QC-1210 Quick Change Install and Operate PDF

Quick-Change QC-1210
Robotic Tool Changer

(Application-specific Drawing Available upon Request)
Installation and Operation Manual
Includes:
Part Number Description
9121-1210AM-0-0-0-0-0-0 Tool Changer—Master
9121-1210AT-0-0-0-0-0-0 Tool Changer—Tool
9121-Jxx-M Valve Adapter with Valve Pass Thru—Master
9121-DB2-MT Control & Signal Module—Master & Tool
9121-AJ2/AK2/AR3-M/T Air Module—Master & Tool
9121-AR4/AR5-T/AR7-T Air Module—Master & Tool
9121-JJ13-M/T Mounting Adapter Assembly—Master & Tool
9121-EF17-M/T Servo Module—Master & Tool
9121-EN9-M/T / ENS9-T Servo Module—Master & Tool
9121-UAA-T Protective Cover—Tool
Some 3-D Model Downloads are available on our website. Contact your Account Representative for more information.
Manual #: 9610-20-2352
Engineered Products for Robotic Productivity

Pinnacle Park 1031 Goodworth Drive  Apex, NC 27539  Tel: 919.772.0115  Fax: 919.772.8259  www.ati-ia.com  Email: info@ati-ia.com
Quick-Change Installation and Operation Manual
Document #9620-20-a-general toc and introduction-07
A. Introduction ................................................................................................................2
1. Glossary of Terms ..............................................................................................3
2. Safety..................................................................................................................5
1.1. General Safety Guidelines ................................................................................. 5
1.2. Explanation of Warnings .................................................................................... 5
1.3. Safety Precautions ............................................................................................. 6
3. Product Overview ...............................................................................................7
4. Terms and Conditions of Sale .............................................................................8
B. Base Tool Changer
C. Control and Signal Module
D. Fluid Air Modules
E. Electrical Modules
F. High Power Modules
G. Interface Plates
H. Other
A-1
A. Introduction
Please contact ATI Industrial Automation with any questions concerning your particular model.
CAUTION: This manual describes the function, application, and safety considerations
of this product. This manual must be read and understood before any attempt is made
to install or operate the product, otherwise damage to the product or unsafe conditions
may occur.
Information contained in this document is the property of ATI Industrial Automation, Inc. (ATI) and shall
not be reproduced in whole or in part without prior written approval of ATI. The information herein is
subject to change without notice. This manual is periodically revised to reflect and incorporate changes
made to the product.
The information contained herein is confidential and reserved exclusively for the customers and authorized
agents of ATI Industrial Automation and may not be divulged to any third party without prior written
consent from ATI. No warranty including implied warranties is made with regard to accuracy of this
document or fitness of this device for a particular application. ATI Industrial Automation shall not be liable
for any errors contained in this document or for any incidental or consequential damages caused thereby.
ATI Industrial Automation also reserves the right to make changes to this manual at any time without prior
notice.
ATI assumes no responsibility for any errors or omissions in this document. Users’ critical evaluation of
this document is welcomed.
Copyright by ATI Industrial Automation. All rights reserved.
How to Reach Us
Sales, Service, and Information about ATI products:
ATI Industrial Automation

1031 Goodworth Drive
Apex, NC 27539 USA
www.ati-ia.com
Tel.: 1-919-772-0115
Fax.: 1-919-772-8259
Email: info@ati-ia.com
Technical support and questions:
Application Engineering
Tel.: 1-919-772-0115
Fax.: 1-919-772-8259
Email: mech_support@ati-ia.com
A-2
1. Glossary of Terms
Term Definition
Arc Prevention Is an ATI exclusive feature that makes it possible to couple/uncouple without
switching power off and preventing damage to the contacts. Arc Prevention extends
the life of all electrical power contacts by eliminating arcing caused by inductive
loads and high inrush current during coupling/uncoupling.
Bearing Race Hardened steel ring in the Tool plate that is engaged by the locking balls during the
locking process.
Cam Circular disc attached to the piston that forces the locking balls outward during the
locking process.
Coupling The physical action of the locking the Master and Tool Plates together.
Cover Plate Simple, blank closure plate on standard Quick-Change Master assemblies which
closes the pneumatic chamber.
Detection Shaft Threaded stem inserted into the back side (top) of the Piston, functions as a target to
actuate the Lock/Unlock switches.
DeviceNetTM A fieldbus communication network used mostly by devices in industrial settings, that
communicates using CAN. DeviceNet is a trademark of ODVA.
Discrete Modules Refers specifically to modules that pass discrete signals and/or power from Master to
Tool. The number of discrete pass-through signals is limited by either the number of
pins on the connector or the number of pins at the pin block interface between Master
and Tool. Some Discrete modules also provide the user the ability to control the Tool
Changer by providing “Latch” and “Unlatch” signals to an integrated valve that locks
and unlocks the Tool changer. The Tool Changer Lock, Unlock, ready-to-lock, and
TSI switch signals can also be provided to the user, these discrete modules are
referred to as Discrete Control/Signal Module.
EIP End-effector Interface Plate – interface plate between the Tool plate and the
customer’s end-effector (tooling).
Electrical Module Any of a wide variety of modules that pass electrical power or signals through the
Master to the Tool and to the end-effector.
End-effector The tool used by the robot to perform a particular function.
EtherNet/IPTM EtherNet/IP (Ethernet Industrial Protocol) is a fieldbus communication network, used
mostly by devices in industrial settings, that communicates using Ethernet.
EtherNet/IP is a trademark of ControlNet International Ltd. used under license by
ODVA.
Fieldbus Is a generic term referring to any one of a number of industrial computer networking
standards. Examples include: CAN, Modbus, and PROFINET.
Gigabit Ethernet Is a term describing various technologies for transmitting Ethernet frames at a rate of
a gigabit per second as defined by the IEEE802.3-2008 standard generally with RJ45,
X-coded M12, or A-coded M12 connectors over CAT6 cabling. Typically used in
vision applications (GigE Vision).
Latch Command that is issued over a communication network to lock (couple) the Master
and Tool Plates.
Lock The physical action of the coupling the Master and Tool Plates together.
Lock Port Pneumatic port on the Master plate to which air is supplied to Lock the Master plate
to the Tool plate.
Lock Sensor A proximity sensor that detects the position of the pneumatically-actuated piston
when it is in the locked or missed tool position.
L/U Lock/Unlock sensing capability allows the customer to determine the state of the
master assembly locking mechanism.
A-3
Master Plate The half of the Tool Changer that is mounted to a robot. The Master plate contains the
locking mechanism.
Multibus An advanced computer bus architecture standard used in industrial applications.
Multibus I is a IEEE-796 16-bit standard, and Multibus II is a IEEE-1296 32-
bit/10MHz bus, at 40Mbyte/s standard.
No-Touch™ Design feature of all ATI Quick-Change products that allows coupling the Master
plate and Tool plate without physical contact prior to locking.
Piston The piston located in the Master plate that actuates the locking mechanism.
Pneumatic Module Any of a wide variety of modules that pass pneumatic power through the Master plate
to the Tool plate and to the end-effector.
PROFINET An Ethernet-based fieldbus used in factory automation.
RIP Robot Interface Plate – interface plate between the robot flange and Master plate.
RTL Proximity sensors that detect when the Master and Tool Plates are close enough to
each other that it is safe to initiate the a latch command and lock the mater and tool
together.
Sensor Plate Cover plate for the back side of the Master plate, seals the pneumatic chamber and
provides mounting points for the Lock/Unlock switches.
SIP Sensor Interface Plate used to adapt the Master plate to the robot flange. The SIP is
essentially a Robot Interface Plate that contains sensors that determine the state
(locked/unlocked/no tool) of the Master plate.
Soft Start Is an ATI exclusive feature that pulses the power on gradually to prevent the large
current spikes that would otherwise occur during the coupling of the master and tool.
This results in a series of much smaller current spikes and prevents significant voltage
drops on the network power.
Teach Plug A device used during the set-up and integration of the robot to override the TSI
circuit.
Tool-ID An individual or set of pushbutton switches on the control/signal Tool module that
provides a unique identification number for each tool when using multiple tools. The
Tool-ID also provides the tool not present indication.
Tool Plate The half of the Tool Changer to which various tools or end-effectors are mounted.
Tool Stand Stand that holds tools not being used by the robot. This is usually supplied by the
customer and is specific to the application.
Trip Dog A physical device used to trip a mechanical switch, use in the Tool Stand Interlock
circuit.
TSI A safety switch used to prevent an unintended tool release when the tool is not in the
tool stand. The Safety switch is tripped when in the stand completing the unlatch
valve circuit allowing the Tool to unlock form the master. The Safety switch can be
mechanical, magnetic, or RFID type.
Uncoupling The physical action of the unlocking the Master and Tool Plates.
Unlatch Command that is issued over a communication network to unlock (uncouple) the
Master and Tool Plates.
Unlock The physical action of the uncoupling the Master and Tool Plates.
Unlock Port Pneumatic port on the Master plate to which air is supplied to Unlock the Master plate
from the Tool plate.
Unlock Sensor A proximity sensor that detects the position of the pneumatically-actuated piston
when it is in the unlocked position.
A-4
2. Safety
The safety section describes general safety guidelines to be followed with this product, explanation of the
notification found in this manual, and safety precaution that apply to the product. More specific notification
are imbedded within the sections of the manual were they apply.
1.1. General Safety Guidelines
Prior to purchase and installation, the customer should verify that the Tool Changer selected is
rated for the maximum loads and moments expected during operation. Refer to product
specifications section in each module of this manual or contact ATI for assistance. Particular
attention should be paid to dynamic loads caused by robot acceleration and deceleration. These
forces can be many times the value of static forces in high acceleration or deceleration situations.
The customer is responsible for ensuring that the area between the Master and Tool sides is clear
of foreign objects during mating and subsequent coupling. Failure to do so may result in serious
injury to personnel.
DANGER: The gap between the Master and Tool sides is a pinch point. All
personnel should be prevented from placing any part of their body or clothing
in the gap, especially during actuation of the locking mechanism.
The customer is responsible for understanding the function of the Tool Changer and implementing
the proper hardware and/or software to operate the Tool Changer safely. The Tool Changer should
be controlled such that there is no chance of locking or unlocking in a position that would
endanger personnel and/or equipment. If the Tool Changer is specified with Lock/Unlock (L/U)
and Ready-to-Lock (RTL) sensing capability, the status should be monitored and proper interlocks
applied to prevent injury to personnel and equipment.
All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the
application without failing. The routing of electrical and pneumatic lines must minimize the
possibility of stress/strain, kinking, rupture, etc. Failure of critical electrical or pneumatic lines to
function properly may result in injury to personnel and equipment.
All electrical power, pneumatic and fluid circuits should be disconnected during servicing.
1.2. Explanation of Warnings
The warnings included here are specific to the product(s) covered by this manual. It is expected
that the user heed all warnings from the robot manufacturer and/or the manufacturers of other
components used in the installation.
DANGER: Notification of information or instructions that if not followed will

result in death or serious injury. The notification provides information about
or the nature of the hazardous situation, the consequences of not avoiding
the hazard, and the method for avoiding the situation.
WARNING: Notification of information or instructions that if not followed

could result in death or serious injury. The notification provides information
about the nature of the hazardous situation, the consequences of not
avoiding the hazard, and the method for avoiding the situation.
A-5
CAUTION: Notification of information or instructions that if not followed

could result in moderate injury or will cause damage to equipment. The
notification provides information about the nature of the hazardous situation,
the consequences of not avoiding the hazard, and the method for avoiding
the situation.
ATTENTION, NOTE, or NOTICE: Notification of specific information or instructions

about maintaining, operating, installation, or setup of the product that if not followed
could result in damage to equipment. The notification can emphasize but is not
limited to specific grease types, good operating practices, or maintenance tips.
1.3. Safety Precautions

WARNING: Remove all temporary protective materials (caps, plugs, tape,
etc.) on locking face of Tool Changer and modules prior to operation. Failure
to do so will result in damage to Tool Changers, modules, and end-of-arm
tooling and could cause injury to personnel.
WARNING: Do not perform maintenance or repair on Tool Changer or

modules with power or air on. Injury or equipment damage can occur with
power or air on. Turn off power and air before performing maintenance or
repair on Tool Changer or modules.
WARNING: During operation, the area between the Master and Tool must
be kept clear. Failure to keep area clear will result in damage to Tool
Changer, modules, or end-of-arm tooling and could cause injury to
personnel.
WARNING: The Tool Changer is only to be used for intended applications

and applications approved by the manufacturer. Using the Tool Changer in
applications other than intended will result in damage to Tool Changer,
modules, or end-of-arm tooling and could cause injury to personnel.
CAUTION: The Master Plate locking mechanism must not be actuated

without being mounted to the robot interface plate. Damage to the Cover
Plate and O-ring may result. Always attach the Master Plate to the Robot
interface plate prior to attempting any operations.
A-6
3. Product Overview
A Tool Changer enhances the flexibility and reliability of a robotic cell. Robotic Tool Changers are used in
automated Tool change applications as well as manual Tool change operations. Robotic Tool Changers also
provide a method for quick Tool change for maintenance purposes.
The Quick-Change robotic Tool Changer has been designed to incorporate high strength in a small, low-
weight package. The Tool change system consists of two primary parts: the Master plate and the Tool plate.
The Master plate is mounted to a robot while the customer supplied end-effector is typically attached to the
Tool plate. The Master plate is typically mounted to the robot with an optional interface plate (SIP or RIP).
The optional Sensor Interface Plate (SIP) plate may also be used for detecting the lock condition of the
Tool Changer and/or Tool plate presence. The use of a SIP is highly recommended for achieving the
highest level of safety and reliability
In operation, the robot can be programmed to select the desired end-effector by coupling the Master plate to
the Tool plate. Electrical signals, pneumatic power and fluids can be transferred to the end-effector(s)
through the Master plate and Tool plate by optional modules and ports. See the respective manuals for
these options for more details on their operation.
The ATI Tool Changer has been designed to provide extremely long life with little maintenance.
A-7
4. Terms and Conditions of Sale

