ATI Technologies SR-61 User manual

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 Manual
U.S. Patent Nos. 6069415 and 6690208
Document #: 9610‑60‑1006

Manual, Collision Sensor,SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
2
Forward
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. Failure to read and understand the information in this manual may result in
damage to equipment or injury to personnel.
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 reect and incorporate changes made to the product.
The information contained herein is condential 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 tness 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 2019 by ATI Industrial Automation. All rights reserved.
How to Reach Us
Sale, Service and Information about ATI products:
ATI Industrial Automation
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati‑ia.com
Tel: [phone]
Fax: [phone]
Application Engineering
Tel: [phone], Option 2, Option 2
Fax: [phone]
E‑mail: mech_support@ati‑ia.com

Manual, Collision Sensor, SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
3
Table of Contents
Forward ............................................................................................................................................ 2
Glossary........................................................................................................................................... 5
1. Safety......................................................................................................................................... 6
1.1 ExplanationofNotications.........................................................................................................6
1.2 General Safety Guidelines............................................................................................................6
1.3 Safety Precautions........................................................................................................................7
2. Product Overview..................................................................................................................... 8
2.1 Product Description......................................................................................................................8
3. Installation ................................................................................................................................ 9
3.1 Mechanical Installation.................................................................................................................9
3.1.1 FastenerTorqueSpecications ..........................................................................................9
3.2 Electrical Connection..................................................................................................................10
3.2.1 Test Switch Functionality.................................................................................................. 11
3.3 Pneumatic Connection ............................................................................................................... 11
3.3.1 Operating Requirements.................................................................................................. 11
3.3.2 Calculating Estimated Pressure Setting........................................................................... 11
3.3.2.1 Calculate Applied Loads ................................................................................... 11
3.3.2.2 Obtain Required Pressure Setting....................................................................13
3.3.3 Determining Exact Pressure Required.............................................................................14
4. Operation ................................................................................................................................ 15
5. Maintenance............................................................................................................................ 16
5.1 Periodic Lubrication Instructions..............................................................................................16
5.1.1 Cover Plate and Stem Disassembly.................................................................................16
5.1.2 Cover Plate and Stem Cleaning and Lubrication .............................................................17
5.1.3 Cover Plate and Stem Re‑assembly................................................................................18
6. Troubleshooting ..................................................................................................................... 19
6.1 Cable Replacement.....................................................................................................................20
6.2 Spring Conversion......................................................................................................................21
6.3 Seal Replacement........................................................................................................................22
6.4 IP65 Boot Replacement ..............................................................................................................23
6.5 Weld Splatter Shield Replacement............................................................................................24
6.6 Flexible Boot Replacement ........................................................................................................25
7. Specications ......................................................................................................................... 26
8. Serviceable Parts ................................................................................................................... 26
8.1 SR‑61 with C5 Boot.....................................................................................................................26

Manual, Collision Sensor,SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
4
9. Drawings ................................................................................................................................. 27
9.1 SR‑61 Collision Sensor with Original Style Switch..................................................................27
9.2 SR‑61 Collision Sensor with Current Style Switch ..................................................................28
10. Terms and Conditions of Sale............................................................................................... 30
6.1 Cable Replacement.....................................................................................................................20
6.2 Spring Conversion......................................................................................................................21
6.3 Seal Replacement........................................................................................................................22
6.4 IP65 Boot Replacement ..............................................................................................................23
6.5 Weld Splatter Shield Replacement............................................................................................24
6.6 Flexible Boot Replacement ........................................................................................................25
7. Specications ......................................................................................................................... 26
8. Serviceable Parts ................................................................................................................... 26
8.1 SR‑61 with C5 Boot.....................................................................................................................26
9. Drawings ................................................................................................................................. 27
9.1 SR‑61 Collision Sensor with Original Style Switch..................................................................27
9.2 SR‑61 Collision Sensor with Current Style Switch ..................................................................28
10. Terms and Conditions of Sale............................................................................................... 30

Manual, Collision Sensor, SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
5
Glossary
Term Denition
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 Collision Sensor body.
Crash The result of a disturbance that displaces the Collision Sensor components from
their standard, working position.
Interface Plate Optional component used to adapt the Collision Sensor body or stem to the
user’s robot or tooling.
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 Collision Sensor 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.

Manual, Collision Sensor,SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
6
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 were 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, SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
7
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.
Refer to Figure 5.5.

