QC-313 Quick Change Install and Operate PDF

Quick-Change QC-313
Robotic Tool Changer

(Application-specific Drawing Available upon Request)
Installation and Operation Manual
Includes:
Part Number Description
9121-313AM-0-00-0-00 Tool Changer—Master
9121-313DT-0-00-0-00 Tool Changer—Tool
9121-Jxx-M Air/Valve/Mounting Adapter
9121-JJ12-M/T Mounting Adapter Assembly—Master & Tool
9121-JJ26-M/T Mounting Adapter Assembly—Master & Tool
9121-VA7-M/SAx-T Control & Signal Module—Master & Tool
9121-FS2-M/T Fluid/Air Module—Master & Tool
9121-EN38-M/T Gigabit Ethernet Pass-through Module—Master & Tool
9121-EN42-M/T Servo Module—Master & Tool
9121-EN43-M/T Servo Module—Master & Tool
9121-HBx -M/T Hydraulic Module—Master & Tool
Some 3-D Model Downloads are available on our website. Contact your Account Representative for more information.
Manual #: 9610-20-2201
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-113 Base Tool Changer-02
Table of Contents
B. Quick-Change Tool Changer ...................................................................................................B-3
QC-113 Series—Quick-Change Tool Changer............................................................................B-3
1. Product Overview...................................................................................................................B-3
1.1 Master Plate Assembly.............................................................................................................. B-4
1.2 Tool Plate Assembly................................................................................................................... B-5
1.3 Optional Modules....................................................................................................................... B-5
2. Installation..............................................................................................................................B-6
2.1 Master Plate Installation............................................................................................................ B-6
2.2 Master Plate Removal................................................................................................................ B-7
2.3 Tool Interface.............................................................................................................................. B-8
2.4 Tool Plate Installation................................................................................................................ B-8
2.5 Tool Plate Removal.................................................................................................................... B-9
2.6 Pneumatic Connections.......................................................................................................... B-10
2.6.1 Valve Requirements and Connections for the Locking Mechanism...............................B-10
2.7 Electrical Connections..............................................................................................................B-11
2.7.1 NPN Type Lock and Unlock Sensors (-SP sensor designation).....................................B-11
3. Operation..............................................................................................................................B-12
3.1 Conditions for Coupling.......................................................................................................... B-13
3.2 Fail-Safe Operation.................................................................................................................. B-13
3.3 Conditions for Uncoupling...................................................................................................... B-14
3.4 Tool Storage Considerations.................................................................................................. B-15
4. Maintenance..........................................................................................................................B-16
4.1 Preventive Maintenance.......................................................................................................... B-17
4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins........................ B-18
4.3 Alignment Pin Replacement.................................................................................................... B-20
4.4 Seal Inspection and Replacement.......................................................................................... B-21
4.5 Pin Block Inspection and Cleaning........................................................................................ B-22
5. Troubleshooting...................................................................................................................B-23
5.1 Lock and Unlock Sensor Replacement Procedures............................................................. B-24
5.2 RTL Flat Pack Style Sensor Replacement (R2 Sensor)........................................................ B-25
5.2.1 RTL Flat Pack Style Sensor Replacement (R1 Sensor).................................................B-26
6. Serviceable Parts.................................................................................................................B-27
6.1 Common Master Parts............................................................................................................. B-27
6.2 Models 9121-113xM-0-0-0-0-SP............................................................................................... B-28
6.3 Tool Plate.................................................................................................................................. B-29
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
B-1
7. Specifications.......................................................................................................................B-30
8. Drawings...............................................................................................................................B-31
8.1 QC-113 Tool Changer............................................................................................................... B-31
B-2
B. Quick-Change Tool Changer
QC-113 Series—Quick-Change Tool Changer

1. Product Overview
The Quick-Change Tool Changer provides flexibility to robot applications by allowing the robot to change
customer tooling (e.g., grippers, vacuum cup tooling, pneumatic and electric motors, weld guns, etc.) automatically.
The Quick-Change consists of a Master Plate and a Tool Plate. The Master Plate is attached to a robot while end-
effectors such as grippers, material handlers, etc. are attached to one or more Tool Plates.
The Master Plate, installed on the robot arm, locks to the Tool Plate with a pneumatically driven locking
mechanism. This locking mechanism uses a patented, multi-tapered cam with ball locking technology and a
patented fail-safe mechanism. The Master allows for the passage of utilities and electrical connections to the Tool
Plate.
In operation, the robot can be programmed to select the desired Customer tooling by coupling the Master Plate to
the Tool Plate. Electrical signals, pneumatic, power, and fluids can be transferred to the customer tooling 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.
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.
For the most current product information and specifications on the QC-113 Series of Tool Changers, please click
the following link: QC-113 Series.
B-3
1.1 Master Plate Assembly

The Master Plate assembly includes an anodized aluminum body, a hardened stainless steel locking
mechanism, and hardened steel alignment pins (see Figure 1.1).
The body or Master Plate has (4) flat sides for mounting of optional modules. In general, flat ‘A’ is
reserved for an air/valve adapter module and a control/signal module. Flats “B”, “C”, and “D” are fully
interchangeable and optional modules can be arranged to suit the application or robot dress, as required.
The locking mechanism consists of a cam, a male coupling, and chrome steel ball bearings.
Tapered pins located on the Master Plate mate with bushings in the Tool Plate to ensure repeatable alignment
during the coupling process. An extreme pressure grease is applied to the cam, male coupling, ball bearings,
and pins to enhance performance and maximize the life of the Master Plate assembly.
Proximity sensors are designed into the body of the Master Plate to verify the lock/unlock position of the
piston and cam. The sensors provide the lock and unlock (L/U) signals through the control/signal module.
Proximity sensor assemblies are mounted to the body of the Master Plate to verify Tool Plate presence when
coupled. The sensors provide a ready-to-lock (RTL) signal through the control/signal module.
A mounting pattern is machined into the Master Plate for mounting to the supplied robot interface plate.
Refer to Section 8—Drawings for details.
Figure 1.1— Master Plate Assembly
Internal Proximity Sensors Location Robot Interface Plate (RIP)

(Lock/Unlock) [Not Visible]
Supplied with Master Plate
Proximity Sensor Assembly
Location (RTL Signal) Lock/Unlock Air supplied
through Air/Valve Adapter
mounted to Flat A
Ball Bearing (6)
Cam
Common Ledge
Male Coupling Feature for Module
mounting
Cable Retaining Tabs

Alignment Pin (2)
Proximity Sensor Assembly

Location (RTL Signal)
B-4
1.2 Tool Plate Assembly

The Tool Plate assembly includes an anodized aluminum body, alignment bushings, and a hardened stainless
steel bearing race. The Tool Plate has (4) flat sides for mounting of optional modules.
Proximity sensor targets are mounted to the body of the Tool Plate to verify Tool Plate presence when
coupled. The targets are used by the proximity sensors in the Master Plate to provide a ready-to-lock (RTL)
signal.
A mounting pattern is machined into the Tool Plate for mounting to customer tooling or a tooling interface
plate. Refer to Section 8—Drawings for details.
Figure 1.2—Tool Plate Assembly
Alignment Pin Bushing (2)
Proximity Sensor Assembly Target (RTL)
Bearing Race
Proximity Sensor Assembly Common Ledge Feature for

Target (RTL) Module mounting
1.3 Optional Modules

There are (4) flats available for mounting of the optional modules for support of various utility pass through,
such as signal, fluid/air, and electric.
For assistance in choosing the right modules for your particular application, visit the QC-113 webpage
(QC-113 Series) and click on compatible modules tab 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. Flats “B”, “C”,
and “D” are fully interchangeable and optional modules can be arranged to suit the application or robot
dress, as required.
The optional modules are mounted to the Master and Tool Plate using a common ledge mounting feature.
Only (2) M6 Socket Head Cap Screws need to be unscrewed in order to remove the module from the
Master/Tool Plate.
B-5
2. Installation
All fasteners used to mount the Tool Changer to the robot and to customer’s tooling should be tightened to a
torque value as indicated. Refer to Table 2.1. Furthermore, removable (blue) Loctite 242 must be used on these
fasteners. The table below contains recommended values based on engineering standards.
WARNING: Do not use lock washer under the head of the mounting fasteners or allow the
mounting fasteners to protrude above the mating surfaces of the Master and Tool Plates.
Allowing fasteners to protrude above the mating surface will create a gap between the Master
and Tool Plates and not allow the locking mechanism to fully engage, this can cause damage
to equipment or personal injury. Make sure the mounting fasteners are flush or below the
mating surfaces of the Master and Tool Plates.
Head of Mounting Fastener Must Be Flush or

Mating Surface Below Mating Surface. (Do Not Use Lock
Washer under Head of Mounting Fastener).
CAUTION: Do not use fasteners that exceed the thread depth in the Tool Changer. Refer to
Section 8—Drawings for details on mounting hole thread depth. Secure the Tool Changer with
the proper length fasteners. This is true for both robot and tool interfaces.
Table 2.1—Fastener Size, Class, and Torque Specifications

Mounting Conditions Fastener Size Recommended
and Property Torque
Class
Master Plate to Robot Interface Plate (6061-T6 aluminum) M10-1.5 38 ft-lbs
Minimum thread engagement of 0.39” (10mm) [1.0X fastener Ø]. Class 12.9 (52 Nm)
Robot Interface to Robot (steel; USS ≥ 90KSI) M8-1.25 20 ft-lbs

Minimum thread engagement of 0.59” (12 mm) [1.5X fastener Ø]. Class 12.9 (27 Nm)
Confirm available engagement with Robot Manufacturer
Tool Plate (aluminum) to Tool Interface Plate (6061-T6-aluminum) M8-1.25 20 ft-lbs

Minimum thread engagement of 0.59” (12 mm) [1.5X fastener Ø]. Class 12.9 (27 Nm)
Do not exceed maximum available thread depth as shown in Sec-
tion 8—Drawings
2.1 Master Plate Installation

1. Make sure mounting surface of the robot arm and RIP are clean and free of debris. Refer to Figure 2.1.
2. Align the dowel pins to the corresponding holes in the RIP and secure the RIP to the robot arm with
customer supplied hardware. If not pre-applied, apply Loctite 242 to threads (see Table 2.1 for proper
fasteners and torque).
3. Align the dowel pins to the corresponding holes in the Master Plate and secure the Master Plate to the
RIP with supplied (6) M10-1.5 Socket Head Cap Screws. If not pre-applied, apply Loctite 242 to threads
(see Table 2.1 for proper fasteners and torque).
4. Connect Lock and Unlock air supplies to the appropriate connections. Refer to Section 2.6—Pneumatic
Connections.
5. Connect utilities to the appropriate module and Master Plate connections.
B-6
Figure 2.1— Typical Master Plate Installation
Robot Arm
Dowel Pin
(Customer Supplied)
Robot Interface Plate (RIP)

