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
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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
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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
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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.

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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
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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

Quick-Change Installation and Operation Manual
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3.3 Tool Module Node
The Tool Node operates as a Group 2-Only Server on the DeviceNet network. The Tool Node supports
Explicit Messages, Polled and Strobe of the predefined Master/Slave Connection set. The Tool Node
supports Quick Connect operation as defined by ODVA (refer to the EDS file for specific information).
The Tool Node does not support the Unconnected Message Manager (UCMM). The MAC ID and
Baud Rate settings for the Tool Node are configured through a DIP switch. Tool-ID is set using (5)
thumbwheel switches. (2) LED’s provide network and module status. Setting the DIP Switches
3.3.1 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 3.6 for details.
3. Re-install the window and tighten the M3 Pan Head Captive Screws.
Figure 3.5—Tool Module Tool-ID Switches, DIP Switches and LED’s
3.3.2 MAC ID
The MAC ID is set by either hardware or software configuration. The range is 0-63. In order
for the MAC ID to be set by software, all DIP switch positions must be on. If the MAC ID is
set by software, the Baud Rate must also be set by software. Refer to Figure 3.4 for detailed
information on DIP switch setup.
3.3.3 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 3.6 for DIP switch setup.
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
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3.3.4 Termination Resistor
Internal termination resistance is not supported in the Tool module. Termination must be
provided through the Master module or externally as required for proper operation of the
network.
Figure 3.6—DeviceNet Tool Module DIP Switch Settings
110
ON
62 3 4 5 7 8 9
10 - O F F : R e s e rv e d
7 8
7 -O F F , 8 - O F F : 125K b p s
7 -ON, 8 -O F F : 250K b p s
7 -O F F , 8 - ON: 500K b p s
7 -ON, 8 - ON: S W s e ta b le
O F F
E x a m p le : M A C ID o f 19
1
ON
62 3 4 5
O F F
P o s iti o n 1 is L e a s t S ig n if ic a n t B it
S w it ch in O F F p o s itio n
S w it ch in O N p o s it io n
Legend:
7, 8 : S e t c o m m u n ic a tio n B a u d R a te a s b e lo w ;
= N o d e 55
S H O W N IN F A C T O R Y D E F A U L T S E T T IN G
1 - 6 : S e t M A C ID
9 - O F F : R e s e rv e d
3.3.5 Tool-ID (Tool Node Only)
The Tool-ID for a particular tool is established from the setup of (5) thumbwheel switches.
The Tool module is available with switches configured to provide 5 independent (0–9)
readings.
3.3.5.1 Setting the Tool-ID Switches
1. Loosen the four M3 Pan head Captive Screws and remove the 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 1 to 9. Set the
Tool-ID to the desired unique five digit number from 11111 to 99999 for
each tool. Refer to Figure 3.5.
3. Re-install the window and tighten the M3 Pan Head Captive Screws.
NOTICE: When replacing the window, ensure that the seal is
positioned correctly to prevent fluid leakage into the module and
damaging the electronics.
NOTICE: The DIP switch
orientation shown is rotated
180º from Figure 3.5.

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3.3.6 Module Status LED
The module status LED (Figure 3.5) is identified on the device board as “MS”. It provides
device status for power and proper operation. Refer to Table 3.1 for the module status LED’s
functions.
3.3.7 Network Status LED
The network status LED (Figure 3.5) is identified on the device board as “NS”. It provides
network status for power and communication. Refer to Table 3.2 for the network status
LED’s functions.
3.3.8 Quick Connect
The Quick-Connect feature can be enabled in the ATI Tool Module. With the Quick-
Connect feature enabled, the ATI tool changer module can reconnect to the DeviceNet
network within 1 sec once power is applied to the pin block during tool change.
Modules with a "Quick Connect Enabled" sticker have this attribute already enabled.
Modules without the sticker require the user to enable the feature using the robot teach
pendant and/or a laptop. The Tool Module may have the Quick Connect option enabled or
disabled depending on when the module was built. Contact ATI if you need assistance
enabling this feature.
If you install a new module into an existing system, check to see if Quick-Connect is enabled
in the old module before replacing. If you see communication faults or delays after module
replacement, check to see if the quick-connect feature is enabled in the new module or if the
new module has the sticker indicating quick-connect was already enabled. Tool Modules with
Quick Connect enabled will not check for duplicate MAC addresses. If the DeviceNet
network includes duplicate MAC addresses, this will cause communication faults. See
Section 6—Troubleshooting for fault causes and correction.
3.4 Tool-Side TSI
The Tool Stand Interlock (TSI) circuit is provided to ONLY allow Tool release while in the stand or
storage location as indicated by actuation of a customer-integrated switch.
A momentary action double-pole, single-throw mechanical limit switch is recommended to be used in
concert with TSI. The limit switch, with 2 sets of normally open (NO) contacts, is integrated on the
EOAT (see Figure 3.7). An interface to the TSI circuit is made available to the customer via a 4-Pin
M12 connector on the Tool module. An off-the-shelf cord set can be utilized to connect this interface to
the limit switch assembly.
3.4.1 TSI Overview
The DB10 module relies on the status of the Ready-to-Lock (RTL) sensors and the TSIV
input to determine when it is appropriate to unlatch the Tool. The RTL sensors indicate if the
Master and Tool are coupled while the TSIV input indicates when the TSI mechanical switch
on the Tool is actuated, thereby indicating that the Tool is in the stand. In order to allow the
Tool Changer to uncouple when a Tool is not present, a relay circuit (RTL Relay) in parallel
with the TSI circuit is utilized. The RTL Relay circuit is located in the Master module and is
triggered by the RTL sensor. If the RTL sensor is low, indicating no Tool presence, then the
RTL Relay circuit is closed allowing the unlatch solenoid valve circuit to be completed and
the Tool Changer to be uncoupled. If the RTL sensor is high, indicating Tool presence, then
the RTL Relay circuit is open and the TSI circuit is passed through to the Tool side.
Once on the Tool side, the TSI circuit is closed by another relay circuit (TSI Relay). The TSI
Relay is located in the Tool module and is triggered by closure of the limit switch. When the
EOAT is in the stand and the limit switch is closed, the TSI Relay is closed, thus making the

