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 • Email: [email protected]
Protector™
Robotic Collision Sensor
SR-61 Manual
U.S. Patent Nos. 6069415 and 6690208
Document #: 9610-60-1006-13

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
2
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 by ATI Industrial Automation. All rights reserved.
How to Reach Us
Sale, Service and Information about ATI products:
ATI IndustrialAutomation
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, Option 2
Fax: [phone]
E-mail: [email protected]

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
3
Table of Contents
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 Replacement of Switch/Connector Block Assembly ...............................................................20
6.2.1 Replacement of Original Style Switch/Connector Block Assembly ..................................21
6.2.2 Replacement of Current Style Switch/Connector Block Assembly...................................22
6.3 Switch Adjustment......................................................................................................................23
6.3.1 Original Style Switch Adjustment......................................................................................23
6.3.2 Current Style Switch Adjustment......................................................................................24
6.4 Spring Conversion......................................................................................................................26
6.5 Seal Replacement........................................................................................................................27
6.6 IP65 Boot Replacement ..............................................................................................................28
6.7 Weld Splatter Shield Replacement............................................................................................29
6.8 Flexible Boot Replacement ........................................................................................................30

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
4
7. Specications ......................................................................................................................... 31
8. Serviceable Parts ................................................................................................................... 31
8.1 SR-61 with C5 Boot.....................................................................................................................31
9. Drawings ................................................................................................................................. 32
9.1 SR-61 Collision Sensor with Original Style Switch..................................................................32
9.2 SR-61 Collision Sensor with Current Style Switch ..................................................................33
10. Terms and Conditions of Sale............................................................................................... 35

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
5
Glossary of Terms
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 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.
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.

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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 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 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 Protector system. Failure to do so may result in damage to
equipment or injury to personnel.

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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
Protector’s signal circuit, and that the robot is in a safe, locked-out condition consistent
with local and national safety standards before performing maintance 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 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 5.5.

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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2. Product Overview
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.
2.1 Product 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 8mm connector is mounted on the side of the Protector body. The user connects to the switch using the
8mm 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
Pneumatic Port
Body
8mm Connector
Switch/Connector
Block Assembly
Cover Plate
Stem

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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3. Installation
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.
3.1 Mechanical Installation
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 specic applications. Another option is for
the user to fabricate their own interface plates.
NOTICE:ThesurfacetowhichtheProtector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 Protector using hardware
appropriately sized for the application. Connect an appropriately sized air line and tting to the Protector.
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 equivilantM4-0.7 Cap Screw 41 in-lbs
M5-0.8 Cap Screw 85 in-lbs.

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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3.2 Electrical Connection
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 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 10–30 VDC.
Figure 3.2—Switch Wiring

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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3.2.1 Test Switch Functionality
Once the Protector has been installed and connected as described in the preceding paragraphs,
proper electrical operation of the unit may be conrmed.
Supply the Protector 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 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 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 Protector requires clean, dry, non-lubricated air delivered from a user-supplied, self-relieving
regulator. The Protector 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 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.
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sufcienttore-seattheProtector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 Protector. Use the diagram
shown in Figure 3.3 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.
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, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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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 18.9mm 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.

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
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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, Protector™,SR-61
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Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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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, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
15
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 outtted 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.

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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 Protector’s signal
circuit, and that the robot is in a safe, locked-out condition consistent with local and national
safety standards before performing maintance or repair on the Collision Sensor.
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 8mm
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 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.
5.1 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 four (4) socket head cap screws securing the Cover Plate assembly to the Body
using an M3 hex key (see Figure 5.1).
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, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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 (see Figure 5.2).
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 (see Figure 5.3).
3. Clean the lubricant from the top surface of the Piston (see Figure 5.4).
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, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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 (see Figure 5.4).
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 at underneath surface of the Stem (see Figure 5.3).
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 5.2).
4. With the Stem assembly upright, set the Cover Plate assembly onto it. Make certain that the
alignment grooves are lined up (see Figure 5.5).
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 5.5).
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.
Figure 5.5—Cover Plate and Stem Alignment

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
19
6. Troubleshooting
The Protector will offer exceptional performance in normal operation. However, the Protector is not a compliance
device and frequent collisions should be avoided to maximize performance and life. The Protector 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 Protector still fails to reset or if the switch fails to close after adjustment 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 protector from free
motion.
Ensure that there are no obstructions either on or around the
tooling or the stem of the Protector. Pay particular attention to
cables and tubing that may become trapped or snagged.
Airsupplyinsufcient
or nonexistant. 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 Protector will
experience excessive nuisance collision sensings and fail to reset.
O-ring or U-cup seals
worn Check to see 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 6.5—Seal
Replacement.
Improper cover and
stem alignment from
maintenance or repair
Check to see if the scribe lines on the Protector cover plate
and stem are aligned or at a 120° off of alignment. If aligned or
slightly missaligned 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 see if the scribe lines on the Protector cover plate and stem are aligned and the mounting surfaces of the body and stem
must be parallel. If slightly missaligned or mounting surface is not
parallel contact ATI.
Open circuit
with unit
reset
Control wiring
damaged. Disconnect the cable from the Protector 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 Protector and use a test box connected per Figure 3.2onthe8mmconnectortoconrmthatthe
switch is closed when the Protector is in the working position. If the
switch is not closed replace, refer to Section 6.2—Replacement of
Switch/Connector Block Assembly.
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 6.6—IP65 Boot Replacement, or Section 6.7—Weld
Splatter Shield Replacement or Section 6.8—Flexible Boot
Replacement.

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
20
6.1 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).
Table 6.1—Cable choices
XX Cable Number Description
BN --- No cable purchased with Protector – 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
6.2 Replacement of Switch/Connector Block Assembly
There are two 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 6.1.
Figure 6.1—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 replacing an original style switch, refer to Section 6.2.1—Replacement of Original Style Switch/Connector
Block Assembly
If replaceing a current style switch, refer to Section 6.2.2—Replacement of Current Style Switch/Connector
Block Assembly