(Supplied with Master Plate)
M8-1.25
Socket Head Cap Screws
(Customer Supplied)
(See Table 2.1)
Dowel Pin
Master Plate
M10-1.5
Socket Head Cap Screws
(See Table 2.1)
2.2 Master Plate Removal

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.
NOTICE: Depending on maintenance or repair being performed, utilities to modules and Master
Plate may need to be disconnected.
1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Master
plate.
2. Turn off all energized circuits (e.g. electrical, air, water, etc.).
3. If needed, disconnect all utilities (e.g. electrical, air, water, etc.). Note: support the master plate while
removing the fasteners.
4. Remove the (6) M10-1.5 Socket Head Cap Screws connecting the Master Plate to the RIP.
B-7
2.3 Tool Interface

The Tool Plate is attached to the customer’s tooling. The Tool Plate is designed with mounting features
such as a recess and/or bolt and dowel holes. These features are used to accurately position and secure the
customer’s tooling. Most often a tool interface plate is utilized to adapt the Tool Plate to customer’s tooling
that is not compatible with the Tool Plate mounting features. Custom tool interface plates can be supplied by
ATI to meet customer’s requirements (see Figure 2.2). Refer to the application drawing.
If the customer chooses to design and build a tool interface plate, the following should be considered:
• The tool interface plate should be designed to include bolt holes for mounting, dowel pins, and a boss
that mates with Tool Plate recess for accurate positioning. The dowel and boss features are important to
prevent rotation.
• The locating boss height should not exceed 0.250” (6.3 mm).
• The thickness of the interface plate must be great enough to provide the necessary thread engagement
for the mounting bolts. Fasteners should be chosen to meet minimum recommended engagement
lengths while not exceeding the maximum available thread depth. Use of bolts that are too long can
cause damage to the tool side changer.
• The plate design should take into account clearances required for Tool Changer module attachments
and accessories.
• The tool interface plate should be designed with a hole in its center to allow for manually returning
the locking mechanism to the unlocked position under adverse conditions (i.e. unintended loss of
power and/or air pressure). The center access hole should be kept small [minimum recommended hole
diameter: 1” (25.4 mm)] to prevent debris from contaminating the locking mechanism while operating
in dirty environments.
2.4 Tool Plate Installation

1. Make sure the mounting surface of the Tool Plate and tool interface plate is clean and free of debris.
Refer to Figure 2.2.
2. Align the dowel pins to the corresponding holes in the Tool Plate and secure the Tool Plate to the tool
interface plate or customer tooling with customer supplied hardware. If not pre-applied, apply Loctite
242 to threads (see Table 2.1).
NOTICE: If an ATI Interface Plate is used, hardware to mount the Tool Plate is supplied with the
Interface Plate.
3. Connect utilities to the appropriate module and Tool Plate connections.
B-8
Figure 2.2— Standard Tool Plate Installation
M8-1.25 Socket Head Cap Screws
(See Table
Table 2.1
2.1 for Torque Values)
(Customer Supplied Hardware)
Tool Plate
Dowel Pins
(Customer Supplied Hardware)
2.5 Tool Plate Removal

Changer or modules.
NOTICE: Depending on maintenance or repair being performed, utilities to modules and Tool
Plate may need to be disconnected.
1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Tool
plate .
2. If needed, disconnect all utilities (e.g. electrical, air, water, etc.).
3. Remove the hardware connecting the Tool Plate to the tooling or tool interface plate.
B-9
2.6 Pneumatic 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 60 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.
2.6.1 Valve Requirements and Connections for the Locking Mechanism

When an air adapter module is utilized that does not contain an integrated solenoid valve, it is
required that a customer supplied 2-position 4-way or 5-way valve be used to actuate the locking
mechanism in the Master Plate. It is imperative that when air is supplied to the Lock or Unlock
Port on the Master Plate, that the opposite port be vented to atmosphere (i.e., when air is supplied
to the Lock Port, the Unlock Port must be open to the atmosphere.) Failure to vent trapped air or
vacuum on the inactive port may inhibit proper shuttling of the valve and prevent coupling and/or
uncoupling from occurring.
CAUTION: The locking mechanism will not function properly when connected
to a 3-way valve as this type of valve is incapable of venting trapped air
pressure from within the Tool Changer. This could result in damage to the
product, attached tooling, or personnel Connect the Lock and Unlock supply air
to a 2-position 4-way or 5-way valve.
Figure 2.3— Lock and Unlock Pneumatic Connections
4 or 5 -way Valve
Supply Clean, Dry,

Non -lubricated Air
Lock Port 60 – 100 psi (4.1– 6.9 Bar)
Exhaust
Open to Atmosphere
Air Adapter without Unlock Port
integrated valve
B-10
2.7 Electrical Connections

Tool Changer is available with integrated lock/unlock sensors. If sensors are not used, plugs will be
provided to seal the locking mechanism. If a control/signal module is to be utilized on Flat A when ordered,
the sensors will be connected to the module prior to shipping.
2.7.1 NPN Type Lock and Unlock Sensors (-SP sensor designation)
These sensors are used on 9120-113AM-000-000-SP.
Table 2.2—NPN (Current Sourcing)
Description Value
Voltage Supply Range 10-30 VDC
Output Current < 200 mA
Nominal Sensing Distance Sn 2.0 mm
Output Circuit NPN make function (NO)
Figure 2.4—NPN Type Lock and Unlock Sensors

NPN (Current Sinking) Connector
Brown (1) (4) Black
+Vs
Z
Black (4)
NPN Output
Blue (3) Brown (1) (3) Blue
0V
B-11
3. Operation
The Master locking mechanism is pneumatically driven to couple and uncouple with the bearing race 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 60 to 100 psi. Robot motion should be halted if the air
supply pressure drops below 60 psi for any reason.
The robot should be programmed to minimize misalignment during coupling and uncoupling. Additionally, the Tool
Stand should be durable and not allow deflection, under uncoupled Tool weight that will take alignment of the Tool
Changer plates outside of accepted offsets. See Figure 3.1 and Table 3.1 for recommended maximum allowable
offsets prior to coupling. In some cases, greater offsets than shown in Table 3.1 can be accommodated by the
Master and Tool Plates, but will increase wear.
Lock-up should occur with the Master Plate in the No-Touch™ Locking zone (see Table 3.1) but not touching the
Tool Plate. As locking occurs, the Master Plate should draw the Tool Plate into the locked position.
Figure 3.1— Offset Definitions
Master Plate
Tool Plate
Cocking
Offset
Z (About X
Twisting and Y)
Y
X, Y, and Z Offset
Table 3.1—Maximum Recommended Offsets Prior to Coupling

Model No-Touch™ Zone X and Y Offset Cocking Offset Twisting Offset
Z Offset (Max)* (Max)† (Max) (Max)
(mm) (mm) (degrees) (degrees)
QC-113 ±1 ±2 ±0.7 ±1
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.
B-12
3.1 Conditions for Coupling

Refer to your Air Valve Adapter and/or Signal/Control module manual’s Operation section for operation
during coupling/uncoupling.
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.
• It is recommended that the mating faces of the Master and Tool not be touching, but be within 0.04” (1
mm) of each other when coupling to minimize stress and wear on the locking mechanism. The locking
mechanism allows the Master to “pull up” the Tool with relatively large gaps between the two sides.
• RTL (Ready-To-Lock) sensor and target are built into the Tool Changer must be positioned within
approximately 0.065” (2 mm) of each other for the sensors to detect Tool presence. This provides the
ability to sense Tool proximity to the Master prior to coupling. RTL signals are not required to couple
the Tool Changer, but are recommended as a further confirmation of coupling prior to removing the
Tool from the tool stand.
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 not suggested or required just prior to coupling. Contact may result in
damage to the unit and/or the robot.
• Verify that the RTL signals are read as “on” (true), if being utilized.
• Turn the Lock output on. Air is supplied to the locking mechanism to couple the Tool Changer.
• A sufficient delay must be programmed between the Lock output being activated and reading the state
of the Lock/Unlock signals, so that the coupling process is completed before checking the locked state.
• The Lock signal should read “on” (true) and the Unlock signal should read “off” (false).
NOTICE: If the locking mechanism has been actuated and both the Lock and Unlock signals are
read as “off” (false), then a “missed tool” condition has occurred (for example, the Tool is not in
the stand or is not positioned properly). In this case an error should be generated and the
robot program halted. The situation requires manual inspection to determine the cause of the
problem.
The locking mechanism must be in the Unlock state before another attempt is made to couple or damage
could occur to the robot and/or the Tool Changer.
3.2 Fail-Safe Operation

A fail-safe condition occurs, when there is an unintended loss of lock air pressure to the Master Plate. When
air pressure is initially lost, the tool changer relaxes and there may be a slight separation between the Master
and Tool Plates. The lock sensor may indicate that the unit is not locked. ATI’s patented fail-safe feature
utilizes a multi-tapered cam to trap the ball bearings and prevent an unintended release of the Tool Plate.
Positional accuracy of the tooling will not be maintained during this Fail Safe condition. The Tool Changer
is not to be operated in the fail-safe condition. Once source air is lost to the unit, movement should be
stopped until air is restored. Once air pressure is reestablished to the Master Plate, the locking mechanism
will energize securely locking the master and Tool Plates together. If equipped, make sure the lock sensor
indicates the Tool Changer is in the locked position before resuming normal operations. It may be necessary
to consult your Control and Signal Module Manual for specific error recovery information.
CAUTION: Do not use the Tool Changer in a fail-safe condition. Do not transport the
tool changer in a fail-safe condition. Possible damage to the locking mechanism could
occur. Re-establish air pressure to Tool Changer before returning to normal operations.
B-13
3.3 Conditions for Uncoupling

Refer to your Air Valve Adapter and/or Signal/Control module manual’s Operation section for operation
during coupling/uncoupling.
• The Tool Changer should be positioned in the Tool Stand in the same location as that when coupling
took place.
• Turn the Lock output off (for double solenoid valve versions).
CAUTION: This Tool Changer may be equipped with a Tool Stand Interlock (TSI)
feature that physically breaks the Unlatch solenoid circuit. Proper use of the TSI will
prevent any unwanted Unlock software commands from being recognized until the
circuit is made.
• Issue the Unlock output. Air is supplied to the locking mechanism to uncouple the Tool Changer.
• A sufficient delay must be programmed between the Unlock output being activated and reading the
state of the Lock/Unlock signals, so that the coupling process is completed before checking the Locked
state.
• 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.
The robot and Master Plate can now proceed to another Tool Plate for coupling and subsequent operations.
B-14
3.4 Tool Storage Considerations

