Ati-ia DB10 User manual

Quick-Change Installation and Operation Manual
Document #9620-20-c-db10-09
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
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Table of Contents
C. Control and Signal Modules.......................................................................................3
DB10—DeviceNet Module ...............................................................................................3
1. Product Overview.................................................................................................3
1.1 DeviceNet Module ............................................................................................................. 3
2. Installation............................................................................................................4
2.1 Installing............................................................................................................................. 4
2.2 Removal............................................................................................................................. 4
2.3 DeviceNet Configuration.................................................................................................... 5
2.4 Utility Schematic ................................................................................................................ 5
3. Product Information..............................................................................................6
3.1 Master Module Node ......................................................................................................... 6
3.1.1 Setting the DIP Switches...................................................................................... 6
3.1.2 MAC ID................................................................................................................. 6
3.1.3 Baud Rate............................................................................................................. 7
3.1.4 Termination Resistor ............................................................................................ 7
3.1.5 Module Status LED............................................................................................... 8
3.1.6 Network Status LED ............................................................................................. 8
3.2 Arc Prevention Circuit........................................................................................................ 9
3.2.1 Arc Prevention Circuit Behavior During Coupling................................................. 9
3.2.2 Arc Prevention Circuit Behavior During Uncoupling........................................... 10
3.3 Tool Module Node ........................................................................................................... 11
3.3.1 Setting the DIP Switches.................................................................................... 11
3.3.2 MAC ID............................................................................................................... 11
3.3.3 Baud Rate........................................................................................................... 11
3.3.4 Termination Resistor .......................................................................................... 12
3.3.5 Tool-ID (Tool Node Only).................................................................................... 12
3.3.6 Module Status LED............................................................................................. 13
3.3.7 Network Status LED ........................................................................................... 13
3.3.8 Quick Connect.................................................................................................... 13
3.4 Tool-Side TSI................................................................................................................... 13
3.4.1 TSI Overview...................................................................................................... 13
3.5 Software........................................................................................................................... 16
4. Operation ...........................................................................................................18
4.1 Recommended Sequence of Operation.......................................................................... 18
5. Maintenance ......................................................................................................20
5.1 Pin Block Inspection and cleaning................................................................................... 20
5.2 Seal Replacement ........................................................................................................... 21
6. Troubleshooting .................................................................................................22
7. Recommended Spare Parts...............................................................................22
8. Specifications.....................................................................................................23
9. Drawings............................................................................................................24

Quick-Change Installation and Operation Manual
Document #9620-20-c-db10-09
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
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Glossary of Terms
TERM
DEFINITION
Auxiliary Power
Available
An input indicating the presence of Auxiliary Power Supply to the ATI Master module.
EOAT
End-Of-Arm-Tool (end effector).
Latch
The output supplied to the ATI Master DeviceNet node to couple the Tool Changer (only
valid for double solenoid valve equipped units).
Lock
A proximity sensor input indicating that the coupling mechanism is in the Lock position.
RTL
A proximity sensor input that senses when the ATI Tool is close.
RTL Relay
A relay circuit present on the ATI Master module that is triggered by the RTL sensor and
allows the Tool Changer to be uncoupled when there is no Tool present.
RTLV
A control reliable input provided for health status monitoring of the RTL Relay.
Solenoid Energized
An input indicating current draw from the valve and the solenoid coil.
TSI
The Tool Stand Interlock feature is a custom ATI safety solution and circuit designed to only
allow Tool Changer release while in the stand or storage location.
TSI Relay
A relay circuit present on the ATI Tool module that is triggered by a tool stand limit switch in
order to close the TSI circuit and allow Tool Changer release.
TSIV
A control reliable input supported for monitoring of a tool stand limit switch used with the
TSI circuit.
TSRV
A control reliable input provided for health status monitoring of the TSI Relay.
Unlatch
The output supplied to the ATI Master DeviceNet node to uncouple the Tool Changer.
Unlock
A proximity sensor input indicating that the coupling mechanism is in the Unlock position.

Quick-Change Installation and Operation Manual
Document #9620-20-c-db10-09
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
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C. Control and Signal Modules
DB10—DeviceNet Module
1. Product Overview
1.1 DeviceNet Module
The DeviceNet modules are required to provide a means for the customer to communicate with and
control the Tool Changer. Refer to Section 3—Product Information of this manual for detailed
DeviceNet programming information and operational capability.
A single or double solenoid valve is provided with the master valve adapter for Lock/Unlock control of
the Tool Changer. The user is only required to provide a pneumatic supply source to the Tool Changer.
Power and signal connectors are provided for interfacing on the Master and Tool modules. When the
Tool Changer is coupled, the Master and Tool modules pass signals using a spring-loaded pin block. A
flexible boot surrounds the pin block to seal the connection from moisture and liquid while coupled.
The DB10 module is designed with special features to afford the user the opportunity to operate the
tool changer in the safest manner possible. In addition to providing the standard Lock, Unlock, and
Ready-to-Lock sensor inputs, the modules are outfitted with Tool Stand Interlock (TSI). The TSI
feature consists primarily of a physical break in the unlatch solenoid valve circuit. The TSI circuit is
designed to allow tool changer release ONLY when the tool is in the stand or storage location. Refer to
Section 3.4—Tool-Side TSI for more information regarding TSI.
The Tool module employs a series of thumbwheel switches for setting of the Tool-ID input. This
allows the customer to distinguish between the different Tools that are being used in a robotic cell or on
a production line. See Section 3.5—Software for DeviceNet bitmap and I/O information.
The DB10 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.
Figure 1.1—DB10M DB10T DeviceNet Module

