Applied Robotics 1303-D05A User manual

648 Saratoga Road
Glenville, NY 12302 USA
Phone: [phone]
Fax: [phone]
Robot Module
1303-D05A
Tool Module
1304-D57A
Tool Changer Safety Control Circuit
Manual 95575 Rev 05
July 1, 2013

1303-D05A & 1304-D57A Manual - 95575 Rev 05 2
Revision Date Author Description
00 2-17-2012 NS Release
01 4-25-2013 JD Editorial Changes
02 5-13-2013 SC Label Changes on Pg. 11 RS Module Figure
03 5-21-2013 NS Updated to include Latching Operation Descriptions
04 5-29-2013 NS Updated Logic table and Programming Operation
05 6-28-2013 NS Changed Size Specifications, Removed Schematic
Revision
All rights reserved. Copyright © 1986—2013 Applied Robotics Inc.
The use of this document is reserved exclusively for the use of Applied Robotics Incorporated customers and
personnel. The information and drawings contained herein are the sole property of Applied Robotics
Incorporated and shall not be divulged to any third party without the prior written consent of Applied Robotics
Inc. The information in this document is subject to change without notice. Applied Robotics makes no
warranty of any kind with regard to this user’s guide, including but not limited to, implied warranties or fitness
for a particular purpose. Applied Robotics Inc. shall not be liable for any errors contained herein or for
incidental or consequential damages in connection with the performance or use of this material.

1303-D05A & 1304-D57A Manual - 95575 Rev 05 3
Contents
1. Precautions ....................................................................................................... 4
2. System Description ............................................................................................ 5
3. State Diagram .................................................................................................... 6
4. Technical Specifications .................................................................................... 7
5. Modules ............................................................................................................. 8
6. Installation.......................................................................................................... 9
6.1 Attachment to Tool Changer ...................................................................... 9
6.2 Air Supply................................................................................................. 10
6.3 Electrical Connections.............................................................................. 10
7. Manual Uncouple ............................................................................................. 12
8. LED Status Indicators ...................................................................................... 12
8.1 Operational Guidelines ............................................................................. 13

1303-D05A & 1304-D57A Manual - 95575 Rev 05 4
1 Precautions
READ MANUAL
Do not start, operate or service machine until you read and understand
operator's manual. Failure to do so could result in serious injury.
HAND CRUSH NOTICE
Indicates the possibility for a crush force between components during
coupling of the Robot and Tool adaptor.
Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
Indicates a situation which, if not avoided, could result in equip-
ment damage and voiding the manufacturer’s equipment warranty.
IGNORING INFORMATION ABOUT POTENTIAL HAZARDS CAN LEAD TO SERIOUS
HARM TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT, AND MAY RESULT IN
THE NULLIFICATION OF THE MANUFACTURERS’ EQUIPMENT WARRANTY.
HEED ALL PRECAUTION NOTICES

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2 System Description
Definitions
Tool – A device that may be attached to a tool changer to perform a specific function
Tool Changer – A device consisting of two adapters, one attached to a robot and one attached to a tool, that
mechanically couple a robot to a tool, allowing a robot to use multiple tools. As a result, a single robot can per-
form multiple functions.
Tool Stand – A device that holds a tool mounted to a tool adapter for later use, as the robot performs other
tasks. A Tool Stand is the safe area for the tool changer to drop off and pick up tools.
Couple – The action of moving the cams outward on the robot adaptor so the tool adaptor will connect.
Uncouple – The action of moving the cams inward on the robot adaptor so the tool adaptor will disconnect.
Safety Function
The reason for a Tool Changer Safety Circuit is to ensure an uncouple signal cannot be applied to the
tool changer while it is not in a safe condition. A safe condition is defined as a tool changer engaged in a tool
stand or in movement without a tool attached to the tool changer. To uncouple, a piston retracts three cams in
the tool changer. It’s this action, if not performed under safe conditions, which can cause injury to a person.
Functional Description
With air on, the tool changer not in a tool stand, and with a tool present, the robot may be moved to
perform tasks. If air is lost to the valves, the tool will remain coupled, as mechanical safety mechanisms in the
robot adaptor prevent uncoupling. The Tool Changer should never be operated without air supplied and, it is the
customers responsibility to make sure the correct air pressure is always being supplied during operation.
When the tool changer needs to be uncoupled, a signal must be sent through two sets of contacts driv-
en by a force guided relay. The solenoid of the two sets of relays are driven by the tool stand present switch and
tool present switch. When the tool stand present switch is actuated, it is safe to couple and uncouple, because
this indicates that the tool has been docked in, and supported by the tool stand. The tool present switch is to
indicate if a tool adapter is coupled to the robot adapter. A tool changer is free to couple and uncouple at any
point if a tool is not present.
After the two uncouple signals are applied and allowed to pass through the safety logic (see Section 3
Stage Diagram). The coils of two independent valves will be powered, causing the tool changer to uncouple.
Both valves are pneumatically interlocked, this means both valves have to be actuated in order to achieve an
uncoupled state.
Once a channel has allowed a valve solenoid to be powered, the channel will be latched in the uncou-
pled state, and as long as an uncouple signal is being applied, that channel will remain latched. This is to pre-
vent any recoupling action while the robot side is separated from the tool side.