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.
The tools may be stored in a Tool Stand when not being used by the robot. ATI provides compatible Tool
Stands designed for durability, longevity, and maximum adaptability to fit most customers’ applications. The
ATI TSM (Tool Stand Meduim) system is compatible with ATI Tool Changer sizes QC-20 to QC-113. The
TSM systems can be equipped with horizontal modules, clamp modules, and different types of tool sensing.
Visit the ATI Web Site http://www.ati-ia.com/products/toolchanger/toolstand/medium/MediumStand.aspx for
products available for your specific application or contact ATI for recommendations and assistance.
If the customer is supplying the tool stand, it should be designed to provide a fixed, repeatable, level, and
stable positions for tool pick-up and drop-off. The tool stand must support the weight of the Tool Changer
Tool Plate, Tool Interface Plate, optional modules, cables, hoses, and customer tooling without allowing
deflection in excess of the offsets specified in Section 3—Operation.
Ideally, the Tool should be hanging vertically in the Tool Stand so that gravity assists to uncouple the Tool
Plate from the Master Plate during unlocking. 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.
A variety of methods may be used to position the Tool in the Tool Stand. A common method is to use
tapered alignment pins and bushings. Robot programming and positional repeatability are vital in tool pick-
up and drop-off, refer to Section 3—Operation.
It is highly recommended 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 safety
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 positioned 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.
Tool Stands may also need to incorporate means for covering Tools and modules to protect them in dirty
environments, such as grinding or welding. Alternatively, positioning Tool Stands in areas shielded from
weld spatter, fluids, adhesives, or other debris would eliminate the need for tool covers.
B-15
4. Maintenance
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.
NOTICE: The cleanliness of the work environment strongly influences the trouble free operation of
the Tool Changer. The dirtier the environment, the greater the need 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.
3) Guards, deflectors, air curtains, and similar devices built into the EOAT and the Tool Stand.
B-16
4.1 Preventive Maintenance

The Tool Changer and optional modules are designed to provide a long life with regular maintenance.
A visual inspection and preventive maintenance schedule is provided in the table below depending upon the
application.
Detailed assembly drawings are provided in Section 8—Drawings of this manual. Refer to module sections
for detailed preventive maintenance steps for all utility modules.
Application(s) Tool Change Frequency Inspection Schedule
General Usage Material Handling Docking Station > 1 per minute Weekly
< 1 per minute Monthly
Welding/Servo/Deburring, Foundry Operations (Dirty All Weekly
Environments)
Checklist
Balls/Alignment Pins/Holes/Bearing Race
гг 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—Cleaning and Lubrication of
the Locking Mechanism and Alignment Pins.
гг 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.
Replace worn alignment pins, refer to Section 4.3—Alignment Pin Replacement.
гг Wear on the balls/bearing race could be an indication of excessive loading.
Mounting Hardware/Interface Connections
гг Inspect for proper torque and interference or wear, abrasions, and cuts of hoses. Tighten and
correct as required.
Seals (Modules)
гг Inspect for wear, abrasion, and cuts.
гг Exposed o-rings and rubber bushings may be subject to damage during normal operation. Replace
damaged o-rings and rubber bushings as needed. Refer to Section 4.4—Seal Inspection and
Replacement
Sensors and Cables
гг Inspect sensor cables and connectors for any damage, cuts, and abrasion.
Electrical Contacts/Pin Block (Modules)
гг Inspect for wear and abrasion.
гг Exposed contacts may be subject to damage during normal operation.
гг Clear debris from the area of the contacts using compressed air.
гг Do not directly clean contacts as abrasion may occur and the performance of the contact may be
compromised. Refer to Section 4.5—Pin Block Inspection and Cleaning.
B-17
4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins
1. The locking mechanism must be in the unlock state before cleaning.
2. Use a clean rag to thoroughly remove the existing lubricant and debris from the ball bearings, the male
coupling, the cam and the alignment pins.
Figure 4.1— Cleaning Ball Bearings and Outer Surfaces of Male Coupling
3. Use a clean rag to thoroughly remove the existing lubricant and debris from the inner surface of the male
coupling and the cam.
Figure 4.2— Cleaning Ball Bearings, Cam and Inner Surfaces of Male Coupling
B-18
4. Check each ball bearing to make sure it moves freely in the male coupling. Additional cleaning may be
necessary to free up any ball bearings that are sticking in place.
Figure 4.3— Check Ball Bearing Movement
5. Apply a liberal coating of lubricant to the ball bearings, the male coupling (inside and out), and the
alignment pins.
Figure 4.4— Apply Lubricant to Locking Mechanism
Apply Lubricant
on Alignment Pins
Apply Lubricant on Inner
and Outer Surface
Surface of Male Coupling
of Male Coupling
B-19
6. Use a clean rag to thoroughly remove the any lubricant and debris from the bearing race and the
bushings from the Tool Plate.
Figure 4.5— Clean Tool Plate Surfaces of Locking Mechanism
Clean Bushing Surfaces
Clean Bearing Race

Surfaces
7. No application of lubrication is necessary on the Tool Plate components.
4.3 Alignment Pin Replacement

1. Unscrew the alignment pin sub-assembly from the Master Plate using a 4mm Allen Wrench (see
Figure 4.6).
NOTICE: 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.
Figure 4.6—4mm Allen Wrench
Alignment Pin Assembly
Set Screw
Ratchet Wrench
4mm Allen Wrench Socket
Master Plate
B-20
Another approach would be to use the access hole in the back side of the Master Plate. In this case, a 3mm
Allen Wrench will be needed (see Figure 4.7).
Figure 4.7—3mm Allen Wrench
3mm Allen
Wrench
2. Once the alignment pin has been removed, verify that the sub-assembly (pin and set screw) are 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 plate of the Master Plate.
3. Apply Loctite 242 and install the Alignment Pin Assembly into the Bushing on the Tool Changer.
Tighten to 60 in-lbs.
4. Apply MobilGrease® XHP222 Special grease to the Alignment Pin (see Section 4.2—Cleaning and
Lubrication of the Locking Mechanism and Alignment Pins
4.4 Seal Inspection and Replacement

1. The seal protect the electrical connection between the Master and Tool module. If the seal becomes worn
or damaged it needs to be replaced.
2. To remove the existing seal, pinch edge of seal with fingers and gently pull the seal away from the pin
block on the Master.
3. Pull the seal off the pin block.
4. To install a new seal, stretch the new seal over the shoulder of the pin block.
5. Push the seal’s hub down against the pin block using finger tip.
Figure 4.8—V-Ring Seal Replacement
Stretch seal over shoulder of pin

block and push seal hub down
against the pin block with finger tip
V-Ring Seal V-Ring Seal
Pinch edge of seal with

fingers and gently pull
away from pin block
B-21
4.5 Pin Block Inspection and Cleaning

1. Inspect the Master and Tool pin blocks for any debris or darkened pins.
Figure 4.9—Inspect Master and Tool Pin Blocks
Blackened Pins
Note: Pin blocks shown are for
illustration purposes only.
Weld Debris
Tool Module Pin Block Master Module Pin Block
2. If debris or darkened pins exist, remove debris using a vacuum, and clean using a nylon brush (ATI part
number 3690-0000064-60).
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 or pins to stick.
Clean contact surfaces with a vacuum and 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 4.10—Stuck Pin and Pin Block Damage
Note: Pin blocks shown are for
illustration purposes only.
Stuck Pins Severe Pin Block Damage
4. If stuck pins or severe pin block damage exists, contact ATI for possible pin replacement procedures or
module replacement.
B-22
5. Troubleshooting
Check these conditions for all symptoms prior to troubleshooting:
• Proper pneumatic and electrical connections have been made to the Quick-Change.
• Air is supplied at a minimum of 60 psi (4.1 Bar).
• 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 The ball bearings and/or cam are not Clean and lubricate as needed to restore smooth
unlock moving freely in the male coupling. operation (see Section 4.2—Cleaning and Lubrication
of the Locking Mechanism and Alignment Pins).
The control module is not operating Check the troubleshooting section of the manual for
correctly. the specific module.
The Master Plate and Tool Plate are Check that the Tool is properly seated in the Tool
not within the specified No-Touch Stand. Refer to Section 3—Operation
zone when attempting to lock.
Re-teach the robot to bring the Master Plate and Tool
Plate closer together prior to attempting to lock.
Ready-To-Lock (RTL) sensors not Check that the Tool is properly seated in the Tool
activated indicating Tool is not Stand.
positioned properly.
Check all cables for damage and that they are
connected properly to the signal control module.
Replace damaged cables as necessary.
Check that both RTL sensors are not damaged.

Replace damaged RTL sensors as necessary..
Re-teach the robot to bring the Master Plate and Tool

Plate closer together prior to attempting to lock.
Unit is locked but Lock sensor/cable is damaged. Replace the lock sensor sub-assembly as necessary.
Lock signal does not Refer to Section 5.1—Lock and Unlock Sensor
read “on” (true). Replacement Procedures.
Lock sensor is out of position. Replace the lock sensor sub-assembly as necessary.
Refer to Section 5.1—Lock and Unlock Sensor
Replacement Procedures.
Unit is unlocked but Unlock sensor/cable is damaged. Replace the unlock sensor sub-assembly as necessary.
Unlock signal does Refer to Section 5.1—Lock and Unlock Sensor
not read “on” (true). Replacement Procedures.
Unlock sensor is out of position. Replace the unlock sensor sub-assembly as necessary.
Refer to Section 5.1—Lock and Unlock Sensor
Replacement Procedures.
B-23
5.1 Lock and Unlock Sensor Replacement Procedures

Changer or modules.
1. Disconnect the Lock and/or Unlock sensor cable connector from the Valve Adapter/Control Module.
2. On the Valve Adapter/Control module on Flat A, remove the two M6 socket head cap screws securing
the module(s) to the Tool Changer body. Refer to Figure 5.1.
3. Lift off the Valve Adapter/Control module from Flats A.
4. Remove the two screws and two retaining clamps on Flat A of the Tool Changer body.
5. Remove the two M3 socket head cap screws that secure the Lock and/or Unlock sensor assembly to the
Tool Changer body.
6. Pull the sensor assembly straight out from the Tool Changer body. There is an O-ring around the cylinder
barrel, ensure O-ring came off with old sensor before continuing. Discard the removed sensor assembly.
CAUTION: The Lock and Unlock sensor assemblies are precision aligned and
permanently assembled at the factory. Do not attempt to disassemble and rebuild.
Figure 5.1— Lock and Unlock Sensor Assembly Replacement
Retaining Clamps
Valve Adapter/Control Module on Flat A