Quick-Change Installation and Operation Manual
Document #9620-20-c-db10-09
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
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2. Installation
The control/signal modules are typically installed by ATI prior to shipment. The steps below outline the field
installation or removal as required.
2.1 Installing
1. It may be necessary to clean the mounting surface on the Tool Changer prior to installing the
module in order to remove any debris that may be present.
2. Using the ledge feature as a guide place the module into the appropriate location on the Tool
Changer body. Align the module with the Tool Changer using the dowels in the bottom of the
ledge feature. Refer to Figure 2.1.
3. If fasteners do not have pre-applied adhesive, apply Loctite 242®to the supplied M6 SHCS
fasteners. Install the two (2) M6 socket head screws securing the module to the Tool Changer and
tighten to 40–70 in-lbs.
4. Power, signal, and auxiliary cables can be connected to the module after attaching the module to
the Spacer or Valve Adapter Modules. Ensure that the connectors are cleaned prior to being
secured as appropriate.
Figure 2.1—Module Installation
2.2 Removal
1. Prior to removing the module use a marker pen to scribe a line or indication between the Tool
Changer and module body as a reminder where the module is to be re-installed.
2. Depending upon the service or repair being done, customer connections up to the module may or
may not need to be disconnected.
3. Remove the socket head cap screws and lift the module from the Tool Changer. Refer to
Figure 2.1.
CAUTION: It is recommended, not to use fasteners with pre-applied adhesive
more than three times. Fasteners used more than three times may come loose
and cause equipment damage. Discard fasteners used more than three times and
install new fasteners with pre-applied adhesive.
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.

Quick-Change Installation and Operation Manual
Document #9620-20-c-db10-09
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
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2.3 DeviceNet Configuration
Various parameters for the DeviceNet modules need to be configured prior to operating the Tool
Changer. Please refer to Section 3—Product Information of this manual for detailed information on
installation and operation of the DeviceNet modules.
2.4 Utility Schematic
Refer to Section 9—Drawings of this manual for customer interface and wiring details for the DB10
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.

Quick-Change Installation and Operation Manual
Document #9620-20-c-db10-09
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
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3. Product Information
The DB10 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. 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 DB10 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 Messages, Polled, Strobe and Change of State/Cyclic of the predefined Master/Slave
Connection set. The Master Node supports Quick Connect operation as defined by ODVA (refer to the
EDS file for specific information). The Master Node does not support the Unconnected Message
Manager (UCMM). MAC ID, Baud Rate and Termination Resistor settings for the Master Node are
configured through a DIP switch. (2) LED’s provide network and module status.
3.1.1 Setting the DIP Switches
1. Loosen the four M3 Pan head Captive Screws and remove the window.
2. Set the DIP switches as needed, refer to Figure 3.2 for details.
3. Re-install the window and tighten the M3 Pan Head Captive Screws.
Figure 3.1—Master Module DIP Switches and LED’s
3.1.2 MAC ID
The MAC ID is set by either hardware or software configuration. The range is 0-63. In order
for the MAC ID to be set by software, all DIP switch positions must be on. If the MAC ID is
NOTICE: When replacing the window, ensure that the seal is positioned correctly
to prevent fluid leakage into the module and damaging the electronics.

Quick-Change Installation and Operation Manual
Document #9620-20-c-db10-09
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
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set by software, the Baud Rate must also be set by software. Refer to Figure 3.2 for detailed
information on DIP switch setup.
3.1.3 Baud Rate
Baud Rate is set by either hardware or software configuration. The possible settings are 125,
250 or 500Kbps. In order for the Baud Rate to be set by software, DIP switch positions 7 and
8 must be on. See Figure 3.2 for DIP switch setup.
3.1.4 Termination Resistor
When DIP switch position 9 is on, a 120resistor is placed across the CAN High and Low
lines and termination to the CAN network is provided. If switch 9 is off, termination must be
supplied by another device or through a termination cap at the end of the network cable.
Figure 3.2—DeviceNet Master Module DIP Switch Settings
SHOWN IN FACTORY DEFAULT SETTING
1
ON 62 3 4 5 7 8 9
9 - ON: Connects the 120Termination Resistor
7 8
7-OFF, 8-OFF: 125Kbps
7-ON,8-OFF: 250Kbps
7-OFF, 8-ON: 500Kbps
7-ON, 8-ON: SW setable
OFF
Example: MAC ID of 27
1
ON 62 3 4 5
OFF
Position 1 is Least Significant
Switch in OFF position
Switch in ON position
Legend:
7, 8: Set communication Baud Rate as below;
= Node 54
1 - 6: Set MAC ID
10
10 - OFF: Reserved

