Operators Manual Robot 322

Valid for serial no.

322 190 - 322 194

File name: 800299a.PM6

PDF file name: 800299a.PDF
File creation date: 1999.06.08
File print date: 1999.10.28
Author: Conny Tångring
No. of pages: 72

Robot 3
22
2
Table of contents
Symbols .......................................................................................... 6
Hydrodemolition in general ........................................................... 7
Concrete is a complex material ................................................................................7
The advantages of testing ......................................................................................... 7
Good bonding quality control is important ............................................................. 7
Calculating the capacity ............................................................................................ 7
Compare the cost ....................................................................................................... 7
Safety instructions ......................................................................... 8
General ........................................................................................................................ 8
Work area .................................................................................................................... 9
Common procedures ...................................................................................................... 9
Body protection ........................................................................................................10
Protective Clothing ....................................................................................................... 10
Head Protection ............................................................................................................. 10
Eye Protection ............................................................................................................... 10
Ear Protection ................................................................................................................ 10
Hand Protection ............................................................................................................ 10
Footwear Protection ..................................................................................................... 10
Noise level indications ............................................................................................10
Emergency medical information ............................................................................11
Lifting the Robot .......................................................................................................11
Robot 322 ...................................................................................... 12
General ......................................................................................................................12
Tools and attachments ............................................................................................12
Controls and connectors .........................................................................................12
Control box ...............................................................................................................13
Operators terminal ...................................................................................................13
Functions and movements .....................................................................................13
Electrical System .......................................................................... 14
General ......................................................................................................................14
A1 main cubicle ........................................................................................................14
Wrong phase relay - K2 ........................................................................................... 16
Emergency stop circuit ........................................................................................... 16
Valve control .............................................................................................................16
Position control ........................................................................................................16
Input listing ................................................................................................................... 17
Pump control ............................................................................................................ 17
PLC ............................................................................................................................ 17
Y0 - Y17 ......................................................................................................................17
X0 - X27 .....................................................................................................................17
Y20 - Y37 ....................................................................................................................17
Output listing ................................................................................................................ 17
Control box ...............................................................................................................18
Function selector switch .........................................................................................18
Joystick .....................................................................................................................19
Step selector switch ................................................................................................20
Tool selector switch (for oscillation or rotor) ........................................................20
Emergency stop .......................................................................................................20
3
 Automatic Start ........................................................................................................20
Automatic Stop ......................................................................................................... 20
Hydraulic system .......................................................................... 21
General ......................................................................................................................21
Controls .....................................................................................................................21
Track speed control - Y13, Y14 and Y15 ..................................................................22
Track position control - Y5, Y6 and Y12 ..................................................................22
Lance turning - Y4 ....................................................................................................22
Cradle movement - Y3 ..............................................................................................22
Tool RPM control - Y2 ............................................................................................... 23
Boom extension - Y7 ................................................................................................ 23
Feed tilt - Y9 ..............................................................................................................23
Feed tip - Y10 ............................................................................................................ 23
Load hydraulics - Y1 ................................................................................................ 23
Mechanical system ....................................................................... 24
General ......................................................................................................................24
Tool assembly...........................................................................................................24
Installing the spacer ..................................................................................................... 24
Repinning the tilt cylinder............................................................................................ 24
Connectors for tools ................................................................................................ 25
Tool selection ................................................................................ 26
Oscillating cassette or rotor ...................................................................................26
Mounting the rotor ................................................................................................... 26
Cassette mounted rotor ................................................................................................ 26
Cradle mounted rotor ................................................................................................... 27
Automatic Level Sensing (option) .......................................................................... 27
Operation ...................................................................................... 28
General ......................................................................................................................28
Manual operation .....................................................................................................28
Tracks ............................................................................................................................. 28
Boom/feed beam ........................................................................................................... 28
Tool functions ............................................................................................................... 28
Automatic operation ................................................................................................ 28
Communication ............................................................................ 29
Connecting power packs......................................................................................... 29
Operators terminal ....................................................................... 30
Description ...............................................................................................................30
Start of the machine ................................................................................................ 30
F1: Monitor ................................................................................................................ 30
F2: Parameters ......................................................................................................... 31
F3: Configuration .....................................................................................................31
F4: Alarms ................................................................................................................. 32
Parameter limits .......................................................................................................32
Test demolition ............................................................................. 33
Preparations ............................................................................................................. 33
Setting up for a test demolition .............................................................................. 34
Service and maintenance............................................................. 35
Preventive Maintenance ..........................................................................................36
every shift / 8 operating hours*; .................................................................................. 36
every week / 40 operating hours*; ............................................................................... 36
every month / 160 operating hours*; ........................................................................... 36
4
 every six months / 960 operating hours*; ................................................................... 36
Maintenance points and torque table ....................................................................37
Lubrication points ....................................................................................................38
Induced sensors.......................................................................................................39
Pulse sensor for cradle ................................................................................................ 39
Pulse sensor for lance turning and zero point reference ......................................... 39
Adjustment of lance turning sensors ......................................................................... 39
Transformer tension control ...................................................................................40
Return line oil filter change .....................................................................................40
Adjusting pressure relief valves ............................................................................41
Cradle motor .................................................................................................................. 41
Rotator motor ................................................................................................................ 41
Replacing hydraulic lines ........................................................................................42
Lance turning actuator ................................................................................................. 42
Hydraulic cylinders ....................................................................................................... 42
Replacing the plain bearings in boom system and track holders ......................42
Tracks ........................................................................................................................43
Checking track tension ................................................................................................. 43
Adjusting track tension ................................................................................................ 43
Oscillating cassette .................................................................................................44
Replacing the oscillating bearing ............................................................................... 44
Replacing the driver motor .......................................................................................... 46
Replacing the driver bearing ....................................................................................... 47
Reaction forces ............................................................................. 48
General ......................................................................................................................48
Calculating reaction force by using the formula ..................................................48
Tables ............................................................................................. 49
Reaction force as a function of pressure and flow .................................................... 49
Max. flow for given pressure and reaction force (Fr) ................................................. 49
Max. flow for given pressure and nozzle diameter (Ø) .............................................. 49
Stability ......................................................................................... 50
Allowable inclinations .................................................................................................. 50
High pressure hoses .................................................................... 51
General ......................................................................................................................51
Technical specifications..........................................................................................51
Series 4000 STW ........................................................................................................... 51
Series 6000 STW ........................................................................................................... 51
Data ........................................................................................................................... 51
Trouble shooting ........................................................................... 52
General ......................................................................................................................52
Systematic approach ...............................................................................................52
Examples of what is supposed to happen ............................................................ 52
Tip! .............................................................................................................................52
Trouble shooting table .............................................................................................53
System diagrams .......................................................................... 54
Hydraulic system .....................................................................................................54
Diection of rotation ..................................................................................................56
Electrical system .....................................................................................................57

Index .................................... 70
5
Symbols

The following symbols are used through out this

document to illustrate different levels of hazards;

NOTE!
This symbolises items that have to be consid-
ered specially. For ex. when performing
service to the hydraulic system.

CAUTION!
This symbolises minor risks involved.
E.g. a splinter in the finger.

WARNING!
This symbolises risks that could cause
serious damage and/or injuries.
E.g. a lost finger, a severe burn wound.

DANGER!
This symbolises risks that could cause
extremely serious damage and/or injuries.
E.g. death.

LIFTING EYE.
The sign indicates were the lifting eye is
positioned.

SQUEEZE/PINCH RISK!
This sign warns of the squeeze/pinch risks
involved.

READ THE MANUAL!

&
This symbol shows that the manual has to be
read BEFORE attempting to operate the
equipment.

6
Hydrodemolition in general
Hydrodemolition was developed for the controlled removal of damaged concrete from sensitive structures
such as bridges and parking decks. Using the unique features of the water jet, can, when set up correctly,
be adjusted to remove only the damaged concrete and leaving the sound. We call this selective removal of
damaged concrete. During the 10 years of commercial use, experience has been gathered and incorpo-
rated in equipment and instruction books.

Concrete is a complex material

which contains not only cement, aggregate and rebars but also porosities and cracks. During hydrodemoli-
tion the water jet will find its way down into the concrete and create an over-pressure. If the pressure
created is higher than the strength of the concrete, a piece of concrete will brake out. With the right water
pressure, flow rate and movement of the water jet , hydrodemolition-equipment can be set to a “quality
depth”. When concrete is affected by salt, frost, pollution or overload, cracks will be created, either from the
surface or horizontally (from frost).

The advantages of testing

When you are up for a hydrodemolition project, it is always good to know the concrete quality, in advance. If
you know the quality you can set the right parameters from the start and you can also estimate the produc-
tion to make your plans better. The best way to get a good quality status is to examine cores drilled out from
the structure. The result of the core examination is also of great interest to the bridge owner as it can guide
him to a better specification of the contract.
Delamination can be found by hammering the surface. When you have delamin- ation, the damage is
severe and the hydro demolition has to take out not only the delaminated concrete but also a bit more in the
structure. This is to make sure that there is no damage left that can ruin the bonding of the new concrete.

Good bonding quality control is important

When the damage is down to or under the rebar you have to make sure that the concrete under the rebars
is removed, to allow for good bonding and for new concrete to be able to protect the rebars in the future.
Hydrodemolition will not create any new micro cracks in the structure.
The quality of the remaining concrete can be visually judged. If remaining cracks and salt can be seen,
hydrodemolition should continue. The bonding between aggregate and cement should be so strong that the
stones should break when hammering on them. The depth of the cutting is normally varying over the
surface as the damage varies. The surface created with hydro demolition will show an uneven surface that
will give a better bonding between the old and new concrete than any other kind of demolition. Tests have
proven almost 100% bonding.

Calculating the capacity

The capacity of the hydrodemolition is affected by the strength of the concrete, the number of micro cracks
and the size, strength and amount of aggregate. Hydrodemolition of carbonised, or full strength concrete is
also possible. Capacity will then go down, sometimes drastically, but it can then be compensated by in-
creased water pressure and 2-3 times higher flow rate. This setting is also used when deep cutting is
required. CONJET Robots are designed to meet this requirement and can safely take the load of 600 kW
when equipment of yesterday only took approximately 300 kW.

Compare the cost

The cost of removing “good” concrete is of course higher but it can many times be justified when the rebars
are to be reused, as when repairing side beams or exchanging expansion joints on bridges. Other areas is
in noise and vibration sensitive areas like public places, hotels and office buildings. Hydrodemolition is a
method that requires less personnel than traditional hand held demolition work. The operator will not be
affected by noise, vibration or overload.

7
Safety instructions

General
High pressure water is a matter to take most serious. Keep the electrical connections out of water, and
make sure that all safety equipment are in working condition.

√ Conjet AB can neither accept responsibility, nor liability if the equipment is not used in the manner it
was intended or designed for. The company shall not be liable if the prescribed safety rules are not
adhered to or if they are ignored by the operator. The same applies to the warning signs and plates
installed on the equipment. Under no circumstances must such plates or signs be removed for any
reason.

√ Never allow the water jet to be aimed at, or come into contact with any part of your body. This could
result in serious personal injury to yourself or someone else.

√ Never attempt to touch a point of leak, from fittings and connections or hoses, with your bare hands.
Or stop leaks by temporarily plugging them. All repair to the high pressure system shall be carried
out with the system depressurised and the engine stopped. Failing to do so could cause serious
personnel injury!

