ATI Technologies SR-61 User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
Protector™
Robotic Collision Sensor
SR-61
U.S. Patent Nos. 6069415 and 6690208
Installation and Operation Manual
Document #9610-60-1006-10
June 2010

Protector Installation & Operation Manual
Document #9610-60-1006-10
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
2
Information contained in this document is the property of ATI Industrial Automation, Inc. (ATI) and shall not be reproduced in
whole or in part without prior written approval of ATI. The information herein is subject to change without notice. This manual
is periodically revised to reflect and incorporate changes made to the product.
The information contained herein is CONFIDENTIAL and reserved exclusively for the customers and authorized agents of ATI
Industrial Automation and may not be divulged to any third party without prior written consent from ATI. No warranty including
implied warranties is made with regard to accuracy of this document or fitness of this device for a particular application. ATI
Industrial Automation shall not be liable for any errors contained in this document or for any incidental or consequential
damages caused thereby. ATI Industrial Automation also reserves the right to make changes to this manual at any time without
prior notice.
ATI assumes no responsibility for any errors or omissions in this document. Users’ critical evaluation of this
document is welcomed.
©Copyright by ATI Industrial Automation. All rights reserved.
How to Reach Us
Sales, Service and Information about other ATI products:
ATI Industrial Automation
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati-ia.com
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Technical support and questions:
Application Engineering
Tel: [phone], Option 2, then option 2
Fax: [phone]
E-mail: [e-mail]
CAUTION: This manual describes the function, application and safety
considerations of this product. This manual must be read and understood
before any attempt is made to install or operate the product, otherwise damage
to the product or unsafe conditions may occur.
!

Protector Installation & Operation Manual
Document #9610-60-1006-10
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
3
Table of Contents
Page
1. Product Overview..................................................................................................................................5
1.1 Introduction...................................................................................................................................5
1.2 Safety Considerations...................................................................................................................5
2. Description............................................................................................................................................6
3. Installation.............................................................................................................................................7
3.1 Operating Requirements...............................................................................................................7
3.2 Mechanical....................................................................................................................................7
3.2.1 Fastener Torque Specifications.......................................................................................8
3.3 Electrical .......................................................................................................................................8
3.3.1 Switch Adjustment...........................................................................................................9
3.3.2 Cable Replacement.......................................................................................................10
3.4 Pneumatic...................................................................................................................................11
3.4.1 Calculating Estimated Pressure Setting........................................................................11
3.4.1.1 Calculate Applied Loads:................................................................................11
3.4.1.2 Obtain required pressure setting ....................................................................12
3.4.2 Determining Exact Pressure Required:.........................................................................13
4. Operation ............................................................................................................................................13
5. Maintenance .......................................................................................................................................14
5.1 General.......................................................................................................................................14
5.2 Replacement of Switch/Connector Block Assembly...................................................................14
5.2.1 Removal.........................................................................................................................14
5.2.2 Replacement..................................................................................................................15
5.3 Periodic Lubrication Instructions.................................................................................................15
5.3.1 Disassembly ..................................................................................................................15
5.3.2 Re-assembly..................................................................................................................17
5.4 Spring Conversion......................................................................................................................18
5.4.1 Disassembly ..................................................................................................................18
5.4.2 Re-assembly..................................................................................................................18
5.5 Seal Replacement ......................................................................................................................19
5.5.1 Disassembly ..................................................................................................................19
5.5.2 Re-assembly..................................................................................................................19
5.6 IP65 Boot Replacement..............................................................................................................20
5.6.1 Disassembly ..................................................................................................................20
5.6.2 Re-assembly..................................................................................................................20
5.7 Weld Splatter Shield Replacement.............................................................................................20
5.7.1 Disassembly ..................................................................................................................20
5.7.2 Re-assembly..................................................................................................................20
6. Troubleshooting..................................................................................................................................21
7. 7. Specifications and Drawings...........................................................................................................23
7.1 SR-61..........................................................................................................................................23
8. Terms and Conditions of Sale ............................................................................................................24