M6 Socket Head Cap Screws
Lock Sensor Assembly

Unlock Sensor Assembly
Connects to "L"
Connects to "U"
7. Install the new Lock and/or Unlock sensor assembly, routing the cable through the two retaining clamps.
8. Secure the sensor assembly using the two M3 socket flat head screws. Tighten to 12 in-lbs (1.4 Nm).
9. Attach the two retaining clamps to the proper locations on the Flat A. Tighten screws to contact.
10. Install the Valve Adapter/Control module on Flats A.
11. If fasteners do not have pre-applied adhesive, apply Loctite 242® to the M6 Socket Head Cap Screws
fasteners. Install the two (2) M6 socket head screws securing the module to the Tool Changer body and
tighten to 40–70 in-lbs (4.5–7.9 Nm).
12. Attach the Lock and/or Unlock sensor cable connectors to the proper connector on the Valve Adapter/
Control module.
13. Confirm the operation of the Unlock sensor by issuing the Unlock command and then checking to see
that the LED in the Unlock sensor body is on.
14. Confirm the operation of the Lock sensor by issuing the Lock command to lock a Tool to the Master and
then checking to see that the LED in the Lock Sensor body is on.
B-24
5.2 RTL Flat Pack Style Sensor Replacement (R2 Sensor)

1. If there is an optional module on Flat D, remove the two M6 socket head cap screws securing
the module to the Tool Changer body.
2. If equipped, lift off the optional modules from Flat D.
3. Remove the two M3 socket flat head cap screws and two cable retaining tabs on Flat D of the
Tool Changer body.
4. Remove the M3 socket flat head cap screw securing the RTL sensor to the Tool Changer body.
5. Unscrew the RTL sensor cable connector from the Valve Adapter/Control Module.
6. Remove the RTL sensor from the cable channel of the Tool Changer body. Discard the removed
RTL sensor.
Figure 5.2— RTL Sensor Replacement (R2 Sensor)
M3 Socket Head Cap Screw

RTL Flat Pack
Style Sensor
M6 Socket Head
Cap Screws
Valve Adapter/Control Module

Connects
to "R2"
(2) Cable Retaining Tabs
Remove Module from Flat D
7. Install the new RTL sensor, routing the cable into the cable channel of the Tool Changer body.
8. Attach the RTL sensor cable to the R2 connector on the Valve Adapter/Control Module.
9. Install the RTL sensor to the Tool Changer body.
10. Apply Loctite 222® to the M3 socket flat head screws. Secure the sensor to the Tool Changer
body and tighten to 60 in-ozs (0.4 Nm).
11. Install the two cable retaining tabs on Flat D of the Tool Changer body and secure with the two
M3 socket flat head cap screws. Tighten to contact.
12. If optional module was removed from Flat D, install the module.
13. If fasteners do not have pre-applied adhesive, apply Loctite 242® to the M6 Socket Head Cap
Screws fasteners. Install the two (2) M6 socket head screws securing the module to the Tool
Changer body and tighten to 40–70 in-lbs (4.5–7.9 Nm).
14. Confirm the operation of the RTL 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 light up.
B-25
5.2.1 RTL Flat Pack Style Sensor Replacement (R1 Sensor)

1. Depending on the robot and interface plate used the Tool Changer Master Plate may have to be
removed. Refer to Section 2.2—Master Plate Removal.
2. Remove the two M3 socket flat head cap screws and two cable retaining tabs on the Valve
Adapter/Control Module.
3. Remove the M3 socket flat head cap screw securing the RTL sensor assembly to the Tool
Changer body.
4. Unscrew the RTL sensor cable connector from the Valve Adapter/Control Module.
5. Remove the RTL sensor from the cable channel of the Valve Adapter/Control Module. Discard
the removed RTL sensor.
Figure 5.3— RTL Sensor Assembly Replacement (R1 Sensor)
(2) Cable Retaining Tabs
RTL Flat Pack Style Sensor
Connect to "R1"
Valve Adapter/Control Module
M3 Socket Head Cap Screw
6. Install the new RTL sensor, routing the cable into the cable channel of the Valve Adapter/
Control Module.
7. Attach the RTL sensor cable to the R1 connector on the Valve Adapter/Control Module.
8. Install the RTL sensor assembly to the Tool Changer body.
9. Apply Loctite 222® to the M3 socket flat head screws. Secure the sensor to the Tool Changer
body and tighten to 60 in-ozs (0.4 Nm).
10. Install the two cable retaining tabs on the Valve Adapter/Control Module and secure with the
two M3 socket flat head cap screws. Tighten to contact.
11. Confirm the 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 light up.
12. Install the Tool Changer Master Plate to the robot arm or interface plate, refer to Section 2.2—
Master Plate Installation.
B-26
6. Serviceable Parts
6.1 Common Master Parts
Common Master Parts
ITEM NO. QTY PART NUMBER DESCRIPTION

1 2 9005-20-2241 7/8” Two Piece Alignment Pin
2 1 9121-113xMX-0-0-0-0 Complete QC-113 Master Plate, No Options
3 1 9121-113M-IP-8551 IP Assy for QC-113 to BC115, 4X M8, 2X 6mm Dowel
Notes:
x = A, B, C, D, E, or F for boss size designation.
B-27
6.2 Models 9121-113xM-0-0-0-0-SP
2
1
9121-113xM-0-0-0-0-SP
1 1 8590-9909999-86 LED NPN Flat Pack Sensor .28M (90 Pico)
2 1 8590-9909999-85 LED NPN Flat Pack Sensor .30M (90 Pico)
3 2 9005-20-1744 Lock/Unlock Sensor Assembly, QC-210 (NPN)
Notes:
B-28
6.3 Tool Plate

1
Tool Plate
1 1 9121-113xT-0-0-0-0 QC-113 Base Tool Assembly, No Options
Notes:
B-29
7. Specifications
Master and Standard Tool Plates
Recommended Max Payload 220 lbs. (100kg) The mass attached to the Tool Changer.
Operating Temperature Range -20–150°F
(-30–66°C)
Operating Pressure Range 60–100 psi Locking mechanism supply pressure
(4.1–6.9 bar) operating range. Supply to be clean, dry, and
filtered to 50 micron or better.
Coupling Force @ 80 psi 2,730 lbs. Axial holding force
1,235 (N)
Recommended Max Moment X-Y 6940 lb-in Maximum recommended working load for
(Mxy) 784 (Nm) optimum performance of the Tool Changer
Recommended Max Torque about 5000 lb-in Maximum recommended working torque for
Z (Mz) 565 (Nm) optimum performance of the Tool Changer
Positional Repeatability 0.0006” Repeatability tested at rated load at one
(0.015 mm) million cycles.
Weight (coupled, no access.) 13.79 lbs. (6.26 kg) Master 8.75 lbs (3.97 kg)
Tool 5.04 lbs (2.29 kg)
Max. Recommended distance 0.10” No-Touch™ locking technology allows the
between Master and Tool Plate (2.5 mm) Master and Tool Plates to lock with separation
when coupling.
Sensor Information, signal name L/U Internal proximity sensors (2) with cable and
(Lock/Unlock) connector for direct wiring to the control/
signal module to indicate locking mechanism
position.
RTL Flat Pack proximity sensor with cable and

(Ready-To-Lock) connector 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 125mm BC, (6) M10 Socket Head Cap
Screws, (2) 10mm Dowels
Tool Plate 115mm BC, (4) M8 Socket Head Cap Screws,

(2) 6mm Dowels
Robot Interface Plate 125mm to 115mm BC, (4) M8 Socket Head

Cap Screws, (2) 6mm Dowels
B-30
Rev. Description Initiator Date
01 Initial Drawing KRZ 05/08/14
153.9 Square
Master & Tool
8. Drawings
4.73
120.3
4X 8.74 Thru Approx. Coupled
14.3 8.4 4X8.7 Thru
From Far Side 74.1 14.3 8.4
for M8 SHCS Master From Far Side
Customer Interface 46.1
for M8 SHCS
Tool
30 Customer Interface
30° Pin
30°
44.05
44.05
36.96 36.96
8.1 QC-113 Tool Changer
55.54 55.54
2 1
37.5° 37.5°
6.06
6.06 2X 6.04 SF 7.6
2X 6.04 SF 7.6
Customer Interface
B-31
Customer Interface
14.88 14.88
17 37.5°
37.5° 115
Interface Plate 115
Note 2
Tool Side
(Projection Only) Side View Master Side
(Projection Only)
ITEM NO. QTY. PART NUMBER DESCRIPTION

1 1 9121-113AMX-0-0-0-0 QC-113 Master Base Assembly (Sleeveless), No Options
2 1 9121-113BT-0-0-0-0 QC-113 Tool with 80mm Recess
NOTES: UNLESS OTHERWISE 1031 Goodworth Drive, Apex, NC 27539, USA
SPECIFIED.
Tel: +1.919.772.0115 Email: info@ati-ia.com
DO NOT SCALE DRAWING. Fax: +1.919.772.8259 www.ati-ia.com
ALL DIMENSIONS ARE IN ISO 9001 Registered Company
MILLIMETERS.
PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY
MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI.
TITLE
DRAWN BY: K. Zachary 05/08/14
Notes:
1. Design is subject to change. CHECKED BY: D. Norton 05/08/14
QC-113 Base Tool Changer
2. Without interface plate Master features ISO 125mm
mounting pattern - (6) M10 SHCS and (2) 10mm dowel. Iso View SCALE SIZE DRAWING NUMBER REVISION
Optional Master side mounting bosses available. Scale 1:3 3rd ANGLE PROJECTION PROJECT # 131028-1 SHEET 1 OF 3 1:2 B 9630-20-113 01
- See Sheet1 - -
QC-113 Master Assembly
21
18
22 23 16
24
15
9
8
B-32
10 1
3
11
4
12
6
SPECIFIED.
7 Tel: +1.919.772.0115 Email: info@ati-ia.com
MILLIMETERS.
5 PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY
TITLE
CHECKED BY: D. Norton 05/08/14
SCALE SIZE DRAWING NUMBER REVISION
3rd ANGLE PROJECTION PROJECT # 131028-1 SHEET 2 OF 3 1:2 B 9630-20-113 01
- See Sheet1 - -
QC-113 Tool Assembly
6 3
2 4
5
B-33
1

