controller R9 Variants, Issue 13
1 Equipment
This book contains original instructions for following tool part numbers:
MODEL VARIATION PART NUMBER
R9 ROW (Rest Of the World) 4222610000
R9 ROW/C (Rest Of the World Local) 4222610387
4222610782
R9 GLB (Global) 4222610001
4222622824
4222622826
4222624806
R9 GLB/C (Global Local) 4222628850
4222628886
4222610272
4222610812
4222611475
4222617192
4222617414
R9 NA (Global and Bulkhead) 4222623488
4222624805
4222610399
4222614386
R9 CN (China only) 4222611136
4222619776
4222620409
4222627070

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Unity Controller R9 Variants, Issue 13
Patents granted and pending.
Whilst every eort is made to ensure all information is correct, Atlas Copco IAS cannot be held
liable for misprints or inaccuracies.
Atlas Copco IAS also reserves the right to change the specications of any product to improve its
function without prior notice.

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Unity Controller R9 Variants, Issue 13
2 Certication
EC Declaration of Conformity
The Authorised Representative for sale of this equipment within the European Economic Area
Thomas Schaumann Atlas Copco IAS Division
Gewerbestrasse 52, Bretten-Goelshausen, 75015, Germany
For the equipment described:
Manufacturer Atlas Copco IAS UK Limited
Description R9 Controller
Model 4222610000, 4222610387, 4222610782
Complies with the principal elements of the safety objectives of the Low Voltage Directive
2006/95/EC and complies with the following harmonised standards.
EN 61000-6- 2:2005 Electromagnetic compatibility (EMC) Generic standards – Immunity
standard for industrial environments
EN 61000-6- 4:2007 Electromagnetic compatibility (EMC) - Generic standards – Emission
standard for industrial environments
EN 60204-1:2006 Safety of Machinery - Electrical equipment of machines - Specication for
general requirements. Category 1 motor emergency stop.
BS EN ISO 4414:2010 Pneumatic uid power. General rules and safety requirements for systems
and their components
BS EN ISO 13849-1:2008 Safety of machinery. Safety-related parts of control systems. General
principles for design.
This equipment should only be used as described in the manual.
Glyn Fargher 15/03/2021 Thomas Schaumann 15/03/2021
Global R&D Manager IAS SPR
Atlas Copco IAS UK Limited
Vice President R&D IA
Atlas Copco IAS Division

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Unity Controller R9 Variants, Issue 13
3 Introduction
3. 1 Scope
This manual will guide the user during set-up, operation and maintenance of the Henrob Self
Pierce Riveting (SPR) equipment. An overview of assembly component parts is provided. System
requirements are detailed in this manual as well as instructions which reference safety and
installation factors of the equipment functionality.
Application of the equipment provided, including the accessories and documentation, is restricted
to use by duly authorised personnel.
All reassembly tasks shall be conducted with due reference to the appropriate manufacturing
and assembly drawings, paying particular heed to fastener torque values and the application of
consumables such as lubricants, sealants and thread-locking compounds.
The illustrations and procedures contained within this document are correct at the date of issue.
3. 2 Intended Use of the Equipment
Atlas Copco IAS warrants the supplied equipment to be correct and t for purpose as described,
declared and agreed in the quotation/sales order or supervening contract.
Atlas Copco IAS accepts no liability for damages arising in whole or in part from:
Non-observance of the supplied instructions.
Any use outside of the declared operating envelope.
Use for a purpose other than the original design intent.
Connection to electrical and pneumatic supplies which do not conform to the
specied ratings of the equipment.
Undeclared use in adverse environmental conditions.
Lack of due care and/or maintenance of the equipment.
Damage arising from external inuences, such as re, ood etc.
Use by unauthorised or untrained personnel.
Arbitrary dismantling and reassembly or unauthorised technical modications.
Use of incorrect rivets or unlicensed replacement parts.
Use of incorrect or unlicensed software.