Protector Installation & Operation Manual
Document #9610-60-1006-10
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
4
Glossary of Terms
Term Definition
Body Cylindrical aluminum housing and air pressure chamber. An interface plate to the user’s robot
is usually attached here.
Cam A hardened steel ring mounted inside the cover on which the hardened steel ball segments
mounted to the stem are nested.
Collision The accidental impact between the end of arm tooling and some obstruction in its path.
Collision Sensing
Switch A switch that changes state to an open circuit when a crash is detected. It is mounted in a
threaded hole in the side of the body under the connector block. It is a normally open, PNP or
NPN metal sensing proximity switch. It appears closed in the working (reset) position since it
is sensing a steel target. The steel target moves out of range in the event of a crash.
Cover Plate Disk-shaped aluminum cover for Protector™ Body.
Crash The result of a disturbance that displaces the Protector™ components from their standard,
working position.
Interface Plate Optional component used to adapt the Protector™ Body or Stem to the user’s robot or
tooling.
Nano Connector 8mm electrical connector mounted in a block attached to the side of the Body.
Piston The component which, together with the Body, creates a pressure chamber. Varying the
pressure in this chamber varies the load required to move the piston.
Reset The ability of the Protector™ to return to its working position when a disturbing force or
displacement is removed.
Stem Round tapered post containing tapped holes and a dowel pin hole. An interface plate to the
user’s tooling is usually attached here.
Switch Target A steel block mounted on top of the Piston, the position of which is sensed by the Collision
Sensing Switch.

Protector Installation & Operation Manual
Document #9610-60-1006-10
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
5
1. Product Overview
1.1 Introduction
The Protector™is a pneumatically-pressurized device offering protection to industrial robots and
tooling in the event of accidental impacts and unanticipated loads. The Protector™works by
“breaking away” from its working geometry in the event of excessive torsional, moment, or
compressive axial forces, or any combination of these. The Protector™cannot respond to pure axial
tension, which is an unlikely mode of loading. Removal of the upsetting force or moment allows the
Protector™ to return to its normal working position.
As a collision occurs, internal motion of the Protector™components cause a switch to change state
to an open circuit. The switch circuit may be monitored by robotic controllers to stop operations
before damage to the robot or tooling occurs. The load threshold at which the Protector™breaks
away is adjustable by controlling the air pressure supplied to the unit.
All Protector™devices provide axial (compression only), torsional, and moment compliance.
1.2 Safety Considerations
The Protector™is not designed for, nor should it be used in, situations involving the safety of
humans or animals. The Protector™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 Protector™is used.
The routing of electrical and pneumatic lines must minimize the possibility of stress, pullout,
kinking, rupture, etc. Failure of some critical electrical and/or pneumatic lines to function properly
may result in injury to personnel and equipment.
CAUTION: The customer should lock out and discharge all energy to the work
cell prior to working on any Protector™system.
!

Protector Installation & Operation Manual
Document #9610-60-1006-10
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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2. Description
The Protector™consists of a piston housing (body) closed with a cover plate assembly. A stem assembly
protrudes through the cover plate assembly. The cover plate assembly incorporates a cam to accurately and
repeatably position the stem assembly. The stem assembly is forced into position against the cam by a
piston. The piston is supported by user supplied compressed air and an optional assist spring. The stem
provides a mounting surface for customized interface plates. Tapped and through holes on the back surface
of the body allow direct bolting of the body to the robot. All load-bearing components and those with wear
surfaces are made of hard-coat anodized aluminum, hardened bearing steel, or hardened tool steel.
A collision sensing switch is positioned in the side of the body. A connector block assembly containing a
Nano connector is mounted on the side of the Protector™body. The user connects to the switch using the
Nano connector for which a variety of cables are available. The user must also supply the Protector™with
dry, regulated, compressed air through a port on the side of the Protector™body. The size and location of
these connections are shown in the drawing provided at the end of this manual.
Figure 2.1—Protector™Collision Sensor