The following Terms and Conditions are a supplement to and include a portion of ATI’s Standard Terms
and Conditions, which are on file at ATI and available upon request.
ATI warrants to Purchaser that robotic Tool Changer products purchased hereunder will be free from
defects in material and workmanship under normal use for a period of three (3) years from the date of
shipment. This warranty does not cover components subject to wear and tear under normal usage or those
requiring periodic replacement. ATI will have no liability under this warranty unless: (a) ATI is given
written notice of the claimed defect and a description thereof within thirty (30) days after Purchaser
discovers the defect and in any event not later than the last day of the warranty period; and (b) the defective
item is received by ATI not later ten (10) days after the last day of the warranty period. ATI’s entire
liability and Purchaser’s sole remedy under this warranty is limited to repair or replacement, at ATI’s
election, of the defective part or item or, at ATI’s election, refund of the price paid for the item. The
foregoing warranty does not apply to any defect or failure resulting from improper installation, operation,
maintenance or repair by anyone other than ATI.
ATI will in no event be liable for incidental, consequential or special damages of any kind, even if ATI has
been advised of the possibility of such damages. ATI’s aggregate liability will in no event exceed the
amount paid by purchaser for the item which is the subject of claim or dispute. ATI will have no liability of
any kind for failure of any equipment or other items not supplied by ATI.
No action against ATI, regardless of form, arising out of or in any way connected with products or services
supplied hereunder may be brought more than one (1) year after the cause of action accrued.
No representation or agreement varying or extending the warranty and limitation of remedy provisions
contained herein is authorized by ATI, and may not be relied upon as having been authorized by ATI,
unless in writing and signed by an executive officer of ATI.
Unless otherwise agreed in writing by ATI, all designs, drawings, data, inventions, software and other
technology made or developed by ATI in the course of providing products and services hereunder, and all
rights therein under any patent, copyright or other law protecting intellectual property, shall be and remain
ATI’s property. The sale of products or services hereunder does not convey any express or implied license
under any patent, copyright or other intellectual property right owned or controlled by ATI, whether
relating to the products sold or any other matter, except for the license expressly granted below.
In the course of supplying products and services hereunder, ATI may provide or disclose to Purchaser
confidential and proprietary information of ATI relating to the design, operation or other aspects of ATI’s
products. As between ATI and Purchaser, ownership of such information, including without limitation any
computer software provided to Purchaser by ATI, shall remain in ATI and such information is licensed to
Purchaser only for Purchaser’s use in operating the products supplied by ATI hereunder in Purchaser’s
internal business operations.
Without ATI’s prior written permission, Purchaser will not use such information for any other purpose or
provide or otherwise make such information available to any third party. Purchaser agrees to take all
reasonable precautions to prevent any unauthorized use or disclosure of such information.
Purchaser will not be liable hereunder with respect to disclosure or use of information which: (a) is in the
public domain when received from ATI; (b) is thereafter published or otherwise enters the public domain
through no fault of Purchaser; (c) is in Purchaser’s possession prior to receipt from ATI; (d) is lawfully
obtained by Purchaser from a third party entitled to disclose it; or (f) is required to be disclosed by judicial
order or other governmental authority, provided that, with respect to such required disclosures, Purchaser
gives ATI prior notice thereof and uses all legally available means to maintain the confidentiality of such
information.
A-8
Document #9620-20-b-1210 series base tool changer-08
Table of Contents
B. Base Tool Changer ......................................................................................................2

QC-1210 Series—Robotic Tool Changer ........................................................................2
1. Product Overview ....................................................................................................... 2
1.1 Master Plate Assembly....................................................................................... 2
1.2 Tool Plate Assembly .......................................................................................... 3
1.3 Optional Modules ............................................................................................... 4
2. Installation .................................................................................................................. 5
2.1 Master Interface ................................................................................................. 5
2.2 Tool Interface ..................................................................................................... 6
2.3 Tool Stand Design ............................................................................................. 7
2.3.1 Tool Locating Features ........................................................................... 8
2.3.2 Tool Stand Sensors ................................................................................ 9
2.4 Pneumatic and Electrical Connections ............................................................... 9
3. Operation .................................................................................................................... 9
3.1 Coupling Sequence .......................................................................................... 10
3.2 Fail-Safe Operation .......................................................................................... 10
3.3 Uncoupling ....................................................................................................... 11
3.4 Integrated Sensors ........................................................................................... 12
4. Maintenance.............................................................................................................. 14
4.1 Preventive Maintenance ................................................................................... 14
4.2 Cleaning, Lubrication, Adjustment and Replacement ....................................... 15
4.2.1 Cleaning and Lubrication of the Locking Mechanism and Alignment
Pins (Master Plate). ........................................................................................ 15
4.2.2 Cleaning the Locking Mechanism and Alignment Pin Bushings
(Tool Plate). .................................................................................................... 17
4.2.3 Lock and Unlock Sensor Assembly Replacement. Figure 4.5 ............... 17
4.2.4 RTL Sensor Replacement (8mm Threaded Barrel Style). ..................... 18
4.2.5 Alignment Pin Replacement (1-1/8‖ Two Piece Pin Sub-Assembly)...... 19
5. Troubleshooting ....................................................................................................... 20
6. Recommended Spare Parts ..................................................................................... 23
7. Specifications ........................................................................................................... 24
8. Drawings ................................................................................................................... 25
B-1
B. Base Tool Changer

QC-1210 Series—Robotic Tool Changer
1. Product Overview
1.1 Master Plate Assembly
The Master base assembly (Master plate) includes an anodized aluminum body, a set of
hardened stainless-steel locking mechanisms, and hardened steel alignment pins (see Figure
1.1).
The Master plate has (6) flat sides for mounting of optional modules. Flat „A‟ is dedicated
for mounting of the control/signal module along with tool changer supply air that is provided
through an air or valve adapter. Flats „B‟, „C‟, „D‟,‟E‟, and „F‟ are fully interchangeable and
optional modules can be arranged to suit the application or robot dress, as required.
The Master plate is comprised of (3) locking mechanisms. Each locking mechanism consists
of a cam, male coupling, and chrome-steel balls. Tapered pins located on the Master plate
mate with holes in the Tool plate to ensure repeatable alignment during the coupling process.
Extreme pressure grease is applied to the cams, male couplings, ball bearings, and pins to
enhance performance and maximize the life of the Master assembly.
Proximity sensors (6 total) are designed into the body of the Master plate to verify the
locked/unlocked position of each locking mechanism. Due to the multiple locking
mechanism design, the proximity sensors are grouped such that (3) sensors are for Lock and
(3) are for Unlock. The Lock/Unlock signal at each locking mechanism is routed to the signal
junction module. The junction module provides the control/signal module with the
Lock/Unlock state of the Master plate. See the cable routing illustrations in Section 3.4 to
understand the relationship between the sensors, junction module and control module.
Three proximity sensors are mounted in the body of the Master plate to verify Tool plate
presence when coupled. The sensors provide (2) Ready-To-Lock (RTL) signals to the
control/signal module. To accomplish a dual RTL signal, (2) of the sensors are wired in
series. See Section 3.4 for more explanation of the RTL layout.
B-2
Ball Bearings (36) Junction Module
Proximity Sensor
Cam (RTL Signal)
Male Coupling
Alignment Pin
Common Ledge Feature

For Module Mounting;
Flats A, B, C, D, E and F
Proximity Sensor
(RTL Signal)
Cable Retaining
Tabs
Lock/Unlock Air Supplied through Proximity Sensor

Air/Valve Adapter Mounted to Flat A (RTL Signal)
Figure 1.1—Master Plate Assembly

1.2 Tool Plate Assembly
The Tool base assembly (Tool plate) includes an anodized aluminum body and 3 hardened
stainless-steel bearing races. The Tool plate has (6) flat sides for mounting of optional
modules.
Proximity Sensor Junction Module

Target (RTL) Adapter
Alignment Pin Bushing
Common Ledge Feature

For Module Mounting;
Proximity Sensor Flats A, B, C, D, E and F
Target (RTL)
Bearing Race
Proximity Sensor
Target (RTL)
Figure 1.2—Tool Plate Assembly
B-3
1.3 Optional Modules

There are (6) flats available for mounting of the optional modules for support of various
utility pass-through, such as signal, fluid/air, and power.
For assistance in choosing the right modules for your particular application, visit our website
to see what is available or contact an ATI Sales Representative directly.
In general, flat „A‟ is reserved for an air/valve adapter module and a control/signal module.
Flat „D‟ is reserved for a signal junction module, however, optional utility modules can still
be added on flat „D‟. Modules for flats „B‟, „C‟, „D‟, „E‟, or „F‟ are interchangeable to suit
the application or the dress-out required.
The optional modules are mounted to the Master or Tool plate using a common ledge
mounting feature. Only (2) M6 SHCS fasteners need to be unscrewed in order to remove the
module from the Master/Tool plate. A secondary mounting support, called a “cleat”, is
factory-installed to the Master and Tool plate on each flat that is occupied with a module.
The cleats provide additional module support for those situations when hoses or cables may
inadvertently be snagged or pulled and may otherwise result in damage to the module.
If modules are added to a tool changer in the field, then the Master and Tool plates may have
to be uninstalled to facilitate the cleat installation.
B-4
2. Installation
All fasteners used to mount the Tool Changer to the robot and to user Tools should be tightened to
a torque value as indicated below. Furthermore, removable (blue) Loctite® 242 must be used
on these fasteners.
CAUTION: Care should be taken to select fasteners for mounting that are not too long,
! such that a gap is formed at the interface.
Maximum
Fastener Size and
Mounting conditions Recommended
Property Class
Torque
Master Plate to RIP (6061-T6 aluminum) M10–1.5 75 Nm
Minimum thread engagement of 15mm (0.59‖) Class 12.9 (55 ft-lbs.)
[1.5X fastener Ø]
Master Plate to RIP (Steel; USS ≥ 90KSI) M10–1.5 75 Nm
Minimum thread engagement of 15mm (0.59‖) Class 12.9 (55 ft-lbs.)
[1.5X fastener Ø]
Tool Plate (aluminum) to End-Effector Interface Plate M10–1.5 52 Nm

(6061-T6 aluminum)
Class 12.9 (38 ft-lbs.)
Minimum thread engagement of 15mm (0.59‖)
[1.5X fastener Ø]
Tool Plate (aluminum) to End-Effector Interface Plate M10–1.5 52 Nm
(7075-T6 aluminum)
Class 12.9 (38 ft-lbs.)
Minimum thread engagement of 15mm (0.59‖)
[1.5X fastener Ø]
2.1 Master Interface

The Master assembly is attached to the robot interface plate (RIP), and both are bolted to the
robot arm. The RIP is designed with mounting features such as a boss and/or bolt and dowel
holes. These features are used to accurately position and secure the Master to the robot. The
RIP is utilized to adapt the Master plate to a specific robot flange that is not compatible with
the Master plate mounting features. Custom RIPs are available upon request. (Refer to
drawings in Section 8 of this manual for technical information on mounting features.)
B-5
Robot Wrist Flange
Robot Interface Plate

With Fasteners and
Dowel Pins
Master Plate, with

Fasteners to
Robot Interface
Plate
Tool Plate, with

Fasteners to Tool
Interface Plate
Tool Interface Plate

(Fasteners and Dowel Pins
Not Shown)
Figure 2.1—Typical Installation (QC-1210 Shown)

If the customer chooses to design and build a robot interface plate, the following should be
considered:
 The interface plate should be designed to include bolt holes for mounting, dowel
pins, and a boss for accurate positioning on the robot and Master plate.
 The thickness of the interface plate must be great enough to provide the necessary
thread engagement for the mounting bolts.
 The interface plate must be properly designed to provide rigid mounting to the
Master plate boss area.
 The plate design should take into account clearances required for Tool Changer
module attachments and accessories.
2.2 Tool Interface
The Tool plate is attached to customer-supplied tooling. The Tool plate is designed with
mounting features such as a bolt and dowel holes. These features are used to accurately
position and secure the end-effector. Most often an End-effector Interface Plate (EIP) is
utilized to adapt the Tool plate to an end-effector that is not compatible with the Tool plate
B-6
mounting features. Custom End-effector Interface Plates can be supplied by ATI to meet
customer requirements (see Figure 2.1) (refer to the application drawing).
When the customer chooses to design and build an End-effector Interface Plate, the
following should be considered:
 The interface plate should be designed to include bolt holes for mounting and dowel
pins that mate with Tool body for accurate positioning.
 The thickness of the interface plate must be great enough to provide the necessary
thread engagement for the mounting bolts.
 The plate design should take into account clearances required for Tool Changer
module attachments and accessories.
 The End-effector Interface Plate should be designed with a set of holes in the center
of each of the three locking mechanisms to allow for manually returning the locking
mechanisms to the unlocked position under adverse conditions (i.e., unintended loss
of power and/or air pressure). The center access holes should be kept small
[recommended hole diameter: 25.4mm (1”)] to prevent debris from contaminating
the locking mechanism while operating in dirty environments.
2.3 Tool Stand Design
CAUTION: Tool Stand design is critical to proper operation of the Tool Changer.
Improperly designed Tool Stands can cause misalignments that will cause jamming and/or
! excessive wear of Tool Changer components.
Z-Compliance is required for the Tool Stand, in order to ensure that the Master remains
fully contacted with the Tool prior to issuing the Unlock command.
CAUTION: During coupling and lock-up, the Tool Stand must allow for movement (float) in
! a plane parallel to the mating surfaces of the Master plate and Tool plates, and in a
direction perpendicular to this plane, towards the Master plate.
In most cases, the tools are stored in a Tool Stand when not being used by the robot. During
coupling and lock-up, the Tool Stand must allow for movement (float) in a plane parallel
with the mating surfaces of the Master plate and Tool plates (X and Y directions). Even
slight misalignment between the Master plate and Tool plate can generate high forces during
lock-up if the Tool plate is not allowed to float into place during lock-up. These high forces
can cause excessive wear and even jamming of the end-effector and robot. The degree of
float required depends on the accuracy of the robot‟s positioning and the repeatability of the
Tool location in the Tool Stand during lock-up. See Figure 2.2 and Table 2.3 for
recommended maximum allowable float (offsets) prior to coupling. The Tool Stand should
be designed to minimize misalignment during coupling and uncoupling. In some cases,
greater offsets than shown in Table 2.3 can be accommodated by the Master and Tool plates,
but will increase wear.
For the QC-1210, the tool stand should have compliance in the Z direction. The robot should
be programmed to fully seat the Tool in the Tool Stand before issuing the Unlock command.
The Unlock sensors need to be active before pulling the Master away. It is possible to
design Tool Stands that hold Tools in the horizontal position, but care must be taken that the
necessary compliance is provided during coupling and uncoupling. In general, “horizontal-
position” Tool Stands cause more wear on the locking mechanism and locating features of
the Tool and Tool Stand.
B-7
Lock-up should occur with the Master plate in the No-Touch™ Locking zone (see Table
2.3), but not touching the Tool plate. As locking occurs, the Master plate should draw the
Tool plate into the locked position.
Tool Stands may also need to incorporate means for covering Tools and electrical modules to
protect them in dirty environments, such as grinding or welding. Alternatively, locating Tool
Stands in areas shielded from weld spatter, fluids, adhesives, or other debris would eliminate
the need for Tool covers.
Cocking Offset
(About X and Y)
X, Y and Z Offset
Figure 2.2—Offset Definitions
No-Touch Zone X and Y Offset Cocking Offset Twisting Offset