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Unity Controller R9 Variants, Issue 13
3. 3 Intended Use of this Manual
This manual is intended to be used by trained operators of the equipment and Atlas Copco IAS
personnel when operating or maintaining the Self Pierce Riveting (SPR) equipment described.
The information contained within this manual is provided as a guide for the intended use of the
Henrob Self Pierce Riveting (SPR) equipment only. The information contained within this manual
does not pertain to any other equipment or its usage.
All users of the Henrob Self Pierce Riveting (SPR) equipment must read and understand the
information contained in this manual.
The safety warnings, cautions and notes should be adhered to at all times when carrying out any
of the procedures in this manual.
3. 4 Retention of Rights
Atlas Copco IAS retains the right to withdraw or change the information within this document, at
any time, without prior notication.
Atlas Copco IAS retains the rights to patents and patents pending, at all times, for this equipment.
3. 5 Warnings, Cautions and Notes
Warnings, cautions and notes appear throughout this document, at the point at which they are
relevant.
WARNING
This Warning symbol identies a potential hazard which may cause
fatal or serious injury to operating and maintenance personnel.
CAUTION
Cautions are intended to prevent possible damage to the component
parts of the equipment.
NOTE
Notes provide important/supporting information. A note is inserted to
aid personnel when working on the equipment.

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Unity Controller R9 Variants, Issue 13
4 Safety
The rivet setter can generate very high forces. Therefore it is most important that the following
safety precautions are observed:
Only trained and authorised operators shall use this equipment. Contact Atlas
Copco IAS or an approved engineer for help if you are in any doubt of your
ability to operate or maintain the equipment.
Isolate Power from the Controller before attempting any maintenance on the
equipment. Lockout procedures should be followed as appropriate.
The rivet setter incorporates a powerful electric motor which generates
an electro-magnetic eld during operation. Operators with a pacemaker
(implanted cardiac device) need to understand the dangers of working in close
proximity to a device generating electro-magnetic interference.
Do not t worn or broken parts to the Controller. Do not t parts obtained from
any source except Atlas Copco IAS or an approved distributor, without prior
agreement from Atlas Copco IAS .
Do contact Atlas Copco IAS or an approved engineer for help if you are in doubt
of your ability to operate or maintain the equipment.
Only trained and authorised operators should use the HMI. Access pass codes
should NEVER be transferred to other operators. For additional access to the
HMI seek advice from your line manager.
It is recommended that the operator use only a nger or touch-screen purpose
pen to avoid damage to the HMI display.
When importing/exporting data via a USB ash drive, it must be a USB powered
device and draw it’s power from the HMI’s USB port.
While every eort has been made to ensure this equipment is safe, a
comprehensive assessment is not possible before the equipment is installed
and commissioned in its ultimate environment. It is therefore incumbent on
the responsible installer/end user of this equipment to conduct a nal risk
assessment of the equipment when installed and to implement any additional
preventative measures identied. The risk assessment must address the integrity
of the control system in accordance with EN ISO 13849.
WARNING
The supply power cable supplies 3-phase 380 - 500VAC electricity,
extreme caution is needed when working within the cabinet.

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Unity Controller R9 Variants, Issue 13
5 Overview
Variation R9 ROW R9 ROW/C
Part No 4222610000 4222610387 4222610782
Thermostat 
UL
CE 
Mains Voltage 400VAC 400VAC 400VAC
Fused Mains
Circuit Breakers Mains 
Capacitor Module
BRF Power 
600 x 600 Enclosure 
800 x 600 Enclosure  
BRF Bulkhead
Connections
External Comms
Bulkhead 
Front Mounted
Disconnect 
Side Mounted
Disconnect
20 A DC Power Supply 
10A DC Power Supply  
Key Switch 
Selector Switch
40 Degrees C Ambient  
45 Degrees C Ambient 
Safety Type DualDry DualDry DualDry
Colour RAL9005 RAL9005 RAL9005