SPECIFIED.
MILLIMETERS.
PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY
TITLE
CHECKED BY: D. Norton 05/08/14
SCALE SIZE DRAWING NUMBER REVISION
3rd ANGLE PROJECTION PROJECT # 131028-1 SHEET 3 OF 3 1:2 B 9630-20-113 01
Quick-Change Installation and Operation Manual US Patent No.: 7,027,893 B2
Document #9620-20-c-du2-04 US Patent No.: 6,840,895 B2
Table of Contents
C. Control and Signal Modules .......................................................................................3
DU2 DeviceNet Modules ..................................................................................................3
1 Product Overview ........................................................................................................................... 3
1.1 Master Module ........................................................................................................................ 3
1.2 Tool Module ............................................................................................................................ 3
2 Installation and Removal ................................................................................................................ 4
2.1 Installing Module..................................................................................................................... 4
2.2 Removing Module .................................................................................................................. 4
2.3 DeviceNet Configuration ........................................................................................................ 5
2.4 Utility Schematic ..................................................................................................................... 5
3 Product Information ........................................................................................................................ 6
3.1 Master Module Node .............................................................................................................. 6
3.1.1 Module and Network Status LED ................................................................................ 6
3.1.2 MAC ID ........................................................................................................................ 6
3.1.3 Baud Rate ................................................................................................................... 6
3.1.4 Setting the DIP Switches ............................................................................................ 7
3.1.5 Termination Resistor ................................................................................................... 7
3.1.6 Cable Drop Length Calculation ................................................................................... 7
3.2 Arc Prevention Circuit ............................................................................................................. 8
3.2.1 Arc Prevention Circuit Behavior During Coupling ....................................................... 8
3.2.2 Soft Start during Coupling ........................................................................................... 8
3.2.3 Arc Prevention Circuit Behavior during Uncoupling .................................................... 9
3.3 Tool Module .......................................................................................................................... 10
3.3.1 Tool-ID Switch ........................................................................................................... 10
3.4 Software ............................................................................................................................... 11
4 Operation ...................................................................................................................................... 12
4.1 Recommended Sequence of Operation ............................................................................... 12
5 Maintenance ................................................................................................................................. 14
5.1 Pin Block Inspection and cleaning........................................................................................ 14
5.2 Seal Replacement ................................................................................................................ 15
6 Troubleshooting ............................................................................................................................ 16
7 Recommended Spare Parts ......................................................................................................... 16
8 Specifications................................................................................................................................ 17
9 Drawings ....................................................................................................................................... 18
C-1
Glossary of Terms
TERM DEFINITION
Auxiliary Power An input indicating the presence of Auxiliary Power at the ATI Master.
Available
DeviceNet Power An input indicating the presence of DeviceNet Power at the ATI Master.
Good
EOAT End-Of-Arm-Tool (end-effector).
A proximity sensor input indicating that the coupling mechanism is in the
Locked
Locked position.
A proximity sensor input that senses when the ATI Tool is in close
RTL
proximity.
A hard-connect input (sourced from the tool) indicating the Master and Tool
Tool Present
are electrically connected to each other.
The output supplied to the ATI Master DeviceNet node to uncouple or
Unlatch
couple the Tool Changer.
A proximity sensor input indicating that the coupling mechanism is in the
Unlocked
Unlocked position.
C-2
C. Control and Signal Modules

DU2 DeviceNet Modules
1 Product Overview
The DeviceNet modules are required to provide a means for the customer to communicate with and control the
Tool Changer in a DeviceNet environment. Refer to Sections 3—Product Information and Section 4—
Operation of this manual for detailed DeviceNet programming information and a summary of module
operational capabilities.
The DU2-M module supports the use of an integrated single solenoid valve, which is provided on the valve
adapter module (9121-Jxx), for Latch/Unlatch control of the Tool Changer. The user is required to provide a
pneumatic supply source to the Tool Changer. Please refer to the appropriate manual for specific module and
Tool Changer requirements.
Standard Mini connectors are provided on the Master and Tool modules for interfacing with Auxiliary Power
(4-Pin) and DeviceNet (5-Pin) signals. 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 (See Figure 1.1).
1.1 Master Module
The DU2 modules are designed with NPN Tool Changer input signals (Locked, Unlocked, and Ready-to-
Lock proximity sensors). The Ready-to-Lock (RTL1 and RTL2) sensors are connected in series. Refer to
Sections 3— Product Information and Section 4—Operation for more information on these attributes.
The Master module has an M8 4-Pin female diagnostic connector for ATI use only.
The DU2-M Module also incorporates ATI’s exclusive Arc Prevention Circuit which extends the life of
all electrical power contacts by eliminating arcing caused by inductive loads and high inrush current
during coupling/uncoupling. Refer to Section 3.2—Arc Prevention Circuit for additional information.
1.2 Tool Module
The Tool module employs a pushbutton switch 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.
The Tool-ID is reported through the Master module bitmap. See Section 3—Product Information for
DeviceNet bitmap and detailed I/O information. A M12 4-Pin female connector supports Thermal1 and
Thermal 2 discrete NPN inputs.
Figure 1.1—DU2 DeviceNet Modules
C-3
2 Installation and Removal

The control/signal modules are typically installed by ATI prior to shipment. The steps below outline the field
installation or removal as required.
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
Changer or modules.
2.1 Installing Module
1. It may be necessary to clean the mounting surface on the Valve Adapter 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 Valve
Adapter. Align the module with the Valve Adapter 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 Valve Adpater and
tighten to 40–70 in-lbs.
4. Customer interface, auxiliary power, DeviceNet, and sensor cables can be connected to the module
after attaching the module to the Valve Adapter. Ensure that the connectors are cleaned prior to
being secured as appropriate.
Figure 2.1—Module Installation
2.2 Removing Module

1. Prior to removing the module use a marker pen to scribe a line or indication between the Valve
Adapter 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. Also, proximity sensor and valve cables may or may not need to be
disconnected.
3. Remove the socket head cap screws and lift the module from the Valve Adaper.
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.
C-4
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 DU2
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.
C-5
3 Product Information
The DU2 modules enable the customer to control and communicate with the Tool Changer through a network
using standard DeviceNet protocol (www.odva.org). A DeviceNet node is established on the Master module,
but not on the Tool. Control of the Tool Changer is realized through the Master Node along with the reporting
of various Tool Changer I/O’s. The Tool module supports Tool-ID reported through the Master and functions
as a pass-through for DeviceNet and Auxiliary Power signals to downstream equipment.
The DU2 modules employ standard Mini connectors, 5-pin for DeviceNet communications and power and 4-
pin for Auxiliary Power. Please refer to Section 9—Drawings for specific module wiring and connector
interface information.
Prior to using 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 Module Node
The Master Node operates as a Group 2-Only Server on the DeviceNet network. The Master Node
supports Explicit Messaging, Polled, Strobe and Change of State/Cyclic communications for the
predefined Master/Slave Connection set. The Master Node does not support the Unconnected Message
Manager (UCMM).
MAC ID and Baud Rate settings for the Master Node are configured through a series of DIP switches.
On board termination resistance is not supported and must be provided externally. LED’s are integral to
the module and report network and module status.
3.1.1 Module and Network Status LED
The module status LED is identified on the module as “MS”. It provides device status for
power and proper operation. Refer to Table 3.1 for an outline of this LED’s operation. The
network status LED is identified on the module as “NS”. It provides network status for power
and communication. Refer to Table 3.2 for an outline of this LED’s operation.
Table 3.1—Master Module Status LED
Color State Indication
None Off No Power
Solid Unrecoverable Fault
Recoverable Fault (Tool Connected)
Red  Serial Communication Errors
Flashing
 Invalid Tool-ID
 Tool Module Returns an Error Message
Solid Normal Operation
Green
Flashing No Tool Connected
Table 3.2—Master Network Status LED

Color State Indication
None Off No Power
Solid Unrecoverable Fault
Red
Flashing Output Error or Configuration Error
Solid Normal Runtime Operation
Green
Flashing Device Is In Idle or Not Allocated to a Master
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, DIP switch positions 7 and 8 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. The default MAC ID setting from the factory for the Master
Node is 54.
3.1.3 Baud Rate
C-6
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. The default Baud Rate setting from the
factory for the Master Node is 500Kbps.
3.1.4 Setting the DIP Switches
1. Loosen four M3 Pan Head Captive Screws and remove window.
2. Set the MAC ID and Baud Rate DIP switches as need.
NOTICE: When replacing the window, ensure that the seal is positioned correctly
to prevent fluid leakage.
3. Re-install the Tool-ID window and tighten the M3 Pan Head Captive Screws
Figure 3.1—DeviceNet Master Module DIP Switches and LED’s
Figure 3.2—DeviceNet Master Module DIP Switch Settings

SHOWN IN FACTORY DEFAULT SETTING, NODE 54
1 2 3 4 5 6 7 8 9 10
MS NS
ON
LED OFF
LED
Set MAC ID (Pos. 1 Least Sign.) Reserved

7-OFF, 8-OFF: 125 Kbps Reserved
7-ON,8-OFF: 250 Kbps (9 & 10 Must Be Off)
7-OFF, 8-ON: 500 Kbps Set Baud Rate
7-ON, 8-ON: Set by S/W
3.1.5 Termination Resistor

Termination resistance is not supported with the Master Node. Required termination resistance
must be provided external to the module.
3.1.6 Cable Drop Length Calculation
Subtract 1 foot from the DeviceNet total drop line budget for each Master node installed on the
network (Note: the Master node can exceed the 24pF limit for the differential input capacitance
between CAN_H and CAN_L by up to 12pF which is equivalent to 1 foot cable).
C-7
3.2 Arc Prevention Circuit

The DU2 Module incorporates ATI’s exclusive Arc Prevention Circuit. The Arc Prevention Circuit
extends the life of all electrical power contacts by eliminating arcing caused by inductive loads and high
inrush current during coupling/uncoupling. The Arc Prevention Circuit makes it possible to
couple/uncouple without switching power off and prevents damage to the contacts. In the DU2 Module,
the Arc Prevention Circuit controls the ON/OFF status of the Device Net 24V power (CAN V+) and
auxiliary power (P1, N1) and (P2, N2). The DU2 module provides an option for the Soft Start feature to
prevent the large current spikes associated with a hard power on signal.
3.2.1 Arc Prevention Circuit Behavior During Coupling
The behavior of the Arc Prevention circuit during coupling can be more clearly understood by
referring to Figure 3.3, which shows the power-on timing diagram for the Arc Circuit. The
Power On Output will be off until the Tool Present Input turns on and the Unlatch Output is
turned off.
Important: The Arc Prevention Circuit will only allow power to pass to the Tool after the
Unlatch Output has been turned off and the Tool Present Input has been turned on.
Figure 3.3—Arc Circuit Power-On Timing
3.2.2 Soft Start during Coupling