Model Z Offset (Max)* (Max)† (Max) (Max)
(mm) (mm) (degrees) (degrees)
QC-1210 1 ±2 ±0.7 ±1
Table 2.3—Maximum Recommended Offsets Prior to Coupling
Notes: * Maximum values shown. Decreasing actual values will minimize wear during
coupling/uncoupling.
† Actual allowable values may be higher in some cases but higher offsets will increase
wear during coupling.
2.3.1 Tool Locating Features
The Tool must be positively and repeatably located in the Tool Stand. A variety of
methods may be used to accomplish this. Whatever method is chosen, it is
important that the required compliance or “float” be built into the locating system.
A common method is to use tapered alignment pins in holes. As the Tool plate is
lifted during locking, the taper lets the Tool float into its locked position even with
small deviations in robot position.
Other Tool locating feature methods include balls and detents, dowel pins in
notched V-grooves, etc. Please consult ATI for recommendations or assistance
with locating feature design for your particular tooling.
Straight cylindrical dowel pins should not be used as they provide too much
surface engagement. During coupling and uncoupling the Tool can bind on these
pins due to misalignment of the Master and Tool plates.
B-8
Robot programming and location repeatability are vital in Tool pick-up and drop-
off.
2.3.2 Tool Stand Sensors
It is highly suggested that the customer provide a sensor that detects the presence
of a properly seated Tool in the Tool Stand. The sensor may be used prior to
coupling to ensure there is a Tool properly seated in the stand. Sensors may also be
used as the robot starts to move away after uncoupling. This provides a fail-safe
measure in the event that a Tool should become jammed in the stand or if the Tool
should fail to release properly from the robot.
Proximity sensors should be located so that the sensing face is vertical to prevent
metal shavings, weld spatter, or other debris from falling on the sensor and
creating false readings.
2.4 Pneumatic and Electrical Connections
The air supply used for coupling and uncoupling the Tool Changer should be clean, dry, and
non-lubricated. A supply pressure in the range of 70 to 100 psi is acceptable for operation of
the locking mechanism, with a setting of 80 psi suggested. The air should be filtered 50
micron or better.
CAUTION: Do not use the Tool Changer in the fail-safe condition. Do not transport the
! Tool Changer in the fail-safe condition. Possible damage to the locking mechanism
could occur.
3. Operation
The Master locking mechanisms are pneumatically-driven to couple and uncouple with the bearing
races on the Tool plate. The Master plate utilizes air ports from an air or valve adapter module to
provide Lock and Unlock pressure to the locking mechanism.
CAUTION: Safe, reliable operation of the Tool Changer is dependent on a continuous

! supply of compressed air at a pressure of 70–100 psi. Robot motion should be halted if
the air supply pressure drops below 70 psi for any reason.
ATTENTION: All Tool Changers are initially lubricated using MobilGrease® XHP222 Special
grease. The end user must apply additional lubricant to the locking mechanism components and
alignment pins prior to start of service (See Section 4.2). Tubes of lubricant for this purpose are
shipped with every Tool Changer. Note: MobilGrease® XHP222 Special is a NLGI #2 lithium
complex grease with molybdenum disulfide.
B-9
3.1 Coupling Sequence

CAUTION: The locking mechanism must be in the Unlock position when attempting to
! couple the Tool Changer. Failure to adhere to this condition may result in damage to
the unit and/or the robot.
Position the Master above the Tool and move the Master into locking position. The mating
surfaces of the Master and Tool should be parallel and not touching. Make sure that the
tapered alignment pins from the Master enter the alignment holes on the Tool. The alignment
pins should be relatively concentric with the alignment holes such that they do not rub
against the edge.
The locking mechanisms allow the Master to “pull up” the Tool with certain gaps between
the two sides. It is recommended that the mating faces of the Master and Tool not be
touching, but be within 0.040” (1 mm) of each other when coupling to minimize stress and
wear on the locking mechanism.
RTL (Ready-To-Lock) sensing is built into the Tool Changer, providing the ability to sense
Tool proximity to the Master prior to coupling. The mating faces of the Master and Tool
must be positioned within approximately 0.055–0.065” (1.40–1.65mm) of each other for the
sensors to detect Tool presence. RTL signals are not required to couple the Tool Changer,
but are essential as a further confirmation of coupling prior to removing the Tool from the
tool stand.
TM
CAUTION: No-Touch locking technology allows the unit to couple with a separation
! distance between the Master and Tool. Direct contact of the Master and Tool mating
surfaces is allowed just prior to coupling, ONLY if Z compliance is built in to the Tool
Stand.
Verify that all the RTL signals are read as “on” (true).
Turn the Unlatch output off.
Turn the Latch output on. Air is supplied to the locking mechanism to couple the Tool
Changer.
A sufficient delay must be programmed between the Latch output being activated and
reading the state of the Lock/Unlock signals, so that the coupling process is completed before
checking the Locked state.
Read the Lock and Unlock signals.
The Lock signal should read “on” (true) and the Unlock signals should read “off” (false).
3.2 Fail-Safe Operation
In the event of air supply loss to the locking mechanism, the Tool Changer will not
uncouple. A slight separation between the Master and Tool plates occurs just after air loss,
but at this point the locking balls become trapped and cannot move without air pressure
being applied to the Unlock port. This feature provides the Tool Changer with a fail-safe
mechanism.
B - 10
ATI‟s patented fail-safe design prevents the Tool plate from being released in the event of air
pressure loss to the Lock port, thereby increasing safety and reliability. Positional accuracy
may not be maintained during air loss, but will be regained once air pressure is re-established
to the Lock port.
CAUTION: Do not use the Tool Changer in the fail-safe condition. Do not transport the
! Tool Changer in the fail-safe condition. Possible damage to the locking mechanism
could occur.
3.3 Uncoupling
Verify that the Tool is FULLY secured and seated in the Tool Stand. Z-compliance is
required for the Tool Stand in order to ensure reliable Unlocking sequence. Once you have
verified that the Tool is FULLY secured in the Tool Stand, turn the Latch output off.
CAUTION: This Tool Changer may be equipped with a Tool Stand Interlock (TSI)
! feature that physically breaks the Unlatch solenoid circuit. Use of the TSI will prevent
any unwanted Unlatch software commands from being recognized until the circuit is
made. See user manual of the respective control module for details and
troubleshooting.
Issue the Unlatch output. Air is supplied to the locking mechanism to uncouple the Tool
Changer.
A sufficient delay must be programmed between the Unlatch output being activated and
reading the state of the Lock/Unlock signals, so that the coupling process is completed before
checking the Locked state.
Read the Lock and Unlock signals.
The Unlock signal should read “on” (true) and the Lock signal should read “off” (false). Any
other condition indicates a problem and the robot program should be halted.
Once the Lock and Unlock signals are verified to be in the proper state, the Master plate may
be moved away from the Tool plate in the axial direction. Check to verify that the RTLs are
all “off” (false) after the Master moves away from the Tool.
The robot and Master plate can now proceed to another Tool for coupling and subsequent
operations.
B - 11
3.4 Integrated Sensors

The QC-1210 Master has a total of (6) proximity sensors for detecting the Lock and Unlock
state of the Tool Changer. For each locking mechanism there is one Lock sensor and one
Unlock sensor. Each sensor pair is distinguished by the corresponding locking mechanism.
For example, locking mechanism #1 has “L1” (Lock sensor #1) and “U1” (Unlock sensor
#1). Also, to eliminate confusion, the Master body, sensor cables, and junction module
connectors are labeled the same way (L1, U1, L2, U2, L3, and U3).
QC-1210 Master
U1 U3
1
RS1 RS3
L1 L3
Flat A / Control Module
Figure 3.1—Lock and Unlock sensors. “L2” and “U2” not visible in this view
Inside the junction module, all (3) Lock sensors are wired in series which provides for one
Locked signal via the connector labeled “L”. The (3) Unlocked sensors are also wired in
series within the junction module which provides for one Unlocked signal via the connector
labeled “U”. Cables connect the “L” and “U” connectors of the junction module to the “L”
and “U” connectors of the control module.
U1, L1, U2, and L2

(not visible in this view)
Control Module U2
QC-1210 Master 1
Junction
Module
R1, R2, U, and L L2

RS3 U3, L3, U, and L
Figure 3.2—Connector view

Figure 3.3 and Table 3.1 show the cables pertaining to the Lock and Unlock sensors. From
the factory, the cables will be labeled to match where they are connected.
B - 12
Figure 3.3—Sensor Cable Routing
Sensor Cable Routing

9121-XXX-M
Lock/Unlock Sensor Junction Module Control Module
ID # # Connector # Connector # RTL Sensor ID
L1 <3> <4> L1
L2 <3> <5> L2
L3 <3> <4> L3
U1 <3> <4> U1
U2 <3> <5> U2
U3 <3> <4> U3
L <6> L
U <6> U
RS1
R1 <1>
RS2
R2 <2> RS3
Cable # from Fig. 3.3 ATI Part Number

PNP with LED Cables (-SL Models) NPN with LED Cables (-SE Models)
<1> 9120-C-3PF-3PF-3PM90 9120-C-3PF-3PF-3PM90-NPN
<2> 9120-C-3PF-3PM90-0030 9120-C-3PF-3PM90-0030-NPN
<3> 9005-20-1613 9005-20-1780
<4> 9120-C-3M5F-3PM90-0020 9120-C-3M5F-3PM90-0020
<5> 9120-C-3M5F-3PM90-0016 9120-C-3M5F-3PM90-0016
<6> 9120-C-3PF90-3PM90-0041 9120-C-3PF90-3PM90-0041-NPN
Table 3.1—Cable Number
B - 13
The QC-1210 Master has (3) RTL sensors. They are designated as “RS1”, “RS2”, and
“RS3”. Sensors “RS1” and “RS2” are wired in series (by means of a splitter cable) and in
this way provide the control module with a single “R1” signal. Only when “RS1” and “RS2”
are both triggered will a Tool presence signal occur at “R1”. The third RTL sensor, “RS3”, is
connected directly to the control module at “R2” to give a second Tool presence signal.
Figure 3.3 and Table 3.1 show the cables pertaining to the RTL sensors. The labels on the
cables indicate which sensors the cables are connected to.
4. Maintenance
ATTENTION: The cleanliness of the work environment strongly influences the trouble-free
operation of the changer. The dirtier the environment, the greater the need is for protection
against debris. Protection of the entire EOAT, the Master, the Tool, and all of the modules may
be necessary. Protective measures include the following: 1) placement of Tools Stands away
from debris generators, 2) covers incorporated into the Tool Stands [see Section 2.3] and 3)
guards, deflectors, air curtains, and similar devices built into the EOAT and the Tool Stand.
4.1 Preventive Maintenance

The Tool Changer and optional modules are designed to provide a long life with regular
maintenance.
A visual inspection and preventative maintenance schedule is provided in the table below
depending upon the application.
Detailed assembly drawings are provided in Section 8 of this manual.
ATTENTION: All Tool Changers are initially lubricated using MobilGrease® XHP222 Special
grease. The end user must apply additional lubricant to the locking mechanism components and
alignment pins prior to start of service (See Section 4.2). Tubes of lubricant for this purpose are
shipped with every Tool Changer. Note: MobilGrease® XHP222 Special is a NLGI #2 lithium
complex grease with molybdenum disulfide.
B - 14
Tool Change Inspection

Application(s)
Frequency Schedule
> 1 per minute Weekly

General Usage
Material Handling
< 1 per minute Monthly
Docking Station
Welding/Servo/
Deburring, Foundry
Operations
All Weekly
(Dirty Environments)
Checklist
Balls/Alignment Pins/Holes/Bearing Race

Inspect for lubrication and wear. A NLGI #2, lithium-based grease with molybdenum disulfide
additive is suggested for locking mechanism and alignment pin lubrication. Over time, lubricants
can become contaminated with process debris. Therefore, it is recommended to thoroughly clean
the existing grease and replace with new as needed. See Section 4.2.
Excessive alignment pin/bushing wear may be an indication of poor robot position during
pickup/drop-off. Adjust robot position as needed. Check Tool Stand for wear and alignment
problems.
Wear on the balls/bearing race could be an indication of excessive loading.
Mounting Hardware/Interface Connections

Inspect for proper torque and interference or wear, abrasions, cuts of hoses, and electrical cables.
Tighten and correct as required.
O-rings/Rubber Bushings
Inspect for wear, abrasion, and cuts.
Exposed o-rings and rubber bushings may be subject to damage during normal operation. Replace
damaged o-rings and rubber bushings as needed.
Electrical Contacts
Inspect for wear and abrasion.
Exposed contacts may be subject to damage during normal operation.
Clear debris from the area of the contacts using compressed air.
Do not directly clean contacts as abrasion may occur and the performance of the contact may be
compromised.
4.2 Cleaning, Lubrication, Adjustment and Replacement

4.2.1 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins
(Master Plate).
1. The locking mechanism must be in the unlock state before cleaning.
B - 15
2. Use a clean rag to thoroughly remove the existing lubricant and debris from
the balls, the male coupling, the cam and the alignment pins.
Figure 4.1—Cleaning balls and outer surfaces of Figure 4.2—Cleaning balls, cam, and inner
male coupling surfaces of male coupling
3. Check each ball to make sure it moves freely in the male coupling. Additional
cleaning may be necessary to free up any balls that are sticking in place.
Figure 4.3—Checking balls to move freely
B - 16
4. Apply a liberal coating of lubricant to the balls, the male coupling (inside and out),
and the alignment pins.
Figure 4.4—Lubrication areas
4.2.2 Cleaning the Locking Mechanism and Alignment Pin Bushings (Tool Plate).
1. Use a clean rag to thoroughly remove any lubricant and debris from the
bearing race and the bushings.
2. No re-lubrication is necessary on the Tool plate components.
4.2.3 Lock and Unlock Sensor Assembly Replacement. Figure 4.5

1. Unscrew the sensor cable connector from the extension cable.
2. Remove the two (2) M3 socket head cap screws that secure the assembly to
the Master body.
3. Slide the sensor assembly out and discard.
CAUTION: The Lock and Unlock sensor assemblies are precision aligned and
! permanently assembled at the factory. Do not attempt to adjust the position of the
sensor or severe damage to the Master may occur.
4. Apply Loctite 222MS to the new M3 socket head cap screws supplied with
the new sensor assembly.
B - 17
5. Check that the new sensor assembly has the o-ring present and that the old o-
ring came off of the Master with the old sensor assembly. Attach the new
assembly to the Master by tightening the M3 screws to 12 in-lbs.
6. Re-attach cables and modules.
7. Confirm operation of the Unlock sensor by issuing the Unlatch command and
then checking to see that the LED in the Unlock sensor body is on.
8. Confirm operation of the Lock sensor by issuing the Latch command to lock a
Tool to the Master and then checking to see that the LED in the Lock sensor
body is on.
Unlock Sensor
Assembly
(3 Places)
Lock Sensor
Assembly
(3 Places)
Figure 4.5—QC-1210 Lock and Unlock Sensor Assemblies
4.2.4 RTL Sensor Replacement (8mm Threaded Barrel Style).