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TSI circuit through the tool side. When the EOAT is out of the stand the TSI Relay is open
and the TSI circuit remains open regardless of any unintentional Unlatch command.
Control reliability monitoring of the Relays, limit switch and TSI circuit is achieved using the
RTLV, TSRV, and TSIV inputs, respectively. Refer to Error! Reference source not found.
for suggested fault monitoring conditions.
The DB10 Master module firmware requires that the TSIV input be true in order for the
Unlatch output command to be executed when a tool is present (i.e. RTL is high). On the
DB10 Tool module, the TSIV input is made available to the customer along with the TSI
circuit via the 4-Pin TSI connector. Refer to the TSI connector details in Section 9—
Drawings of this manual.
Table 3.3c
Sensor/Input1
State1
Sensor/Input2
State2
Comment
RTL
0
Tool Module*
Present*
**RTL Not Operating Properly.
RTL
0
RTLV
1
**RTL Relay or RTL Not Operating Properly.
RTL
1
RTLV
0
RTL Relay or RTL Not Operating Properly.
TSIV
0
TSRV
1
**TSI Relay or Switch Not Operating Properly.
TSIV
1
TSRV
0
TSI Relay or Switch Not Operating Properly.
TSIV
1
Clear of Stand
Yes
**Switch Failed Closed or Tied Off?
TSRV
1
Clear of Stand
Yes
TSI Relay Failed Closed?
* Slave Module Present as evidenced by Tool Presence Input or ability to read Tool ID
** Dangerous situation where an unintentional Unlatch command could result in Tool release.

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Figure 3.7—Tool Stand Interlock (TSI)
NOTICE: This tool changer is equipped with Tool Stand Interlock (TSI). Special
procedures are required to uncouple the tool changer. Refer to Section 4.1—
Recommended Sequence of Operation.
DB10 Master Module
DB10 Tool Module

Quick-Change Installation and Operation Manual
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3.5 Software
Working EDS files for the Master and Tool nodes are available from our website (www.ati-
ia.com/download/edsfiles) or by e-mail, reference the part numbers given below:
DB10-M Node EDS file: 9030-20-1009
DB10-T Node EDS file: 9030-20-1010
I/O bitmaps for the DeviceNet nodes are provided in the tables below. The default settings are Node 54
for the Master module and Node 55 for the Tool module.
Table 3.4—I/O Bitmap, Robot Input From Master DB10-M Module (Node 54)
Bit #
Name
Description/Function
0
Lock
Tool Changer Lock Prox I/P
1
Unlock
Tool Changer Unlock Prox I/P
2
Solenoid Energized
Latch/Unlatch Solenoid Energized I/P
3
Auxiliary Power Available
Auxiliary Power Present I/P
4
RTL
Ready-to-Lock Prox I/P
5
TSIV
TSI Switch Verify I/P
6
RTLV
RTL Relay Verify I/P
7
TSRV
TSI Relay Verify I/P
Table 3.5—I/O Bitmap, Robot Output To Master DB10-M Module (Node 54)
Bit #
Name
Description/Function
0
Latch
ToolChanger Valve Latch O/P
1
Unlatch
ToolChanger Valve Unlatch O/P
2
N/A
3
N/A
4
N/A
5
N/A
6
N/A
7
N/A
* Latch O/P only applicable for Double Solenoid Valve Adapter Versions

Quick-Change Installation and Operation Manual
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Table 3.6—I/O Bitmap, Robot Input Node 55 (DB10-T Module)
Bit #
Name
Description/Function
0
Low Bit
Tool-ID Byte 1
N/A
1
N/A
2
N/A
3
N/A
4
SW1 Bit 1
5
SW1 Bit 2
6
SW1 Bit 4
7
High Bit
SW1 Bit 8
8
Low Bit
Tool-ID Byte 2
SW2 Bit 1
9
SW2 Bit 2
10
SW2 Bit 4
11
SW2 Bit 8
12
SW3 Bit 1
13
SW3 Bit 2
14
SW3 Bit 4
15
High Bit
SW3 Bit 8
16
Low Bit
Tool-ID Byte 3
SW4 Bit 1
17
SW4 Bit 2
18
SW4 Bit 4
19
SW4 Bit 8
20
SW5 Bit 1
21
SW5 Bit 2
22
SW5 Bit 4
23
High Bit
SW5 Bit 8