Quick-Change Installation and Operation Manual
Document #9620-20-c-db10-09
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
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3.1.5 Module Status LED
The module status LED is identified on the device board as “MS”. It provides device status
for power and proper operation. Table 3.1 outlines this LED’s functions:
Table 3.1—Module Status LED
Status
LED Function
Note
No Power
Off
No power applied. Check voltage is 24 VDC.
Operational
Green
Normal operation.
Standby
Flashing Green
Device needs commissioning/standby state.
Configuration missing, incomplete or incorrect.
Recoverable Fault
Flashing Red
Recoverable fault.
Unrecoverable Fault
Red
Unrecoverable fault.
Self Tests
Flashing Green-Red
Device is performing self tests.
3.1.6 Network Status LED
The network status LED is identified on the device board as “NS”. It provides network status
for power and communication. Table 3.2 outlines this LED’s functions:
Table 3.2—Network Status LED
Status
LED Function
Note
No Power/ Off Line
Off
Device not on line. Check Baud Rate.
Device has not completed the duplicate MAC ID
test.
Module Status is On. Check for termination resistor.
Device not powered. See Module Status.
On Line, Not
Connected.
Flashing Green
Device is on line but connection is not established.
Device not allocated to a master.
OK
On line, Connected
Green
Device is on line with connections established.
Device is allocated to a master.
Connection Timeout
Flashing Red
One or more I/Os are timed out.
Critical Link Failure
Red
Failed communication. Error detected and incapable
of communication.
Duplicate MAC ID or Bus off.
Communication Faulted
and Received and
Identify Communication
Fault Request –Long
Protocol Message
Flashing Green-Red
A specific Communication Faulted Device. Device
has received and accepted an Identify
Communication Faulted Request –Long Protocol
message.

Quick-Change Installation and Operation Manual
Document #9620-20-c-db10-09
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
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3.2 Arc Prevention Circuit
The DB10 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 DB10 Module, the Arc Prevention Circuit controls the ON/OFF status of the following three
power signals:
1. Device Net Power (CAN V+)
2. Switched Auxiliary 1 Power V+
3. Unswitched Auxiliary 2 Power V+
The behavior of the Arc circuit is more fully described in the following sections.
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 Prevention
circuit. Starting at the top of the diagram, the LATCH command is issued thus initiating
locking of the Master and Tool.
Soon after locking is initiated, electrical contact between Master and Tool Pin Contacts
occurs (this time is designated t1in the diagram). The magnitude of time t1is a function of
many factors including the weight of the EOAT, the distance between the Master and Tool
when the LATCH command is issued, how well the Master and Tool are aligned during pick-
up, etc.
As soon as electrical contact is made and the LATCH command is issued, the Arc Prevention
Circuit will turn on DeviceNet, Auxiliary 1, and Auxiliary 2 power. The time delay between
the electrical contacts becoming fully engaged and when power is actually available to the
EOAT (time t2in the diagram) is less than 100ms.
Figure 3.3—Arc Circuit Power-On Timing
LATCH command
Electrical Contact Between
Master and Tool
DeviceNet, Aux. 1, and
Aux. 2 Power
t1
t2
t1= Tool Changer Lock Time
t2= Power Switch ON-delay
ON
OFF
ON
OFF
ON
OFF
NOTICE: The Arc Prevention Circuit will only allow power to pass to the Tool
after the LATCH command has been issued and the Master and Tool electrical
contacts are fully engaged. Loss of the LATCH command after it has been
issued does not turn off power to the Tool. It is recommended that the LATCH
output command remain true until the LOCKED input goes true and remains
true. Only after the coupling operation is complete, should the LATCH command
be made false. Refer to the Recommended Sequence of Operation in Appendix
A for additional details.

Quick-Change Installation and Operation Manual
Document #9620-20-c-db10-09
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
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3.2.2 Arc Prevention Circuit Behavior During Uncoupling
The behavior of the Arc Prevention Circuit during uncoupling can be more clearly
understood by referring to Figure 3.4 which shows the power-off timing diagram for the Arc
Prevention Circuit. Starting at the top of the diagram, the UNLATCH command is issued
thus initiating uncoupling of the Master and Tool.
Immediately after the UNLATCH command is issued, the Arc Prevention Circuit will turn
off DeviceNet, Auxiliary 1, and Auxiliary 2 power. The power-off time delay between the
UNLATCH command and the switching off of power (designated t3in the diagram) is less
than 50ms.
Some time after power is turned off and the Master and Tool begin to separate, electrical
contact between Master and Tool Pin Contacts will be lost. This occurs with a delay,
designated t4in the diagram, after the UNLATCH command is issued. The magnitude of time
t4is a function of many factors, including the weight of the EOAT, the friction between
Master and Tool alignment pins, etc. but is usually not shorter than 100ms.
Figure 3.4—Arc Circuit Power-Off Timing
UNLATCH command
DeviceNet, Aux. 1, and
Aux. 2 Power
Electrical Contact Between
Master and Tool
t3
t4
t3
t4
= Power Switch Off Delay
=Tool Changer Unlock Time
ON
OFF
ON
OFF
ON
OFF