1. Remove the sensor cable connector from the sensor.
2. Loosen the jam nut securing the sensor to the Master body.
3. Unscrew/remove the sensor from the Master and discard.
4. Screw the new sensor/cable assembly into the Master body until the face of
the sensor is flush with the surrounding face of the Master body. Turn the
sensor back ¼ turn. Use a crowfoot and a torque wrench to tighten the jam
nut to 20 in-lbs of torque.
5. Replace the sensor cable if needed.
6. Re-attach the cable connector to the control/signal module.
7. Confirm operation of the new sensor by bringing a metallic object into close
proximity to the face of the sensor and watching for the LED in the body of
the sensor to come on. ATTENTION: “R1” consists of sensors “RS1” and
“RS2” wired in series. Therefore, a metallic object has to be used at both
B - 18
locations in order to view the LED indicator of either sensor. See QC-1210
RTL Cabling in Section 3.4.
1 of 3 Ready-To-Lock Sensors
Figure 4.6—Barrel-style RTL sensor
4.2.5 Alignment Pin Replacement (1-1/8‖ Two Piece Pin Sub-Assembly)

1. Unscrew the alignment pin sub-assembly from the Master plate using a 5mm
hex key. Note: If for any reason the pin cannot be removed using the hex
socket in the tip, it may be necessary to remove it by other means such as
Vise Grip pliers. Another approach is to use the access hole in the back side
of the Master plate. In this case, a 4 mm hex key will be needed.
2. Once the alignment pin has been removed verify that the sub-assembly (pin
and set screw) is intact. If the set screw portion of the sub-assembly did not
come out it will be necessary to remove it separately using the access hole in
the back side of the Master plate.
3. Apply Loctite® 242 (or similar thread locking compound) to the M8 set
screw in the new alignment pin.
4. Install the alignment pin into the bushing and screw it into place. Apply 60
in-lb of torque to fully tighten it.
B - 19
5. Troubleshooting
Check these conditions for all symptoms prior to troubleshooting:
 Proper pneumatic and electrical connections have been made to the Tool Changer.
 Air is supplied at a minimum of 70 psi.
 No air or vacuum can be trapped in a de-energized Lock or Unlock port (pressure must be
vented to atmosphere).
Symptom Cause Resolution
Unit will not Lock or Unlock or The ball bearings and/or cam Clean and lubricate as needed to
the locking mechanisms are are not moving freely in the restore smooth operation (see
jammed. male coupling. Section 4—Maintenance).
The Master and Tool are not Check that the Tool is properly
within the specified No-Touch seated in the Tool Stand. Re-
zone when attempting to Lock. teach the robot to bring the
Master and Tool closer together
before attempting to Lock.
Master and Tool are not Check that the Tool is properly
parallel (all three RTL sensors seated in the Tool Stand. Re-
are not on when trying to lock). teach the robot to bring the
Master and Tool closer together
and parallel prior to attempting to
Lock.
Verify RTLs (RS1, RS2, and
RS3) are all on.
Tool Drop-off Distance is too Check that the Tool is properly
large. positioned in the Tool Stand and
the Tool is fully seated. Check
that the UNLATCH command is
not being issued with the Tool
sitting above the Tool Stand and
the robot is not trying to ―drop‖
the Tool into the nest.
B - 20

Unit is fully locked but Locked Individual Lock sensor/cable Check LED light on each of the
input to control module is not damage. three Lock sensors.
ON
If OFF check for cable damage
and a secure connection to the
junction module. Replace sensor
and/or cable as needed.
Main Lock sensor cable If all individual Lock sensor LEDs
damage. are on, check the main Lock
cable connecting the junction
module and control module.
NOTE: Individual sensors are
wired in series in the junction
module. All sensors must be ―on‖
to get the main Lock input ―on‖.
Check for cable damage and a
secure connection to control
module. Replace as needed.
Junction Module failure. If individual Lock sensors/cables
and main Lock cable are found to
be good, replace junction module.
Unit is fully unlocked but Individual Unlock sensor/cable Check LED light on each of the
Unlock input to control module damage. three Unlock sensors.
is not ON.
If OFF check for cable damage
and a secure connection to the
junction module. Replace sensor
and/or cable as needed.
Main Unlock sensor cable If all individual Unlock sensor
damage. LEDs are on, check the main
Unlock cable connecting the
junction module and control
module. NOTE: Individual
sensors are in series in the
junction module. All sensors must
be ―on‖ to get the main Unlock
input ―on‖.
Check for cable damage and a
secure connection to control
module. Replace as needed.
Junction Module failure. If individual Unlock sensor/cables
and main Unlock cable are found
to be good, replace control
module.
B - 21

R1 input (RS1 and RS2 Master not in position. Reprogram pick-up point so
sensors) not on. Master and Tool are parallel and
within 1 mm of each other.
Sensor/cable damage. Check the RS1 and RS2 sensor
faces and cables for damage.
Replace if necessary.
NOTE: These sensors are wired
in series in the cable harness.
Both sensors must be ―on‖ to get
the R1 (RTL1) input ―on‖.
Check splitter cable from R1
connector at the control module
to RS1 and RS2 sensors.
Replace as needed.
R2 input (RS3 sensor) not on. Master not in position at Pick- Reprogram pick-up point so
up. Master and Tool are parallel and
within 1 mm of each other.
Sensor/cable damage. Check the RS3 sensor face for
damage. Replace if necessary.
Check cable between RS3
sensor and the R2 connector at
control module for damage and
replace as needed.
B - 22
6. Recommended Spare Parts
Assembly Part Number Description

Master Plate 9121-1210AM-0-0-0-0-0-0 Complete QC-1210 Master Plate, No Options
9005-20-1569 1-1/8‖ Two Piece Alignment Pin
9005-20-1198 Master Cleat Assy.
See Section 8 for Additional Information
Tool Plate 9121-1210AT-0-0-0-0-0-0 Complete QC-1210 Tool Plate, No Options

9005-20-1199 Tool Cleat Assy.
See Section 8 for Additional Information
Other 9005-20-1605 Tool Junction Module Adapter
PNP with LED Cables (-SL)

8590-9909999-34 PNP Proximity Sensor (RTL)
9005-20-1604 PNP Master Signal Junction Module
9005-20-1613 PNP Lock/Unlock Sensor Assembly
L/U Cable, Pentafast Female Straight to Picofast Male Right
9120-C-3M5F-3PM90-0016
Angle, 0.16 m
9120-C-3M5F-3PM90-0020
Angle, 0.20 m
9120-C-3PF-3PF-3PM90 PNP RTL Cable, RS1 & RS2 to R1
9120-C-3PF-3PM90-0030 PNP RTL Cable, RS3 to R2
PNP L/U Cable, Picofast Female Right Angle to Picofast
9120-C-3PF90-3PM90-0041
Male Right Angle, .41 m
NPN with LED Cables (-SE)

8590-9909999-34 PNP Proximity Sensor (RTL)
9005-20-1780 NPN Lock/Unlock Sensor Assembly
9005-20-1781 NPN Master Signal Junction Module
9120-C-3M5F-3PM90-0016
Angle, 0.16 m
9120-C-3M5F-3PM90-0020
Angle, 0.20 m
9120-C-3PF-3PF-3PM90-NPN NPN RTL Cable, RS1 & RS2 to R1
9120-C-3PF-3PM90-0030-NPN NPN RTL Cable, RS3 to R2
NPN L/U Cable, Picofast Female Right Angle to Picofast
9120-C-3PF90-3PM90-0041-NPN
Male Right Angle, .41 m
B - 23
7. Specifications
Master and Tool Plates

Suggested Payload Limit 2980 lbs. The mass attached to the Tool Changer.
(1350 kg)
o
Operating Temperature Range -20–150 F
o
(-30–66 C)
Operating Pressure Range 70–100 psi Locking mechanism supply pressure operating
(4.8–6.9 bar) range. Supply to be clean, dry, and filtered to 50
micron or better.
Coupling Force @ 80psi 21,000 lbs. Axial holding force.

(9,525 kg)
Static Moment Capacity (X, Y) 48,000 in-lb Maximum recommended working load for
5,423 (Nm) optimum performance of the Tool Changer.
(Z) 48,000 in-lb Torsion

5,423 (Nm)
Positional Repeatability 0.0006 in. Repeatability tested at rated load at one million
(0.015 mm) cycles.
Weight (coupled, no access.) 62 lbs. Master 18 kg / Tool 10 kg

(28 kg)
*Does not include RIP or TIP assemblies
TM
Max. Recommended distance 0.04in. No-Touch locking technology allows the
between Master and Tool Plate (1 mm) Master and Tool Plates to lock with separation
when coupling.
Sensor Information, signal L/U Internal proximity sensors (6) with cable and
name (Lock/Unlock) connector to indicate locking mechanism
position.
RTL Proximity sensors (3) with cable and connector

(Ready-To-Lock) for direct wiring to control/signal module to
indicate Master and Tool mating surfaces within
close proximity of each other.
Mounting/Customer Interface
Master Plate See Section 8
Tool Plate See Section 8
B - 24
8. Drawings
B - 25
B - 26
B - 27
Document #9620-20-c-db2-11
Table of Contents
C. Control and Signal Modules .......................................................................................3
DB2—DeviceNet Module .................................................................................................3
1. Product Overview .................................................................................................3
1.1 DeviceNet Module .....................................................................................3
2. Installation ............................................................................................................5
2.1 Installing ....................................................................................................5
2.2 Removal ....................................................................................................5
2.3 DeviceNet Configuration............................................................................6
2.4 Utility Schematic ........................................................................................6
3. Product Information ..............................................................................................7
3.1 Master Node ..............................................................................................7
3.1.1 Setting the DIP Switches ........................................................................ 7
3.1.2 MAC ID ................................................................................................... 7
3.1.3 Baud Rate .............................................................................................. 8
3.1.4 Termination Resistor .............................................................................. 8
3.1.5 Module Status LED ................................................................................. 8
3.1.6 Network Status LED ............................................................................... 9
3.2 Tool Node ..................................................................................................9
3.2.1 Setting the DIP Switches ........................................................................ 9
3.2.2 MAC ID ................................................................................................. 10
3.2.3 Baud Rate ............................................................................................ 10
3.2.4 Termination Resistor ............................................................................ 10
3.2.5 Tool ID (Tool Node Only) ...................................................................... 10
3.2.6 Module Status LED ............................................................................... 11
3.2.7 Network Status LED ............................................................................. 11
3.2.8 Quick Connect ...................................................................................... 11
3.3 Software ..................................................................................................11
4. Operation ...........................................................................................................13
5. Maintenance ......................................................................................................15
5.1 Pin Block Inspection and cleaning ...........................................................15
5.2 Seal Replacement ...................................................................................16
6. Troubleshooting .................................................................................................17
7. Recommended Spare Parts ...............................................................................17
8. Specifications .....................................................................................................18
9. Drawings ............................................................................................................19
C-1
Glossary of Terms
TERM DEFINITION
Auxiliary Power An input indicating the presence of Auxiliary Power Supply to the ATI Master module.
Available
EOAT End-Of-Arm-Tool (end effector).
The output supplied to the ATI Master DeviceNet node to couple the tool changer (only
Latch
valid for double solenoid valve equipped units).
Lock A proximity sensor input indicating that the coupling mechanism is in the Lock position.
RTL A proximity sensor input that senses when the ATI Tool is close.
A relay circuit present on the ATI Master module that is triggered by the RTL sensor and
RTL Relay
allows the tool changer to be uncoupled when there is no Tool present.
RTLV A control reliable input provided for health status monitoring of the RTL Relay.
Solenoid Energized An input indicating current draw from the valve and the solenoid coil.
The Tool Stand Interlock feature is a custom ATI safety solution and circuit designed to only
TSI
allow tool changer release while in the stand or storage location.
A relay circuit present on the ATI Tool module that is triggered by a tool stand limit switch in
TSI Relay
order to close the TSI circuit and allow tool changer release.
A control reliable input supported for monitoring of a tool stand limit switch used with the
TSIV
TSI circuit.
TSRV A control reliable input provided for health status monitoring of the TSI Relay.
Unlatch The output supplied to the ATI Master DeviceNet node to uncouple the tool changer.
Unlock A proximity sensor input indicating that the coupling mechanism is in the Unlock position.
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C. Control and Signal Modules

DB2—DeviceNet Module
1. Product Overview
1.1 DeviceNet Module
The DeviceNet modules are required to provide a means for the customer to communicate with and
control the tool changer. Refer to Section 3—Product Information of this manual for detailed
DeviceNet programming information and operational capability.
A single or double solenoid valve is provided with the master valve adapter for Lock/Unlock control of
the tool changer. The user is only required to provide a pneumatic supply source to the tool changer.
Power and signal connectors are provided for interfacing on the Master and Tool modules. When the
tool changer is coupled, the Master and Tool modules pass signals using a spring-loaded pin block. A
flexible boot surrounds the pin block to seal the connection from moisture and liquid while coupled.
The DB2 module is designed with special features to afford the user the opportunity to operate the tool
changer in the safest manner possible. In addition to providing the standard Lock, Unlock, and Ready-
to-Lock sensor inputs, the modules are outfitted with Tool Stand Interlock (TSI). The TSI feature
consists primarily of a physical break in the unlatch solenoid valve circuit. The TSI circuit is designed
to allow tool changer release ONLY when the tool is in the stand or storage location.
A momentary action double-pole, single-throw mechanical limit switch is recommended to be used in
concert with TSI. The limit switch is integrated on the EOAT (see Figure 1.1 and Figure 1.2). An
interface to the TSI circuit is made available to the customer via a 4-Pin Eurofast (12mm) connector on
the Tool module. An off the shelf cord set can be utilized to connect this interface to the limit switch
assembly.
In order to allow the tool changer to uncouple when a Tool is not present, a relay circuit (RTL Relay)
in parallel with the TSI circuit is utilized. The RTL Relay circuit is located in the Master module and is
triggered by the RTL sensor. If the RTL sensor is low, indicating no Tool presence, then the RTL
Relay circuit is closed allowing the unlatch solenoid valve circuit to be completed and the tool changer
to be uncoupled. If the RTL sensor is high, indicating Tool presence, then the RTL Relay circuit is
open and the TSI circuit is passed through to the Tool side.
Once on the Tool side, the TSI circuit is closed by another relay circuit (TSI Relay). The TSI Relay is
located in the Tool module and is triggered by closure of the limit switch. When the EOAT is in the
stand and the limit switch is closed, the TSI Relay is closed, thus making the TSI circuit through the
tool side. When the EOAT is out of the stand the TSI Relay is open and the TSI circuit remains open
regardless of any unintentional Unlatch command.
Control reliability monitoring of the Relays, limit switch and TSI circuit is achieved using the RTLV,
TSRV and TSIV inputs, respectively. Refer to Table 4.1 for suggested fault monitoring conditions.
The DB2 Master module firmware requires that the TSIV input be true in order for the Unlatch output
command to be executed when a tool is present (i.e. RTL is high). On the DB2 Tool module, the TSIV
input is made available to the customer along with the TSI circuit via the 4-Pin TSI connector. Refer to
the TSI connector details in Section 9—Drawings of this manual.
The Tool module employs a series of thumbwheel switches for setting of the Tool ID input. This allows
the customer to distinguish between the different Tools that are being used in a robotic cell or on a
production line. See Section 3.3—Software for DeviceNet bitmap and I/O information.
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Figure 1.1—DB2 DeviceNet Module
Figure 1.2—Tool Stand Interlock
DeviceNet Master
Module
DeviceNet Tool
Module
Tool Stand Interlock Safety Feature:
The Tool Stand Interlock (TSI) Feature is provided with this tool changer.
A 4-Pin Eurofast connector found on the Tool module is designed for use with a tool
stand present switch. Two sets of NO, double-pole single-throw, contacts are required on
the switch. One set energizes a tool-side relay to make the Valve circuit, while the
second set provides an input for fault monitoring. This switch should be integrated onto
the EOAT to sense when the tool is in the stand.
If an Unlatch command is given and the tool is not docked properly, the Unlatch
command will not be recognized. This prevents the accidental release of the tool outside
of the tool stand.
A teach plug is available to override the TSI safety feature during initial setup and
maintenance situations.
Please refer to the manual for specific details regarding the TSI feature.
NOTICE: This tool changer is equipped with Tool Stand Interlock (TSI). Special procedures are
required to uncouple the tool changer. Refer to Section 4—Operation.
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2. Installation
The control/signal modules are typically installed by ATI prior to shipment. The steps below outline the field
installation or removal as required.
WARNING: Do not perform maintenance or repair on Tool Changer or modules unless

the tool is safely supported or docked in the tool stand and all energized circuits (e.g.
electrical, air, water, etc.) have been turned off. Injury or equipment damage can occur
with tool not docked and energized circuits on. Dock the tool safely in the tool stand
and turn off all energized circuits before performing maintenance or repair on Tool
Changer or modules.
2.1 Installing
1. It may be necessary to clean the mounting surface on the Tool Changer prior to installing the
module in order to remove any debris that may be present.
2. Using the ledge feature as a guide place the module into the appropriate location on the Tool
Changer body. Align the module with the Tool Changer using the dowels in the bottom of the
ledge feature. Refer to Figure 2.1.
3. If fasteners do not have pre-applied adhesive, apply Loctite 242® to the supplied M6 SHCS
fasteners. Install the two (2) M6 socket head screws securing the module to the Tool Changer and
tighten to 40–70 in-lbs.
4. Power, signal, and auxiliary cables can be connected to the module after attaching the module to
the Spacer or Valve Adapter Modules. Ensure that the connectors are cleaned prior to being
secured as appropriate.
Figure 2.1—Module Installation
2.2 Removal
1. Prior to removing the module use a marker pen to scribe a line or indication between the Tool
Changer and module body as a reminder where the module is to be re-installed.
2. Depending upon the service or repair being done, customer connections up to the module may or
may not need to be disconnected.
3. Remove the socket head cap screws and lift the module from the Tool Changer. Refer to
Figure 2.1.
CAUTION: It is recommended, not to use fasteners with pre-applied adhesive
more than three times. Fasteners used more than three times may come loose
and cause equipment damage. Discard fasteners used more than three times and
install new fasteners with pre-applied adhesive.
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2.3 DeviceNet Configuration