Protector Installation & Operation Manual
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Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
7
3. Installation
3.1 Operating Requirements
The Protector™requires clean, dry, non-lubricated air delivered from a user-supplied, self-relieving
regulator. The Protector™is certified for accurate, repeatable operation when supplied with air at
20–90 psi (1.4–6.2 bar ) of pressure operated in an environment with an ambient temperature range
of 40–120°F (5–50°C). For connection to the user’s controls, the Protector™is equipped with a
collision sensing switch. When the Protector™is in the collision mode or the electrical cable to the
switch is disconnected an open circuit is generated.
Proper sizing of the Protector™is imperative for the safe and reliable operation of the unit. Contact
ATI for assistance in selecting the proper unit.
Equivalent spring assist options of 5 psi (P05), 10 psi (P10), and 15 psi (P15) are available.
3.2 Mechanical
The Protector™is commonly mounted with its body toward the robot and its stem toward the user
tooling, however, this is strictly up to the user. The Protector™can be mounted directly to the robot
or to the user tooling using the dowel pin holes and the clearance / tapped holes in the Protector™
body. Should this not be possible, an interface plate must be fabricated.
A second interface plate is often required for mounting to the Protector™stem. Such interface plates
may be ordered from ATI as blank plates or machined as necessary for specific applications.
Another option is for the user to fabricate their own interface plates.
Once any required machining of the interface plates is complete, mount the Protector™using
hardware appropriately sized for the application. Connect an appropriately sized air line and fitting
to the Protector™. Do not supply air pressure at this time.
All mounting hardware should be tightened. The use of an industrial thread-locking compound is
recommended for all fasteners.
CAUTION: The surface to which the Protector™body is mounted must be flat
and smooth, and provide support for the entire surface of the body.
!
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–
30 VDC.
!
CAUTION: The level of the desired or required air pressure will vary
according to the weight, loading, and motion of the user’s tooling. Exercise
caution while increasing the air pressure supplied to the Protector™. When
the pneumatically-supplied force is sufficient to re-seat the Protector™the
toolin
g
will move to its workin
g
p
osition.
!

Protector Installation & Operation Manual
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3.2.1 Fastener Torque Specifications
M3-0.5 Cap Screw 19 in-lbs
M4-0.7 Cap Screw 41 in-lbs
M5-0.8 Cap Screw 85 in-lbs.
Table 3.1—Recommended torques for ATI supplied fasteners
3.3 Electrical
The Protector™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 (see Table 3.4), utilize the
brown-black-blue color code indicated.
Figure 3.2—Switch Wiring
CAUTION: Before connecting or uncoupling the air supply to the Protector™
insure that the air supply is turned off and that all trapped air has been vented.
!

Protector Installation & Operation Manual
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Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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Once the Protector™has been installed and connected as described in the preceding paragraphs
proper electrical operation of the unit may be confirmed.
Supply the Protector™with approximately 15 psi (1 bar) and insure that the unit is electrically
connected to the user’s control circuit or to a test box per Figure 3.2. The switch should appear
closed.
Manually push the Protector™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 Protector™and it will return to its working position. The test light will illuminate
3.3.1 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 Protector™. 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 Protector™.
3. Remove the user-installed mounting hardware from the Protector™and remove the
unit. Take the unit to a test bench equipped with a clean working surface and
compressed air.
4. Insure that the Protector™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 approx. 15 psi (1 bar) to the unit unless equipped
with a preload spring.)
5. Loosen and remove the screw holding the connector block in place (see Figure 5.1).
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 3.2.
8. Attach an interface plate to the stem of the Protector™.
9. Center the Protector™ under the press ram (see Figure 3.3).
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” (1.5mm) stroke.
Set the dial ring to zero.
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 d) and e) as necessary to obtain the desired switch setting.
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 10–30
VDC.
!