√ Use only Conjet AB Original spare parts, such as approved fittings, hoses and valves, that are
certified to withstand a pressure of up to a minimum of the working pressure of the unit.

√ Be aware of pinch risks when working in confined spaces.

√ Be aware of ice buildup when working in temperatures close to the freezing point of water. Could
case accidents by slipping.

√ Always disconnect the main power line when conducting service to the electrical system.

√ Conjet Robot 322 is NOT EX-approved.

Do NOT commence high-pressure operation before checking the following points;

1. “Chinese fingers”/wire mesh hose, mounted and securely attached to high pressure components such
as; connections between high pressure hoses, connections between lance and high pressure hose,
high pressure hose connection to the high pressure pump.
2. Lance attachment, secured. Check that the moving parts are tightened to the cradle/oscillating cas-
sette.
3. Hose quality/pressure rating, corresponding to applications pressure level.
4. The risk of “blowing through” the surface. Confirm that no damage is done to personnel and/or material,
in case the jet should brake through the surface.
5. Ensure that the protection hood is positioned firmly against the surface. (Item 3, page 3)
6. Protection of the area around the work area.
Safety zone = 30 metres.

Additional
information
See leaflet “RECOMMENDED
PRACTICES FOR THE USE OF
MANUALLY OPERATED HIGH
PRESSURE WATER JETTING
SYSTEMS” for further informa-
tion regarding high pressure
water.

8
Work area
The operator of this unit has the total responsibility for the working DANGER!
area. The operator has to make sure that unauthorized personnel
are not inside the working area! Be aware of the tilt
The work area around the equipment shall be secured with tarps risk when operat-
or similar, if there is a risk of debris escaping from the included ing in slopes.
protection. Observe the increased risk of uncontrolled debris fly- ALWAYS work
ing around, when operating over head! with the electrical cubicle
Flying debris could cause injury to bystanders and vehicles down hills!
passing the work area.
Consider the noise level when working in populated areas.

Common procedures
Always press emergency stop button when performing preventive
maintenance so that no other personnel can operate the unit, en-
dangering your health, at the same time.
When performing preventive maintenance to the electric system,
unplug the main incoming power. For maintenance in the hydraulic
system; unload all functions so that they do not “collapse” when
the hose is opened.
Be sure to notify your fellow workers when commencing hydro-
demolition, so that no one is positioned in the danger zone around
the working area. Check the setup at least twice!
WARNING!
When working in slopes -or down hills, operate the unit so that the
feed beam is up the slope! Failing to do so could cause serious
injury to personnel and/or to the equipment if the unit would over-
turn.
2 persons are needed to remove the protection hood when serv-
ice is performed. Make sure that the hood is refitted and secured
before commencing hydrodemolition. DO NOT LET UNAUTHOR-
ISED PERSONNEL AP-
PROACH THE UNIT WHILE
IN OPERATION!
Do not use the boom
system or any part of it as a
lifting device! The unit
should NOT be used to
transport personnel!

Correctly positioned
temporary wall

9
Body protection
The Protective clothing and other items listed below shall be worn by the operator/s and others working
close by.

Protective Clothing
The operator should be supplied with a waterproof overall to pro-
tect him against water spray and flying particles. Waterproof cloth-
ing will however NOT protect the operator from direct impact
from the water jet. Such protection can only be provided by a
metal shield or barrier. Consequently, the operator must be ex-
tremely careful to always keep the water jet aimed away from
himself or anyone else nearby.

Head Protection
• Helmets must be worn at all times, both by the operator and
by other persons within the safety area of the equipment
• Hard hats or helmets worn must be of the type capable of
withstanding the mechanical shock of load equivalent to 10
G in 8 ms without fracturing.
• The helmet worn by the operator must also have a safety
visor to protect the face and eyes.

Eye Protection
• The operator and others within the safety area shall always
wear or use a helmet visor or safety goggles to protect the
eyes against spray and flying particles.

Ear Protection
• All personnel exposed to noise levels exceeding 90 dB (A)
Fig. Protective clothing
for more than one hour, shall wear effective ear mufflers or
ear plugs.

Hand Protection
• The operator shall always wear a thick pair of leather or canvas gloves when operating the equipment.

Footwear Protection
• The operator shall wear suitable footwear, such as boots with steel toecaps at least 5 mm (0,2") thick.
The toecap should cover at least 30% of the boot length.

Noise level indications

The Robot 322 noise levels has been measured, according to ISO 4872 (General SPL with machinery at
work). Noise measurements has also been recorded at the operators ear according to ISO 11201.
Typical sound pressure level for Robot 322 with High pressure engaged: 11,2 - 11,9 Bell(A).
The table below describes the minimum distance to the robot for a sound pressure level less than 8,5
Bell(A)

n Water jetting with protection covering the demolition area: 8,5 metres

n Water jetting with protection NOT covering the demolition area: 13,4 metres

10
Emergency medical information
If an accident should occur, immediate hospitalisation should be arranged for personnel who may have
sustained an equipment related injury. In such cases, it is vital that medical personnel be informed of all the
facts relevant to the injury. All operators of High Pressure Water Jetting equipment should wear or have in
their possession a water proof tag or card describing the type of work and the possibility of injury caused by
the use of High Pressure equipment.

THIS TAG SHOULD BE PRESENTED TO THE OPERATOR, BY THE EMPLOYER!

Lifting the Robot

Before lifting the Robot, it is very important that these instructions
are read and fully understood. NOTE
The Robot is equipped with 1 lifting eye. It is located underneath
the cover lid on the robots cover (See picture below).
Position the boom system with the feed beam on the ground.
DO NOT LIFT THE ROBOT WITH THE FEED BEAM POINT-
ING TO THE ROOF!
Undo the cover and lift the lifting eye. (See picture below). At-
tach the appropriate lifting device. I.e hook or shackle to the lifting
eye.
Refit the cover when lift is completed. Attach the lifting de-
vices to the marked
lifting-eye positions.

Robot 322 weighs

approximately 1 040kg
(2 293 lbs).

WARNING!

Lifting eye on Robot 322

DO NOT WALK UNDER

HANGING LOAD!

11
Robot 322

General
The Robot 322 has been designed for the purpose of removing concrete and coatings from various sur-
faces using a high pressure water jet. These surfaces include harbours, bridges, piers, docks, ships and
other vessels and structures exposed to harsh environment.
The Robot 322 is designed as a tool car-
rier based on a tracked substructure. The Boom system Telescoping boom
control system contains reliable and well rotator attached to tilt and
lift mechanisms
known hydraulic- and electrical
components, for the operation The feed beam with
of the robots different func- the protection
tions. The carriers functions attached
concentrate around the track
function and manoeuvrability.
The track speed can be indi- R ob ot 32
2
vidually adjusted in slow move-
ment as well as during the automatic
operation sequence. With this feature,
it is possible to work around bends al-
lowing the tracks to operate with different
Oscillating
speeds. cassette

Tools and attachments

The front part of the undercarridge forms a platform on which different tools and attachments can be
mounted. The standard attachment is the feed beam. The feed beam is mounted on a rotator. A telescopic
boom extends the reach together with the tilting device. A yet another feature, the feed lift allows the feed
beam to tip forwards 30 degrees and backwards 10 degrees for access joints and other hard to reach areas.

Controls and connectors

The robot is operated by means of a light weight control box. This connects to the robot alongside with pump
communication and the main power connections. In the same area a 24VDC work light power outlet is
found.
Should the robot indicate wrong phase, the insert in the main connector is manually switched to the
correct phase. The unit can not be started or operated with the wrong phase indicator active.
Also located on the main panel on Electrical Operators terminal Track
the robot are; a motor START/STOP control
controls
button, a wrong phase indicator, a valves
power ON button as well as an opera-
tors terminal.
Tool controls
The hydraulic controls are located
to the right of the electrical controls.
The large dials regulate the track speed
left and right side. Below, on a sepa-
rate panel, throttle valves for cradle
speed, lance turning speed and oscilla-
Main switch, restart indicator
tion speed. and emergency stop
Cradle and lance turning speed are ad-
justed individually, left and right
side while oscillation only needs Connectors
a single valve.
Controls and connectors on the
control panel

12
Control box
In order to keep weight and size to a minimum, the number
Switches
of manipulators has been kept to a minimum. In order to
achieve this object, a function selector switch have been in-
stalled. This switch determines which set of function should be oper-
ated by the joystick. The joystick operates in all directions; N(orth),
E(ast), S(outh) and W(est) as well as NE, SE, SW and NW. This does
NOT necessarily mean that all functions operate in all these position,
but the joystick can be placed in these positions.
In addition to the above two manipulators, two buttons and two
switches can be found; a step switch that decides wether or not to
step and in what direction. A switch that turns oscillation ON and
Function
OFF. The buttons START and STOP the automatic operation control switch
of the robot. Buttons Joystick

Operators terminal
The operators terminal provides the operator with information
and options that can be changed according to the specific task.
It allows the operator to communicate with the control system
of the robot.
From this terminal, parameters such as Number of strokes,
Lance turning angle, Step time and Start direction are set.
There are 4 different screens that can be viewed with the ter-
minal; Monitor, Parameter, Configuration and Alarm. These 4 sepa-
rate alternatives are accessed by pressing one of the four func- Startup screen on the opertors terminal
tion keys.
F1 - Monitor screen
F2 - Parameter screen
F3 - Configuration screen
and
F4 - Alarm screen.

Functions and movements

On the tool carrier itself, there are 2 main functions; Left track and
Right track. The tracks can operate, as mentioned earlier, in separate
speeds set for each track. This is done by means of the two throttle
valves that operate each track individually in slow mode as well as
during the step.

Trottle check valves for track speed

control

13
Electrical System

General
The electrical system in Robot 322 operates on a variety of tensions and frequencies. 400 at 50/60 Hz or
440-460-480 at 50/60 Hz depending on order configuration. The power rating differs between the two ver-
sions; 7,5 kW at 400VAC-50 Hz and 8,6 kW at 440VAC-60 Hz. In both cases the robot requires 3 phase and
ground to function properly.
The high tension is utilised to run the main motor operating the hydraulic pump. It also feeds the external
transformer. The transformer outputs a DC tension at approximately 26 V. It may vary with the incoming
power but should stay in the range of 24 to 28,5 VDC.
The electrical system is divided into separate subsystems or sub-parts.

A1 Main cubicle
AS1 Control box
AX1 Connectors for tool
AX2 Connecting box on oscillating cassette T1
AX3 Connecting box for level sensing sensors (Op-
tion)
T1 Transformer TransformarT1 at the back of
main cubicle A1
XS3 Main power supply
XS2 Communication with power pack or high pressure pump

A1 main cubicle
The main cubicle contains all electrical components for the operation of the robot. The following components
can be found on the outside of the cubicle;

SH4 Main motor start

H1 Wrong phase light indicator
SH3 Emergency stop circuit reset button
E100 Operators terminal

On the door

Q1 Main power switch

H2 Restart Automatic light
S1 Emergency stop

Q1 H2 S1

14
As the power is connected to the XS3 connector, the relay K2 checks the phase Electrical plug
sequens. If it is incorrect, the light H1 illuminates. At this point the with phase
operator has to disconnect the incoming power and turn the phase sequence
switch inside the incoming power connector. switch.
Once the main power phase is corrected, the system is ready to
operate.
The robots functions are controlled by a PLC (Programmable Logic
Control). This in turn is fed with input from the operators terminal (E100)
located on the main cubicle. The parameters fed from the terminal are
used to operate the robot in automatic mode. In manual mode the
input originates in the control box and the function selector switch as
well as the joy stick.