1303-D05A & 1304-D57A Manual - 95575 Rev 05 6
Diagnostic Coverage
The diagnostic coverage monitors the status of the Tool Stand Present, Tool Present, and the Output
Valve Spool Position through a set of normally open and normally closed contacts. In order for proper opera-
tion of the system, all dual channel devices need to operate simultaneously. A resistor/capacitor combination is
included, such that the uncouple signal to the valve shall remain present approximately (1) second after initial
loss of valve signal. This is to ensure there are no “nuisance trips” while the switches and relays change state. A
customer is given a single point to monitor and may supply a monitoring signal. This signal is applied across all
diagnostic coverage contacts and should not be lost during normal operation. If any single channel fails to oper-
ate within (1) seconds of its complimentary channel, a loss of monitoring signal will occur. The customer also
has the option of monitoring the signal directly and can determine what defines a nuisance trip.
3 State Diagram
tAbnormal Operation - describes a condition not expected during Normal Operation, The result is always a safe
condition being met.
Condition of Tool Changer Tool
Present
Status
Tool Stand
Present
Status
Output
Valve Prox
Status
Uncouple
Ability
Operation Condition,
Safety Action
Tool Changer Coupled, No
Stand, No Tool Present Signal 101Yes Abnormal Operationt,
Uncouple Allowed
Tool Changer Coupled, No
Stand, Tool Present Signal 001No Normal Operation, Forced Couple
Tool Changer Coupled, In
Stand, No Tool Present Signal 111Yes Abnormal Operation, Forced Couple
Tool Changer Coupled, In
Stand, Tool Present Signal 011Yes Normal Operation, Uncouple Allowed
Tool Changer Uncoupled, No
Stand, No Tool Present Signal 100Yes Normal Operation, Uncouple Allowed
Tool Changer Uncoupled, No
Stand, Tool Present Signal 000No Abnormal Operation, Forced Couple
Tool Changer Uncoupled, In
Stand, No Tool Present Signal 110No Abnormal Operation, Forced Couple
Tool Changer Uncoupled, In
Stand, Tool Present Signal 010Yes Normal Operation, Uncouple Allowed
The State Diagram below shows the status of each individual sensor/switch that makes up the Safety Function
and Diagnostic Coverage. The Tool Present Status Switch is normally closed and will show a “1” when NO tool
is present. The Tool Stand Present Status Switch is normally open and will show a “1” when there is a tool
present. The Output Valve Prox is normally open and detects spool position, which shows a “1” when the valve
spool is not actuated. The LEDs show in section 8 of this manual will correspond to this diagram by being ON
when the listed condition shows a “1”.

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4 Technical Specifications
Minimum Safety Classification Cat. 3 PLd EN ISO 13849-1
MTTFd 68 Years
Mission Time 20a (20 years)
Robot Side Dimensions 120mm x 118mm x 128mm
Tool Side Dimensions 108mm x 59mm x 22mm
Enclosure Rating IP 65 (When Coupled)
Connection Type 3 x M12 (Robot Side)
1 x M12 (Tool Side)
Robot Side Weight 1.75 Kg
Tool Side Weight 0.16 Kg
Power Consumption 400mA Max
Max Voltage DC 30VDC
Operating Temperature 5 - 60 °C
Supply Pressure 16 Bar Max
Tool Stand Sensing Safety Interlock Switch
(Approved Safety Rated Switch)
Tool Present Sensing Dual Output Safety Prox Switch
Air Valves Dual valves with interlocking manifold and
direct spool monitoring