Manual, Collision Sensor,SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
8
2. Product Overview
The Collision Sensor is a pneumatically‑pressurized device offering protection to industrial robots and tooling in
the event of accidental impacts and unanticipated loads. The Collision Sensor 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 Collision Sensor cannot respond to pure axial tension, which is an unlikely mode of loading. Removal of
the upsetting force or moment allows the Collision Sensor to return to its normal working position.
As a collision occurs, internal motion of the Collision Sensor 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 Collision Sensor breaks away is adjustable by controlling the air
pressure supplied to the unit.
All Collision Sensor devices provide axial (compression only), torsional, and moment compliance.
2.1 Product Description
The Collision Sensor 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
8 mm connector is mounted on the side of the Collision Sensor body. The user connects to the switch using
the 8 mm connector for which a variety of cables are available. The user must also supply the Collision
Sensor with dry, regulated, compressed air through a port on the side of the Collision Sensor body. The size
and location of these connections are shown in the drawing provided at the end of this manual.
Figure 2.1—Collision Sensor Collision Sensor
Pneumatic Port
Body
8mm Connector
Switch/Connector
Block Assembly
Cover Plate
Stem

Manual, Collision Sensor, SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
9
3. Installation
The Collision Sensor is commonly mounted with its body toward the robot and its stem toward the user tooling,
however, this is strictly up to the user.
3.1 Mechanical Installation
The Collision Sensor can be mounted directly to the robot or to the user tooling using the dowel pin holes
and the clearance / tapped holes in the Collision Sensor body. Should this not be possible, an interface plate
must be fabricated.
A second interface plate is often required for mounting to the Collision Sensor stem. Such interface plates
may be ordered from ATI as blank plates or machined as necessary for specic applications. Another option
is for the user to fabricate their own interface plates.
NOTICE: ThesurfacetowhichtheCollisionSensorbodyismountedmustbeatandsmooth
and provide support for the entire surface of the body.
Once any required machining of the interface plates is complete, mount the Collision Sensor using
hardware appropriately sized for the application. Connect an appropriately sized air line and tting to the
Collision Sensor.
NOTICE: 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, refer to Section 3.1.1—Fastener Torque Specications.
Figure 3.1—Installation
Switch Connector
SR-61 Collision Sensor
Optional Interface Plate (Body)
Custom Interface plates available from ATI
Optional Interface Plate (Stem)
Custom Interface plates available from ATI
Mounting Fasteners
Customer Supplied
M4 Mounting Fasteners (Customer Supplied)
(ATI Supplied with custom Interface Plates)
M4 Mounting Fasteners (Customer Supplied)
(ATI Supplied with custom Interface Plates)
(2) Dowel Pins (Customer Supplied)
(ATI Supplied with custom Interface Plates)
Dowel Pin (Customer Supplied)
(ATI Supplied with custom Interface Plates)
Pneumatic Port
3.1.1 FastenerTorqueSpecications
Table 3.1—Recommended Torques for ATI Supplied Fasteners
Fastener Size Torque Recommended Thread Locker
M3‑0.5 Cap Screw 19 in‑lbs Loctite 222 or equivalentM4‑0.7 Cap Screw 41 in‑lbs
M5‑0.8 Cap Screw 85 in‑lbs.

Manual, Collision Sensor,SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
10
3.2 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 (refer to Table 6.1), 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 3.2—Switch Wiring

Manual, Collision Sensor, SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
11
3.2.1 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 3.2. 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.
3.3 Pneumatic Connection
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 M5 pneumatic ttings. The pressure setting required for a particular application can be estimated
using the procedure outlined in Section 3.3.2—Calculating Estimated Pressure Setting The exact pressure
required must be determined through testing using the procedure outlined in Section 3.3.3—Determining
Exact Pressure Required.
3.3.1 Operating Requirements
The Collision Sensor requires clean, dry, non‑lubricated air delivered from a user‑supplied,
self‑relieving regulator. The Collision Sensor is certied for accurate and 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
Collision Sensor is equipped with a collision sensing switch. When the Collision Sensor is in the
collision mode or the electrical cable to the switch is disconnected an open circuit is generated.
Proper sizing of the Collision Sensor 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.
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 Collision Sensor. When the
pneumatically‑suppliedforceissufcienttore‑seattheCollisionSensorthe
tooling will move to its working position.
3.3.2 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:
3.3.2.1 Calculate Applied Loads
Figure 3.3 can be used to convert the forces acting on the end‑effector tooling into
the resulting moment, torque, and axial loads applied to the Collision Sensor. Use
the diagram shown in Figure 3.3 and the formulas below to calculate the worst‑case
applied loads for your application. All (3) load cases—axial, torque, and moment—
should be assessed for their static, dynamic, and working force components.
NOTICE: 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.