Protector Installation & Operation Manual
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Figure 3.3—Checking Switch Height Adjustment
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 Protector™ using the user-installed mounting hardware.
3.3.2 Cable Replacement
If the cable attached to your Protector™becomes broken or worn, replacement cables
may be purchased as follows:
Protector Model Number: 9610-061-Pxx-XX-x-x-x. (x = any value).
XX Cable Number Description
BN ---
No cable purchased with Protector™– choose one of
the following replacement cables
BB 8590-9909999-15 High-flex cable with straight screw-on connector, 5M
(16.4 ft.) long with flying leads
BC 8590-9909999-06 High-flex cable with 90osnap-on connector, 5M (16.4
ft.) long with flying leads
BD 8590-9909999-89 High-flex cable with 90oscrew-on connector, 10M
(32.8 ft.) long with flying leads
BE 8590-9909999-116 High-flex cable with 90oscrew-on connector, 5M
(16.4 ft.) long with flying leads
BT 8590-9909999-48 High-flex cable with straight snap-on connector, 5M
(16.4 ft.) long with flying leads
BU 8590-9909999-07 High-flex cable with straight snap-on connector, 10M
(32.8 ft.) long with flying leads
Table 3.4—Cable choices
CAUTION: Before putting the Protector™back into operation, confirm that the
switch is functioning properly. See Section 3.3.
!

Protector Installation & Operation Manual
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3.4 Pneumatic
Compressed air is to be supplied to the port marked “P” in the range of 20 psi to 90 psi. This port
accepts #10-32 or M4 pneumatic fittings. The pressure setting required for a particular application
can be estimated using the procedure outlined in section 3.4.1. The exact pressure required must be
determined through testing using the procedure outlined in section 3.4.2.
3.4.1 Calculating Estimated Pressure Setting
In order to determine the proper pressure setting for the collision sensor one must consider
all static and dynamic loads to which it is subjected. These include the loads produced due to
the static weight of the tooling, the inertial loads imposed by robot motion and the loads
produced by the end-effector when performing its intended tasks. Once these loads are
calculated the nominal pressure setting for the break-away point can be determined. The
calculation proceeds as follows:
3.4.1.1 Calculate Applied Loads:
Figure 3.5 can be used to convert the forces acting on the end-effector tooling
into the resulting moment, torque, and axial loads applied to the Protector. Use
the diagram shown in Figure 3.5 and the formulas below to calculate the worst-
case applied loads for your application. All three load cases—Axial, Torque, and
Moment—should be assessed for their Static, Dynamic, and Working force
components.
Note: Not all of the component forces (Static, Dynamic, and Working) are
present during all phases of the robot program. As a result, the worst case
conditions for Axial, Torque, and Moment loads may occur at different times in
the program.
Figure 3.5—Collision Sensor Loading Diagram

Protector Installation & Operation Manual
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Formulas:
Axial Load (F) = F2
Torque (T) = F3*D3
Moment(M)=
Notes:
F1, F2, & F3 consist of the sum of their respective Static, Dynamic, and Working force
components; and should always be positive for purposes of calculating break-away pressure
settings.
D1 should include the distance from the end of the stem to the internal pivot point on the
collision sensor (.75” or 18.9mm on an SR-61) and the thickness of the tooling side interface
plate (.47” or 12mm on an SR-61 with optional blank interface plate).
a. Static Force: The load applied by tooling weight while the robot arm is idle. This
includes the weight of all parts attached to the Protector, acting at the assembly’s center
of gravity along the direction of gravity.
b. Dynamic Force: The inertial force imposed at the center of gravity of the tooling due to
acceleration of the robot arm. This force acts in the direction opposite of motion.
Dynamic forces are additive to static forces and must be carefully considered to ensure
proper sizing of the protector.
c. Working Force: Forces are generated at the tool-tip under normal working conditions. If
these forces and their location are known, they can be converted into loads on the
Protector using the same technique.
3.4.1.2 Obtain required pressure setting
The pressure setting required can be approximated from the following formula:
P = Pm + Pt + Pf + PmA+ PtA
Where Pm, Pt, and Pf are the pressure components related to the moment, torque,
and force load components expected at the break-away. PmAand PtAare the
dynamic versions of Pm and Pt. Dynamic forces from axial loading can usually
be ignored since the robot is usually not accelerating in the axial direction. Pm,
Pt, and Pf are calculated using the following formulas, where M, T, and F are the
expected loads at the set pressure break-away:
English Units: lb-in, psi, lb Metric Units: N-m, Bar, N
Pm = (M x 0.376) – 3.3 Pm = (M x 0.2294) – 0.2
Pt = (T x 0.444) – 6.3 Pt = (T x 0.2708) – 0.4
Pf = F x 0.462 Pf = F x 0.00719
PmAand PtAare calculated using the following formulas where A is the
maximum acceleration in gravities (G’s):
English Units: lb-in, psi, G’s Metric Units: N-m, Bar, G’s
Pm = (M x 0.376 x A) – 3.3 Pm = (M x 0.2294 x A) – 0.2
Pt = (T x 0.444 x A) – 6.3 Pt = (T x 0.2708 x A) – 0.4
Example: For an SR-61 with a static moment load of 50 lb-in, a static torque
load of 30 lb-in, no axial load, and an acceleration of 2 G’s, the pressure setting
is calculated as follows:
√(F1*D1)2+ (F2*D2)2