High current spikes can cause voltage drops on the power supply and potentially may lead to
network faults. The Arc Prevention Circuit has an ATI exclusive Soft Start feature that pulses
the power on gradually in the beginning, preventing the large current spike that would
otherwise occur if there were only one hard on signal. This results in a series of much smaller
current spikes and prevents significant voltage drops on the network power. Figure 3.4 shows
how the Soft Start feature effectively reduces the voltage drop on network power. To
implement the Soft Start feature, the Soft_Start_Enable bit (Bit 4) must be turned on, Refer to
Table 3.4.
Figure 3.4—Soft Start Feature
Voltage Drop and Current Spike Voltage Drop and Current Spike
with Hard ON Signal with Soft Start Feature
C-8
3.2.3 Arc Prevention Circuit Behavior during Uncoupling

The behavior of the Arc Prevention Circuit during uncoupling can be more clearly understood
by referring to Figure 3.5 which shows the power-off timing diagram for the Arc Prevention
Circuit. Starting from right to left of the diagram, the Unlatch Output command is issued thus
initiating uncoupling of the Master and Tool.
Immediately after the Unlatch Output is turned on, the Arc Prevention Circuit will turn off the
Power On Output. Sometime after power is turned off and the Master and Tool begin to
separate, electrical contact between Master and Tool Pin Contacts will be lost and the Tool
Present Input will go off.
Figure 3.5— Arc Circuit Power-Off Timing
C-9
3.3 Tool Module

In addition to providing Tool-ID, the Tool module also functions as a pass-through for DeviceNet and
Auxiliary Power signals to downstream equipment, refer to Section 9—Drawings.
3.3.1 Tool-ID Switch
A pushbutton switch is provided on the Tool module for setting the Tool-ID number. There are
ten possible Tool-ID values available.
NOTICE: When there is no Tool mated to the Master, the Tool Presence bit will
become low and each Tool-ID bit will be assigned a value of 1, which translates to
a Tool-ID of 15. Since a Tool-ID of 15 is impossible, (there are only 0–9 digits on
the thumbwheel switch) one could use this as an added indication that the Tool is
not present.
Figure 3.6 shows the location of the Tool-ID switch and push buttons. After adjustment is
completed, ensure that the seal and window are re-positioned correctly to prevent a leakage
path to inside the module.
Figure 3.6—Tool Module Tool-ID Pushbutton Switch
3.3.1.1 Set the Tool-ID

The pushbutton switch is provided on the Tool module for setting of a Tool-
ID number. Each Tool should be set to unique number from 0-9.
1. Loosen four M3 Pan Head Captive Screws and remove Tool-ID window.
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 0 to 9. Set
the Tool-ID to the desired unique number each Tool.
NOTICE: When replacing the window, ensure that the seal is

positioned correctly to prevent fluid leakage.
3. Re-install the Tool-ID window and tighten the M3 Pan Head Captive
Screws.
C - 10
3.4 Software
A working EDS file for the Master node is available from our website:
(www.ati-ia.com/download/edsfiles) or by e-mail, reference the part number given below.
DU2-M Node EDS file 9031-20-1038
An I/O bitmap for the Master node is provided in the Table 3.3 and Table 3.4.
Table 3.3—I/O Bitmaps, Robot Inputs from ATI Master (9121-DU2-M)
Byte Bit# Name Description/Function
0 Locked Tool Changer Locked Proximity Sensor Input
1 Unlocked Tool Changer Unlocked Proximity Sensor Input
2 Input and Logic Power Good Input and Logic Power Present Input
3 Valve Power Available Valve Power Present Input
1
4 RTL Ready-to-Lock Proximity Sensor Input (Series R1 and R2)
5 Thermal 1 Thermal 1 Input
6 Thermal 2 Thermal 2 Input
7 - (Reserved)
0 Tool-ID 1 Tool-ID
1 Tool-ID 2 Tool-ID
2 Tool-ID 4 Tool-ID
3 Tool-ID 8 Tool-ID
2 4 Tool Present Hard-Connect Tool Present Input
5 Error on Unlatch Output Unlatch output overload
6 Lock/Unlock Sensor Fault Lock & Unlock Inputs True at the same time
Indicates that Arc Prevention Circuit is turned ON and
7 Tool Power Is ON
power is provided to the Tool
Table 3.4—I/O Bitmap, Robot Outputs to ATI Master (9121-DU2-M)

Byte Bit# Name Description/Function
0 Unlatch Unlatch Solenoid Valve Output
1 -- (Reserved)
2 -- (Reserved)
3 Clear Errors Reset errors, allow affected I/O to be reactivated
1 4 Soft Start Enable Enables the Arc Prevention soft start functionality.
Bit employed to facilitate end-of-line testing. FOR ATI USE
5 Arc Prevention Override
ONLY.
6 - (Reserved)
7 - (Reserved)
C - 11
4 Operation
A procedure in Section 4.1—Recommended Sequence of Operation is to be used as a general guide when
programming a robot or PLC for use with a Tool Changer and DU2 control/signal modules. This procedure is
intended for "automatic" modes used during normal application processes. Recommendations for operation in
“teach” or “manual” modes where the operator has the teach pendant in-hand will be addressed in a separate
Troubleshooting Guide. A thorough understanding of the advanced diagnostic and fault reporting capability is
required to proficiently operate this product.
4.1 Recommended Sequence of Operation
1. Start The robot and Tool Changer Master are free of the stand or storage location, the Tool
Changer is uncoupled and the Tool Changer locking mechanism may be fully retracted (unlocked
condition) or fully extended (missed Tool condition, i.e.; Locked and Unlocked inputs are false). The
tool is by itself in the Tool Stand.
a. The RTL input is false.
b. The ATI Tool and any downstream DeviceNet node(s) are offline.
c. The DeviceNet Power Good and Auxiliary Power Available inputs are true and must remain
so at all times.
d. Tool-ID invalid (all 1  0xFFFF)
2. Unlock the Master. (This must be done prior to the Master entering the Tool to prevent the ball
bearings from impinging on the Tool bearing race.)
a. The Unlatch output command is made true.
b. The Unlocked input goes true, indicating that the Tool Changer locking mechanism is fully
retracted and the Unlatch operation is complete.
3. Robot and Master move into the Tool, are parallel and within 0.15” to 0.06” of the Tool (i.e.; the
module contact pins are touching, but the RTL sensors have not yet sensed the targets on the Tool).
4. Robot and Master move within 0.06” of the Tool.
a. The RTL input is true, indicating that it is okay to couple the Tool.
b. The Tool Present goes true, indicating that the Master and Tool are in close proximity of each
other.
c. The Arc Prevention circuit turns power on to the end-of-arm tooling.
d. Communication is initiated with the ATI Tool and downstream nodes. When the Tool Present
input goes true Tool-ID becomes available via DeviceNet communications within 100–150ms.
e. Shortly thereafter, communications should be established with the downstream DeviceNet
nodes.
5. Couple the Tool Changer.
a. The Unlatch output is made false.
b. The Unlocked input goes false a short time later, indicating piston travel. Subsequently, the
Locked input goes true, indicating that the coupling operation is complete.
6. Robot moves away from the Tool Stand with the Tool Changer coupled.
7. Normal operation
a. The following inputs are true:
i. Locked
ii. DeviceNet Power Good
iii. Auxiliary Power Available
iv. RTL
v. Tool Present
b. The following inputs are false:
i. Unlocked
c. The following outputs are false:
i. Unlatch
8. Robot moves into the Tool Stand with the Tool Changer coupled.
C - 12
9. Uncouple the Tool Changer.

a. The Unlatch output is made true.
b. The Locked input goes false a short time later and subsequently the Unlocked input goes true,
indicating that the uncoupling operation is complete.
10. Robot and Master move away from the Tool, are parallel and between 0.15” to 0.06” of the Tool.
a. The RTL input becomes false.
b. Arc Prevention circuit turns power off to the end-of-arm tooling.
c. Communication is lost with the ATI Tool and downstream nodes.
d. The Tool Present is false.
e. Tool-ID invalid (all 1  0xFFFF)
11. Robot and Master in free space (>0.15” from the Tool)
a. The following inputs are true:
i. Unlocked
ii. DeviceNet Power Good
iii. Auxiliary Power Available
b. The following inputs are false:
i. Locked
ii. RTL
iii. Tool Present
iv. Tool-ID invalid (all 1  0xFFFF)
C - 13
5 Maintenance
The DU2 modules are designed to provide a long life with little maintenance required. Once installed the
operation of the control modules is generally trouble free. 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.
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

C - 14
2. If debris or darkened pins exist, remove debris using a vacuum, and clean using a nylon brush (ATI
part number 3690-0000064-60).
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).
4. If stuck pins or severe pin block damage exists, contact ATI for possible pin replacement
procedures or module replacement.
5.2 Seal Replacement

Replace the V-Ring seal:
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.
Figure 4.3—V-Ring seal Replacement
C - 15
6 Troubleshooting
Refer to table below for troubleshooting information:
Symptom Possible Cause / Correction
Unit will not lock or Verify that ball bearings are moving freely. Clean and lubricate as needed (see
unlock Tool Changer Manual Maintenance Section).
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.
Verify that the valve is operating properly.
Sensors not operating Verify that cables are connected correctly (Refer to the Tool Changer Manual).
properly (but Ensure that the Tool Plate is securely held to the Master Plate and that nothing
DeviceNet is is trapped between their surfaces, and that there is no air trapped in the Unlock
operating correctly). (U) air port.
Loss of DeviceNet Check/Replace DeviceNet cabling up-stream of Tool Changer modules.
Communication Inspect DeviceNet Module contact pins for debris/wear.
Check nodes up-stream of Tool Changer node 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.
No Power on the Verify that the UNLATCH Output is LOW.
Tool-side Verify that the Tool Power Is ON bit is HIGH.
Verify that the Tool Presence bit is HIGH.
Loss of Aux. Power Loss of DeviceNet power on the Master side will cause loss of Aux. Power to the
on the Tool-side Tool. The Arc Prevention Circuit relies on DeviceNet power to operate. Restore
DeviceNet Power to the Master to restore Aux. Power to Tool.
7 Recommended Spare Parts