Various parameters for the DeviceNet modules need to be configured prior to operating the tool
changer. Please refer to Section 3—Product Information of this manual for detailed information on
installation and operation of the DeviceNet modules.
2.4 Utility Schematic
Refer to Section 9—Drawings of this manual for customer interface and wiring details for the DB2
modules.
WARNING: All pneumatic fittings and tubing must be capable of withstanding the
repetitive motions of the application without failing. The routing of electrical and
pneumatic lines must minimize the possibility of over stressing, pullout, or kinking
the lines. Failure to do so can cause some critical electrical and/or pneumatic
lines not to function properly and may result in injury to personnel or damage to
equipment. Follow the robot manufacturer’s guidelines and carefully route hoses
and cables to avoid damage.
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3. Product Information
The DeviceNet modules enable the customer to control and communicate with the tool changer through a
network using standard DeviceNet protocol. DeviceNet nodes are established on the Master and Tool side
modules. The modules employ standard connectors, 5-pin Mini for DeviceNet communications and power and
4-pin Mini for Auxiliary power. Please refer to drawings in Section 8 for specific module wiring and connector
interface information.
Prior to use of the tool changer and the DeviceNet modules, various hardware settings must be configured.
Communicating with the DeviceNet Modules requires knowledge of DeviceNet standards and operation.
3.1 Master Node
The Master Node operates as a Group 2-Only Server on the DeviceNet network. The Master Node
supports Explicit Messages, Polled, Strobe and Change of State/Cyclic of the predefined Master/Slave
Connection set. The Master Node supports Quick Connect operation as defined by ODVA (refer to the
EDS file for specific information). The Master Node does not support the Unconnected Message
Manager (UCMM). MAC ID, Baud Rate and Termination Resistor settings for the Master Node are
configured through a DIP switch. (2) LED’s provide network and module status.
3.1.1 Setting the DIP Switches

1. Loosen the four M3 Pan head Captive Screws and remove the window.
2. Set the DIP switches as needed, refer to Figure 3.2 for details.
3. Re-install the window and tighten the M3 Pan Head Captive Screws.
NOTICE: When replacing the window, ensure that the seal is positioned correctly
to prevent fluid leakage into the module and damaging the electronics.
Figure 3.1— Master Module DIP Switches and LED’s
3.1.2 MAC ID
The MAC ID is set by either hardware or software configuration. The range is 0-63. In order
for the MAC ID to be set by software, all DIP switch positions must be on. If the MAC ID is
set by software, the Baud Rate must also be set by software. Refer to Figure 3.2 for detailed
information on DIP switch setup.
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3.1.3 Baud Rate

Baud Rate is set by either hardware or software configuration. The possible settings are 125,
250 or 500Kbps. In order for the Baud Rate to be set by software, DIP switch positions 7 and
8 must be on. See Figure 3.2 for DIP switch setup.
3.1.4 Termination Resistor
When DIP switch position 9 is on, a 120resistor is placed across the CAN High and Low
lines and termination to the CAN network is provided. If switch 9 is off, termination must be
supplied by another device or through a termination cap at the end of the network cable.
Figure 3.2—DeviceNet Master Module DIP Switch Settings

Legend:
SHOWN IN FACTORY DEFAULT SETTING
Switch in OFF position

1 2 3 4 5 6 7 8 9 10
ON
= Node 54
OFF
Switch in ON position
10 - OFF: Reserved
9 - ON: Connects the 120Termination Resistor
7, 8: Set communication Baud Rate as below;
7 8
7-OFF, 8-OFF: 125Kbps
7-ON,8-OFF: 250Kbps
7-OFF, 8-ON: 500Kbps
7-ON, 8-ON: SW setable
1 - 6: Set MAC ID
Example: MAC ID of 27
1 2 3 4 5 6
ON
OFF
Position 1 is Least Significant
3.1.5 Module Status LED

The module status LED is identified on the device board as “MS”. It provides device status
for power and proper operation. The following table outlines this LED’s functions:
Table 3.1—Module Status LED
Status LED Function Note
No Power Off No power applied. Check voltage is 24 VDC.
Operational Green Normal operation.
Standby Flashing Green Device needs commissioning/standby state.
Configuration missing, incomplete or incorrect.
Recoverable Fault Flashing Red Recoverable fault.
Unrecoverable Fault Red Unrecoverable fault.
Self Tests Flashing Green-Red Device is performing self tests.
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3.1.6 Network Status LED

The network status LED is identified on the device board as “NS”. It provides network status
for power and communication. The following table outlines this LED’s functions:
Table 3.2—Network Status LED
Status LED Note
No Power/ Off Line Off Device not on line. Check Baud Rate.
Function
Device has not completed the duplicate MAC ID test.
Module Status is On. Check for termination resistor.
Device not powered. See Module Status.
On Line, Not Connected. Flashing Device is on line but connection is not established.
Green
Device not allocated to a master.
OK Green Device is on line with connections established.
On line, Connected Device is allocated to a master.
Connection Timeout Flashing One or more I/Os are timed out.
Red
Critical Link Failure Red Failed communication. Error detected and incapable of communication.
Duplicate MAC ID or Bus off.
Communication Faulted and Received Flashing A specific Communication Faulted Device. Device has received and
and Identify Communication Fault Green- accepted an Identify Communication Faulted Request – Long Protocol
Request – Long Protocol Message Red message.
3.2 Tool Node

The Tool Node operates as a Group 2-Only Server on the DeviceNet network. The Tool Node supports
Explicit Messages, Polled and Strobe of the predefined Master/Slave Connection set. The Tool Node
supports Quick Connect operation as defined by ODVA (refer to the EDS file for specific information).
The Tool Node does not support the Unconnected Message Manager (UCMM). The MAC ID and
Baud Rate settings for the Tool Node are configured through a DIP switch. Tool ID is set using (5)
thumbwheel switches. (2) LED’s provide network and module status.
3.2.1 Setting the DIP Switches
2. Set the DIP switches as needed, refer to Figure 3.4 for details.
NOTICE: When replacing the window, ensure that the seal is positioned correctly
to prevent fluid leakage into the module and damaging the electronics.
Figure 3.3—Tool Module Tool-ID Switches, DIP Switches and LED’s
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3.2.2 MAC ID
The MAC ID is set by either hardware or software configuration. The range is 0-63. In order
for the MAC ID to be set by software, all DIP switch positions must be on. If the MAC ID is
set by software, the Baud Rate must also be set by software. Refer to Figure 3.4 for detailed
information on DIP switch setup.
3.2.3 Baud Rate
Baud Rate is set by either hardware or software configuration. The possible settings are 125,
250 or 500Kbps. In order for the Baud Rate to be set by software, DIP switch positions 7 and
8 must be on. See Figure 3.4 for DIP switch setup.
3.2.4 Termination Resistor
Internal termination resistance is not supported in the Tool module. Termination must be
provided through the Master module or externally as required for proper operation of the
network.
Figure 3.4—DeviceNet Tool Module DIP Switch Settings
Legend:
S H O W N IN F A C T O R Y D E F A U L T S E T T IN G
S w it c h in O F F p o s it io n
1 2 3 4 5 6 7 8 9 10
ON
= N ode 55
OFF
S w it c h in O N p o s it io n
1 0 - O F F : R e s e rv e d
9 - O F F : R e s e rv e d
7 , 8 : S e t c o m m u n ic a t io n B a u d R a t e a s b e lo w ;
NOTICE: The DIP switch 7 8
orientation shown is rotated 7 -O F F , 8 -O F F : 1 2 5 K b p s

180º from Figure 3.3.
7 - O N ,8 -O F F : 2 5 0 K b p s
7 -O F F , 8 -O N : 5 0 0 K b p s
7 - O N , 8 - O N : S W s e t a b le
1 - 6 : S e t M A C ID
E x a m p le : M A C I D o f 1 9
1 2 3 4 5 6
ON
OFF
P o s it io n 1 is L e a s t S ig n if ic a n t B it
3.2.5 Tool ID (Tool Node Only)

The Tool ID for a particular tool is established from the setup of (5) thumbwheel switches.
The Tool module is available with switches configured to provide 5 independent (0–9)
readings.
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3.2.5.1 Setting the Tool-ID Switches

2. Use a non-conductive tool (e.g., plastic stylus) to press on the Tool-ID
pushbuttons to increase (+) or decrease (-) the digit value from 1 to 9. Set the
Tool-ID to the desired unique five digit number from 11111 to 99999 for
each tool. Refer to Figure 3.3.
NOTICE: When replacing the window, ensure that the seal is

positioned correctly to prevent fluid leakage into the module and
damaging the electronics.
3.2.6 Module Status LED

The module status LED is identified on the device board as “MS”. It provides device status
for power and proper operation. Refer to Table 3.1 for the module status LED’s functions.
3.2.7 Network Status LED
The network status LED is identified on the device board as “NS”. It provides network status
for power and communication. Refer to Table 3.2 for the network status LED’s functions.
3.2.8 Quick Connect
The Quick-Connect feature can be enabled in the ATI Tool Module. With the Quick-
Connect feature enabled, the ATI tool changer module can reconnect to the DeviceNet
network within 1 sec once power is applied to the pin block during tool change.
Modules with a "Quick Connect Enabled" sticker have this attribute already enabled.
Modules without the sticker require the user to enable the feature using the robot teach
pendant and/or a laptop. The Tool Module may have the Quick Connect option enabled or
disabled depending on when the module was built. Contact ATI if you need assistance
enabling this feature.
If you install a new module into an existing system, check to see if Quick-Connect is enabled
in the old module before replacing. If you see communication faults or delays after module
replacement, check to see if the quick-connect feature is enabled in the new module or if the
new module has the sticker indicating quick-connect was already enabled. Tool Modules with
Quick Connect enabled will not check for duplicate MAC addresses. If the DeviceNet
network includes duplicate MAC addresses, this will cause communication faults. See
Section 6—Troubleshooting for fault causes and correction.
3.3 Software
Working EDS files for the Master and Tool nodes are available from our website (www.ati-
ia.com/download/edsfiles) or by e-mail, reference the part numbers given below:
DB2-M Node EDS file 9030-20-1009
DB2-T Node EDS file 9030-20-1010
I/O bitmaps for the DeviceNet nodes are provided in Table 3.3. The default settings are Node 54 for
the Master module and Node 55 for the Tool module.
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Table 3.3—I/O Bitmap, Robot Input Form the Master DB2-M Module (Node 54)
Bit # Name Description/Function
0 Lock Tool Changer Lock Prox I/P
1 Unlock Tool Changer Unlock Prox I/P
2 Solenoid Energized Latch/Unlatch Solenoid Energized I/P
3 Auxiliary Power Available Auxiliary Power Present I/P
4 RTL Ready-to-Lock Prox I/P
5 TSIV TSI Switch Verify I/P
6 RTLV RTL Relay Verify I/P
7 TSRV TSI Relay Verify I/P
Table 3.4—I/O Bitmap, Robot Output To Master DB2-M Module (Node 54)
0 Latch ToolChanger Valve Latch O/P
1 Unlatch ToolChanger Valve Unlatch O/P
2 N/A
3 N/A
4 N/A
5 N/A
6 N/A
7 N/A
* Latch O/P only applicable for Double Solenoid Valve Adapter Versions
Table 3.5—I/O Bitmap, Robot Input From Tool DB2-T Module (Node 55)
0 Low Bit Tool ID Byte 1 N/A
1 N/A
2 N/A
3 N/A
4 SW1 Bit 1
5 SW1 Bit 2
6 SW1 Bit 4
7 High Bit SW1 Bit 8
8 Low Bit Tool ID Byte 2 SW2 Bit 1
9 SW2 Bit 2
10 SW2 Bit 4
11 SW2 Bit 8
12 SW3 Bit 1
13 SW3 Bit 2
14 SW3 Bit 4
16 Low Bit Tool ID Byte 3 SW4 Bit 1
17 SW4 Bit 2
18 SW4 Bit 4
19 SW4 Bit 8
20 SW5 Bit 1
21 SW5 Bit 2
22 SW5 Bit 4
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4. Operation
Please refer to the flow chart in Figure 3.4 for a logical description of the DeviceNet commands,
coupling procedure and diagnostic checks.
Table 4.1 is provided below with suggested fault monitoring conditions.
Table 4.1—Fault Monitoring

Sensor/Input1 State1 Sensor/Input2 State2 Comment
RTL 0 Tool Module* Present* **RTL Not Operating Properly.
RTL 0 RTLV 1 **RTL Relay or RTL Not Operating Properly.
RTL 1 RTLV 0 RTL Relay or RTL Not Operating Properly.
TSIV 0 TSRV 1 **TSI Relay or Switch Not Operating Properly.
TSIV 1 TSRV 0 TSI Relay or Switch Not Operating Properly.
TSIV 1 Clear of Stand Yes **Switch Failed Closed or Tied Off?
TSRV 1 Clear of Stand Yes TSI Relay Failed Closed?
* Slave Module Present as evidenced by Tool Presence Input or ability to read Tool ID
** Dangerous situation where an unintentional Unlatch command could result in Tool release.
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Figure 4.1—DeviceNet Logical Operation and Diagnostic (DB2-M w/ Single Solenoid Valve Adapter)
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5. Maintenance
The DeviceNet modules are designed to provide a long life with little maintenance required. The modules are
not designed to be field serviced as all point-to-point wiring connections are soldered. Component replacement
is limited to the V-Ring seal on the Master.
WARNING: Do not perform maintenance or repair on Tool Changer or modules unless

the tool is safely supported or docked in the tool stand and all energized circuits (e.g.
with tool not docked and energized circuits on. Dock the tool safely in the tool stand
and turn off all energized circuits before performing maintenance or repair on Tool
Changer or modules.
If the Tool Changer is being used in dirty environments (e.g., welding or deburring applications), care should
be taken to limit the exposure of the Tool Changer. Idle Tool assemblies should be covered to prevent debris
from settling on the mating surface. Also, the Master assembly should be exposed for only a short period of
time during Tool change and down time.
Under normal conditions, no special maintenance is necessary, however it is recommended that periodic
inspections be performed to assure long-lasting performance and to assure that unexpected damage has not
occurred. Perform the following visual inspection monthly:
 Inspect mounting fasteners to verify they are tight and if loose, then tighten to the proper torque.
 Cable connections should be inspected during maintenance periods to ensure they are secure. Loose
connections should be cleaned and re-tightened as appropriate. Inspect cable sheathing for damage,
repair or replace damaged cabling. Loose connections or damaged cabling are not expected and may
indicate improper routing and/or strain relieving.
 Inspect the Master and Tool pin blocks for any pin damage, debris or darkened pins. Refer to
Section 5.1—Pin Block Inspection and cleaning.
 Inspect V-Ring seals for wear, abrasion, and cuts. If worn or damaged, replace. Refer to
Section 5.2—Seal Replacement.
5.1 Pin Block Inspection and cleaning