Protector Installation & Operation Manual
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P = [(50 lb-in x 0.376) – 3.3) + (30 lb-in x 0.444) – 6.3] + [(50 lb-in x 0.376 x
2G’s) – 3.3]
= 15.5 psi + 7 psi + 34.3 psi
= 56.8 psi
A nominal air pressure setting of 57 psi is required.
Notes:
1. If the calculated pressure required is above 90 psi do not install the unit.
Contact ATI to determine the correctly sized collision sensor model for the
application.
2. If the unit is equipped with P05 (5 psi equivalent), P10 (10 psi equivalent, or
P15 (15 psi equivalent) preload spring, subtract this pressure to determine
the actual pressure to be supplied.
3.4.2 Determining Exact Pressure Required:
1. Set the pressure approximately 5 psi (0.3 Bar) higher than the pressure calculated in
procedure 3.1.
2. Run the robot through a fully loaded cycle.
3. Watch for crash signals.
If the collision sensor does not generate a crash signal (open circuit) slightly reduce the
pressure until a crash signal is generated and then increase the pressure slightly until the
unit runs without false crash signals.
If the collision sensor does generate a crash signal increase the pressure slightly until the
unit runs without false crash signals.
Note: If the pressure required is above 90 psi remove the unit from service and contact
ATI to determine the correctly sized collision sensor model for this application.
4. Operation
With the Protector™mounted and connected pneumatically and electrically the unit may be placed into
operation. If possible, for safety and convenience, position the Protector™and the tooling vertically so that
the load is suspended below the Protector™. Apply low-pressure air (2–15psi, 0.15–1bar) to the unit.
Gradually increase the air pressure until the desired working pressure is applied.
In operation, the Protector™should be supplied with the minimum air pressure necessary to allow
continuous, un-interrupted operation of the unit. Nuisance collision detections caused by high accelerations
and unanticipated loads will occur if the air pressure is too low. The magnitude of overhung loads, robot
accelerations, and applied loads prevent ATI from recommending air pressure settings. Where high robot
accelerations are anticipated the user may wish to supply the Protector™with electronically variable or
multiple, switchable air supplies. Alternatively, where working loads are small the Protector™may be
outfitted with auxiliary springs and supplied with high-pressure air only during robot moves. Using these
techniques, the Protector™may be supplied with higher air pressure when higher loads or accelerations are
anticipated.
CAUTION: Use of pressures in excess of 90 psi can result in excessive
damage to the unit in the event of a crash and voids the warranty.
!

Protector Installation & Operation Manual
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14
5. Maintenance
5.1 General
The Protector™is a reliable device fabricated using heavy-duty components. In normal operation
the unit requires no maintenance if proper air quality and pressures are maintained. Service kits are
available in the event that the Nano connector or collision sensing switch becomes damaged.
Proper collision sensing should be verified on a regular basis. This can be scheduled twice a year or
as a part of any robot or work cell preventative maintenance activities.
In applications where a high number of collisions occur on a regular basis, the life of the Protector™
can be extended with periodic maintenance. Partial disassembly allows the unit to be cleaned, re-
greased, and reassembled without special tools or adjustment procedures. Such maintenance work
should be conducted every 5,000 or fewer collisions.
5.2 Replacement of Switch/Connector Block Assembly
5.2.1 Removal
1. Remove the mounting screw using a 2.5mm hex key (see Figure 5.1).
2. Pull the Connector Block away from the Protector™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 5.1—Removal of Switch/Connector Block Assembly from the Protector™
CAUTION: Do not adjust or remove either of the two (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. See Figure 5.4.
!
CAUTION: In all instances where the Protector™is to be examined, installed,
or removed from service, insure that air pressure has been vented from the
unit, that electrical current is not supplied to the Protector’s™signal circuit, and
that the robot is in a safe, locked-out, condition consistent with local and
national safety standards.
!