Description Part Number
DU2 Master Module Assembly 9121-DU2-M
DU2 Tool Module Assembly 9121-DU2-T
DeviceNet Termination Resistor for Female Mini Receptacle 9120-5MM-TR
Closure Cap for Female Mini Receptacles 3690-0000049-00
Brush, Blue Nylon All Purpose (Contact Pin Cleaning) 3690-0000064-60
See Section 9—Drawings of this manual for spare parts directly associated with the DU2 modules.
C - 16
8 Specifications
DU2 DeviceNet Master Module
Factory Default MAC ID 54, Baud Rate 500 Kbps. The DU2 modules conform to the DeviceNet
Configuration Specification Volume 3, Edition 1.2 (Reference Conformance Case #10423).
Interface Connections Auxiliary Power: Mini, 4-Pin Male supporting two Auxiliary Power Circuits
DeviceNet: Mini, 5-Pin Male
Integrated Tool Changer I/O:
 4X M8, 3-pin female connectors supporting Tool Changer Locked,
Unlocked, and Ready-to-Lock proximity sensors. RTL Sensors are NPN
sensor in series.
 1X M8, 4-pin female connector for (ATI Diagnostics use only).
Electrical Rating Power Pass-Thru:
 N1 and N2 Auxiliary Power: 5A, -19 to -29 V
P1 and P2 Auxiliary Power: 0 V
Note: Arc prevention is applied to P1 and P2 Auxiliary Power.
 CAN V+ (DeviceNet) Power: 5A, 12-30 V
Note: Arc prevention is applied to CAN V+ power.
Signal Pass-Thru: 3A, 30V maximum
Tool Changer Control:
 Lock, Unlock, and Ready-to-Lock sensors: 10-30 V operational voltage
Note: CAN V- Power provides power to the L, U, and RTL sensors.
 Latch/Unlatch integrated solenoid valve: -19 to -29 V operational voltage
Note: N2 Power provides power to the Latch/Unlatch solenoid valve.
*Current Draw 220mA @ 24V, 250 mA @ 15 V: Master and Tool (Locked and RTL sensors “on”)
Weight 2.28 lbs (1.03 kg)
DU2 DeviceNet Tool Module

Factory Default (1) Independent Tool-ID switch, reading a (0–9) position
Configuration (factory set to Tool Position 1)
Interface Connections Auxiliary Power: Mini, 4-Pin, Female
DeviceNet: Mini, 5-Pin, Female
Thermal Connector: 4-Pin , M12 Female
Electrical Rating Power Pass-Thru:
 N1 and N2 Auxiliary Power: 5A, -19 to -29 V
P1 and P2 Auxiliary Power: 0 V
 CAN V+ (DeviceNet) Power: 5A, 12-30 VDC
Signal Pass-Thru: 3A, 30V maximum
*Current Draw totals for DeviceNet-powered circuits, not including downstream I/O devices and Auxiliary
powered valves. Please refer to the module manufacturer for these specifications.
C - 17
9 Drawings
C - 18
C - 19
C - 20
C - 21
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
1. Product Overview .................................................................................................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
C-1
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.
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.
tool is safely supported or docked in the tool stand and all energized circuits (e.g.
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.
6. Recommended Spare Parts

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-AR8-02
Table of Contents
1. Product Overview...................................................................................................................... 2
2. Installation and Removal.......................................................................................................... 3
2.1 Module Installation......................................................................................................................... 3
2.2 Module Removal............................................................................................................................. 4
3. Operation................................................................................................................................... 4
4. Maintenance............................................................................................................................... 4
4.1 Master-Side Self-Sealing Valve..................................................................................................... 4
4.2 Tool-Side Self-Sealing Valve......................................................................................................... 5
5. Troubleshooting........................................................................................................................ 5
6. Serviceable Parts...................................................................................................................... 5
7. Specifications............................................................................................................................ 6
8. Drawings.................................................................................................................................... 7
8.1 AR8-M AR8-T.................................................................................................................................. 7
45
D. Air Modules
AR8—Air Module
1. Product Overview
Modules providing air utility are attached to the Master and Tool plates. When the Tool Changer is coupled, the
AR8 Master module passes air supply to AR8 Tool module for customer tooling.
Figure 1.1—AR8 Air Modules

R 1/2 Air Ports (2)
AR8-M Module
Self Sealing Valve (2)
Self Sealing Valve (2)

Common Ledge
Mounting Feature
AR8-T Module
R 1/2 Air Ports (2)
The Master (AR8-M) and Tool (AR8-T) Modules each contain (2) self-sealing valves. Self-sealing valves are not to
be used for vacuum utility.
46
2. Installation and Removal

The air modules are typically installed on Tool Changers by ATI prior to shipment. The steps below outline field
installation or removal as required. For detail information refer to Section 8—Drawings.
CAUTION: Air supply should be clean and dry. Supply pressure should not exceed 100 psi
and should be filtered 50 micron or better. Connection lines should be properly strain-relieved.
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.
2.1 Module Installation

To attach air modules to the Tool Changer:
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. Place the module into the appropriate location on the Tool Changer. Align the dowels on the module with
the dowel holes on the Tool Changer mounting ledge. 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 (2) M6 socket head screws securing the module to the Tool Changer and tighten to 89 in-lbs.
4. Connect customer plumbing to the module.
Figure 2.1—Installation and Removal of the AR8 Module
M6 Socket Head Screws
AR8 Module
Tool Changer
47
2.2 Module Removal

To remove air modules from the Tool Changer:
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.
(2) 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 (2) check ports for the AR8-T.
4. Maintenance
Once installation is completed, 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). Lubricate seals periodically with NLGI-2
grease. 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. Refer to
Section 8—Drawings.
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.
5. To re-install the valve assembly, all components should be arranged in order as they were removed. See
drawings in Section 8—Drawings.
6. Loctite-222 or similar thread locker should be applied to the threaded end of the stem, re-install and
tighten to 10 in-lbs. 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.
48
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 a 10mm hex key. Refer to Section 8—Drawings. It may
be necessary to remove the tool side air module to have access to the plug. Refer to the Section 2.2—
Module Removal for instructions for module removal.
2. Once the plug 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 plug assembly contains a dowel pin. The dowel pin should be inspected for straightness, replace the
plug assembly if the dowel pin is bent.
5. To re-install the valve assembly, all components should be arranged in order as they were removed. See
drawings in Section 8—Drawings.
6. Care should be taken not to damage the O-ring around the plug base during installation. Apply NLGI-2
grease to the o-ring and torque the plug to 30 in-lbs.
5. Troubleshooting
Refer to the table below for troubleshooting information.
Symptom Possible Cause Correction
Air Leakage Damaged/Worn seals Replace seals. Refer to Section 4.1—Master-
Side Self-Sealing Valve and Section 4.2—Tool-
Side Self-Sealing Valve.
Debris blocking valve seal Clean in and around valve components.
Ensure 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. Refer to Section 4.1—Master-Side
Self-Sealing Valve and Section 4.2—Tool-Side
Self-Sealing Valve.
Corrosion Consult ATI for assistance.
Poor Flow Flow path blockage Inspect valve components and supply/return
lines for blockage, clean/repair as necessary.
Refer to Section 4.1—Master-Side Self-Sealing
Valve and Section 4.2—Tool-Side Self-Sealing
Valve.
Debris blocking valve seal Clean in and around valve components.
Ensure air stream is free of large particulates,
filter as necessary.
Modules Won't Bent stem, dowel pin Replace stem, dowel pins as necessary. Check
Couple module attachment to tool changer. Check
robot program and ensure parallel approach
trajectory during tool changer coupling. Refer
to Section 4.1—Master-Side Self-Sealing
Valve and Section 4.2—Tool-Side Self-Sealing
Valve.
6. Serviceable Parts
See drawings in Section 8—Drawings of this manual.
49
7. Specifications
Air Module AR8-M/AR8-T
Weight 0.91 lbs. (0.42 kg) AR8 Master Module
0.77 (0.35 kg) AR8 Tool Module
Materials of Various Anodized aluminum housings and stainless steel
Construction valve components, Nitrile seals,
PVC Tool side port plug.
Pneumatic Ports (qty) (2) Maximum pressure of 100psi (6.9bar), Nitrile
Size R 1/2 seals.
Cv 1.6 Self-sealing on AR8 Master

Self-sealing on AR8 Tool
(Cannot operate under a vacuum.)
50
8. Drawings
AR8 Master Module

9121-AR8-M
AR8 Master Module
9121-AR8-M
86 AR8 Tool Module
9121-AR8-T
8.1 AR8-M AR8-T
86
2X Rc1/2 (BSPT)
Checked Ports
23.6 23.6 38.1

45.3
AR8 Tool Module
9121-AR8-T 2X Rc1/2 (BSPT)
Checked Ports
Tool Changer
Mounting Surface 17.7
20.1
51
Tool Changer
AR8 Master Module Mounting Surface 41.3
9121-AR8-M
38.1 23.6 23.6
86.8
Coupled
Approx.
AR8 Tool Module NOTES: UNLESS OTHERWISE 1031 Goodworth Drive, Apex, NC 27539, USA
SPECIFIED.
Materials of Construction: 9121-AR8-T Tel: +1.919.772.0115 Email: info@ati-ia.com
• Housings - Anodized Aluminum DO NOT SCALE DRAWING. Fax: +1.919.772.8259 www.ati-ia.com
• Springs - Stainless Steel MILLIMETERS.
• Valve Components - Stainless Steel, PVC, & Nitrile Rubber PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY
TITLE
Guidelines for Operation: DRAWN BY: D.Lawson-4/2/14
1. Filter air passed through the modules. CHECKED BY: D.Swanson-4/2/14
AR8 Module Drawing
2. Lubricate seals periodically with NLGI-2 grease.
3. Keep mating surfaces clean and free of debris SCALE SIZE DRAWING NUMBER REVISION
3rd ANGLE PROJECTION PROJECT # 131121-1 SHEET 1 OF 2 2:3 B 9630-20-AR8 01
- See Sheet1 - -
AR8 Master Module AR8 Tool Module

(9121-AR8-M) (9121-AR8-T)
8 Loctite 7649 - 222 / 10 in-lb
8 30 in-lb
3 Magnalube
2 Magnalube
1 Magnalube
after Installation
6
7 4
2 Magnalube
5
6 Magnalube 1
Magnalube Bores
7
4 Loctite 242 / 89 in-lb