1. Inspect the Master and Tool pin blocks for any debris or darkened pins.
Figure 4.2—Inspect Master and Tool Pin Blocks
2. If debris or darkened pins exist, remove debris using a vacuum, and clean using a nylon brush
(ATI part number 3690-0000064-60).
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NOTICE: Do not use an abrasive media, cleaners, or solvents to clean the contact pins.
Using abrasive media, cleaners, or solvents will cause erosion to the contact surface.
Clean contact surfaces with a vacuum or non-abrasive media such as a nylon brush (ATI
part number 3690-0000064-60).
3. Inspect the Master and Tool pin blocks for stuck pins or severe pin block damage.
Figure 4.3—Stuck Pin and Pin Block Damage
4. If stuck pins or severe pin block damage exists, contact ATI for possible pin replacement
procedures or module replacement.
5.2 Seal Replacement

1. To remove the existing seal, pinch edge of seal with fingers and gently pull the seal away from the
pin block on the Master.
2. Pull the seal off the pin block.
3. To install a new seal, stretch the new seal over the shoulder of the pin block.
4. Push the seal’s hub down against the pin block using finger tip.
Figure 4.4—V-Ring seal Replacement
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6. Troubleshooting
Refer to the flow chart in Figure 4.1 for troubleshooting information, as well as the table below:
Symptom Possible Cause / Correction

Unit will not lock or unlock Verify that ball bearings are not moving freely. Clean and lubricate
as needed (see Section 4 - Maintenance).
Check air supply
Check that exhaust port is properly vented (check muffler)
Verify that DeviceNet and DeviceNet signals are operating correctly.
Verify that the Master and Tool are within the specified No-Touch
zone when attempting to lock.
Sensors not operating properly (but Verify that cables are connected correctly
DeviceNet is operating correctly).
Verify that the sensors are set correctly (Refer to SIP Kit
Installation).
Ensure that the Tool Plate is securely held to the Master Plate, that
nothing is trapped between their surfaces, and that there is no air
trapped in the Unlock (U) air port.
Loss of DeviceNet Communication Check/replace DeviceNet cabling up- and down-stream of Tool
Changer modules
Inspect DeviceNet Module contact pins for debris/wear
Check nodes up- and down-stream of Tool changer nodes for
failures. These failures can “masquerade” as Tool Changer node
faults.
Verify DeviceNet network and cabling is properly tuned
Lower Baud Rate if communication problems persist.
Check for duplicate MAC addresses, particularly duplicates of
modules with quick-connect enabled.
Note: If using Quick-Connect, Check that the ATI Tool module and
the scan list both have the quick-connect feature enabled. Check
for duplicate MAC addresses, particularly duplicates of modules
with quick-connect enabled.

See Section 9—Drawings of this manual.
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8. Specifications
DeviceNet Module
Master Node
Factory configuration DB2-M MAC ID 54, Baud 500 Kbps, termination resistance “on”, “Mini”
style Bus and Auxiliary Power connectors (male).
Current Draw 63mA Does not include solenoid, which uses Auxiliary Power.
125mA Tool coupled, TSIV off.
183mA Tool coupled, TSIV on.
Tool Node
Factory configuration DB2-T MAC ID 55, Baud 500Kbps, No termination resistance. “Mini”
style Bus and Auxiliary Power connectors (female). (5)
Independent Tool ID switches, each reading a (0–9) position.
Current Draw 61mA Tool by itself.
Supports Mechanical Limit Switch interface with TSI circuit.
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9. Drawings
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Document #9620-20-c-jj13-05
No Installation and Operation Manual exists for this module. A drawing is attached.
For additional information, please refer to our catalog or contact our Sales department. We will
be glad to assist you.
How to Reach Us
Sales, Service and Information about ATI products:

Apex, NC 27539 USA
www.ati-ia.com
Tel: 919.772.0115
Fax: 919.772.8259
E-mail: info@ati-ia.com
Tel: 919.772.0115
Fax: 919.772.8259
E-mail: mech_support@ati-ia.com
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Document #9620-20-c-jxx air-valve adapters with valve signal pass thru-10
Table of Contents
C. Control and Signal Modules ..................................................................2

Jxx Valve Adapters with Valve Signal Pass Thru .....................................2
2. Installation ............................................................................................................2
2.1 Installing ....................................................................................................3
2.2 Removing ..................................................................................................3
3. Operation .............................................................................................................4
4. Maintenance ........................................................................................................5
5. Troubleshooting ...................................................................................................5
6. Recommended Spare Parts .................................................................................6
7. Specifications .......................................................................................................6
8. Drawings ..............................................................................................................7
8.1 Available Master Valve Adapters with Valve Signal Pass Thru .................7
8.2 QC-210 Integrated Tool Changer Valve Arrangement (3 Sheets) .............8
8.3 QC-310 Integrated Tool Changer Valve Arrangement (3 Sheets) ...........11
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C. Control and Signal Modules

Jxx Valve Adapters with Valve Signal Pass Thru
1. Product Overview
Valve Adapters are required to provide a pneumatic air supply to the Tool Changer Master for actuation of the
locking mechanism. Valve Adapters come outfitted with integrated single- or double-solenoid valves mounted
to Flat ‘A’ of the Tool Changer Master. Control of the integrated valve is accomplished though an accessory
electrical module. In the case of Valve Adapters with Valve Signal Pass Thru, the lock/unlock signal from the
Control/Signal Module to the Valve Adapter is transmitted via a small, internal pin block. Figure 1.1 shows the
Control/Signal Module to Valve Adapter electrical interface. Many variations of the Valve Adapter with Valve
Signal Pass Thru are available, depending upon the Tool Changer size and type of porting required by the
customer (see Section 8—Drawings for a complete listing of available adapters and customer drawings).
Figure 1.1—Valve Signal Pass Thru
2. Installation
Valve Adapters are typically installed by ATI prior to shipment. The steps below outline the field installation
or removal as required.
WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the
tool is safely supported or docked in the tool stand and all energized circuits (e.g.
with tool not docked and energized circuits on. Dock the tool safely in the tool stand and
turn off all energized circuits before performing maintenance or repair on Tool Changer or
modules.
C-2
2.1 Installing
1. It may be necessary to clean the mounting surface on the tool changer prior to installing the
2. (2) O-rings are required on the Master tool changer interface. Make sure these o-rings are
present and lightly lubricated (refer to Figure 2.1).
Figure 2.1—Valve Adapter Installation
3. Using the ledge feature as a guide place the module adjacent to the ‘A’ tool changer mounting
surface. Align the module with the tool changer using the dowels in the bottom of the ledge
feature. Apply Loctite 242 to the supplied M6 SHCS fasteners and tighten to 110 in-lbs.
4. Apply Loctite 242 the two supplied M5 SFHCS fasteners and tighten to 60 in-lbs.
5. Make electrical and pneumatic connections up to the Valve Adapter housing as required.
Ensure that the connectors are cleaned prior to being secured as appropriate.
2.2 Removing
1. If there is a Control/Signal Module piggy-backed on the Valve Adapter this may need to be
removed prior to removal of the Valve Adapter (refer to Figure 2.2). Disconnect any
pneumatic connections to the Control/Signal Module and Valve Adapter as required. Also,
proximity sensor and valve cables may or may not need to be disconnected.
2. Remove the Valve Adapter mounting fasteners and pull the module off the tool changer.
3. Make sure that the o-rings are retained at the tool changer master mounting interface.
C-3
Figure 2.2—Control/Signal Module

3. Operation
It is important that the Valve Adapter be supplied with clean, dry, non-lubricated air supplied between 60 and
100 psi (4.5–6.9 Bar) and filtered at 50 microns or better. Valve Adapters are supplied with the tool changer to
provide a fully integrated solution. The customer is only required to supply the Valve Adapter with a single air
supply (see Figure 3.1).
Figure 3.1—Valve Adapter Air Supply Port
The electrical connection for valve control is made through internal pin blocks, as described in Section 1—
Product Overview and detailed in drawings in Section 8—Drawings of this manual. The control of the single-
C-4
or double-solenoid valve is integrated with an ATI-supplied Control/Signal Module that is piggy-backed onto
the Valve Adapter.
Access to a valve manual override is provided on the Valve Adapters. Reference the drawings in Section 8—
Drawings for location of the override on the Valve Adapter and the recommended tools for its actuation.
Use of the manual override should be restricted to contingency situations and only when the robot and tool are
in the stand or storage location. Actuation of the Unlatch valve manual override will result in tool changer
release.
DANGER: Tool Changer release will occur with actuation of the Unlatch valve manual
override. Use of the manual override is restricted to contingency situations. The Tool
Changer and Tool should be in a stand or storage location prior to actuation of the manual
override.
4. Maintenance
Valve Adapters should require little maintenance. The only wear components are the valve itself and an exhaust
muffler. Under normal operating conditions, the valve will last for millions of cycles.
WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the
tool is safely supported or docked in the tool stand and all energized circuits (e.g.
with tool not docked and energized circuits on. Dock the tool safely in the tool stand and
turn off all energized circuits before performing maintenance or repair on Tool Changer or
modules.
5. Troubleshooting
Valve Adapters with Valve Signal Pass Thru are provided with LEDs to indicate whether or not power is being
supplied to the single- or double-solenoid valve. This can be a valuable troubleshooting tool. Figure 5.1 shows
the location of the LEDs. Note that in a single-solenoid Valve Adapter, only the LED on the UNLOCKED side
will turn on when power is supplied to the valve.
Figure 5.1—Valve Adapter LOCKED and UNLOCKED LED Locations
C-5
Follow the suggested actions listed in Table 5.1 when attempting to troubleshoot the Valve Adapter. If issues
persist, contact your closest ATI representative.
Symptom Possible Cause / Correction
Changer not locking/unlocking Check for air leaks and o-ring integrity.
on command.
Check/Replace muffler; ensure clean air supply.
Single-solenoid: Monitor UNLOCKED side LED to verify

power is supplied to valve.
Double-solenoid: Monitor LOCKED and UNLOCKED LEDs
to verify power is supplied to valve.
Verify that the fasteners connecting the Control/Signal

Module to the Valve Adapter are properly tightened.
Check/verify valve power supply at Control/Signal Module.
Table 5.1—Valve Adapter Troubleshooting Measures
DANGER: Tool Changer release will occur with actuation of the Unlatch valve manual
override. Use of the manual override is restricted to contingency situations. The Tool
Changer and Tool should be in a stand or storage location prior to actuation of the valve for
troubleshooting purposes.

Assembly ATI Part Number Description
MAC Series 48 Single-Solenoid Wash-down Valve w/ LED (DC)
3425-0000016-01
Various MAC #48B-AUA-000-GEUA-1GE MOD4507
(See MAC Series 48 Double-Solenoid Wash-down Valve w/ LED (DC)
Section 8.1 3425-0000015-01
for Listing) MAC #48B-BUA-000-GEUA-1GE MOD4507
3490-1010002-00 1/8NPT Exhaust Muffler, 4CFM, 1-1/8"L, Ø.437"
7. Specifications
Valve Adapters with Valve Signal Pass Thru

Valves
Single-solenoid Valve 250mA @ 24VDC MAC Series 48B-AUA, DC Voltage (6W Coil)
Double-solenoid Valve 250mA @ 24VDC MAC Series 48B-BUA, DC Voltage (6W Coil x 2)
Solenoid Resistance ~325KΩ Typical resistance measured across valve coil

(DC versions)
C-6
8. Drawings
8.1 Available Master Valve Adapters with Valve Signal Pass Thru
Part Number Valve Ports Compatible QC

9121-JP4-M Double Solenoid R QC-210
9121-JP5-M Double Solenoid R QC-310
9121-JP6-M Single Solenoid R QC-210
9121-JP7-M Single Solenoid R QC-310
9121-JR2-M Single Solenoid NPT QC-210

9121-JR3-M Single Solenoid, NPT QC-310/510/1210
9121-JR4-M Dual Double Solenoid, G QC-210
w/ Proximity and Pressure Sensors
9121-JS2-M Single Solenoid G QC-210

9121-JS3-M Single Solenoid G QC-310/510/1210
9121-JT2-M Double Solenoid NPT QC-210

9121-JT3-M Double Solenoid NPT QC-310/510/1210
9121-JT5-M Double Solenoid, NPT QC-210
Ground-switched (Sinking)
9121-JU2-M Double Solenoid G QC-210

9121-JU3-M Double Solenoid G QC-310/510/1210
C-7
8.2 QC-210 Integrated Tool Changer Valve Arrangement (3 Sheets)
C-8
C-9
C - 10
8.3 QC-310 Integrated Tool Changer Valve Arrangement (3 Sheets)
C - 11
C - 12
C - 13
Document #9620-20-D-AJ2,AK2,AR2-08
Table of Contents
D. Air Modules ..................................................................................................................2

AJ2-M/T, AK2-M/T, AR2-M/T ............................................................................................2
1. Product Overview.................................................................................................2
2. Installation ............................................................................................................3
2.1 Installation .................................................................................................3
2.2 Removal ....................................................................................................3
3. Operation .............................................................................................................3
4. Maintenance.........................................................................................................3
4.1 Master-Side Self-Sealing Valve .................................................................3
4.2 Tool-Side Self-Sealing Valve .....................................................................4
7. Specifications .......................................................................................................5
8. Drawings ..............................................................................................................6
8.1 AJ2 Master and Tool Module Drawing.......................................................6
8.2 AK2 Master and Tool Module Drawing ......................................................7
8.3 AR2 Master and Tool Module Drawing......................................................8
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com
D-1
D. Air Modules
AJ2-M/T, AK2-M/T, AR2-M/T
1. Product Overview
Modules providing air and vacuum service are attached to the Master and Tool plates. Refer to the table
and figure below for a description of the specific modules being presented in this section.
AJ2-M (10) ¼” NPT self-sealing ports, air only (Master side)
AJ2-T (10) ¼” NPT self-sealing ports, air only (Tool side)
AK2-M (10) ¼” BSPP “G” self-sealing ports, air only (Master side)
AK2-T (10) ¼” BSPP “G” self-sealing ports, air only (Tool side)
AR2-M (10) ¼” BSPT “R” self-sealing ports, air only (Master side)
AR2-T (10) ¼” BSPT “G” self-sealing ports, air only (Tool side)
Table 1.1—Air Modules