Protector Installation & Operation Manual
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15
5.2.2 Replacement
1. Provide 5 to 15 psi of air to the unit at the port marked “P” (unless the unit is
equipped with preload springs).
2. Screw the new proximity switch clockwise into the hole on the side of the body until
it bottoms.
3. Rotate the connector block along with the proximity switch to prevent damage to the
wires.
4. Screw the proximity switch out 1 turn (counterclockwise).
5. Perform switch adjustment per section 3.3.1.
6. Press the Connector Block Assembly firmly against the body of the Protector™while
tightening the screw. When tightened securely, the Connector Block Assembly should
rest parallel to its mounting surface.
5.3 Periodic Lubrication Instructions
5.3.1 Disassembly
Note: Cleaning may be accomplished with a clean, dry rag. For more thorough cleaning, use
isopropyl alcohol.
1. Remove the four (4) socket head cap screws securing the Cover Plate assembly to the
Body using an M3 hex key (see Figure 5.3).
CAUTION: Do not attempt to pry or wedge the Cover Plate assembly and Body
apart. Doing so can damage the mating surfaces and may render the parts
unusable.
!
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.
!
CAUTION:
Figure 5.2—Piston location during proximity switch installation
!
CAUTION: Turning the proximity switch without turning the connector block more
than 180ocould result in damage to the proximity switch wires.
!

Protector Installation & Operation Manual
Document #9610-60-1006-10
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16
2. Remove the Cover Plate assembly by carefully pulling it straight up and off of the
Body. This may be difficult due to the close fit of the dowel pins used to align the
parts. It may be necessary to hold the unit up by the Cover Plate and lightly tap on the
Stem with a rubber or plastic mallet. Note: The dowel pins are pressed into the Cover
Plate and are a slip fit into the Body.
Figure 5.3—Disassembly of Cover Plate
3. Clean the lubricant from the working surfaces of the Cam and the Clearance Ring. Set
the Cover Plate assembly aside for later re-use (see Figure 5.4).
4. Remove the Stem assembly and clean the lubricant from the working surfaces of the
ball segments and the Stem. Set the Stem assembly aside for later re-use (see Figure
5.5).
5. Clean the lubricant from the top surface of the Piston (see Figure 5.6).
Figure 5.4—Cleaning and Re-lubricating the Cover Plate Assembly
CAUTION: The Cover Plate assemblies and Stem assemblies are factory
assembled as matched parts. Do not allow either of these assemblies to be mixed
with those from other units.
!

Protector Installation & Operation Manual
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Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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Figure 5.5—Cleaning and Re-lubricating the Stem
Figure 5.6—Cleaning and Re-lubricating Top Surface of Piston
5.3.2 Re-assembly
1. Apply a generous coating of CRC Extreme Pressure Moly C.V. Joint Grease (Moly
Grease) to the top surface of the Piston (see Figure 5.6).
2. Apply a generous coat of Moly Grease to each of the three (3) ball segments on the
Stem Assembly and to the rounded edge of the shoulders between the ball segments.
Apply a layer of Moly Grease to the flat underneath surface of the Stem (see Figure
5.5).
3. Apply a generous coat of Moly Grease to each of the three (3) v-grooves in the Cam
and to the rounded edge of the Clearance Ring (see Figure 5.4).
4. With the Stem assembly upright, set the Cover Plate assembly onto it. Make certain
that the alignment grooves are lined up (see Figure 5.7).
5. Place the Stem and Cover Plate together onto the Body. Make certain that the
alignment grooves in the Plate and the Stem are still lined up (see Figure 5.7).
6. Press the Cover Plate down onto the Body.
7. Apply Loctite®222MS to the four (4) socket head cap screws and thread them into
the Body. Tighten the screws securely.