Quick-Change Installation and Operation Manual
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4. Operation
This Recommended Sequence of Operations procedure is to be used as a general guide when programming a
robot or PLC for use with a Tool Changer and DB10 control/signal modules. This procedure is intended for
"automatic" modes used during normal application processes.
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 input true 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. RTLV is false.
c. The ATI Tool and any downstream device is offline.
d. The Auxiliary Power Available input is true provided the Auxiliary Power 1 power
supply is on.
e. TSIV is false.
f. TSRV is false.
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 Latch output command is made false and the Unlatch output command is made
true.
b. The Solenoid Energized input is made true.
c. The Unlocked input goes true and remains 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 0.125” 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 TSIV inputs go true, indicating that the Master and Tool are in close proximity of
each other and verifying the operation of the TSI limit switch.
b. Power is not yet available on the Tool.
c. The RTL input is true, indicating that it is okay to couple the Tool.
d. RTLV is true.
5. Couple the Tool Changer.
a. The Unlatch output is made false and the Latch output is made true.
b. The Unlocked input goes false a short time later, indicating piston travel.
Subsequently, the Locked input goes true and remains true, indicating that the
coupling operation is complete. It is recommended that the Latch command be made
false after the Locked input goes true.
c. The Arc Prevention circuit makes power available to the Tool.
Sometime thereafter, Tool-ID will become available and communications should be
established with the downstream DeviceNet device(s).

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6. Robot moves away from the Tool Stand with the Tool Changer coupled.
a. The TSI limit switch becomes deactivated, and the TSIV and TSRV input goes false
7. Normal operation
a. The following inputs are true:
i. Locked
ii. Auxiliary Power Available
iii. RTL
iv. RTLV
b. The following inputs are false:
i. Solenoid Energized
ii. Unlocked
iii. TSIV
iv. TSRV
c. The following outputs are false:
i. Latch
ii. Unlatch
8. Robot moves into the Tool Stand with the Tool Changer coupled.
a. When the Tool is returned to the stand, the TSI limit switch becomes activated and
the TSIV input goes true, indicating that it is safe to uncouple the Tool Changer.
b. TSRV becomes true.
9. Uncouple the Tool Changer.
a. The Latch output is made false and the Unlatch output is made true.
b. Power on the Tool turns off.
c. Communication is lost with the downstream devices.
d. Tool-ID becomes unavailable.
e. The Locked input goes false a short time later and subsequently the Unlocked input
goes true and remains true, indicating that the uncoupling operation is complete.
10. Robot and Master move away from the Tool, are parallel and between 0.125” to 0.06” of
the Tool.
a. The RTL inputs are false.
b. RTLV is false.
11. Robot and Master move away from the Tool, are parallel and > 0.125” from the Tool (the
module contact pins are no longer touching).
12. Robot and Master in free space.
a. The following inputs are true:
i. Unlocked
ii. Auxiliary Power Available
b. The following inputs are false:
i. Locked
ii. RTL
iii. RTLV
iv. TSIV
v. TSRV

Quick-Change Installation and Operation Manual
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5. Maintenance
The DeviceNet modules are designed to provide a long life with little maintenance required. The modules are
not designed to be field serviced as all point-to-point wiring connections are soldered. Component replacement
is limited to the V-Ring seal on the Master.
If the Tool Changer is being used in dirty environments (e.g., welding or deburring applications), care should
be taken to limit the exposure of the Tool Changer. Idle Tool assemblies should be covered to prevent debris
from settling on the mating surface. Also, the Master assembly should be exposed for only a short period of
time during Tool change and down time.
Under normal conditions, no special maintenance is necessary, however it is recommended that periodic
inspections be performed to assure long-lasting performance and to assure that unexpected damage has not
occurred. Perform the following visual inspection monthly:
Inspect mounting fasteners to verify they are tight and if loose, then tighten to the proper torque.
Cable connections should be inspected during maintenance periods to ensure they are secure. Loose
connections should be cleaned and re-tightened as appropriate. Inspect cable sheathing for damage,
repair or replace damaged cabling. Loose connections or damaged cabling are not expected and may
indicate improper routing and/or strain relieving.
Inspect the Master and Tool pin blocks for any pin damage, debris or darkened pins. Refer to
Section 5.1—Pin Block Inspection and cleaning.
Inspect V-Ring seals for wear, abrasion, and cuts. If worn or damaged, replace. Refer to
Section 5.2—Seal Replacement.
5.1 Pin Block Inspection and cleaning
1. Inspect the Master and Tool pin blocks for any debris or darkened pins.
Figure 4.1—Inspect Master and Tool Pin Blocks
2. If debris or darkened pins exist, remove debris using a vacuum, and clean using a nylon brush
(ATI part number 3690-0000064-60).
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.