NOTE:
Both the Master and Tool side modules are supplied with (10) self-sealing ports. Self-sealing ports are not
to be used for vacuum service.
Figure 1.1—Air Module (AK2 shown), Anodized Aluminum Construction
D-2
2. Installation
The air modules are typically installed by ATI prior to shipment. The steps below outline the field
DANGER: Power and air should always be removed prior to maintenance or repair.
2.1 Installation
2. Align the module to the holes in the tool changer mounting surface using the dowels that are
pressed into the module housing. Push the module up flush with the tool changer surface.
3. Apply Loctite-222 (or similar) thread locker to the socket head cap screws and tighten using a hex
key.
4. Connect customer plumbing to the module.
2.2 Removal
1. All customer plumbing connections to the module need to be purged and disconnected. Once the
supply lines have been turned off, the self-sealing valves on the module can be manually actuated
to purge the line pressure. Cover the valves with a rag prior to purging in order to keep the air
from impinging upon any person.
2. Remove the socket head cap screws and pull the module off the tool changer.
3. Operation
The air modules are designed to pass air utilities from the Master to the Tool for use by the customer’s
tooling.
Ten (10) self-sealing valves are provided on the Master side and the Tool side so that the air circuits do not
discharge during tool change and also so that the circuits upstream of the tool changer do not have to be
closed down prior to tool change.
4. Maintenance
Once installed the operation of the air modules is generally trouble free. Periodically, the condition of the
self-sealing valves should be checked. Replace any damaged or degraded components as necessary. Any
contamination in or around the mating surfaces of the modules should be removed with industrial contact
cleaner. During inspection, ensure that the fasteners attaching the modules to the tool changer are secure.
The modules may be field serviced as needed. The following list describes how to perform various
operations.
4.1 Master-Side Self-Sealing Valve

1. The self-sealing valve assembly (stem, check valve, spring and seals) can be inspected by
removing the stem using a 2.5mm hex key. Be careful not to strip the hex on the stem during
removal.
2. Once the stem is removed all seals can be inspected and replaced as required.
3. The spring in the assembly should be inspected and replaced as required.
4. The stem should be inspected for straightness and replaced if bent.
D-3
5. To re-install the valve assembly, all components should be arranged in order as they were
removed. (See drawings in Section 8.)
6. Loctite-222 (or similar) thread locker should be applied to the threaded end of the stem and the
stem re-installed. The piston will have to be pushed down flush with the mating surface in order to
get the stem thread started. It is important that the U-cup seal around the check valve is not
damaged during this step. A small, flat-head screwdriver can be used to ensure that the U-cup seal
is fully located in the recess and not folded over itself prior to screwing in the stem.
4.2 Tool-Side Self-Sealing Valve

1. The self-sealing valve assembly (plug, spring, piston and seals) can be inspected by removing the
plug on the bottom of the air module using either a spanner wrench or 8mm hex key. It may be
necessary to remove the tool side air module to have access to the plug. (Refer to the Section 2
Installation for instructions for module removal.)
2. Once the plug is removed all seals can be inspected and replaced as required.
4. The plug may contain a dowel pin. The pin should be inspected for straightness and replaced if
bent.
removed. (See drawings in Section 8.)
6. Care should be taken not to damage the O-ring around the plug base during installation.
5. Troubleshooting
Problem Cause Remedy
Air Leakage Damaged/Worn Replace seals.
seals
Debris blocking Clean in and around valve components. Ensure
valve seal air stream is free of large particulates, filter as
necessary.
Bent stem Replace stem. Check module attachment to tool
changer. Check robot program and ensure
parallel approach trajectory during tool changer
coupling.
Corrosion Consult ATI for assistance.
Poor Flow Flow path blockage Inspect valve components and supply/return
lines for blockage, clean/repair as necessary.
necessary.
Modules Won't Bent stem, dowel Replace stem, dowels as necessary. Check
Couple pin module attachment to tool changer. Check robot
program and ensure parallel approach trajectory
during tool changer coupling.
D-4

See drawings in Section 8 of this manual.
7. Specifications
Air Modules AJ2-M, AJ2-T
AK2-M, AK2-T
AR2-M, AR2-T
Weight (coupled) 4.6 lbs (2.1 kg) AJ2-M, AJ2-T

AK2-M, AK2-T
AR2-M, AR2-T
Materials of Construction Various Anodized aluminum housings and

stainless steel valve components,
Nitrile seals,
PVC Tool side port plug.
Pneumatic Ports AJ2-M/T (10) ¼“ NPT (1.4) Maximum pressure of 100psi

(qty) Size (Cv) AK2-M/T (10) ¼“ BSPP “G“ (1.4) (6.9bar), Nitrile seals, Self-sealing on
AR2-M/T (10) ¼“ BSPT “R“ (1.4) Master, and Tool (cannot operate
under a vacuum).
D-5
8. Drawings
8.1 AJ2 Master and Tool Module Drawing
D-6
8.2 AK2 Master and Tool Module Drawing
D-7
8.3 AR2 Master and Tool Module Drawing
D-8
Document #9620-20-d-ar4 ar5t ar7t-03
Table of Contents
D. Air Modules ..................................................................................................................2

AR4-M, AR4-T, AR5-T, AR7-T...........................................................................................2
2. Installation ............................................................................................................3
2.1 Installation .................................................................................................3
2.2 Removal ....................................................................................................3
3. Operation .............................................................................................................3
4. Maintenance ........................................................................................................3
4.1 Master-Side Self-Sealing Valve .................................................................4
4.2 Tool-Side Self-Sealing Valve .....................................................................4
7. Specifications .......................................................................................................5
8. Drawings ..............................................................................................................6
D-1
D. Air Modules
AR4-M, AR4-T, AR5-T, AR7-T
1. Product Overview
Modules providing air and vacuum service are attached to the Master and Tool plates. Refer to the table and
figure below for a description of the specific modules being presented in this section.
AR4-M (8) R 3/8 (BSPT) self-sealing ports, air only (Master side)
AR4-T (8) R 3/8 (BSPT) self-sealing ports, air only (Tool side)
AR5-T (8) R 3/8 (BSPT) pass-through ports, air only (Tool side)
(4) R 3/8 (BSPT) self-sealing ports and (4) R 3/8 pass-through ports, air only
AR7-T
(Tool side)
Table 1.1—Air Modules
NOTE:
The Tool module can be supplied with either (8) self-sealing ports (AR4-T), (8) pass-through ports (AR5-
T), or (4) self-sealing and (4) pass-through ports (AR7-T). The Master module is only available as self-
sealing. Self-sealing ports are not to be used for vacuum service.
Figure 1.1—Air Module, Anodized Aluminum Construction
D-2
2. Installation
The air modules are typically installed by ATI prior to shipment. The steps below outline the field
WARNING: Do not perform maintenance or repair on Tool Changer or modules with

power or air on. Injury or equipment damage can occur with power or air on. Turn off
power and air before performing maintenance or repair on Tool Changer or modules.
2.1 Installation
2. Align the module to the holes in the tool changer mounting surface using the dowels that are
pressed into the module housing. Push the module up flush with the tool changer surface.
3. Apply Loctite-222 (or similar) thread locker to the socket head cap screws and tighten using a hex
key.
4. Connect customer plumbing to the module.
2.2 Removal
1. All customer plumbing connections to the module need to be purged and disconnected. Once the
supply lines have been turned off, the self-sealing valves on the module can be manually actuated
to purge the line pressure. Cover the valves with a rag prior to purging in order to keep the air
from impinging upon any person.
2. Remove the socket head cap screws and pull the module off the tool changer.
3. Operation
The air modules are designed to pass air utilities from the Master to the Tool for use by the customer’s
tooling.
Eight (8) self-sealing valves are provided on the Master side so that the air circuits do not discharge during
tool change and also so that the circuits upstream of the tool changer do not have to be closed down prior to
tool change.
The Tool is available with eight (8) check ports for the AR4-T, (8) pass-through ports for the AR5-T, or (4)
checked ports and (4) pass-through ports for the AR7-T.
4. Maintenance
Once installation, the operation of the air modules is generally trouble free. Periodically, the condition of
the self-sealing valves should be checked. Replace any damaged or degraded components as necessary.
Mating surfaces should be keep clean. Use a vacuum to remove any debris and clean in and around the
mating surfaces of the modules using a nylon brush (ATI part number 3690-0000064-60). During
inspection, ensure that the fasteners attaching the modules to the Tool Changer are secure.
The modules may be field-serviced as needed. The following list describes how to perform various
operations.
WARNING: Do not perform maintenance or repair on Tool Changer or modules

with power or air on. Injury or equipment damage can occur with power or air on.
Turn off power and air before performing maintenance or repair on Tool Changer or
modules.
D-3
4.1 Master-Side Self-Sealing Valve

1. The self-sealing valve assembly (stem, check valve, spring and seals) can be inspected by
removing the stem using a 2.5mm hex key. Be careful not to strip the hex on the stem during
removal.
2. Once the stem is removed all seals can be inspected and replaced as required.
4. The stem should be inspected for straightness and replaced if bent.
removed. (See drawings in Section D-8.)
6. Loctite-222 (or similar) thread locker should be applied to the threaded end of the stem and the
stem re-installed. The piston will have to be pushed down flush with the mating surface in order
to get the stem thread started. It is important that the U-cup seal around the check valve is not
damaged during this step. A small, flat-head screwdriver can be used to ensure that the U-cup seal
is fully located in the recess and not folded over itself prior to screwing in the stem.
4.2 Tool-Side Self-Sealing Valve

1. The self-sealing valve assembly (plug, spring, piston and seals) can be inspected by removing the
plug on the bottom of the air module using either a spanner wrench or 8mm hex key. It may be
necessary to remove the tool side air module to have access to the plug. (Refer to the Section 2
Installation for instructions for module removal.)
2. Once the plug is removed all seals can be inspected and replaced as required.
4. The plug may contain a dowel pin. The pin should be inspected for straightness and replaced if
bent.
removed. (See drawings in Section D-8.)
6. Care should be taken not to damage the O-ring around the plug base during installation.
D-4
5. Troubleshooting
Problem Cause Remedy
Air Leakage Damaged/Worn Replace seals.
seals
necessary.
Bent stem Replace stem. Check module attachment to tool
changer. Check robot program and ensure
parallel approach trajectory during tool changer
coupling.
Corrosion Consult ATI for assistance.
Poor Flow Flow path blockage Inspect valve components and supply/return lines
for blockage, clean/repair as necessary.
necessary.
Modules Won't Bent stem, dowel Replace stem, dowels as necessary. Check
Couple pin module attachment to tool changer. Check robot
program and ensure parallel approach trajectory
during tool changer coupling.

See drawings in Section 8 of this manual.
7. Specifications
Air Modules AR4-M
AR4-T, AR5-T, AR7-T
Weight 2.89 lbs (1.31 kg) AR4-M
2.04 lbs (0.93 kg) AR4-T
2.04 lbs (0.93 kg) AR5-T
2.04 lbs (0.93 kg) AR7-T
Materials of Construction Various Anodized aluminum housings and stainless

steel valve components, Nitrile seals,
PVC Tool side port plug.
Pneumatic Ports AR4-M (8) R 3/8 (1.6) Maximum pressure of 100psi (6.9bar), Nitrile
(qty) Size (Cv) AR4-T (8) R 3/8 (1.6) seals.
AR5-T (8) R 3/8 (1.6) Self-sealing on AR4 Master
AR7-T (4) + (4) R 3/8 (1.6) Self-sealing on AR4 Tool
Pass-through on AR5 Tool
Self-sealing and pass-through on AR7 Tool
(Cannot operate under a vacuum.)
D-5
8. Drawings
D-6
D-7
D-8
Document # 9620-20-e-ef17-03
Table of Contents
E. Electrical Modules .......................................................................................................2

EF17—Servo Module .......................................................................................................2
1.1 Servo Module..............................................................................................2
2. Installation ............................................................................................................3
3. Operation .............................................................................................................3
4. Maintenance.........................................................................................................3
7. Specifications .......................................................................................................5
8. Drawings ..............................................................................................................6
8.1 EF17 Mechanical and Electrical Assembly .................................................6
8.2 Servo Remote Battery Backup Module w/ MicroFast Cable .......................7
E-1
Document # 9620-20-e-ef17-03
EF17—Servo Module
1. Product Overview
1.1 Servo Module
A servo module may be provided on the tool changer to pass electrical power and signal connections
to a transgun servomotor. (See Section 8 for drawings, pinouts, and wiring information.) The
connectors on this module are located such that power and signal cables can be routed separately. On
the Tool module a third connector is provided to allow the connection and use of a remotely mounted,
cable connected, battery module to maintain the servo settings during periods when the tool is not in
use. By design, power and signal circuits are electrically isolated from each other and from the tool
changer. The signal wiring has EMI/RF shielding to protect it from noise.
Figure 1.1—Servo Modules
Compliant spring probes are provided on the Master and fixed contact pins on the Tool. Both the
power and signal connectors are electrically isolated from the servo module by mounting them in
non-conductive plates.
E-2
Document # 9620-20-e-ef17-03
Both the power and signal circuits are designed to be water resistant, but they are not waterproof. On
the power circuit, the central pin is first to mate and last to break during a tool change. For safety
reasons, it is recommended that this pin be used as designated ground. On the signal circuit, the
central pin is the first to mate and last to break during a tool change. It is recommended that this pin
be used as the designated ground. To avoid unintentional human contact, the Master spring pins are
recessed below an insulated surface on both the power and signal circuits.
CAUTION: To avoid damage to the contacts, never uncouple the unit without first
! disconnecting and discharging the power that passes through these pins. This is
especially true if high voltage circuits are involved.
2. Installation
The servo modules are typically installed on tool changers by ATI prior to shipment. The steps below outline
field installation or removal as required.
1) Remove the two (2) M6 socket head screws securing the module to the tool changer.
2) After removing these screws lift the module assembly off the tool changer body.
3) Installation is the reversal of the previous two steps.
3. Operation
The servo modules are designed to work with specific industrial servomotors and drives, providing a separable
joint in the power and signal wiring. To maximize the service life of these components the following points
should be observed:
1) Do not couple or uncouple the servo modules unless electrical power has been disconnected and
discharged both upstream and downstream from the modules. Arcing and contact damage will
occur if this is not observed.
2) Properly route and secure all cables, particularly on the Master side. Failure to observe this point
may result in premature failure of the industrial electrical connectors. Poor cable routing can also
result in wires and cables being pinched in the joint between the tool changer halves.
4. Maintenance
Once installed, the operation of the servo modules is generally trouble free. Periodically the condition of the
module contacts should be checked. Any contamination should be removed with industrial contact cleaner.
During inspection, insure that the fasteners attaching the modules to the Quick-Change bodies are still secure.
The modules are not designed to be field serviced as all point-to-point wiring connections are soldered.
Component replacement is limited to the V-Ring seal on the Master and backup battery replacement on the
Tool (where applicable.)
Seal Replacement:
1) To replace the V-Ring seal, use a small screwdriver or similar to gently pry the seal away from the
pin block on the Master then pull the seal off the pin block.
2) To install a new seal, stretch it over the shoulder of the pin block and use a small screwdriver to
push the seal’s hub down against the pin block.
E-3
Document # 9620-20-e-ef17-03
5. Troubleshooting
The servo modules provide a separable joint in the cabling between a servomotor and its controller/drive.
Failure of the motor to operate for any reason must be diagnosed electrically.
Symptom Possible Cause Correction

Cable Damage Pinched, torn, or fatigued cables Replace cables.
Obstruction Object trapped between modules Remove object, re-attempt coupling.
Servo Module Contact Coupling/Uncoupling under load. Revise operating procedures to only
Damage couple/uncouple with power
disconnected and discharged. Field
replacement of module contacts is not
possible.
Servo Module Contact Environment Clean Master and Tool side module
Contamination contacts with contact cleaner
The following sequence is recommended for troubleshooting servo motor problems.