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Unity Controller R9 Variants, Issue 13
Variation R9 GLB
Part No 4222610001 4222622824 4222622826 4222624806
Thermostat 
UL 
CE 
Mains Voltage 380-500VAC 380-500VAC 380-500VAC 380-500VAC
Fused Mains 
Circuit Breakers Mains
Capacitor Module 
BRF Power
600 x 600 Enclosure 
800 x 600 Enclosure
BRF Bulkhead
Connections
External Comms
Bulkhead 
Front Mounted
Disconnect
Side Mounted
Disconnect 
20 A DC Power Supply 
10A DC Power Supply
Key Switch   
Selector Switch 
40 Degrees C Ambient
45 Degrees C Ambient 
Safety Type DualDry DualDry DualDry Dual Dry
Colour RAL9005 RAL9005 RAL9005 RAL9005

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Unity Controller R9 Variants, Issue 13
Variation R9 GLB/C
Part No 4222628850 4222628886 4222610272
Thermostat 
UL 
CE
Mains Voltage 380-500VAC 380-500VAC 380-500VAC
Fused Mains
Circuit Breakers Mains 
Capacitor Module 
BRF Power
600 x 600 Enclosure 
800 x 600 Enclosure
BRF Bulkhead
Connections
External Comms
Bulkhead 
Front Mounted
Disconnect
Side Mounted
Disconnect 
20 A DC Power Supply 
10A DC Power Supply
Key Switch
Selector Switch 
40 Degrees C Ambient
45 Degrees C Ambient 
Safety Type Congurable Congurable Congurable
Colour RAL9005 RAL9010 RAL9016

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Unity Controller R9 Variants, Issue 13
Variation R9 GLB/C
Part No 4222610812 4222611475 4222617192 4222617414
Thermostat 
UL 
CE
Mains Voltage 380-500VAC 380-500VAC 380-480VAC 380-480VAC
Fused Mains
Circuit Breakers Mains 
Capacitor Module 
BRF Power
600 x 600 Enclosure 
800 x 600 Enclosure
BRF Bulkhead
Connections  
External Comms
Bulkhead 
Front Mounted
Disconnect
Side Mounted
Disconnect 
20 A DC Power Supply 
10A DC Power Supply
Key Switch
Selector Switch 
40 Degrees C Ambient
45 Degrees C Ambient 
Safety Type Congurable Congurable Congurable Congurable
Colour RAL9005 RAL9016 RAL9005 RAL9005

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Unity Controller R9 Variants, Issue 13
Variation R9 NA
Part No 4222623488 4222624805 4222610399 4222614386
Thermostat 
UL 
CE 
Mains Voltage 380-500VAC 380-500VAC 380-500VAC 380-500VAC
Fused Mains
Circuit Breakers Mains 
Capacitor Module 
BRF Power
600 x 600 Enclosure 
800 x 600 Enclosure
BRF Bulkhead
Connections
External Comms
Bulkhead   
Front Mounted
Disconnect
Side Mounted
Disconnect 
20 A DC Power Supply 
10A DC Power Supply
Key Switch 
Selector Switch
40 Degrees C Ambient
45 Degrees C Ambient 
Safety Type Congurable Congurable Congurable Feedback
Colour RAL9005 RAL9005 RAL9005 RAL9005

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Unity Controller R9 Variants, Issue 13
Variation R9 CN
Part No 4222611136 4222627070 4222619776 4222620409
Thermostat
UL
CE
Mains Voltage 380VAC 380VAC 380VAC 380VAC
Fused Mains
Circuit Breakers Mains 
Capacitor Module
BRF Power 
600 x 600 Enclosure
800 x 600 Enclosure 
BRF Bulkhead
Connections
External Comms
Bulkhead 
Front Mounted
Disconnect 
Side Mounted
Disconnect
20 A DC Power Supply
10A DC Power Supply 
Key Switch
Selector Switch
40 Degrees C Ambient 
45 Degrees C Ambient
Safety Type DualDry DualDry Feedback DualDry
Colour RAL9005 RAL7035 RAL9005 RAL9005

