ATI Technologies SR-61 Operating and safety instructions

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
Robotic Collision Sensor
SR‑61 Switch Replacement Manual
U.S. Patent Nos. 6069415 and 6690208
Document #: 9610‑60‑1014

Manual, Collision Sensor Switch Replacement,SR‑61
Document #9610‑60‑1014‑02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
2
Table of Contents
1. Safety......................................................................................................................................... 3
1.1 ExplanationofNotications.........................................................................................................3
1.2 General Safety Guidelines............................................................................................................3
1.3 Safety Precautions........................................................................................................................4
1.4 Electrical Connection....................................................................................................................5
1.4.1 Test Switch Functionality....................................................................................................6
1.4.2 Replacement of Original Style Switch/Connector Block Assembly ....................................6
1.4.3 Replacement of Current Style Switch/Connector Block Assembly.....................................8
1.5 Switch Adjustment........................................................................................................................9
1.5.1 Original Style Switch Adjustment........................................................................................9
1.5.2 Current Style Switch Adjustment......................................................................................10

Manual, Collision Sensor Switch Replacement,SR‑61
Document #9610‑60‑1014‑02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
3
1. Safety
The safety section describes general safety guidelines to be followed with this product, explanation of the
notications found in this manual, and safety precautions that apply to the product. More specic notications are
imbedded within the sections of the manual where they apply.
1.1 ExplanationofNotications
The notications included here are specic to the product(s) covered by this manual. It is expected that the
user heed all notications from the robot manufacturer and/or the manufacturers of other components used
in the installation.
DANGER: Notication of information or instructions that if not followed will result in
death or serious injury. The notication provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
WARNING: Notication of information or instructions that if not followed could result
in death or serious injury. The notication provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
CAUTION: Notication of information or instructions that if not followed could result
in moderate injury or will cause damage to equipment. The notication provides
information about the nature of the hazardous situation, the consequences of not
avoiding the hazard, and the method for avoiding the situation.
NOTICE: Notication of specic information or instructions about maintenance, operation,
installation, or setup of the product that if not followed could result in damage to equipment. The
notication can emphasize specic grease types, good operating practices, or maintenance tips.
1.2 General Safety Guidelines
The Collision Sensor is not designed for, nor should it be used in, situations involving the safety of humans
or animals. The Collision Sensor is designed as a safety device to protect industrial components and
machinery from damage resulting from collisions and impacts. In all situations the user is responsible for
insuring that applicable safety practices are followed as outlined by the manufacturer of the equipment on
which the Collision Sensor is used.
The routing of electrical and pneumatic lines must minimize the possibility of stress, pullout, kinking,
rupture, etc. Failure of critical electrical and/or pneumatic lines to function properly may result in injury to
personnel and damage to equipment.
CAUTION: The customer should lock out and discharge all energy to the work cell prior
to working on any Collision Sensor system. Failure to do so may result in damage to
equipment or injury to personnel.

Manual, Collision Sensor Switch Replacement,SR‑61
Document #9610‑60‑1014‑02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
4
1.3 Safety Precautions
WARNING: Do not perform maintenance or repair on the Collision Sensor with air
pressure applied, current supplied to the sensor, or the robot not in a safe condition.
Injury or equipment damage can occur if this is not observed. Always ensure that air
pressure has been vented from the unit, that electrical current is not supplied to the
Collision Sensor’s signal circuit, and that the robot is in a safe, locked‑out condition
consistent with local and national safety standards before performing maintenance or
repair on the Collision Sensor.
WARNING: The Collision Sensor is only to be used for intended applications and
applications approved by the manufacturer. Using the Collision Sensor in applications
other than intended will result in damage to Collision Sensor or end‑of‑arm tooling and
could cause injury to personnel.
CAUTION: Do not adjust or remove either of the (2) set screws installed in the wall of
the body. Doing so may result in damage to the unit or failure of the switch to operate.