Manual, Collision Sensor,SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
12
Figure 3.3—Collision Sensor Loading Diagram
Formulas:
Axial Load (F) = F2
Torque (T) = F3*D3
Moment (M) =
NOTICE:
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 18.9 mm on an SR‑61) and the
thickness of the tooling side interface plate (.47” or 12 mm 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 Collision Sensor,
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 Collision Sensor.
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 Collision Sensor using the same technique.

Manual, Collision Sensor, SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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3.3.2.2 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. PmA and PtA are 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
PmA and PtA are 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:
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.
NOTICE:
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.
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.

Manual, Collision Sensor,SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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3.3.3 Determining Exact Pressure Required
1. Set the pressure approximately 5 psi (0.3 Bar) higher than the pressure calculated in
Section 3.3.2—Calculating Estimated Pressure Setting.
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.
NOTICE: 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.
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.

Manual, Collision Sensor, SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
15
4. Operation
With the Collision Sensor mounted and connected pneumatically and electrically the unit may be placed into
operation. If possible, for safety and convenience, position the Collision Sensor and the tooling vertically so that the
load is suspended below the Collision Sensor. 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 Collision Sensor should be supplied with the minimum air pressure necessary to allow continuous,
uninterrupted 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 Collision Sensor with electronically variable or multiple, switchable air supplies.
Alternatively, where working loads are small the Collision Sensor may be outtted with auxiliary springs and
supplied with high‑pressure air only during robot moves. Using these techniques, the Collision Sensor may be
supplied with higher air pressure when higher loads or accelerations are anticipated.

Manual, Collision Sensor,SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
16
5. Maintenance
WARNING: Do not perform maintenance or repair on the Collision Sensor with air pressure
applied, current supplied to the sensor, or the robot in an unsafe 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.
The Collision Sensor 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 8 mm connector or collision sensing switch becomes damaged.
Proper collision sensing should be veried on a regular basis. This can be scheduled twice a year or as a part of any
robot or work cell preventive maintenance activities.
In applications where a high number of collisions occur on a regular basis, the life of the Collision Sensor 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.
5.1 Periodic Lubrication Instructions
5.1.1 Cover Plate and Stem Disassembly
Note: Cleaning may be accomplished with a clean, dry rag. For more thorough cleaning, use
isopropyl alcohol.
1. Remove the (4) socket head cap screws securing the cover plate assembly to the body using an
M3 hex key (refer to Figure 5.11).
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.
2. Remove the cover plate assembly by carefully pulling it straight up and off of the body. This
may be difcult due to the close t 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 t into the body.
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.
Figure 5.1—Disassembly of Cover Plate

Manual, Collision Sensor, SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
17
5.1.2 Cover Plate and Stem Cleaning and Lubrication
1. Clean the lubricant from the working surfaces of the cam and the clearance ring. Set the cover
plate assembly aside for later re‑use (refer to Figure 5.22).
2. 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 (refer to Figure 5.33).
3. Clean the lubricant from the top surface of the piston (refer to Figure 5.44).
Figure 5.2—Cleaning and Re‑lubricating the Cover Plate Assembly
Figure 5.3—Cleaning and Re‑lubricating the Stem
Figure 5.4—Cleaning and Re‑lubricating Top Surface of Piston

Manual, Collision Sensor,SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
18
5.1.3 Cover Plate and Stem 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 (refer to Figure 5.44).
2. Apply a generous coat of moly grease to each of the (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 at underneath surface of the stem (refer to Figure 5.33).
3. Apply a generous coat of moly grease to each of the (3) v‑grooves in the cam and to the
rounded edge of the clearance ring (refeFigure 5.22).
4. With the stem assembly upright, set the cover plate assembly onto it. Make certain that the
alignment grooves are lined up (refer to Figure 5.55).
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 (refer to Figure 5.55).
6. Press the cover plate down onto the body.
7. Apply Loctite® 222MS to the (4) socket head cap screws and thread them into the body. Tighten
the screws securely.
Figure 5.5—Cover Plate and Stem Alignment