The main cubicle contains the following items;

W-L

F2
XS1
F3
P21
F1
K2 Q1 K3 PNOZ
F1

XS2

PLC

XS3

K2 Phase sequence relay P21 Optocoupler-signal inverter

Q1 Main switch Cradle pulse
F1 Motor starter PLC System controls
F3 Automatic fuse-from T1 XS1 Connection to control box
K3 Relay-Load high pressure XS2 Connection to Power Pack or
F2 Automatic fuse-to T1 high pressure pump
K1 Contactor XS3 Main power inlet (not in picture)
PNOZ Emergency stop relay W-L Work light output socket

15
Wrong phase relay - K2
The Phase relay K2, monitors the phase sequence at start up. It basically means that the phases R-S and
T has to be present in a certain order for the main motor to rotate the correct way. If it doesn’t, the relay will
not activate, illuminating the warning light.
The relay is protected by the automatic fuse F1, which also protects the main motor M1.

NOTE: IF F1 FALLS/TRIPS, THE PHASE RELAY WILL INDICATE “WRONG

PHASE” EVEN IF THE PHASE SEQUENCE IS CORRECT!

Emergency stop circuit

A very important part of the system is the PNOZ relay. While the circuit between terminals S12 and S11 are
closed, the relay is activated/closed. That means that the circuit between pins 13 > 14, 23 > 24 and 33 > 34
are closed. As soon as the circuit S12 > S11 is broken/opened, the relay falls and the system stops.
When that happens, the PNOZ relay has to be reset with the switch SH3, located on the A1 (main
cubicle) panel.
NOTE: The robots emergency stop circuit stops the Conjet Power pack.

Valve control
The hydraulic valves in the Robot 322 are ON/OFF type valves. They operate in
two modes; on or off (open or closed). When 24 VDC is applied to the valve coil, the
valve opens (on). When the no tension is present, the valve closes (off).
On each valve coil, there is a “induction protection” mounted. It protects the
PLC output contacts and relays from the induced current when switching the ten-
sion off. Do not operate the valves without this protection installed.

Induction protection

Position control
The cradle motor is equipped with an induced sen-
sor. This sensor counts the pulses generated by the
motor as it travels along the feed beam. An induced
sensor is mounted on the cradles protective hood
(Picture). It is activated by the ”flag” mounted on the
feed beam. This flag serves as the zero point flag.
When the flag activates the sensor, the PLC updates
the actual cradle position with zero (0).

Zero point sensor mounted on the cradle motor

protection and the flag.

16
Pump control
The pump circuit is connected to the emergency stop relay (PNOZ) as well. This solution enables the
system to shut down the connected high pressure pump, is case of an emergency. The relay K3 loads the
pump when high pressure is called for, by switching the control voltage, supplied by the Power pack itself,
from one pin to the other. If the circuit is broken, the Power pack shuts down.

PLC
Switch pos. 0 1 2 3 4 5 6 7
The PLC controls the movement of all functions. In
Symbol
manual mode, using the inputs from the function
Contacts/input
switch on the control box as well as from the joy-
1-2 / X10 X X X X
stick, also located on the control box.
3-4 / X11 X X X X
Depending on the position of the function switch, 5-6 / X12 X X X X

certain in and outputs are engaged. Connection table for function switch in control box

The PLC is equipped with a number of in and

outputs. They are, as the hydraulic valves, digital. On
or off.
Below you find the list with the designated functions of the in and outputs to and from the PLC:

Input listing Output listing

In Function Terminal/connector Out Function Terminal/valve
X0 Cradle pulse XS8:3/203 Y0 Main motor 51
X1 Cradle reference XS8:4/204 Y1 Load High pressure 53
X2 Lance turning pulse negative XS8:5/205 Y2 Y1 Load hydraulics 151
X3 Lance turning pulse positive XS8:6/206 Y3 Oscillation or rotor 152
X4 Joystick input 1 - 4 W1:3/123 Y4 Cradle A side 153/Y3:A
X5 Joystick input 2 - 5 W1:4/124 Y5 Cradle B side 154/Y3:B
X6 Joystick input 3 - 3 W1:5/125 Y6 Lance A side 155/Y4:A
X7 Joystick input 4 - 6 W1:6/126 Y7 Lance A side 156/Y4:B

X10 Selector switch input 1 - 2 W1:7/127 Y10 Side slide A side 157/Y5:A
X11 Selector switch input 2 - 4 W1:8/128 Y11 Side slide B side 158/Y5:B
X12 Selector switch input 3 - 6 W1:9/129 Y12 Track extension A side 159/Y6:A
X13 Automatic start W1:10/130 Y13 Track extension B side 160/Y6:B
X14 Automatic stop W1:11/131 Y14 Feed level A side (OUT) 161/Y7:A
X15 Oscillation ON/OFF W1:12/132 Y15 Feed level B side (IN) 162/Y7:B
X16 Select step ON/OFF W1:13/133 Y16 Boom rotoator A side 163/Y9:A
X17 Select step FWD/BKWD W1:14/134 Y17 Boom rotoator B side 164/Y9:B

X20 PNOZ relay X3:14/41 Y20 Enable track extension 165/Y12

X21 Main motor start SH4:4/54 Y21 Enable high speed transport 166/Y13
X22 Hyd.oil temp switch INX22 (Option) Y22 Left track A side 167/Y14:A
X23 Hyd.oil level switch INX23 (Option) Y23 Left track B side 168/Y14:B
X24 Level sensing 1 XS8:7/207 (Option) Y24 Right track A side 169/Y15:A
X25 Level sensing 2 XS8:8/208 (Option) Y25 Right track A side 170/Y15:B
X26 Level sensing 3 XS8:9/209 (Option) Y26 Feed tilt A Y9:A
X27 Level sensing 4 XS8:10/210 (Option) Y27 Feed tilt B Y9:B

Y30 Feed flip A Y10:A

Y31 Feed flip B Y10:B
Y32 Spare 3 A Y11:A
Y33 Spare 3 B Y11:B
Y34 Reserve
X0 - X27 Y35 Reserve
Y20 - Y37 Y36 Reserve
Y0 - Y17 Y37 Automatic restart indication 55

PLC configuration.
• Inputs are designated “Xx” were x is a number from 0 to 27.
• Outputs are designated “Yx” were x is a number from 0 to
37. Y20 - Y37 are located on a separate output module.

17
Control box

Step selector Tool selector

switch switch

Function selector switch

Emergency
stop

Joy stick
Auto-start Auto-stop

Control box, robot 322.

The control box is a very light weight construction. It contains a few buttons and switches as well as a joy
stick for the operation and control of the Robot 322. The function selector switch, located in the centre of the
control box, determines what function should be operated by the joy stick. It has 8 positions marked 0 - 7.
The joy stick is located to the right of the function selector switch. It operates the functions determined by
the function selector switch. The joy stick operates in all directions.
Placed on the left side are two switches; step mode/direction and tool on/off. Below them are the auto-
matic start and stop buttons.
On the right side of the control box: emergency stop. It is protected by a aluminium guard to prevent un-
accidental activation of the emergency stop.

Function selector switch

Position 0: Starting the robot

To start the robot, connect the main cord and watch the phase sequence indicator . If

illuminated, invert the phases and reconnect the main cord. Press -button. Ensure that

the function selector switch is in position 0 (zero) and press . Failing to position the function selector

switch in position ZERO will prohibit the robot to start. This is for safety reasons only.

Position 1: Track width control and side slide (ENABLED IN AUTOMATIC MODE)

The width of tracks can be adjusted in position 1 and side slide operates in positions 1
and 5. Side slide means that the under carriers position can be adjusted on the tracks by
sliding it on the frame. This works only if tracks are not extended maximum.

18
Position 2 and 3: Moving the robot (DISABLED IN AUTOMATIC MODE)

The robot is manoeuvred by means of the single joystick. The position of the function selector
switch determines which speed is used. Moving the selector from ZERO to position 2 enables
HIGH SPEED movement while position 3 enables SLOW SPEED movement.
In either position, the tracks are operated simultaneously when the joystick is moved for-
wards (or backwards). In position 3 the speed will be what is set on the track control valves.
Moving the joystick to East or West enables a so called centre turn. This means that one
track moves forwards while the other moves backwards, creating a centre turn. The centre turn
will always be in slow speed.(Centre turn is ENABLED IN AUTOMATIC MODE)

Position 4: Tilting and rotating (ENABLED IN AUTOMATIC MODE)

In position 4, the boom system / feed beam is rotated and/or tilted.

Position 5: Boom extension and side slide (ENABLED IN AUTOMATIC MODE)

Position 5: Again side slide and boom extension. Side slide is thought to be useful when
operating on horizontal surfaces. A drift can be compensated for by activating the side
slide during the cut. The actual distance compensated for with the side slide depends on
the extension width of the tracks.

Position 6: Feed slide (option) and feed tip (ENABLED IN AUTOMATIC MODE)

In this position only one function is connected; feed tip. The feed tips 30 degrees outwards and
10 degrees inwards. Useful when working on bridge joints and in confined areas.

Position 7: Cradle and lance turning control (DISABLED IN AUTOMATIC MODE)

The last position of the function switch operates the cradle and lance turning control. Moving
the joystick SW (South-West) or SE, moves the cradle. NW and NE moves lance turning. The
joystick moved East turns the lance turning to the set position and then activates the cradle.
West does the same in the other direction. All this in order to set the actual cutting width as easy
as possible.

Joystick
As described earlier, the joystick can be moved in all possible directions. Some functions work simultane-
ously when moved for ex SE or NE, while some only works N,E,S and W.

NW NE

W E

SW SE

19
Step selector switch
The step selector switch serves two main functions: turn step ON or OFF as well
as setting the step direction. Depending on how the Number Of Strokes are set,
step can be completely inverted.
ZERO position turns step OFF.
Switch towards LEFT inverts the step when Number Of Strokes are set to 1/0.
Switch towards RIGHT leaves the step when Number Of Strokes are set to 1/0 in a so called normal
mode.

Tool selector switch (for oscillation or rotor)

Turns oscillation or rotor ON or OFF depending on the switch position. The illus-
trated position is in the OFF position.

Emergency stop
On the side of the control box, an emergency stop is found. It is covered by a yellow “frame” to prevent
accidental activation of the button. The button is reset by turning the emergency stop.

Automatic Start
This button starts the automatic operation of the unit.

Automatic Stop
This button stops the automatic operation of the unit.

20
Hydraulic system

General
The hydraulic system is powered by a gear pump with fixed displacement. As soon as the electrical motor
starts, the pump starts to deliver oil. Since the “load hydraulics valve” is inactivated, only a low pressure is
build up in the system. As soon as a function is operated, in either manual or automatic mode, the load
hydraulic valve activates. This in turn, builds up the hydraulic pressure in the system to what is set on the
load hydraulic valve.