9
5 3 Loctite 242 / 89 in-lb
52
ITEM QTY. PART NUMBER DESCRIPTION
NO.
1 2 3410-0001067-01 O-ring, 10mm x 2mm, Buna N, Dur. 90
2 2 3410-0001284-01 O-ring, .669OD x .047 wall, 70D, Buna-N
3 2 3500-1066016-15A M6 x 16mm SHCS Blue Dyed Magni ND Microspheres
4 2 3540-0105010-21 5mm x 10mm Dowel Pin SST
5 2 3700-20-1457 SW-150A Tool Check Valve Piston
6 2 3700-20-1460 SPRING, F/A TOOL
7 1 3700-20-8571 Housing, Air, (2) Rc1/2, 3/8 Valve, Tool
8 2 9005-20-1515 3/8" Check Port Long Plug with Dowel
ITEM QTY. PART NUMBER DESCRIPTION Notes:
NO. Service Kit 9120-F1-T-Kit consists of (1) each of items 1, 2, & 6
1 2 3410-0001065-01 O-Ring 14MM X 2MM Buna Service Kit 9120-F5-T-Kit consists of (1) each of items 1, 2, 5, 6, & 8
2 2 3410-0001068-01 Mini U-Cup Seal 18mm ID x 22mm Buna
3 2 3410-0001183-01 O-Ring 6MM X 2MM Buna D90 NOTES: UNLESS OTHERWISE 1031 Goodworth Drive, Apex, NC 27539, USA
4 2 3500-1066016-15A M6 x 16mm SHCS Blue Dyed Magni ND Microspheres SPECIFIED.
5 2 3540-0105010-21 5mm x 10mm Dowel Pin SST DO NOT SCALE DRAWING. Fax: +1.919.772.8259 www.ati-ia.com
6 2 3700-20-1459 SW-150A Master Fluid / Air Spring SS ALL DIMENSIONS ARE IN ISO 9001 Registered Company
MILLIMETERS.
7 2 3700-20-2994 Master Check Valve Piston, FA44 PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY
8 2 3700-20-2996 VALVE STEM, HIGH STRENGTH TITLE
DRAWN BY: D.Lawson-4/2/14
9 1 3700-20-8570 Housing, Air, (2) Rc1/2, 3/8 Valve, Master
CHECKED BY: D.Swanson-4/2/14
AR8 Module Drawing
Notes:
Service Kit 9120-F2-M-Kit consists of (1) each of items 1, 2, 3, & 6 SCALE SIZE DRAWING NUMBER REVISION
Service Kit 9120-F4-M-Kit consists of (1) each of items 1, 2, 3, 6, 7, & 8 3rd ANGLE PROJECTION PROJECT # 131121-1 SHEET 2 OF 2 1:2 B 9630-20-AR8 01
Document # 9620-20-e-ef23-02
Table of Contents
E. Electrical Modules ...................................................................................................... 2

EF23—Servo Module ....................................................................................................... 2
1. Product Overview ................................................................................................ 2
2. Installation ........................................................................................................... 3
2.1 Installing ..................................................................................................... 3
2.2 Removal ..................................................................................................... 4
3. Operation............................................................................................................. 4
4. Maintenance ........................................................................................................ 5
4.1 Pin Block Inspection and cleaning ............................................................. 5
4.2 Seal Replacement ...................................................................................... 6
5. Troubleshooting................................................................................................... 7
5.1 Servo Module, Drive or Motor Troubleshooting Procedure ........................ 7
6. Recommended Spare Parts ................................................................................ 7
7. Specifications ...................................................................................................... 8
8. Drawing ............................................................................................................... 9
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Document # 9620-20-e-ef23-02
E. Electrical Modules
EF23—Servo Module
1. Product Overview
A servo module may be provided on the tool changer to pass electrical power and signal connections to a
transgun servomotor. (See Section 8—Drawing for pinouts and wiring information.) The connectors on this
module are located such that power and signal cables can be routed separately. 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 (EF23)
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.
CAUTION: Never couple or uncouple the unit without first disconnecting and
discharging the power that passes through the contacts. This is especially true if high
voltage circuits are involved. Arcing and contact damage will occur if this is not
observed. Always disconnect and discharge electrical power from both upstream and
downstream modules.
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.
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Document # 9620-20-e-ef23-02
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.

modules.
2.1 Installing
DANGER: For electrical modules using > 60VDC or 42VAC, NO contact should be
attempted before removing power. This includes attaching and disconnecting
cables to mating connectors or any contact with the Tool Changer or its
components. Arcing and damage will occur if this is not observed. Remove power
before attaching, disconnecting any cables or attempting any maintenance of Tool
Changer.
1. It may be necessary to clean the mounting surface on the Tool Changer prior to installing the
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 Tool Changer body. Ensure that the connectors are cleaned prior to being secured as
appropriate.
Figure 2.1—Module Installation
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Document # 9620-20-e-ef23-02
2.2 Removal
attempted before removing power. This includes attaching and disconnecting
cables to mating connectors or any contact with the Tool Changer or its
components. Arcing and damage will occur if this is not observed. Remove power
before attaching, disconnecting any cables or attempting any maintenance of Tool
Changer.
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, power, signal, and auxiliary 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.
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:
CAUTION: 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. Remove power and
discharge both upstream, and downstream modules before coupling or uncoupling
modules.
CAUTION: 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
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Document # 9620-20-e-ef23-02
4. Maintenance
Once installed the operation of the servo modules are generally trouble free. 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.
attempted before removing power. This includes attaching and disconnecting cables or
any contact with the Tool Changer or its components. Arcing and damage will occur if
this is not observed. Remove power before attaching, disconnecting any cables or
attempting any maintenance of Tool Changer.

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 4.1—Pin Block Inspection and cleaning.
 Inspect V-Ring seals for wear, abrasion, and cuts. If worn or damaged, replace. Refer to Section
4.1 Pin Block Inspection and cleaning
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Document # 9620-20-e-ef23-02
2. If debris or darkened pins exist, remove debris using a vacuum, and clean using a nylon brush
(ATI part number 3690-0000064-60).
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).
4. If stuck pins or severe pin block damage exists, contact ATI for possible pin replacement
procedures or module replacement.
4.2 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.
Figure 4.3—V-Ring seal Replacement
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Document # 9620-20-e-ef23-02
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

Servo Motor Object trapped between modules Remove object, then re-attempt coupling.
intermittently Ensure that the spring pins on the Master-side can
functioning or not Servo Module Contact Pin
Contamination or damaged move freely and are not bound by debris. Clean the
functioning at all spring pins. Clean Tool-side module contacts refer
to Section 4.1—Pin Block Inspection and cleaning.
Inspect seal, replace if damaged refer to Section
Contact Pin Separation due to air Ensure that the Tool Changer has proper pneumatic
supply to Tool Changer connections and air is supplied to proper
specification. Refer to Tool changer section of this
manual for air supply requirements.
Coupling/Uncoupling Tool Revise operating procedures to only
Changer under load. couple/uncouple with power disconnected and
discharged. Field replacement of module contacts is
not possible.
Cable Damage: Pinched, torn, or Examine cables for damage, perform a continuity
fatigued cables test on cables and replace any bad cables.
Servo Module damaged Refer to Section 5.1—Servo Module, Drive or Motor
Troubleshooting Procedure.
Drive or Motor damaged Refer to Section 5.1—Servo Module, Drive or Motor
Troubleshooting Procedure.
5.1 Servo Module, Drive or Motor Troubleshooting Procedure
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. Ensure 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.
6. Recommended Spare Parts

See Section 8—Drawing of this manual.
E-7
Document # 9620-20-e-ef23-02
7. Specifications
9121-EF23-M Master Servo Module with 7-pin power connector, 17-pin signal connector, and 5-Pin Weld
Monitoring connector
Interface Connections Power: MS3102E20-15P PMC, Circ. OST Shell Size 20, 7-pin male contacts.
Signal: Bendix MS3012A-20-29P, 17-pin male contacts

Auxilary: Turck FSFDL 4.5 M12 5-Pin male (Weld Monitoring )
Electrical Rating Power Pass-Through: Motor current – Spring-loaded, gold-plated, and serrated pins. Central
contact first to make and last to break
 Input Power: (7) 13 Amp, 500VAC/700VDC Max.
Signal Pass-Through: Encoder current & voltage – Spring-loaded, gold-plated, and serrated pins.
Central contact first to make and last to break
Signal wiring has EMI/RF shielding
9121-EF23-T Tool Servo Module with 7-pin power Connector, 17-pin signal connector, 5-Pin Weld Monitoring
connector, and 2-Pin battery back-up connector
Interface Connections Power: MS3102E20-15S PMC, Circ. OST Shell Size 20 with 7-pin female contacts.
Signal: Bendix MS3012A-20-29s with 17-pin female contacts
Auxilary: Turck FKFDL 4.5 M12 5-Pin female (Weld Monitoring )
Amphenol MS3102A12S-3P, male threaded, 2-pin male contacts (Battery back-up)
Electrical Rating Power Pass-Through: Motor current – Spring-loaded, gold-plated, and serrated pins. Central
contact first to make and last to break
Signal Pass-Through: Encoder current & voltage – Spring-loaded, gold-plated, and serrated pins.
Central contact first to make and last to break
Signal wiring has EMI/RF shielding
Input Power: (17) 3 Amp, 250VAC/30VDC Max.
E-8
Document # 9620-20-e-ef23-02
8. Drawing
E-9
Document # 9620-20-e-ef23-02
E - 10
Document # 9620-20-e-ef23-02
E - 11
Document # 9620-20-e-ef23-02
E - 12
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
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
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-NA-03
Other 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
H-1

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Quick-Change QC-313

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. Quick-Change Tool Changer

QC-113 Series—Quick-Change Tool Changer

1.1 Master Plate Assembly

Figure 1.1— Master Plate Assembly

Internal Proximity Sensors Location Robot Interface Plate (RIP)

Cable Retaining Tabs

Proximity Sensor Assembly

1.2 Tool Plate Assembly

Figure 1.2—Tool Plate Assembly

Alignment Pin Bushing (2)

Proximity Sensor Assembly Target (RTL)

Proximity Sensor Assembly Common Ledge Feature for

1.3 Optional Modules

Head of Mounting Fastener Must Be Flush or

Table 2.1—Fastener Size, Class, and Torque Specifications

Robot Interface to Robot (steel; USS ≥ 90KSI) M8-1.25 20 ft-lbs

Tool Plate (aluminum) to Tool Interface Plate (6061-T6-aluminum) M8-1.25 20 ft-lbs

2.1 Master Plate Installation

Robot Interface Plate (RIP)

2.2 Master Plate Removal

2.3 Tool Interface

2.4 Tool Plate Installation

2.5 Tool Plate Removal

2.6 Pneumatic Connections

2.6.1 Valve Requirements and Connections for the Locking Mechanism

Figure 2.3— Lock and Unlock Pneumatic Connections

Supply Clean, Dry,

2.7 Electrical Connections

Figure 2.4—NPN Type Lock and Unlock Sensors

Figure 3.1— Offset Definitions

Table 3.1—Maximum Recommended Offsets Prior to Coupling

3.1 Conditions for Coupling

3.2 Fail-Safe Operation

3.3 Conditions for Uncoupling

3.4 Tool Storage Considerations

4.1 Preventive Maintenance

Clean Bearing Race

7. No application of lubrication is necessary on the Tool Plate components.

4.3 Alignment Pin Replacement

Figure 4.6—4mm Allen Wrench