1303-D05A & 1304-D57A Manual - 95575 Rev 05 8
1303-D05A
S.1-EM-R-V-ISO 13849-SCM
1304-D57A
S.1-EM-T-V-ISO 13849-SCM
5 Modules

1303-D05A & 1304-D57A Manual - 95575 Rev 05 9
With the Robot and Tool Adapter uncoupled and apart, install both the robot and tool side module on side one
of the tool changer.
4 x ARI # 49798 SCR, SOC
HD CAP M5 X 100 SS
4 x ARI # 48028 SCR, SOC
HD CAP M5 X 16 (SS
6 Installation
6.1 Attachment to Tool Changer
Robot Module
Tool Module

1303-D05A & 1304-D57A Manual - 95575 Rev 05 10
Connect the Air Supply to the 6mm air fitting show below:
6mm Air Supply
Fitting
Connect the customer “Monitor Point” to the M12 connector, J1. This connection will provide feedback to
show all channels are working correctly in the Safety Control Module.
Female M12
Connector, J1
6.2 Air Supply
6.3 Electrical Connections
Upon supplying air to the Safety Control Module, the robot adaptor will
be forced coupled. Make sure the tool adaptor is not within range of the
robot side cams to cause an undesired couple. Make sure all objects and
fingers are clear of the cams and mating surfaces when air is supplied.

1303-D05A & 1304-D57A Manual - 95575 Rev 05 11
Power and Uncouple are supplied on two separate M12 connections J3 and J2, respectively. Connect the appro-
priate cables to the connectors J3 and J2 as shown below:
Uncouple, J2
Power, J3
Connect the tool side module connector T1 to an approved tool stand present safety switch. Refer to your man-
ufacturer’s tool stand connection manual for how the tool stand present switch should be installed.
Make sure an uncouple signal is not being supplied by the cable you care
connecting to J2. This could cause the robot side to couple. Make sure all
objects and fingers are clear of the cams when connecting J2.
Tool Stand Safety
Switch, T1

1303-D05A & 1304-D57A Manual - 95575 Rev 05 12
With all cables and air fittings properly installed the Safety Module is ready for operation. Please refer to the
system description on Page 5 and State Diagram on page 6 for how the module functions. During initial pro-
gramming or if an undesired or abnormal state is achieved, the two M5 screws may be removed from the face
of the cover to manually actuate the valves to uncouple. To do this, air will need to be supplied to the valves
and both valves will need to be actuated with a small flat head screwdriver (approx. 3.5mm). This is done by
inserting the flat head screw driver into the slot and turning it 90 degrees clockwise, locking it in position.
ARI # 49335 SCR, BUT
HD SOC CAP M5 X 6 STL
Valve Access Holes
Eight LEDs show the function of each individual channel in the Safety Module along with the Power, and Mon-
itor Point Status. In order to function properly, an LED’s on/off status should match between row 1 and row 2.
If there is a mismatch between corresponding rows, the customer monitor signal will be lost. The LEDs and
their corresponding function are shown in the diagram below:
Valve Spool Position
LED On: Spool Coupled
LED Off: Spool Uncoupled
Tool Stand Present
LED On: Tool Stand Present
LED Off: Tool Stand Absent
Tool Present (Prox)
LED Off: Tool Present
LED On: Tool Absent
7 Manual Uncouple
8 LED Status Indicators
This operation should never be preformed while a tool is present. Opera-
tion of the manual uncouple with a tool present may result in death or
serious injury.
Monitor Point LED
(SCM OK)
Power LED

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8.1 Operational Guidelines
Review the guidelines below to understand how
the Safety Control Module operates.
 Manual uncouple may be used in a case where a new tool is being installed and there is no tool stand pre-
sent signal to interface with the Safety Control Module. Please see section 7 for how manual uncouple
operates.
 The Customer Monitor point supplied with the Safety Control Module should be constantly monitored to
ensure that the Safety Control Module is operating properly. A loss of this signal is an indication of failure
within the safety system. Should the Customer Monitor point still provide a signal, and the tool changer
will not uncouple, check the LED status lights for diagnosis (see section 8).
 Monitoring of the couple and uncouple status is required as the Safety Control Module will force coupled
if any unsafe state is reached. The Safety Control Module only internally incorporates tool present and tool
stand present. Monitoring status of the couple and uncouple state prior to docking or undocking a tool is
the responsibility of the end user. Failure to monitor this state may cause damage to the tool changer.