6
5

12
7 1 11
3
2,3 9
10 8

13

Hydraulic system, Robot 322

The hydraulic system is build up of the following components;

n Electrical motor (1) and pump (2) mounted on the oil tank (3). The oil cooler (4) with fan (5) is
integrated with the motor.
n Three (3) separate valve sections for the different functions.
- Track movements (6)
- Tool control functions (7)
- Boom control functions (8)
n Return line filter (9) with indicator (10)
n Filler cap (11) on the hydraulic tank.
n Pressure manometer (12)
n Level glass with thermometer (13) under the electrical cubicle

Controls
The movements of the robot are controlled by means of throttle valves.
They are all gathered on a panel next to the electrical cubicle for easy
reach. Large symbols indicate the function for each control.
Hydraulic controls

21
Track speed control - Y13, Y14 and Y15
The track speed is controlled with the two throttle valves
on the top of the panel. Left and right side track is control-
led individually. The setting on the throttle valves will
be the stepping speed in automatic mode. By adjust-
ing the throttle valves, the robot can operate around bends
when needed. It can also be used to compensate for the
deviation caused by reaction force, when working verti-
cally.

Throttle valves for track speed

Track position control - Y5, Y6 and Y12

The robots track width can be altered hydraulically to en-
sure stability during hydro demolition. This is done by se-
lecting function number 1. When operating the
function(valves Y6 and Y12), the track that operates easi-
est will move out to it outer position, followed by the side
that moved a bit harder.
If the tracks have not been extended to the maximum,
side slide can be used. This function operates in selection
1 and/or 5. When the function is activated, valve section ValveY12 for side slide
Y5 only, activates.

Lance turning - Y4
The lance turning is operates by valve section Y4. It oper-
ates a rotator gear mounted on the cradle. It is very im-
portant that the circuit is free from air. This has to be con-
sidered when replacing a hose or similar.
Two throttle valves control the movement of lance turn-
ing left and right side individually.

Throttle valves for lance turning speed control

Cradle movement - Y3
The cradle speed is controlled by a similar set of throttle
valves as for the lance turning. They are located under-
neath the lance turning valves to the left.

Throttle valves for cradle speed control

22
Tool RPM control - Y2
The standard tool is the oscillating cassette. The RPM of
the oscillation is controlled by means of one single throttle
valve located to the right of the cradle speed valves.

Boom extension - Y7 Throttle valve for tool RPM control

Feed tilt - Y9
Feed tip - Y10
These cylinders operate the position of the feed beam.
They are all equipped with hydraulic locks to prevent the
load from falling during a stand still or in case of a broken
hose.

Hydraulic lock

Feed tilt
Boom extension

Hydraulic locks

Feed tip

Load hydraulics - Y1
The load hydraulic valve, Y1 plays a key role in the system.
As mentioned before, the system incorporates a gear pump
that delivers the maximum amount of oil at all times (when
motor is ON). But the oil pressure remains low until the Y1
valve activates (closes). What happens is basically that a
restriction is introduced in the system. The size of the re-
striction determines the operating pressure.
Setting the operating pressure is done with the set screw
located on valve block (7 - previous page).
Set screw for
operating pressure

23
Mechanical system

General
The robot 322 is manufactured with durability in mind. The
sub-frame and hydraulic tank are integrated from start.
The sub-frame houses the track extension guides as well
as the holder for the operating tool. I.e standard feed beam.

The sub-frame houses the track slide and

extension guides

Tool assembly
The demolition tool support is bolted onto the carrier. By inserting an extension be-
tween carrier and tool support, reach is increased by 400 mm.
NOTE: with boom system extension installed, maximum re- 3
action force is limited to 950 N!
1
Installing the boom system
extension
In order to reach 2 400 mm, a separate extension may be
installed. It is a relaitevely simple operation that however
demands a lifting aid for the boom/feed beam console.
1 Secure the boom/feed beam console in the hoist
(or similar).
2 Undo the bolts attaching the boom/feed beam
console to the carrier.
3 Lift the slightly forwards and up in order 2
to fit the boom system extension.
4 Redo the bolts to the carrier.
Use a lifting device when inserting the boom system
5 Lower the boom/feed beam console extension. Note the 3 circled lifting points.
onto the boom system extension and
fit the bolts.

Repinning the tilt cylinder

The tilt cylinder allows the feed beam to tilt +-45 de-
grees. Depending on the “pin position” the tilt can be
repositioned with reference to the boom system.
1 To repin the tilt cylinder unload the feed beam 2
against the floor or in a hoist.
2 Undo the two bolts, securing the feed beam
against the tilt cylinder.
3 Operate the tilt cylinder to the next position
and refit the two bolts.
3

Geometry is easily changed by repinning the tilt

cylinder.

24
Connectors for tools
When mounting a different tool, symbols on the lift- BOOM EXTENSION [Y7]: Connected
ing bracket indicates how the tool should be attached to the extension cylinder on the boom.
to the carrier both electrically as well as hydrauli-
cally. The list below describes the function of the con-
necting plate, when attaching a tool to the robot.

BOOM SWING [Y8]: Connected to

the boom system rotator.

FEED TILT [Y9]: Connected to the tilt

cylinder on the feed beam.

Symbols indicate how the tool should be connected.

(See section below - Connectors for tools) FEED TIP [Y10]: Connected to the
tip cylinder on the feed beam.

TOOL [Y2]: ei-

ther the oscillating
cassette or a hy-
draulic rotor. The di- FEED EXTENSION [Y11] (OP-
rection of rotation is TIONAL): Not connected.
impor tant, espe-
cially for the oscillat-
Direction of ing cassette. Make
rotation should be sure that the motor
anti-clockwise. turns anti-clockwise
when looking at the ELECTRICAL SIGNALS:
grease nipple. To alter the direction of rotation, switch XS8 contains the signals
the two hoses. from the cradle motor sen-
If the rotor fails to operate, the hoses are most sor and the two sensors for
likely not correctly connected. The rotor circuit is lance turning. XS9 is an op-
equipped with a check valve mounted on the rotor. If tional connector not currently
the hydraulic hoses are connected wrongly, the ro- in use.
tor will not operate since the hydraulic oil passes
through the check valve and not through the rotor. DRAIN: Only used when a hydraulic
rotor is mounted.

CRADLE [Y3]: the cradle circuit has

to be connected so that cradle moves
TOWARDS LEFT when the joystick is op-
erated SW in function 7. Cradle should
move TOWARDS RIGHT when the joy-
stick is operated SE in function 7.

LANCE TURNING [Y4]: the lance

turning circuit has to be connected so
that lance turns TOWARDS LEFT when
the joystick is operated NW in function 7.
Lance should turn TOWARDS RIGHT
when the joystick is operated NE in func-
tion 7.

25
Tool selection

Oscillating cassette or rotor

There are basically two types of tools to choose from: oscillating cassette or rotor.
The oscillating cassette is mainly used for deeper demolition depths while the rotor is suitable for scarify-
ing applications as well as paint removal.
The rotor can be mounted in two ways: as a “bolt-on” tool in the oscillating cassettes lance holder (cas-
sette mounted), or as a “bolt-on” tool on the cradle plate (cradle mounted).
The latter type means that the robot will be used solely as a rotor holder, while the first type, mounted in
the lance holder, allows a quicker change between the two types of tools.
The hydraulically driven rotor is connected to the hydraulic system on the ports marked

. An additional connection, for drain, has to be made to

ensure correct operation of the rotor. The drain is connected

to the port marked .

The rotors are equipped with a check-valve to prevent it

from cavitating, when the hydraulic media is shut off. The
check-valve allows hydraulic oil to circulate through the ro-
tor by the rotors own force, prohibiting cavitation.

Mounting the rotor

Cassette mounted rotor

To install the cassette mounted rotor, the original lance MAKE SURE THAT YOUR ROTOR IS EQUIPPED
assembly has to be removed from the lance vice, as well
WITH THE CORRECT AMOUNT AND SIZE OF
as the protection from the feed beam.
NOZZLES PRIOR TO MOUNTING!
1 The rotor is mounted in the place of the lance.
2 Swing the rotor towards the side you intend to work
and secure the rotor by means of the support
bracket. (The rotor on the picture is turned to the
left)
3 Tighten the lance vice. 5
4 Mount the protective “scraper” as a replacement
for the original protection. The side supports serves
as guides for the rotor over the surface.
5 Connect the P (pressure), T (tank) and D (drain)
4
lines to the rotor, according to the diagram above. 3 1
6 Set the parameter F2:2 (Lance turning angle) to
0/0. 2
7 Connect the high pressure hose to the rotor. Cassette mounted rotor turned to the left.

During operation, keep the side supports on the scraper at a constant distance from the surface to ensure
correct alignment of the rotor.

26
Cradle mounted rotor
To install the cradle mounted rotor the original complete MAKE SURE THAT YOUR ROTOR IS EQUIPPED
lance assembly including the rotator for lance turning,
WITH THE CORRECT AMOUNT AND SIZE OF
has to be removed from the cradle plate, as well as the
protection. NOZZLES PRIOR TO MOUNTING!

1 The rotor is mounted directly on the cradle plate.

Observe the position of the rotor holder!
2 Swing the rotor towards the side you intend to 1
work and tighten the lance vice.
3 Mount the protective “scraper” as a replacement
for the original protection. The side supports
serves as guides for the rotor over the surface.
5
4 Connect the P (pressure), T (tank) and D (drain) Dp
lines to the rotor, according to the diagram above.
5 Set the parameter F2:2 (Lance turning angle) to
0/0.
6 Connect the high pressure hose to the rotor.
During operation, keep the side supports on the scraper
at a constant distance from the surface to ensure correct The rotor holder is mounted directly on the cradle
alignment of the rotor. plate

The drain pipe (Dp) will leak some water during operation. The water origins from the seal inside the
rotor and is absolutely normal.

3
2

The protective scraped acts as a ground stop for the Cradle mounted rotor turned to the left.
protection of the rotor.

Automatic Level Sensing (option)

The Robot 322 is prepared for automatic level sensing. It means that the level of the feed beam/tool
assembly is kept constant to the surface by means of 4 rollers. These four rollers are mounted 2 by 2 on
each side of the feed beam/tool assembly. As they roll over the surface, the rollers activates sensors
indicating that it is too far OR to close to the surface. The system then adjust the boom extension and/or the
feed tilt function to compensate for that.
In Configuration menu F3:1 the choice is made:

1. 0=(N) or 1. 1=(Y)
When setting the Automatic level sensing to ON (1=(Y) ) the feed beam will automatically search for the
surface. This will continue while working in automatic mode. When pressing the STOP button on the remote
control box, Automatic Level Sensing is automatically turned OFF (0=(N)).
If the STOP button is kept pressed for more than 2 seconds, Automatic Level Sensing stays ON when
the STOP button is released.

27
Operation

General
The robot 322 is operated in one of two modes; manual or automatic. In manual mode, the robot is posi-
tioned on site for the cut. In automatic mode, the cut is performed.
There are several parameters that has to adjusted prior to commencing hydro demolition; number of
strokes, angle of attack, turning points and so on.
In the following pages, these proceedures will be explained.

Manual operation
There are basically three sub parts to operate; tracks, boom/feed and tool. All these functions are operated
with the joy stick on the control box in conjunction with the function selector switch. We will go through the
functions one by one.