1) First examine all the cables, cable connectors, and power sources for problems and correct as
necessary.
2) Use a known good set of cables (power and signal) to bypass the servo modules and directly
connect the drive to the motor.
3) If the motor does not operate properly with known good cables, the problem is in the drive or
motor. Troubleshoot these components using that manufacturer’s procedures.
4) If the motor operates properly, use the known good cables from step 2 to connect between the servo
drive and ATI Master servo module. Use a second set of known good cables to connect the Tool
servo module to the motor.
5) If the motor operates properly, the problem is in the old cables which must be repaired or replaced.
6) If the motor does not operate properly, the problem is in the servo module.
7) Examine the servo modules for damage to their electrical connectors and contact pins. Clean all
accessible surfaces, where necessary. Insure that the spring pins on the Master side can move freely
and are not bound by debris. Clean the spring pins with contact cleaner to restore free operation.
8) If the above steps fail to restore proper operation, contact ATI for service.
E-4
Document # 9620-20-e-ef17-03

See drawing in section 8 of this manual.
7. Specifications
Servo Module EF17
Weight x.xx lbs (x.xx kg) Master

x.xx lbs (x.xx kg) Tool
(# Contacts) Motor Current (7) 13 Amp, 500VAC / Spring-loaded, gold-plated, and serrated
and Voltage Specification 700VDC Max. pins on Master side. Central contact on
Tool Side is first to make and last to
break.
(# Contacts) Encoder Current (19) 3 Amp, 250VAC / Spring-loaded, gold-plated, and serrated
& Voltage Specification 30VDC Max. pins on Master side. Central contact on
Tool Side is first to make and last to
break.
All contacts may not be utilized. See module drawing in Section 8 for actual wiring.
Shielding Signal wiring has EMI/RF shielding
Connectors See Drawing, Section 8
E-5
Document # 9620-20-e-ef17-03
8. Drawings
8.1 EF17 Mechanical and Electrical Assembly
E-6
Document # 9620-20-e-ef17-03
8.2 Servo Remote Battery Backup Module w/ MicroFast Cable
E-7
Document #9620-20-e-en9-08
Table of Contents
E. Electrical Modules .......................................................................................................2

EN9/ENS9—Servo and Discrete I/O Module...................................................................2
1.1 Servo and Discrete I/O Module ....................................................................2
2. Installation ............................................................................................................3
3. Operation .............................................................................................................4
4. Maintenance.........................................................................................................4
7. Specifications .......................................................................................................7
8. Drawings ..............................................................................................................8
8.1 EN9 Servo Module .......................................................................................8
8.2 ENS9 Module Drawing ...............................................................................12
8.3 ENC Tool-side Cover Plate ........................................................................16
E-1
EN9/ENS9—Servo and Discrete I/O Module
1. Product Overview
1.1 Servo and Discrete I/O Module
A servo module may be provided on the Tool Changer to pass electrical power and signal
connections to a servomotor. (See Section 8 for drawing, pinout, and wiring information.) The
connectors on this module are located such that the power and signal cables can be routed separately.
By design, power and signal circuits are electrically isolated both from each other and the Tool
Changer.
WARNING: Do not perform maintenance or repair on Tool Changer or modules

with power or air on. Injury or equipment damage can occur with power or air on.
Turn off power and air before performing maintenance or repair on Tool Changer or
modules.
9121-JJ13-M EN9 Master

Rail Assembly,
Master side
9121-JJ13-T EN9 Tool

Rail Assembly,
Tool side
Figure 1.1—Servo Modules (EN9-M and EN9-T shown)
When an EN module is not used on the Tool-side, an ENC-T may be supplied (per customer request)
to protect the Master side servo module from dust, debris, and weld spatter.
Figure 1.2—EN Modules Tool-side Cover Plate
E-2
Compliant spring probes are provided on the Master and fixed contact pins on the Tool. Both the
power and signal connectors are electrically isolated from the servo module by mounting them in
non-conductive plates.
Both the power and signal circuits are designed to be water-resistant, but they are not waterproof. On
the power circuit, the central pins are first-to-mate and last-to-break during a Tool change. For safety
reasons, it is recommended that these pins be used as designated ground. On the signal circuit, the
central pins are first-to-mate and last-to-break during a Tool change. It is recommended that these
pins be used as the designated ground. To avoid unintentional human contact, the Master spring pins
are recessed below an insulated surface on both the power and signal circuits.
The EN9 servos are of a modular design. A mounting rail is used to attach the electrical modules to
the Tool Changer. A symmetric mounting pattern on the mounting rail allows the customer to
position servo modules where they best fit the application. The modular design also allows for ease of
maintenance when servo modules must be repaired or replaced.
CAUTION: To avoid damage to the contacts, never uncouple the unit without
first disconnecting and discharging the power that passes through these pins.
This is especially true if high voltage circuits are involved.
2. Installation
The servo modules are typically installed on Tool Changers by ATI prior to shipment. The steps below outline
field installation or removal as required.
To remove or attach the mounting rails to the Tool Changer:
1. Remove the two (2) M6 socket head screws securing the rail to the Tool Changer.
2. After removing these screws lift the rail assembly off the Tool Changer body.
3. Installation is the reversal of the previous two steps. Torque the M6 socket head screws to 89 in-lb
(10 Nm).
To remove or attach individual servo modules or cover/spacers to the mounting rails:
1. Remove the two M3 socket head screws securing the servo module to its neighbors along with the
flat key plate.
2. Remove the M6 socket flat head screw securing the module to the mounting rail.
3. Lift the module off the rail and slide it forward to remove it from the Tool Changer.
4. Installation is the reversal of the previous three steps. Torque the M3 socket head screws to 12 in-lb
(1.3 Nm); torque the M6 socket flat head to 44 in-lb [5 Nm].
E-3
3. Operation
The servo modules are designed to work with specific industrial servomotors and drives, providing a separable
joint in the power and signal wiring. To maximize the service life of these components the following points
should be observed:
1. The servo modules are not a switch and must not be used as a switch. Do not couple or uncouple the
servo modules unless electrical power has been disconnected and discharged both upstream and
downstream from the modules. Arcing and contact damage will occur if this is not observed.
2. Properly route and secure all cables, particularly on the Master side. Failure to observe this point may
result in premature failure of the industrial electrical connectors. Poor cable routing can also result in
wires and cables being pinched in the joint between the Tool Changer halves.
4. Maintenance
Once installed, the operation of the servo modules is generally trouble free. Periodically, the condition of the
module contacts should be checked. Replace any damaged or degraded components as necessary. Mating
surfaces should be kept clean. Use a vacuum to remove any debris and clean in and around the mating surfaces
of the modules using a nylon brush (ATI part number 3690-0000064-60). During inspection, ensure that the
fasteners attaching the modules to the Tool Changer are secure.
The modules are not designed to be field-serviced as all point-to-point wiring connections are soldered or
crimped. Component replacement is limited to the V-Ring seal on the Master. The following list describes how
to perform this operation.
WARNING: Do not perform maintenance or repair on Tool Changer or modules with
power or air on. Injury or equipment damage can occur with power or air on. Turn off
power and air before performing maintenance or repair on Tool Changer or modules.
Seal Replacement:
1. To replace the V-Ring seal, use a small screwdriver or similar to gently pry the seal away from the pin
block on the Master then pull the seal off the block.
2. To install a new seal, stretch it over the shoulder of the pin block and use a small screwdriver to push
the seal’s hub down against the plastic pin block.
E-4
5. Troubleshooting
The servo modules provide a separable joint in the cabling between a servomotor and its controller/drive.
Failure of the motor to operate for any reason must be diagnosed electrically.
Symptom Possible Cause Correction

Cable Damage Pinched, torn, or fatigued cables Replace cables.
Obstruction Object trapped between modules Remove object, re-attempt coupling.
Servo Module Contact Coupling/Uncoupling under load. Revise operating procedures to only
Damage couple/uncouple with power
disconnected and discharged. Field
replacement of module contacts is not
possible.
Servo Module Contact Environment Clean Master and Tool side module
Contamination contacts with contact cleaner
The following sequence is recommended for troubleshooting servo motor problems.

1. First examine all the cables, cable connectors, and power sources for problems and correct as necessary.
2. Use a known good set of cables (power and signal) to bypass the servo modules and directly connect
the drive to the motor.
3. If the motor does not operate properly with known good cables the problem is in the drive or motor.
Troubleshoot these components using that manufacturer’s procedures.
4. If the motor operates properly, use the known good cables from step 2 to connect between the servo
drive and ATI Master servo module. Use a second set of known good cables to connect the Tool servo
module to the motor.
5. If the motor operates properly the problem is in the old cables which must be repaired or replaced.
6. If the motor does not operate properly the problem is in the servo module.
7. Examine the servo modules for damage to their electrical connectors, and contact pins. Clean all
accessible surfaces where necessary. Insure that the spring pins on the master side can move freely and
are not bound by debris. Clean the spring pins with contact cleaner to restore free operation.
8. If the above steps fail to restore proper operation contact ATI for service.
E-5

Part Number Description
EN9 Master
9121-EN9-M EN8 Master Servo Module Assembly with Radial
DDK 28-pin Connector
9121-JJ12-M 3-position Master Rail Assembly
9121-JJ13-M 4-position Master Rail Assembly
4010-0000030-01 V-Ring Seal
3700-20-6758 Servo Key
EN9 Tool
9121-EN9-T EN7 Tool Servo Module Assembly with Radial
9121-JJ12-T 3-position Tool Rail Assembly
3700-20-6758 Servo Key
EN9S Tool
9121-ENS9-T EN9S Tool Servo Module Assembly with Axial
3700-20-6758 Servo Key
ENC Tool
9121-ENC-T Tool-side Cover Plate for EN Modules
E-6
7. Specifications
Servo Module EN9-M/EN9-T
Weight 1.65 lbs (0.75 kg) EN9 Master Module

1.65 lbs (0.75 kg) EN9 Tool Module
1.70 lbs (0.77 kg) ENS9 Tool Module
0.27 lbs (0.12 kg) ENC Tool Cover
1.6 lbs (0.73 kg) 3-position Mounting Rail (JJ12), Master

1.3 lbs (0.59 kg) 3-position Mounting Rail (JJ12), Tool
1.9 lbs (0.86 kg) 4-position Mounting Rail (JJ13), Master

1.6 lbs (0.73 kg) 4-position Mounting Rail (JJ13), Tool
(# Contacts) Motor Current & (4) 15 Amp, 500VAC Max. Spring-loaded, gold-plated and serrated
Voltage Specification pins on Master-side. Central contacts
on Tool-side are first-to-make and last-
to-break.
(# Contacts) Encoder Current (14) 3 Amp, 30VDC Max. Spring-loaded, gold-plated and serrated
& Voltage Specification (Includes Shields) pins on Master-side. Central contacts
on Tool-side are first-to-make and last-
to-break.
(The number of wires/pins used is determined by customer-specified requirements).
Shielding Internal shielding provided per customer specification.
Connectors See Drawings, Section 8
E-7
8. Drawings
8.1 EN9 Servo Module
E-8
E-9
E - 10
E - 11
8.2 ENS9 Module Drawing
E - 12
E - 13
E - 14
E - 15
8.3 ENC Tool-side Cover Plate
E - 16
Document #9620-20-F-NA-02
High-Power Modules are not used in this application. For a list of available options please refer
to our catalog or contact our Sales department. We will be glad to assist you.
How to Reach Us

Apex, NC 27539 USA
www.ati-ia.com
Tel: 919.772.0115
Fax: 919.772.8259
Tel: 919.772.0115
Fax: 919.772.8259
ATI Industrial Automation, 1031 Goodworth Drive, Apex, NC 27539 (919)-772-0115 www.ati-ia.com
F-1
Document #9620-20-G-NA-03
Interface Plates are not used in this application. For a list of available options please refer to our
catalog or contact our Sales department. We will be glad to assist you.
How to Reach Us

Apex, NC 27539 USA
www.ati-ia.com
Tel: 919.772.0115
Fax: 919.772.8259
Tel: 919.772.0115
Fax: 919.772.8259
G-1
Document #9620-20-H-UAA-03
No Installation and Operation Manual exists for this module. A drawing is attached.
For additional information, please refer to our catalog or contact our Sales department. We will
be glad to assist you.
How to Reach Us

Apex, NC 27539 USA
www.ati-ia.com
Tel: 919.772.0115
Fax: 919.772.8259
Tel: 919.772.0115
Fax: 919.772.8259
H-1
Document #9620-20-H-UAA-03
H-2

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Quick-Change QC-1210

Robotic Tool Changer

Installation and Operation Manual

Engineered Products for Robotic Productivity

B. Base Tool Changer

C. Control and Signal Module

D. Fluid Air Modules

F. High Power Modules

ATI Industrial Automation

Technical support and questions:

DANGER: Notification of information or instructions that if not followed will

WARNING: Notification of information or instructions that if not followed

CAUTION: Notification of information or instructions that if not followed

ATTENTION, NOTE, or NOTICE: Notification of specific information or instructions

1.3. Safety Precautions

WARNING: Do not perform maintenance or repair on Tool Changer or

WARNING: The Tool Changer is only to be used for intended applications

CAUTION: The Master Plate locking mechanism must not be actuated

4. Terms and Conditions of Sale

B. Base Tool Changer ......................................................................................................2

B. Base Tool Changer

Ball Bearings (36) Junction Module

Common Ledge Feature

Lock/Unlock Air Supplied through Proximity Sensor

Figure 1.1—Master Plate Assembly

Proximity Sensor Junction Module

Alignment Pin Bushing

Common Ledge Feature

1.3 Optional Modules

Tool Plate (aluminum) to End-Effector Interface Plate M10–1.5 52 Nm

2.1 Master Interface

Robot Wrist Flange

Robot Interface Plate

Master Plate, with

Tool Plate, with

Tool Interface Plate

Figure 2.1—Typical Installation (QC-1210 Shown)

No-Touch Zone X and Y Offset Cocking Offset Twisting Offset

Table 2.3—Maximum Recommended Offsets Prior to Coupling

CAUTION: Safe, reliable operation of the Tool Changer is dependent on a continuous

3.1 Coupling Sequence

3.4 Integrated Sensors

Flat A / Control Module

U1, L1, U2, and L2

R1, R2, U, and L L2

Figure 3.2—Connector view

Figure 3.3—Sensor Cable Routing

Sensor Cable Routing

Cable # from Fig. 3.3 ATI Part Number

4.1 Preventive Maintenance

Tool Change Inspection

> 1 per minute Weekly

Balls/Alignment Pins/Holes/Bearing Race

Wear on the balls/bearing race could be an indication of excessive loading.

Mounting Hardware/Interface Connections

Exposed contacts may be subject to damage during normal operation.

4.2 Cleaning, Lubrication, Adjustment and Replacement

Figure 4.3—Checking balls to move freely

Figure 4.4—Lubrication areas

4.2.3 Lock and Unlock Sensor Assembly Replacement. Figure 4.5

Figure 4.5—QC-1210 Lock and Unlock Sensor Assemblies

4.2.4 RTL Sensor Replacement (8mm Threaded Barrel Style).

Figure 4.6—Barrel-style RTL sensor