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Unity Controller R9 Variants, Issue 13
6 Components
The Controller is designed to operate the servo riveting tool. It contains the HMI (Human-Machine
Interface), Servo Drive, I/O and all necessary power/communications and safety circuits.
The control logic (software) is contained in the servo drive internal PLC (Programmable Logic
Controller).
6
10
9
8
7
12
11
13 14
15
16
42 3
5
3
1
1 - HMI (Human Machine Interface) KF5
2 - Isolator Switch (Main Disconnect) QZ1
3 - Controller Locks (require key)
4 - 3 phase + PE (+N) 400VAC 50/60 Hz, 20A
5 - Fan Unit GQ1
6 - USB Access XF2
7 - Service RJ45 Connection XF3
8 - System Disable SF1
9 - System Select Indication PF1
10 - Mode of Operation Selector Switch
(Maintenance/Manual/Auto) SF2
11 - Motor Power and Encoder Gland and
External Communications
12 - Pendant XD7
13 - Communications Input
(Devicenet IP) XF1
14 - 24V DC Output XD5
15 - 240VAC Bulk Rivet Feeder Power XD8
16 - Customer Safety XD6

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Unity Controller R9 Variants, Issue 13
1
2 3 4 56 7
8 9 10 11 12 13 14 15 16
VIDEO
1 - Servo Drive Power Section and Servo
Safe Motion Control KF4
2 - Drive Circuit Breaker 10A QA2
3 - MCB Circuit Breaker 4A QA3
4 - 24V 3phase Switched Mode Power
supply (10A) TA1
5 - Bulk Rivet Feeder Power MCB 6A QA4
6 - Main Disconnect QZ1
7 - Internal Thermostat BT1
8 - Emergency Stop Contactor QA1
9 - Filter EMC/RFI Motor Drives KF1
10 - Safety Zone Module KF3
11 - DC Buer CA2
12 - 4A Circuit Breaker FC1
13 - 2A Circuit Braker FC2
14 - Feed Controller, gateway for BL20 I/O
System and MODBUS TCP KF6
15 - Ethernet Switch, 8 Port Unmanaged
XF4
16 - Fan Unit 24VDC GQ1
NOTE
R9 ROW Controller type shown for illustration purposes only.
Refer to the schematic drawing for detailed information of the
controller in use.

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Unity Controller R9 Variants, Issue 13
6. 1 HMI
Human Machine Interface enables the user to interact with operating software.
To ensure optimum performance of the equipment and HMI:
Avoid prolonged exposition to direct sunlight to evade the risk of overheating
the device.
The equipment is not intended for installation in contact with corrosive chemical
substances.
Check the resistance of the front panel lm to a specic substance before
installation.
Do not use tools of any kind (screwdrivers, etc.) to operate the touch screen of
the panel.
NOTE
Extended use of HMI in environments where the surrounding air
temperature is 45°C or higher may degrade back-light quality, reliability
and durability.

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Unity Controller R9 Variants, Issue 13
6. 2 Internal
WARNING
If the system is turned o using the local disconnect there will still be
live wires connected to the top of the disconnect
NOTE
Ensure lters in the Fan Enclosures of the Controller are checked
regularly for blockage. Replace as needed.
6. 3 Cables
There are up to 5 cables that connect from the Controller to the Rivet Setting Tool (dependant on
conguration).
These are as follows:
Motor power (up to 600V AC 3ph)
Encoder power and feedback signals
Devicenet
24V DC
240V AC
WARNING
Electric shock hazard up to 600V AC 3ph.
Before making or breaking the motor power connection the supply to
the Controller must be isolated and proved dead.