Tracks
The tracks are operated in functions 1, 2, 3 and 5. Selecting function 1,
the joy stick increase the track width when it is pushed N(orth), decreases
the track width when pushed S(outh).
Pushed W(est) the carrier slides to the left, pushed E the carrier slides
to right. This function is also found in function 5.
Selecting function 2 enables HIGH track speed. This speed is not ad-
justable, while function 3 selects the speed set on the throttle valves. This
is also the speed used during stepping.
In this selection (2 or 3) the robot can be turned around its centre axis.
Function selector switch
A centre turn. Pushing the joy stick W runs the right track forwards and the
left track backwards. Pushing the joy stick E inverts the function.

Boom/feed beam
Function 4 operates the rotator and tilt function of the boom and feed beam. Pushing the joy stick W or E
operates the rotator. The joystick towards N or S operates the tilt cylinder for the feed beam.
These functions can be operated simultaneously, and are activated in manual as well as in automatic
mode.

Tool functions
Selecting function 7 activates the tool valves when the joy stick is manoeuvred. This function is slightly
different from the others in that respect that the function operates in joy stick position NW, NE, SW, SE, W
and E.
To operate the lance turning function, the joy stick is pushed N to begin with. Then the joy stick is moved
either NW or NE to activate the lance turning valves. The joy stick may be moved directly to NW or NE.
The same applies to the cradle function. Move the joy stick S first, and the over to SW or SE.
Pushing the joy stick due W (or E) activates the cradle movement cycle. I.e the lance turning turns to the
set angle of attack prior to moving the cradle. In this case it is important that he lance is positioned vertical
before starting the cycle. This feature is handy when setting the turning points since the lance will point to
exactly were it will be during the automatic sequence.

Automatic operation
In this mode some of the functions are disabled. The parameters you have fed into the PLC are used to
guide the robot during the hydrodemolition phase. Automatic mode is entered when the START button is
pressed. Automatic mode ends when the STOP button is pressed.
The START button has to be repressed every 2 minutes in order to reactivate the automatic cycle.

28
Communication

Connecting power packs

There are two separate scenarios when connecting the power pack: using a Conjet Power pack and using
a NON Conjet Power pack.
Using the Conjet power pack is by far the easiest scenario. The communication cable is attached to
socket XS2 on the robot and to the counter socket in the Conjet Power pack. Done. All necessary signal are
connected and the system is ready to go.
Using a NON Conjet power pack involves a little more effort.
As shown on the drawing below, the signal to load the pump are connected to pins 5,6 and 7 in socket
XS2. The emergency stop is connected between pins 3 and 4 in the same plug.

ES1 symbolises the control system in a Conjet Power pack.The HP is were NON Conjet Power
pack and Robot 322 meets.

NOTE: The Power pack / high pressure pump should only be activated through the robots control
system!

29
Operators terminal

Description
The operators terminal provides the operator with an interface to
the robots control system.
The terminal is a text based interface that can show 2 lines
with 20 characters on each.

When needed, the arrow keys are

used to display text and options not fitted on the screen. Some

values are toggled using the enter key while others are

entered as numeric values. To enter a numeric vale, one has to press NUM followed by the appropri-
ate numeric key.
The keys are:

Start of the machine

When the machine is started in the morning, the screen
beside is displayed. Notice the [*.]. Star and a dot. The left
star indicates that the zero point for cradle has been set,
while the right side dot indicates that lance turning zero
point has not. The system will proceed automatically when
the lance turning has passed the zero point once. This is done by selecting function 7 (cradle) and
operating the joy stick W and E until the zero points has been set.
The system need to see the ZERO POINT on every stroke why calibration in this system includes
passing the flag (or centre point for lance turning) once before the system is happy.
The different screens are accessed by pressing one of the four function keys; F1 to F4 as described
below.

F1: Monitor
This is the screen that is displayed after the zero points
has been set. It indicates as follows:
1. Current cradle position IN PULSES.
2. Time for cut. (Miuntes:seconds)
3. Cradle speed in meters / minute
4. Lance turning time.
5. Operating hours:minutes / high pressure
hours:minutes.
This screen is accessed at any time by pressing F1

30
F2: Parameters
As you can see, there are 4 main operational parameters needed for the day to day operation of the robot
322. These are:
1. Turning points for the cradle IN PULSES*.
2. Turning points for lance turning IN PULSES.
3. Number of strokes before stepping.
4. Step time.
*We have not converted the width or attack angle into millimetres
and/or degrees for the simple reason of ease of use. Rather than
saying that it is x amount of distance, we say it is x amount of pulses.

1. Setting the turning points for the cradle is done in one of two ways. Pressing ENTER with the cursor
on the > symbol moves the actual value (in square brackets []) to the appropriate side of the / sign. If the
actual position is negative, the value is moved to the left side of the / sign. Positive is moved to the right side
of the same sign. It is also possible to enter a numeric value in the two fields. Handy when adjusting the
width during the actual cut..
2. As for lance turning points the numeric value has to be entered, using the NUM key. Maximum is -8
and 8 were they correspond to approx. 30 degrees inclination on both sides. A total of 60 degrees.
3. The number of strokes have been maximized to 9 for forward and backward stroke.
4. The step time is exactly what it says. In the example above the step valves will open 1,2 seconds after
one stroke of the cradle. If number of strokes would have been set to 1/1, the valves would have opened 0,6
seconds for the step backwards. The speed is set with the track control valves.
This screen is accessed with F2

F3: Configuration
Here we find the seldom altered options. These are:
1. Level sensing 0=No 1=Yes.
2. Start direction.
3. Wait for step 0=No 1=Yes
4. Auto start delay. Maximum 9,9 seconds.
5. Turn on 0=Pulse 1=Flags.
6. Step on 0=TRacks 1=ROtor and 2 =MAst.

The level sensing option can be turned on or off in this selection. When turned ON, the tool will auto-
matically search for the surface. During automatic operation, the tool will automatically align to the surface.
When pressing the stop button, level sensing will automatically shut off, unless the stop button is kept
pressed for more than 2 seconds. After that time, level sensing will remain activated.
Start direction tells the lance to start turn towards left or right. Actually decides what side to step on
when setting an equal total larger than 2, of number of strokes (2/0, 2/2, 4/2 and so on)
Wait for step turned ON, waits for the step to complete before turning the lance.
Auto start delay allows pressure from the pump to build up prior to starting the lance turning and cradle
operation.
Turn on.. In case of a sensor failure in the motor, the ZERO POINT sensor on the cradle can be used for
turning width. Setting an extra flag on the other side allows the system to turn there when this option is set
to 1=Flags.
Step on.. activates the appropriate output valve for step.
This screen is accessed with F3.

31
F4: Alarms
4 alarms reside in the system. 1=Cradle, 2=lance turning and 3=ZERO point reference.
Any one of these activated turns the ZERO into a ONE.
0->1.
In line 2. we find the setting for cradle when turning on
flags. This is the maximum amount of seconds allowed for
a right to left side stroke and left to right side stroke. These
are set on the two potentiometers on the PLC...

Potentiometers for setting

the cradle alarm time when
turning on FLAGS

Parameter limits
The following values are the min. and max. values allowed to enter:
Function Min/max values Units
F2:1 Turning points for cradle -9999 to -3 / 3 to 9999 Pulses from motor
F2:2 Turning points for lance turning -8 to 0 / 0 to 8 Pulses from flags
F2:3 Number of strokes before stepping 0 to 9 / 0 to 9
F2:4 Step time 0 to 9,9 Seconds

F3:4 Start delay 0,1 to 9,9 Seconds

F4:2 Alarm time 0 - 255 / 0 - 255 Seconds

32
Test demolition

Preparations

DANGER!
Make sure before you start, that the area around the unit (Robot),
is safe and that the surroundings are protected against flying de-
bris. Personnel using the equipment shall read this manual, or in
some other way be trained for the equipment, before operating.
Personnel, operating and assisting the operation of the Robot,
shall wear protective clothing according to page 8. (For more in-
formation see the ‘Recommendations for the use of High Pres-
sure Water Jetting’, section 6: Protective Clothing and Personnel
Protection’).
Make sure that the protective hood over the robot is securely fas-
tened before commencing operation! The operator has the respon-
sibility for the working area.
MAKE SURE THAT THE JET IS AIMED AT THE
WORKING SURFACE, PRIOR TO STARTING THE He has to make sure that no
HIGH PRESSURE WATER PUMP! unauthorized personnel are
within the working area of
NEVER, UNDER ANY CIRCUMSTANCE, AIM THE WATER JET
the unit at any time.
AT ANYTHING ELSE THAN THE HYDODEMOLITION TARGET.
I.e. THE CONCRETE SURFACE!
FAILING TO DO SO MAY RESULT IN FATAL INJURY OR SEVERE DAMAGE!
MAKE SURE THAT THE PROTECTION IS FITTED AND FUNCTIONING PRIOR TO COMMENCING THE
WORK! ENSURE THAT THE PROTECTION COVERS THE PATCH AS FAR AS POSSIBLE!
WHEN WORKING ON FLOORS, WALLS OR IN CEILINGS, CONSIDER THE RISK OF “BLOWING
THROUGH”THE CONCRETE SURFACE AND TAKE PROPER ACTION TO SECURE THE DANGER AREA
ON THE “OTHER” SIDE OF THE CONCRETE SURFACE.

Protective hood Hose arresters

Protection

Preparing the Robot 322 for a test demolition

33
Setting up for a test demolition
1 Attach the control box to the electrical socket marked XS1, on the robot.
2 Connect the power pack communication cable to the socket marked XS2.
3 Attach the high pressure hoses and the hose arrester/s to the rotor/oscillating cassette. Use two hose
arresters / wire mesh hoses, in-between two high pressure hoses.
4 Connect the electrical supply to the robot. (Correct the phase sequence if necessary).
5 Select function 0 (ZERO) and start the motor.
6 Set zero points for the cradle and lance turning.
7 Select and set the parameters that you will use. (Turning positions, angle of attack, number of strokes
and step time)
8 Set speeds of the different functions; cradle, lance turning, oscilttation and step.
9 Adjust the nozzle height, so that the nozzle nut tip is approximately 15 mm from the surface with the
lance at zero degrees. This is done by levelling the feed beam system and afterwards adjusting the
lance in its holder.

Make sure that the protective hood seals against the surface!

10 Start the Power pack and allow it to “air out” before commencing operation.
11 Press the START button and make a short test cut. Readjust the parameters if necessary, to suit the
specific job.

Fig.
Always use HOSE ARRESTERS
(2). Secure them with shackles (3).
Connect the chain from the feed
beam to the hose arrester on the
hose to unload the oscillating
cassette during operation.
Failing to unload the oscillating
cassette could mean operational
problems

Note! Don’t adjust more than 2

parameters at the time!