Manual, Collision Sensor, SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
19
6. Troubleshooting
The Collision Sensor will offer exceptional performance in normal operation. However, the Collision Sensor is not
a compliance device and frequent collisions should be avoided to maximize performance and life. The Collision
Sensor is designed to automatically return to its working position once the disturbing force is removed. Should this
fail to happen the following examinations should be performed to verify proper operation of the unit.
If the Collision Sensor still fails to reset or if the switch fails to close when the unloaded unit is in its working
condition, contact ATI.
Symptom Cause Resolution
Unit fails
to return to
its working
position
Mechanical
obstruction preventing
the Collision Sensor
from free motion.
Ensure that there are no obstructions either on or around the
tooling or the stem of the Collision Sensor. Pay particular attention
to cables and tubing that may become trapped or snagged.
Airsupplyinsufcient
or nonexistent.
Check the supply air pressure. Ensure that the supply air pressure
issufcienttosupporttheloadsplacedupontheunit.Referto
Section 3.3.2—Calculating Estimated Pressure Setting for more
information. If the supply pressure is too low the Collision Sensor
will experience excessive nuisance collision sensing and fail to
reset.
O‑ring or u‑cup seals
worn
Check to refer to if there is air pressure loss due to air escaping
past O‑ring or u‑cup seals. Air leak may be detectable from
air leaking past stem. If air is leaking replace seals, refer to
Section 6.3—Seal Replacement.
Improper cover and
stem alignment from
maintenance or repair
Check to refer to if the scribe lines on the Collision Sensor cover
plate and stem are aligned or at a 120° off of alignment. If aligned
or slightly misaligned refer to Internal component damage. If
120° out of alignment refer to Section 5.1.1—Cover Plate and
Stem Disassembly and Section 5.1.3—Cover Plate and Stem
Re‑assembly to correct stem alignment.
Internal component
damage
Check to refer to if the scribe lines on the Collision Sensor cover
plate and stem are aligned and the mounting surfaces of the
body and stem must be parallel. If slightly misaligned or mounting
surface is not parallel contact ATI.
Open circuit
with unit
reset
Control wiring
damaged.
Disconnect the cable from the Collision Sensor and check
the continuity of the cable. If damaged replace cable, refer to
Section 6.1—Cable Replacement. If not damaged examine the
system for logic problems.
Switch is not
functioning
Disconnect the cable from the Collision Sensor and use a test box
connected per Figure 3.2onthe8mmconnectortoconrmthat
the switch is closed when the Collision Sensor is in the working
position. If the switch is not closed replace, contact ATI.
Excessive
force required
todeect
stem
Regulator set at too
high a pressure Lower pressure setting.
Regulator is not
self‑relieving. Replace regulator with self‑relieving regulator.
Optional Equipment
Optional boot
or EPDM
seal leaking Boot damaged
Inspect the boot for tears or damage replace if damaged. Refer
to Section 6.4—IP65 Boot Replacement, or Section 6.5—Weld
Splatter Shield Replacement or Section 6.6—Flexible Boot
Replacement.

Manual, Collision Sensor,SR‑61
Document #9610‑60‑1006‑14
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
20
6.1 Cable Replacement
If the cable attached to your Collision Sensor becomes broken or worn, replacement cables may be
purchased as follows:
Collision Sensor model number: 9610‑061‑Pxx‑XX‑x‑x‑x (x = any value).
Table 6.1—Cable Choices
XX Cable Number Description
BN ‑‑‑ No cable purchased with Collision Sensor – choose one of
the following replacement cables
BB 8590‑9909999‑15 High‑excablewithstraightscrew‑onconnector,5M
(16.4ft.)longwithyingleads
BC 8590‑9909999‑06 High‑excablewith90ºsnap‑onconnector,5M(16.4ft.)
longwithyingleads
BD 8590‑9909999‑89 High‑excablewith90ºscrew‑onconnector,10M(32.8ft.)
longwithyingleads
BE 8590‑9909999‑116 High‑excablewith90ºscrew‑onconnector,5M(16.4ft.)
longwithyingleads
BT 8590‑9909999‑48 High‑excablewithstraightsnap‑onconnector,5M
(16.4ft.)longwithyingleads
BU 8590‑9909999‑07 High‑excablewithstraightsnap‑onconnector,10M
(32.8ft.)longwithyingleads