Protector Installation & Operation Manual
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Figure 5.7—Cover Plate and Stem Alignment
5.4 Spring Conversion
The collision sensor may be equipped with an assist spring which provides a force equivalent to 5
psi (P05), 10 psi (P10) or 15 psi (P15) of applied pressure. An SR-61 may be field converted to add
an assist spring or to contain a different range spring.
5.4.1 Disassembly
1. Remove Cover Plate assembly and Stem assembly per section 5.3.1.
2. Remove the two (2) M4 dog point setscrews using an M2.5 hex key (see Figure 5.7).
(If unit is equipped with an assist spring, temporarily place the Stem assembly on top
of the Piston and push down while removing the setscrews.)
3. Remove the Stem assembly, Piston assembly and assist spring (if present).
5.4.2 Re-assembly
1. Place the new assist spring into the counter bore in the body.
2. Place the Piston assembly in the Body, orienting the notches in the ribs on the piston
with the screw holes in the body and the Switch Target with the Proximity Switch
(see Figure 5.8).
3. Temporarily place the Stem assembly on top of the Piston assembly.
4. Apply Loctite® 222MS to the two (2) M4 dog point setscrews.
5. Push the Piston assembly down until its main surface is below the step in the body
bore and hold in place. (An arbor press may be used for this purpose.)
6. Screw the two (2) M4 dog point setscrews clockwise until they touch the piston and
then counterclockwise one turn.
7. Remove the Stem assembly.
8. Replace the Cover Plate assembly and Stem assembly per section 5.3.2.

Protector Installation & Operation Manual
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19
Figure 5.8—Piston Orientation
5.5 Seal Replacement
5.5.1 Disassembly
1. Disassemble Cover assembly and Stem Assembly per section 5.3.1.
2. Disassemble Piston per section 5.4.1.
3. Remove and discard o-ring from groove on outside of Piston.
4. Remove and discard u-cup from groove in center bore of Piston.
5.5.2 Re-assembly
1. Apply Magnalube-G (Teflon/Petroleum base grease) to the new o-ring and u-cup.
2. Apply Magnalube-G to the body bore and post.
3. Assemble the new o-ring to the outer piston groove.
4. Assemble the new u-cup in the groove in the center bore of the piston making certain
that the grooved end faces the plain round end of the piston (see Figure 5.9).
4. Re-assemble Piston per section 5.4.2.
5. Re-assemble Stem Assembly and Cover Assembly per section 5.3.2.
Figure 5.9—U-cup Orientation

Protector Installation & Operation Manual
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20
5.6 IP65 Boot Replacement
5.6.1 Disassembly
1. Remove four (4) M3 x 6 SFHCS and Shield Retainer (see figure 5.10).
2. Remove Boot and discard.
3. Use a clean cloth soaked in isopropyl alcohol to remove gasket sealer from the Stem
and Cover Plate.
5.6.2 Re-assembly
1. Apply Permatex® Grade 2 gasket sealer to top of Stem below flange and to center
band of Cover Plate (see Figure 5.10).
2. Install new Boot by stretching the center hole over the Stem. Line up the screw holes
and clearance slots with those in the Cover Plate.
2. Place the Boot Retainer on top of the Boot. Line up the screw holes and clearance
slots.
4. Apply Loctite® 222MS to threads of (4) M3 x 6 SFHCS and install through Boot
Retainer and Boot into Cover Plate. Tighten until Boot is slightly compressed.
Figure 5.10—IP65 Boot Replacement
5.7 Weld Splatter Shield Replacement
5.7.1 Disassembly
1. Remove four (4) M3 x 6 SFHCS and Shield Retainer (see Figure 5.11).
2. Remove Weld Shield and EPDM Seal and discard.
5.7.2 Re-assembly
1. Install new EPDM Seal by stretching the center hole over the Stem.