34
Service and maintenance
The only way to keep your equipment in good working condition,
is to persistently carry out the necessary service and maintenance
at regular intervals. The equipment is exposed to a very wearing WARNING!
environment . The concrete-paste mixed water, acts like grinding
paste on the body works. If it accidentally enters the hydraulic
system, it might suffer severe damages, which will create down-
time, unless the right spare parts are at hand.
NOTE: Oil spill on a cut surface will destroy the bonding for the
new concrete.
Only use Conjet AB’s Original spare parts. Before attempting serv-
icing the equipment; turn off main power supply, unload the hy-
draulic system (rest boom system against surface, apply brake Hydraulic oil can reach
blocks on wheels etc.).
temperatures above
60º C / 140º F.
ONLY PERSONNEL WITH APPROPRIATE KNOWLEDGE, SHOULD ACCESS THE SYS-
Beware of the risk for
TEM.
skin wounds!
Avoid direct skin
NOTE: When replacing the electrical motors, the phase sequence
has to be individually checked for that component. The phase might contact with hydraulic
not be correct, even if warning is not displayed on the screen. oil. Use protective
gloves!

35
Preventive Maintenance The equipment should be
that should be carried out ... washed and cleaned at the
end of every shift, in order
to prevent the concrete to
every shift / 8 operating hours*; harden (or burn), onto the
machine.
(8:1) Check hydraulic oil level (refill with correct, quality oil only).
(8:2) Check and grease (1x nipple) oscillating cassette and all moving
parts, for loose bolts, damages and wear. (See Torque List later in this manual).
(8:3) Check the control- and power cables for damages and wear.
Apply some contact spray to the control cable connections XS1 and XS2.

NOT the XS3!

(8:4) Check the high pressure components for wear and damages. (Nozzle, nozzle nut etc.).
(8:5) Check the hydraulic hoses and nipples for wear and leaks.
(8:6) Check and grease the cylinder attachments (6x nipple).

Check locking devices for cylinders and boom head.

(8:7) Check condition of hose arresters. Replace if necessary.

(8:8) Check the nozzle and nozzle nut, for wear. Replace if necessary
(8:9) Check sensors and cables for damages.
(8:10) Check the function of emergency stops.
(8:11) Check the play in the plain bearings for boom system.

every week / 40 operating hours*;

(40:1) Check the protective rubber skirts on the feed beam.

(40:2) Check the bolt torque for the boom head assembly and feed beam.

(40:3) Check track tension and adjust if necessary.

(40:4) Check oil cooler cells. Clean if necessary.
(40:5) Check oil return line pressure. Replace return line filter cartridge if pressure is too high.
(40:6) Check oil pressure. Adjust if necessary.
(40:7) Check rollers on cradle plate, adjust the play if necessary.

every month / 160 operating hours*;

(160:1) Check for water in the hydraulic oil. (Replace if necessary).
(160:2) Check tension from the transformer T1.

every six months / 960 operating hours*;

(960:1) Change the hydraulic oil and filter cartridge.
(960:2) Change gear oil in the rotator.
(960:3) Change gear oil in the tracks.

* Which ever comes first!

36
Maintenance points and torque table

40:4 8:5

8:9
960:4
40:5,6

8:2

Item 40:4, 40:5, 40:6, 160:2, 160:4, 960:1,

40:7

Items 8:2, 8:4, 8:5, 8:7, 8:8, 8:9, 40:7

960:3

8:1

160:1

Item 40:3, 960:3 Items 8:1, 160:1

8:3
8:3

8:3 Bolt 8.8 10.9 12.9

M8 24 Nm 33 Nm 40 Nm

M10 47 Nm 65 Nm 79 Nm
8:3
M12 81 Nm 114 Nm 136 Nm

Item 8:3, 8:10 M14 128 Nm 181 Nm 217 Nm

M16 197 Nm 277 Nm 333 Nm

37
Lubrication points

8:5
8:6
8:6
8:2

Item 8:5, 8:6 Item 8:2, 8:5

960:2

8:11
8:6 40:2

8:6
8:6
8:6
8:6
40:1 8:6

Item 8:6 Item 8:6, 8:11, 40:1, 40:2, 960:2

Recommended lubricants
Grease nipples: NLGI class 2
According to DIN 51 818
Rotator gears: ISO VG 150
Volumes: Track gears = 2 x 0,3 l
Rotator gear = 0,5 l
Hydraulic system: Tellus T46
Viscosity grade: ISO VG 46
Temperature range: +15°C to +30°C
Volume: 40 Litres

Note: If you are working in extreme ambient temperatures,

please contact your dealer for a replacement oil quality.

38
Induced sensors
Hydraulic motor
Pulse sensor for cradle
When replacing the sensor for cradle pulses, it is of great importance
that the sensor is remounted correctly. O-ring
The sensing range is very short (0,8 mm) so the sensor has
to be shimmed as it was from factory.
The motor has a marking near the mounting hole for the
sensor that indicates the thickness of the necessary shims.
The shims are available in four different thicknesses: 0,1
- 0,2 - 0,3 and 0,5 mm.
Transducer
The marking determines the total thickness of the
shims.
Shaft Shims

For example: Pulse sensor for cradle motor

ð the motor is marked 6.

ð the shim thickness is totally 0,6 mm.

NOTE: Maximum torque: 30 +-5 Nm!

Remounting the sensor placing the correct amount of shims on the sensor.

Refit the O-ring onto the sensor and mount the sensor into the motor.

Pulse sensor for lance turning and zero point reference

The sensors for lance turning and zero point reference
are of the same type. They have a sensing range of 4 mm.
Therefore it is important that the triggering object (flag) is SENSOR
within this range.
Setting the distance is done by means of the two lock FLAG
nuts on the sensor. It is important that excessive force is
not used when mounting the sensors.

Sensor for zero point reference

Adjustment of lance turning sensors

The sensors may have to be adjusted after replacement.
They have to be set so that S206
√ they both give signal (inputs X2 AND X3) when the
lance is in the vertical position. (Zero degrees)

√ the flag completely passes the sensor (NO signal

on input X2 or X3) when the lance is turned maxi- S205
mum to left or right. (30 degrees)
The sensors are adjusted sideways in its holder after Sensors for lance turning position
loosening the plastic nut.
Make sure that the sensor is mounted with the same gap as before. 1-3 mm from the sensor flag.

39
Transformer tension control
Checking the transformer tension should be done at regu-
lar intervals. Too high tension (>30VDC) is harmful to the
electrical components, while too low tension could disrupt
the operation.
The tension is checked either in the transformer itself,
after dismounting the protective hood on the robot and
the protective plate over the transformer connections
(framed).
Set the measuring probe well above 24VDC before
measuring.

Cover plate on transformer T1.

WARNING!

HIGH TENSION!
Only qualified
electricians should
perform this task!

Return line oil filter change

Replace the filter insert at least once every six months, or when the 1
return line pressure, located on the return filter housing, exceeds
1,4 bar (20 P.S.I.). NOTE: the oil should be at normal operational
temereature!
Filter lid
To replace the insert stop the hydraulic pump and undo the filter lid
(1).
Lift out the filter insert (2)
Check the inside of the filter housing and clean out all particles
that might be caught inside.
Push the new filter insert into the housing. Make sure that the Return filter
insert seats in the bottom of the housing. Position the lid and re- housing
mount the lid by hand.

WARNING! 2

Hydraulic oil can

reach temperatures
above 60 degrees Filter insert
Celsius.
Beware of the risk
for skin burns!
Avoid direct skin
contact with
hydraulic oil. Use
protective gloves!
Return line filter assembly

40
Adjusting pressure relief valves
The pressure relief valves installed in the cradle and boom rotator circuits, serves as load holding valves. I.e.
when leaving the feed beam in vertical position, the cradle remains in the same position, without falling
down uncontrolled.
The cradle will however move slightly, due to the internal leakage in the motor. This is normal. The
pressure relief valves are adjusted from factory, but may need some fine tuning on the specific machine.

Cradle motor
The valve is mounted in the tower for boom rotator. The
valve should be adjusted so that;
n No noise is heard when operating the cradle
n The cradle remains in position with feed
Adjustment screw on the
beam vertical. pressure relief valve
To adjust
Remove the cap nut, that locks the set screw and adjust
the allen head screw one complete turn (clock wise or anti-
clock wise). Refit the cap nut.
Repeat until the function is OK.

Adjustment screws on the

pressure relief valve

Load holding valve for the cradle motor

Rotator motor
The rotator load holding valve is equal to the cradle motor
load holding valve. There is however a slight difference in
the connection of the two.
The load holding valve for the rotator is equipped with a
hose connecting to the negative1 brake for the rotator.
In all other respects, they are the same.

Load holding valve for the rotator motor

1 Brake is released when pressure is applied

41
Replacing hydraulic lines
When a hydraulic hose shows signs of wear, it should be replaced. Conjet AB uses type R2AT hoses

Keep in mind that the hydraulic oil can be very hot.

Coming into contact with the hot oil will cause injury!
Refit the protective covers around the hose, after replacement. And as with all hydraulics, cleanliness is
of the essence! Use plugs for open ends. Make sure that the hose is not pinched or twisted, not even
pressurized, after refitting a new hose.

Lance turning actuator

After replacing a hydraulic hose to the lance turning actuator, it is impor-
tant that all air is evacuated from the circuit. This is done by attaching a
hose between the two normally plugged connections on the actuator.
With the hose in place, manouvre the feed beam and oscillating cas-
sette so that it becomes the robots highest point. At this point, open the
throttle check valves for the lance turning circuit maximum and operate the
lance turning function for approximately 1 minute. (The actuator may or may
not move, but that is normal.)
Refit the plugs on the actuator and bring down the feed beam to nor-
mal position again.
The hose fitted to the actuator
for evacuating the air

Hydraulic cylinders
The hydraulic cylinders may need the same type of “airing-out”. The symptom of air in the circuit is lack of
power in the function, or an unsteady motion of it.
The safetst way of eliminating the intrusion of air, during a hose replacement, is to fill the hose with
correct quality of hydraulic oil, prior to fitting it.
If that is not possible, air may be bled from the circuit after fitting the hose.

Replacing the plain bearings in boom system and

track holders
The plain bearings in the boom and track systems should NOT be greased, since the concrete mixes with
the grease and forms an excellent grinding paste. NOTE that plain bearings are also mounted on the boom
systems INNER tube. Only accesible after dismounting the plain bearings in the OUTER tube!

OUTER TUBE

INNER TUBE

Outer plain bearings for boom system with Plain bearings in the track extension bracket with
moutning screws ( 16+16) circled. moutning screws (24 x 2) circled.

42
Tracks

Checking track tension

To check the track tension, position the unit on a flat surface. Lift the carrier using the lifting eye, off the
ground so that the tracks hangs free. Measure the distance at the centre roller to the track, according to the
picture.
The measurement should be between 10 to 15 mm.

Track tension from centre roller to track.

Adjusting track tension

The grease contained in the hydraulic track is
pressurised. Never loosen the grease valve (1)
more than one [1] turn! If the valve is loosened
too much you risk expelling grease under pres-
sure and possible injury to the operator. This also
applies to grease nipple (2).
Remove gravel and mud prior to adjusting the 3
track tension!
Tightening
1 Remove the cover plate (3) to ac-
cess the adjustment system.
2 Connect a grease gun to the grease
nipple (2) and add grease until ten-
sion falls inside the specified values.
(10 to 15 mm).
1
Loosening
2
1 Remove the cover plate (3) to ac-
cess the adjustment system.
2 Turn the grease valve (1) counter
clock wise no more than one [1]
turn. That is enough to loosen the
track.
3 If grease doesn’t drain, slowly ro-
tate the track. Adjusting the track tension
4 When correct track tension is obtained, re-tighten the grease valve.