Manual, Collision Sensor Switch Replacement,SR‑61
Document #9610‑60‑1014‑02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
5
1.4 Electrical Connection
The Collision Sensor is connected to the user’s control wiring as a normally‑open PNP or NPN proximity
switch. The following sketch details the connections between the internal switch and the pins in the
connector block assembly. Optional mating cables, available from ATI, utilize the brown‑black‑blue color
code indicated.
CAUTION: The user is responsible for connecting the collision sensor to their controls
and providing an “electrical load” in series with the collision sensing switch. The switch
is rated for instrument level signals of 100mA (max.) at 10–30VDC.
Figure 1.1—Switch Wiring

Manual, Collision Sensor Switch Replacement,SR‑61
Document #9610‑60‑1014‑02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
6
1.4.1 Test Switch Functionality
Once the Collision Sensor has been installed and connected as described in the preceding
paragraphs, proper electrical operation of the unit may be conrmed.
Supply the Collision Sensor with approximately 15 psi (1 bar) and ensure that the unit is
electrically connected to the user’s control circuit or to a test box per Figure 1.1. The switch
should appear closed.
Manually push the Collision Sensor to simulate a collision while observing the switch output.
When the collision occurs the switch will open and the test light will turn off.
Release the Collision Sensor and it will return to its working position. The test light will illuminate.
1.4.2 Replacement of Original Style Switch/Connector Block Assembly
1. Remove the mounting screw using a 2.5 mm hex key (see Figure 1.2).
2. Pull the connector block away from the Collision Sensor being careful not to strain
the wires inside.
3. Loosen the locknut on the proximity switch.
4. Screw the proximity switch out of the body.
5. Discard the entire assembly.
Figure 1.2—Removal of Switch/Connector Block Assembly from the Collision Sensor
6. Provide 5 to 15 psi of air to the unit at the port marked “P” (unless the unit is equipped with
preload springs).
CAUTION: If the piston is not up against the dog point screws while screwing
in the proximity switch, applying air to the unit could damage the proximity
switch. Make sure the Stem is locked into position indicating the piston is
against the dog point screws.

Manual, Collision Sensor Switch Replacement,SR‑61
Document #9610‑60‑1014‑02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
7
Figure 1.3—Piston Location During Proximity Switch Installation
7. Screw the new proximity switch clockwise into the hole on the side of the body until it bottoms.
8. Rotate the connector block along with the proximity switch to prevent damage to the wires.
9. Screw the proximity switch out 1 turn (counterclockwise).
10. Perform switch adjustment per Section 1.5.1—Original Style Switch Adjustment.
11. Press the connector block assembly rmly against the body of the Collision Sensor while
tightening the screw. When tightened securely, the connector block assembly should rest
parallel to its mounting surface.

Manual, Collision Sensor Switch Replacement,SR‑61
Document #9610‑60‑1014‑02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
8
1.4.3 Replacement of Current Style Switch/Connector Block Assembly
1. Remove the mounting screw using a 2.5 mm hex key (see Figure 1.4).
2. Pull the connector block away from the Collision Sensor.
3. Discard the entire assembly.
Figure 1.4—Removal of Switch/Connector Block Assembly from the Collision Sensor
9160-SENSOR-061-2
M3 Socket Head Cap Screw
4. Provide 5 to 15 psi of air to the unit at the port marked “P” (unless the unit is equipped with
preload springs).
5. Make sure the spring is on the sensor and the O‑ring is seated in the connector block. Press the
connector block assembly rmly against the body of the Collision Sensor while tightening the
screw to 64 in‑ozs. When tightened securely, the connector block assembly should rest parallel
to its mounting surface.
Figure 1.5—Switch/Connector Block Assembly installation
Spring
O-Ring
6. Perform switch adjustment per Section 1.5.2—Current Style Switch Adjustment.