43
Oscillating cassette
The oscillating cassette needs overhauling from time to time. The wear parts in the oscillating mechanism is
the oscillating bearing on the driver shaft.
By applying some grease on a regular basis, lifetime is maintained.

Replacing the oscillating bearing

Start by removing the bearing cover on the bearing housing (pic-
ture 1).

Picture 1

Then undo the bearing nut with the special tool attached to the
oscillating cassette (picture 2)

Picture 2

Remove the complete bearing housing by first removing the bolts attaching the rubber damper to the
lance attachment (picture 3) and pry the housing off the damper (picture 4) using screwdrivers or similar.

Picture 3 Picture 4

44
 Inspect the seal mounted in the bearing housing (NOTE:
the seal SHOULD be mounted “inside-out”) and replace if
necessary (picture 5).
Tap the bearing out of the housing, inspect the housing
and fit a new bearing.

Picture 5

Check the grease nipple in the bearing housing cover

and install a new if damaged.
NOTE: after remounting the bearing cover, check that
there is a slight play between bearing housing and the bear-
ing cover (picture 6).

SLIGHT PLAY

Picture 6

45
Replacing the driver motor
The motor is replaced from the other side of the oscillating housing.
Start by removing the bolts attaching the motor to the driver
(picture 7)

Picture 7

Insert short screws into the holes. These can be used as pry
points when removing the motor (picture 8).

Picture8

Remove the motor from the driver. (picture 9)

Check the condition of the key and replace if necessary.
Remount the motor in the reverse order.

Picture 9

46
Replacing the driver bearing
The driver bearing or the driver itself may need replacement. The driver and bearing are accessible after
removing the oscillation motor.

Remove the lid over the driver bearing (picture 10).

NOTE: this seal is mounted as normal!. Not “inside-out”!

Picture 10

Remove the motor and tap out the driver and bearing (picture 11)

Picture 11

Remove the circlip on the driver and press the bearing off
the driver (picture 12)
(When refitting a new bearing on the driver, a hydraulic press
may be needed.)

Picture12

47
Reaction forces

General
The robots ability to cope with flow and pressure is, in the case of Robot 322, measured in reaction force.
That is a more true way of determining how much the design can operate
with.
Reaction force is a function of the available flow (litres or gallons per
minute) and pressure (in bar or PSI)

The Robot 322, WITHOUT BOOM SYSTEM EXTEN-

SION, can operate with a maximum reaction force
of 1 400 N.
WITH the boom system extension, a maximum of
950 N is allowed!

Calculating reaction force by using

the formula
Discharge velocity (V) Boom system extension

V= P * 0,98 * 14,01

Reaction force for water jets (Fr)

Fr = V * Q * 0,017
Abbrevations Conversions
Fr = Newton 1 BAR = 14,5038 PSI
Q = Litres/minute 1 L = 0,26 US Gal.
V = Metres/second 1 L = 0,22 UK Gal.
P = Bar
As an example;
You want to use 1 100 bar at 120 l/minute. In order to calculate the reaction force, You need to know the
discharge velocity. By using the formula above You get the following results:

1 100 = 33,166
33,166 x 0,98 = 32,5
32,5 x 14,01 = 455,36 m/sec.

Now You can continue to calculate the reaction force..

455,36 x 120 = 54 643,51
54 643,51 x 0,017 = 928,94 N

The reaction force (Fr) from the example above equals 929 N. That is well below the maximum allowed
reaction force for the robot 322.

48
 Tables

Reaction force as a function of pressure and flow

The values inside the square are the reaction forces (Newton) generated when using the flow of water
(Q=litres/minute) at the stated pressure levels (BAR).
Values < 1 400 N are within the acceptable range WITHOUT boom system extension: ○ ○ ○ ○ ○ ○
Values < 950 N are within the acceptable range WITH boom system extension:
Pressure (BAR)
Q 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500
35 231 245 258 271 283 295 306 316 327 337 347 356 365 374 383 392 400 408
45 297 315 332 348 364 379 393 407 420 433 446 458 470 481 493 504 515 525
55 363 385 406 426 445 463 480 497 513 529 545 560 574 588 602 616 629 642
65 429 455 480 503 526 547 568 588 607 626 644 661 678 695 712 728 743 759
75 495 525 554 581 606 631 655 678 700 722 743 763 783 802 821 840 858 875
85 561 595 627 658 687 715 742 768 794 818 842 865 887 909 931 951 972 992
95 627 665 701 735 768 799 830 859 887 914 941 967 992 1016 1040 1063 1086 1109
105 693 735 775 813 849 884 917 949 980 1010 1040 1068 1096 1123 1150 1175 1201 1225
○ ○ ○ ○
115 759 805 849 890 930 968 1004 1040 1074 1107 1139 1170 1200 1230 1259 1287 ○1315 1342
○○ ○1337
○ ○ ○1368
○ ○ ○ ○
125 825 875 923 968 1011 1052 1092 1130 1167 1203 ○
1238 1272 1305 1399 1429 1459
○ ○ ○ ○
135 891 945 996 1045 1092 1136 1179 1220 1260 1299 ○1337 1373 1409 1444 1478 1511 1544 1575
○ ○ ○ ○ ○ ○
145 957 1015 1070 1122 1172 1220 1266 ○
1311 1354 1395 1436 1475 1514 1551 1587 1623 1658 1692
155 1023 1085 1144 1200 1253 1304 ○ ○
○1354 1401 1447 1492 1535 1577 1618 1658 1697 1735 1772 1809
165 1089 1155 1218 ○ ○○
1277 ○1334
○ ○
1389 1441 1492 1540 1588 1634 1679 1722 1765 1806 1847 1887 1926
○ ○
175 1155 1225 1292 ○1355 1415 1473 1528 1582 1634 1684 1733 1780 1827 1872 1916 1959 2001 2042
185 1221 1295 ○ ○
○1365 1432 1496 1557 1616 1672 1727 1780 1832 1882 1931 1979 2025 2071 2115 2159
195 ○ ○
1287 ○1365 1439 1510 1577 1641 1703 1763 1821 1877 1931 1984 2035 2086 2135 2183 2230 2276
○
205 1353 1435 1513 1587 1658 1725 1790 1853 1914 1973 2030 2086 2140 2193 2244 2295 2344 2392
215 1419 1505 1587 1664 1738 1809 1878 1944 2007 2069 2129 2187 2244 2300 2354 2407 2458 2509

Max. flow for given pressure and reaction force (Fr)

The values inside the square are the maximum flow of water (litres/minute) you can use at the stated
pressure levels (BAR) for the two reaction force (F r=Newton) levels (950 and 1 400 Newton)
Pressure (BAR)
Fr 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500
950 144 136 129 123 118 113 109 105 102 99 96 94 91 89 87 85 83 82
1400 212 200 190 181 173 167 161 155 150 146 142 138 134 131 128 125 123 120

Max. flow for given pressure and nozzle diameter (Ø)

The values inside the square are the flow of water (litres/minute) required for the stated pressure (BAR).
Pressure (BAR)
Ø 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500
1,2 24 26 27 29 30 31 32 33 35 36 37 38 39 40 41 41 42 43
1,3 29 30 32 34 35 37 38 39 41 42 43 44 45 46 48 49 50 51
1,4 33 35 37 39 41 42 44 46 47 48 50 51 53 54 55 56 58 59
1,5 38 41 43 45 47 49 51 52 54 56 57 59 60 62 63 65 66 68
1,6 43 46 49 51 53 55 57 59 61 63 65 67 69 70 72 74 75 77
1,7 49 52 55 58 60 63 65 67 69 71 74 76 78 79 81 83 85 87
1,8 55 58 61 64 67 70 73 75 78 80 82 85 87 89 91 93 95 97
1,9 61 65 68 72 75 78 81 84 87 89 92 94 97 99 102 104 106 108
2,0 68 72 76 80 83 87 90 93 96 99 102 105 107 110 113 115 118 120
2,1 75 79 84 88 92 95 99 102 106 109 112 115 118 121 124 127 130 132
2,2 82 87 92 96 101 105 109 112 116 120 123 127 130 133 136 139 142 145
2,3 90 95 100 105 110 114 119 123 127 131 135 138 142 145 149 152 155 159
2,4 98 104 109 115 120 125 129 134 138 142 147 151 155 158 162 166 169 173
2,5 106 113 119 124 130 135 140 145 150 155 159 163 168 172 176 180 184 188
2,6 115 122 128 135 141 146 152 157 162 167 172 177 181 186 190 195 199 203
2,7 124 131 138 145 152 158 164 169 175 180 186 191 196 200 205 210 214 219
2,8 133 141 149 156 163 170 176 182 188 194 200 205 210 216 221 226 230 235
2,9 143 151 160 167 175 182 189 195 202 208 214 220 226 231 237 242 247 252
3,0 153 162 171 179 187 195 202 209 216 223 229 235 241 247 253 259 265 270
3,1 163 173 182 191 200 208 216 223 231 238 245 251 258 264 270 277 282 288
3,2 174 184 194 204 213 222 230 238 246 253 261 268 275 282 288 295 301 307
3,3 185 196 207 217 226 236 244 253 261 269 277 285 292 299 306 313 320 327
3,4 196 208 219 230 240 250 260 269 277 286 294 302 310 318 325 333 340 347

49
Stability
The stability for the Robot 322 has been calculated focusing on the robots tilt angle against the horizontal
surface. The calculations has been made with the assumption of 140 Nm in reaction force and 350 N extra
load at the nozzle.
The calculations are based on the assumption that the tracks are extended as far as possible, in order to
optimize the stability. That means that in positions 3 - 7, the track is extended 400 mm in the direction of the
X-arrow. In positions 1,2,7 and 8, the carrier is placed in the centre of the tracks.
The black stripe in the drawings, symbolises the cradle position.

Allowable inclinations
The following indications should be used as guidelines.
max angle max angle
Description / position (no counterweight) (with 50 kg. counterweight)
Transport position, 1 and 2 29° 34°
Vertical hydrodemolition1, 5 and 6 23° 26°
Under/up hydrodemolition1, 7 and 8 8° 10°

Pos.1 Pos.3 Pos.5 Pos.7

Pos.2 Pos.4 Pos.6 Pos.8

When working in slopes, the robot should always have the

feed beam, or rotor, facing up the slope!

For optimum stability, ensure a track width of min. 1 000

mm during operation!

1
Calculated reaction force = 170 Nm

50
High pressure hoses

General
Several types of high pressure hoses are available. They are selected from the available flow and working
pressure of the high pressure pump. As a general rule of thumb, working pressure of the hose should never
be less than the maximum working pressure of the high pressure pump.
Failing to select the correct high pressure hose could cause severe injury to personel
working with the robot.
Conjet AB primarily uses two types of high pressure hose; the 4000 series or the 6000 series with the
dimensions 1/4”, 1/2 or 3/4”. The difference between the 4000 series and the 6000 series is the pressure
reinforcement of the hose.
The high pressure hoses should be “looked after”. With that meaning that the hose should be protected
against unnecessary outer abuse. Such abuse could be trucks and cars running over the unprotected hose,
a too small bending radius, a direct hit from the high pressure water and so on..
Should the hose be layed out on site with a chance of vehicles running over it, the high pressure hose
should be placed in a artificial groove. I.e planks, or similar, with the same height as the selected high
pressure hose, on each side of the hose.

Technical specifications

Series 4000 STW

Inner core: DN 6(1/4”)=Polyoxymethylene, DN 12(1/2”) and 20(3/4”)=Polyamide
Pressure reinforcement: Four spiral layers of high tensile steel wire
Outer cover: Polyamide
Colour: Blue

Series 6000 STW

Inner core: DN 5(1/4”)=Polyoxymethylene, DN 12(1/2”) and 20(3/4”)=Polyamide
Pressure reinforcement: Six spiral layers of high tensile steel wire
Outer cover: Polyamide
Colour: DN 5(1/4”)=Blue, DN 12(1/2”) and 20(3/4”)=Black

Data
Series STW DN Max.working pressure Min.bending radius1 Weight

4006 6(1/4”) 1 640 bar 155 mm 325 g/m

40122 12(1/2”) 1 300 bar 200 mm 820 g/m
40202 20(3/4”) 1 000 bar 250 mm 1 390 g/m
6005 5(1/4”) 2 500 bar 150 mm 405 g/m
6008 8(5/16”) 2 500 bar ? mm ? g/m
60122 12(1/2”) 1 800 bar 300 mm 1 360 g/m
60202 20(3/4”) 1 400 bar 350 mm 1 815 g/m

1 Minimum allowable bending radius at the inside of bend

2 Covered with black rubber

51
Trouble shooting

General
Since the Robot 322 will work in a very demanding environment including water, moisture, flying debries,
vibration etc., “things” may fail. It may be a hydraulic component, a electrical cord or an operator mistake
that causes the down-time. The important issue is to determine the source of failure and minimize down-
time.
In order to determine the source of failure it is of great importance that the trouble shooter has a good
knowlege of the normal function of the Robot 322. I.e how is it supposed to work..
Without understanding the function of the Robot, trouble shooting may turn out to a “replace-it-and-
hope-that-it-works”-type of operation.
To keep the documentation at hand, is important. Also important is to have the right tools for trouble
shooting the unit. A digital instrument and a set of tools that covers the basic needs for maintenance.

Systematic approach
As time is money, in most cases, a systematic approach is vital. Below, you will find a few examples that will
try to point out how the systematic approach is thought to be performed.

l Let us assume that the unit is operating along in automatic mode, when all of a sudden the cradle
fails to start after lance turning. What’s wrong?
Questions: is it the cradle function that has failed OR is it lance turning? Is the problem electric,
hydraulic, mechanincal or operational?
To find out, check the easiest items first:
l did the operator forget to restart automatic operation? Yes or No.
l test the function in manual mode. Turn selector switch to position 7 and the joystick SW and SE.
Did the cradle work?
l turn the joystick NW and NE. Did lance turning work?
l now turn the joystick W and E. Did the cradle start when lance turning completed?
Continue with the more demanding tests by removing the hood and check:
l LED on vavle section. Do they illuminate when the function is activated?
l hydraulic pressure. Is it 140 bar when a function is activated?
Continue with the most demanding tests by opening the electrical cubicle and check:
l incoming tension. Is it according to specifications?
l 24VDC circuit. Is it within specifications?
l inputs to the PLC. Are they illuminating according to settings?
l outputs from the PLC. Are they illuminating according to operated functions?
By creating a list of actions, checking them one by one and evaluate the results, the failing part is more or
less circled.

Examples of what is supposed to happen

The following should happen in order to move the..
CRADLE l function key in position 7; inputs X10, X11 and X12=ON
l joystick SW or SE; input X6+X5 or X6+X7
l output to valve section Y3; output Y4=Y3:A, Y5=Y3:B
LANCE TURNING l function key in position 7; inputs X10, X11 and X12=ON
l joystick SW or SE; input X4+X5 or X4+X7
l output to valve section Y4; output Y6=Y4:A, Y7=Y4:B
These two examples applies to the remaining functions as well, but the in and outputs differ according to the
electric- and hydraulicschematics. In order to operate any function, correct hydraulic pressure is assumed!

Tip!
LOOK FOR THE OBVIOUS FIRST! Before embarking on the trouble shooting ship, review the settings once
more. Is the unit calibrated? Is the throttle valve open? Is the motor running? Is the alarm reset? Is the
pump connected properly? Is the control box connected?
It is easy to overlook even the most ovious cause for failure....

52
Trouble shooting table

Problem/symptom Probalble cause Solution

Wrong phase indication The phases (R,S and T) arrive in Alter the phase sequence by turn-
the incorrect order (S,R and T), ing the phase switch in the incom-
running the electrical motor in the ing power socket
wrong direction.

Not all phases (R,S and T) arrive. Check ALL phases and correct at
the source. Check fuse F1.

No function activates. No signal to load hydraulics. Check output Y2 and LED on valve
section Y1.
No hydraulic fluid in the hydraulic Top up with correct quality oil.
tank.
Motor will not start when pressing Wrong phase. Check phase sequence on input
the Motor Start button. X20. (The indicating lamp might be
broke.)
Tension is to low. Check tension between all phases.

No signal on input X21 when start Check connection between the

button is pressed. Motor Start button and input X21.

No power to the relay K1 Check output Y0 for tension on out

put according to diagram.

Function selector is NOT in posi- Turn function switch to 0

tion 0
Automatic operation will not start No signal on X14 when not press- Check connection from STOP but-
when START is pressed. ing STOP ton in control box to input X14,
according to diagrams.

No signal on X13 when pressing Check connection from START

START button in control box to input X13,
according to diagrams

Operate the cradle pass the ZERO

Cradle is not calibrated.
flag on the feed beam.

Lance turning is not calibrated Operate lance turning left to right

and right to left. Align the lance
turning vertically.

Calibration is not possible. The No signal on input X1 when cali- Check that the flag is present on
dots on the main screen [..], does brating the cradle. the feed beam.
not change to stars [**].
Inputs X2 and X3 does not acti- Check that the sensor gives a sig-
vate simultaneously when lance is nal when activated manually.
vertical. First check that the sensors gives
a signal to the PLC. If so adjust
the sensors in the holder so they
activate simultaneously when the
lance is vertical.

53
System diagrams

Hydraulic system

54
55
System diagrams

Diection of rotation

56
System diagrams

Electrical system

57
58
59
60
61
62
63
64
65
66
67
68
69
 enter key 30 J
Index Eye Protection 10
Joystick 19
F joystick 13
F1 15 K
Specialtecken F1 FALLS 16
F1: Monitor 30 K1 15
4000 STW 51
F2 15 K2 15
6000 STW 51
F2: Parameters 31 K3 15
A F3 15 L
actual cradle position 16 F3: Configuration 31
F4: Alarms 32 Lance turning 22
arrow keys 30
Feed slide 19 Level glass 21
attachment 12
Feed tilt 23 Level Sensing 27
Automatic fuse 24VDC 15
Feed tip 23 lifting eye 11
Automatic fuse 400VAC 15
feed tip 19 Listing - PLC in/output 17
Automatic Level Sensing 27
Filler cap 21 Load high pressure 15
Automatic operation 13, 28
flag 16 Load hydraulics 23
automatically search 27
flow for given pressure 49 load the pump 29
B flow for given pressure and lubricants 39
nozzle diameter 49 Lubrication points 38
bearing housing 44
flow for given pressure and
Body protection 10 M
reaction force 49
boom 12
Flying debris 9 main cubicle 14
Boom extension 19, 23
Footwear Protection 10 main functions 13
Boom/feed beam 28
formula 48 Main motor start 14
C frequencie 14 Main power inlet 15
function keys 30 Main power switch 14
Calculating reaction force 48 function selector switch 18 Main switch 15
Calculating the capacity 7 function switch 17 Maintenance points 37
Cassette mounted 26 Manual operation 28
Connecting power packs 29 G maximum reaction force 24
Connection table for function Mechanical system 24
Good bonding 7
switch in control bo 17 motor 12
Connection to control box 15 H Motor starter 15
Connection to Power Pack 15 Mounting the rotor 26
Contactor 15 H1 14
H2 14 Moving the robot 19
control box. 12
Cradle control Hand Protection 10 N
Lance turning control 19 Head Protection 10
high pressure hose 51 Noise 10
Cradle motor 41
HOSE ARRESTERS 34 NUM 30
cradle motor 16
hose arresters numeric key. 30
Cradle mounted 27
wire mesh hose numeric values 30
Cradle movement 22
chinese fingers 34
O
D hydraulic controls 12
Hydraulic system 21 oil filter 40
driver motor 46
hydraulic valves 16 oil tank 21
E Hydrodemolition in general 7 Operation 28
Operators terminal
E100 14 I 13, 14, 30
Ear Protection 10 Optocoupler 15
Induced sensors 39
Electrical motor 21 Original spare parts 8
Input listing 17
Emergency medical informa- oscillating bearing 44
install the cassette mounted
tion 11 Oscillating cassette or rotor?
rotor 26
Emergency stop 14, 20 26
install the cradle mounted
Emergency stop circuit 16 oscillating housing 46
rotor 27
Emergency stop circuit reset oscillation 20
14 Output listing 17
Emergency stop relay 15

70
P Step selector switch 20 Y3 22
sub-frame 24 Y4 22
P21 15 symbols 25 Y5 22
Parameter limits 32 System controls 15 Y6 22
PHASE SEQUENCE 16 Y7 23
Phase sequence relay 15 T Y9 23
phase sequence switch 15
tarps 9
plain bearings 42 Z
tension 14
play 45
Test demolition 33 zero point reference 39
PLC 15
thermometer 21
PNOZ 15, 16
throttle valves 21
power rating 14
tilt angle 50
pressure and flow 49
tilt cylinder 24
Pressure manometer 21
Tilting and rotating 19
Pressure reinforcement 51
tilting device 12
pressure relief valves 41
Tool functions 28
Preventive Maintenance 36
Tool RPM control 23
Protective Clothing 10
Tool selection 26
protective hood 34
Tool selector switch 20
pump circuit 17
torque table 37
Q track holders 42
Track position control 22
Q1 14, 15 Track speed control 22
R track tension 43
Track width control 18
Reaction forces 48 Tracks 28, 43
Recommended lubricants 39 tracks speed 12
Repinning 24 Transformer 40
Replacing hydraulic lines 42
Hydrulic cylinders 42 U
Restart Automatic 14 unloading the oscillating
Return line filter 21 cassette 34
Return line oil filter 40
Rotator motor 41 V
Lance turning angle 26, 27
W-L 15
rotor 20, 26
valve sections 21
rubber damper 44
Volumes 39
S Work area 9
Work light output socket 15
S1 14 working pressure 51
Safety wrong phase 12
Common procedures 9 wrong phase indicator 12
Safety instructions 8 Wrong phase light indicator
sensor for cradle 39 14
sensor for lance turning 39
Series 4000 STW 51 X
Series 6000 STW 51
XS1 15
Service and maintenance 35
XS2 15
setting the Automatic level
XS3 15
sensing 27
SH3 14 Y
SH4 14
shut down the high pressure Y1 23
pump 17 Y10 23
side slide 19 Y12 22
stability 50 Y13 22
standard attachment 12 Y14 22
Start of the machine 30 Y15 22
Starting the robot 18 Y2 23

71