Manual, Collision Sensor Switch Replacement,SR‑61
Document #9610‑60‑1014‑02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
9
1.5 Switch Adjustment
There are (2) styles of switch/connector block assemblies for the SR‑61 Collision Sensor. The original style
has a larger connector body than the current style. The current style has an adjustment set screw in the side
of the connector body, refer to Figure 1.8.
Figure 1.6—Determine the Switch/Connector Block Assemblies Style
0.65"
0.91"
Original Style Switch/Connector Block Current Style Switch/Connector Block
Small Connector Block
Large Connector Block
Adjustment Set Screw
If adjusting an original style switch, refer to Section 1.5.1—Original Style Switch Adjustment
If adjusting a current style switch, refer to Section 1.5.2—Current Style Switch Adjustment
1.5.1 Original Style Switch Adjustment
Note: The switch is factory adjusted to open after the stem has traveled .020” in the axial direction.
Adjustments should only be made if replacing the switch.
1. De‑energize all electrical and pneumatic power supplied to the Collision Sensor. Drain all stored
air and electric power in compliance with standard (OSHA) safety practices and standards.
2. Disconnect the air lines and signal wires connected to the Collision Sensor.
3. Remove the user‑installed mounting hardware from the Collision Sensor and remove the unit.
Take the unit to a test bench equipped with a clean working surface and compressed air.
4. Ensure that the Collision Sensor returns to its reset or working position with the stem fully
extended and the alignment mark on the stem in line with the alignment mark on the cover plate
(Temporarily supply approximately 60 psi (4 bars) to the unit.
5. Loosen and remove the screw holding the connector block in place (see Figure 1.7).
6. Taking care not to break the wires, pull the connector block away from the body. Loosen the
locknut on the proximity switch.
7. Connect a test box per Figure 1.1.
8. Attach an interface plate to the stem of the Collision Sensor.
9. Center the Collision Sensor under the press ram (see Figure 1.7).
10. Set a dial indicator in contact with the interface plate and adjust it so that the probe is
vertical. Set the dial indicator height so that it can read at least .06” (1.5 mm) stroke. Set the
dial ring to zero.

Manual, Collision Sensor Switch Replacement,SR‑61
Document #9610‑60‑1014‑02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
10
11. Push on the press handle until the switch circuit opens and check the distance traveled on the
dial indicator.
12. If the distance traveled is greater than desired turn the proximity switch counterclockwise. If the
distance traveled is less turn the proximity switch clockwise.
13. Repeat steps (11) and (12) as necessary to obtain the desired switch setting.
Figure 1.7—Checking Switch Height Adjustment
Sensor
Lock Nut
Sensor
Arbor
Press
Arbor
Press Ram
Interface
Plate
Dial
Indicator
14. Tighten the locknut on the proximity sensor.
15. Slide the connector block over the proximity sensor carefully routing the wires into the slotted
area under the proximity sensor. Line up the dowel pin with the hole in the body and the screw
hole with the threaded hole in the body.
16. Apply Loctite 222MS to the M3 mounting screw and thread it into the body. Tighten the
screw securely.
17. Re‑install the Collision Sensor using the user‑installed mounting hardware.
CAUTION: Before putting the Collision Sensor back into operation, conrm that
the switch is functioning properly. See Section 1.4.1—Test Switch Functionality.
1.5.2 Current Style Switch Adjustment
Note: The switch is factory adjusted to open after the stem has traveled .020” in the axial direction.
Adjustments should only be made if replacing the switch.
1. De‑energize all electrical and pneumatic power supplied to the Collision Sensor. Drain all stored
air and electric power in compliance with standard (OSHA) safety practices and standards.
2. Disconnect the air lines and signal wires connected to the Collision Sensor.

Manual, Collision Sensor Switch Replacement,SR‑61
Document #9610‑60‑1014‑02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
11
3. Remove the user‑installed mounting hardware from the Collision Sensor and remove the unit.
Take the unit to a test bench equipped with a clean working surface and compressed air.
4. Ensure that the Collision Sensor returns to its reset or working position with the stem fully
extended and the alignment mark on the stem in line with the alignment mark on the cover plate
(Temporarily supply approximately 60 psi (4 bars) to the unit.
5. Connect a test box per Figure 1.1.
6. Attach an interface plate to the stem of the Collision Sensor.
7. Center the Collision Sensor under the press ram (see Figure 1.8).
8. Set a dial indicator in contact with the interface plate and adjust it so that the probe is
vertical. Set the dial indicator height so that it can read at least .06” (1.5 mm) stroke. Set the
dial ring to zero.
9. Push on the press handle until the switch circuit opens and check the distance traveled on the
dial indicator.
10. If the distance traveled is greater than desired turn the adjustment screw counterclockwise. If
the distance traveled is less turn the adjustment screw clockwise.
11. Repeat steps (9) and (10) as necessary to obtain the desired switch setting.
Figure 1.8—Checking Switch Height Adjustment
Arbor Press Ram
Dial Indicator
Adjustment Screw
Interface Plate
Arbor Press
12. Re‑install the Collision Sensor using the user‑installed mounting hardware.
CAUTION: Before putting the Collision Sensor back into operation, conrm that the
switch is functioning properly. See Section 1.4.1—Test Switch Functionality.