ATI Technologies SR-81 User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: +1‑919.772.0115 • Fax: +1‑919.772.8259 • www.ati‑ia.com
Robotic Collision Sensor
SR‑81, SR‑101, SR‑131, SR‑176, SR‑221
Manual
U.S. Patent Nos. 6069415 and 6690208
Document #: 9610‑60‑1004

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
2
Foreword
Please contact ATI Industrial Automation with any questions concerning your particular model.
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.
©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]
Fax: [phone]
E‑mail: applicationsengineers@ati‑ia.com

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
3
Table of Contents
Foreword.......................................................................................................................................... 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 Electrical Connection..................................................................................................................12
3.1.1 Test Switch Functionality..................................................................................................12
3.2 Pneumatic Connection ...............................................................................................................13
3.2.1 Operating Requirements..................................................................................................13
3.2.2 Calculating Estimated Pressure Setting...........................................................................13
3.2.2.1 Calculate Applied Loads ...................................................................................13
3.2.2.2 Obtain Required Pressure Setting....................................................................15
3.2.3 Determining Exact Pressure Required.............................................................................15
4. Operation ................................................................................................................................ 16
5. Maintenance............................................................................................................................ 16
5.1 Periodic Lubrication Instructions..............................................................................................17
6. Troubleshooting and Service Procedures ........................................................................... 21
6.1 Troubleshooting..........................................................................................................................22
6.2 Service Procedures.....................................................................................................................23
6.2.1 Replacement of Connector Block Assembly ....................................................................23
6.3 Flexible Boot Replacement ........................................................................................................25
7. Specications ......................................................................................................................... 26
8. Serviceable Parts ................................................................................................................... 28
8.1 Cable Replacement.....................................................................................................................28

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
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9. Drawings ................................................................................................................................. 29
9.1 SR‑81............................................................................................................................................29
9.2 SR‑101..........................................................................................................................................31
9.3 SR‑131..........................................................................................................................................33
9.4 SR‑176..........................................................................................................................................35
9.5 SR‑221..........................................................................................................................................37
9.6 Collision Sensor Interface Plate Dowel Pin Insertion..............................................................39
10. Terms and Conditions of Sale............................................................................................... 40

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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Glossary
Term Denition
8 mm Connector 8 mm electrical connector mounted in block attached to the side of the body.
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 Sensing Switch A mechanical switch that changes state to an open circuit when a crash is
detected. It is mounted in the center of the body.
Collision The accidental impact between the end of arm tooling and some obstruction in
its path.
Cover Plate Disk‑shaped aluminum cover for Collision Sensor body.
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.

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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1. Safety
The safety section describes general safety guidelines to be followed with this product, explanation of the
notications found in this manual, and safety precautions that apply to the product. More specic notications are
imbedded within the sections of the manual where they apply.
1.1 ExplanationofNotications
The notications included here are specic to the product(s) covered by this manual. It is expected that the
user heed all notications from the robot manufacturer and/or the manufacturers of other components used
in the installation.
DANGER: Notication of information or instructions that if not followed will result in
death or serious injury. The notication provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
WARNING: Notication of information or instructions that if not followed could result
in death or serious injury. The notication provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
CAUTION: Notication of information or instructions that if not followed could result
in moderate injury or will cause damage to equipment. The notication provides
information about the nature of the hazardous situation, the consequences of not
avoiding the hazard, and the method for avoiding the situation.
NOTICE: Notication of specic information or instructions about maintenance, operation,
installation, or setup of the product that if not followed could result in damage to equipment. The
notication can emphasize specic grease types, good operating practices, or maintenance tips.
1.2 General Safety Guidelines
The Collision Sensor is not designed for, nor should it be used in, situations involving the safety of humans
or animals. The Collision Sensor is designed as a safety device to protect industrial components and
machinery from damage resulting from collisions and impacts. In all situations the user is responsible for
insuring that applicable safety practices are followed as outlined by the manufacturer of the equipment on
which the Collision Sensor is used.
The routing of electrical and pneumatic lines must minimize the possibility of stress, pullout, kinking,
rupture, etc. Failure of critical electrical and/or pneumatic lines to function properly may result in injury to
personnel and damage to equipment.
CAUTION: The customer should lock out and discharge all energy to the work cell prior
to working on any Collision Sensor system. Failure to do so may result in damage to
equipment or injury to personnel.

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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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 (3) 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 5.1.

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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2. Product Overview
The Collision Sensor is a pneumatically‑pressurized device oering 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 mounting of the Collision Sensor. 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 inside 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 connector for
which a variety of cables are available, refer to Section 8.1—Cable Replacement. The user must supply the
Collision Sensor with dry, regulated, compressed air through a port on the side of the Collision Sensor body.
Figure 2.1—Collision Sensor
3-Pin 8 mm Connector
Switch/Connector Block Assembly
Body
Pneumatic Port
Cover Plate
Stem

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
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3. Installation
The Collision Sensor is typically mounted with its body toward the robot and its stem toward the user tooling,
however this is up to the user.
The Collision Sensor can be mounted to the robot using an interface plate. A second interface plate may be required
for mounting the Collision Sensor stem to the tooling. Blank and custom interface plates are available from ATI.
Users may 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.
NOTICE: Do not supply air pressure at this time.
Dowel pins are required at all interfaces to minimize movement between components. Interface plates, supplied
by ATI, come with dowel pins and mounting bolts for attachment to the Collision Sensor. The dowel pins are press
t into the interface plates and slip t into the Collision Sensor. They are not typically installed prior to shipment.
Refer to drawing 9230‑60‑1150 in Section 9—Drawings for the proper depths to press these dowel pins into the
interface plates.
Table 3.1—Recommended Torques for ATI Supplied Fasteners
Fastener Size Torque Recommended Thread Locker
M5‑0.8 Cap Screw 45–60 in‑lbs. Loctite 222 or equivalent
M6‑1.0 Cap Screw 80–105 in‑lbs.
Loctite 242 or equivalent
M8‑1.25 Cap Screw 190 – 250 in‑lbs.
M10‑1.50 Cap Screw 390 – 520 in‑lbs.
M12‑1.75 Cap Screw 55 – 75 ft‑lbs.
Tools required: Variety of Allen wrenches (hex keys)
Supplies required: Loctite 222
1. Attach the robot interface plate to the robot ange, locate using the dowel pin. It is recommended to use thread
locking compound on all mounting fasteners. Refer to Table 3.1 for torque.
Figure 3.1—Install Robot Interface Plate
Mounting Fasteners
Supplied by Customer
Robot Interface Plate
Locating Dowel Pin
Robot Flange

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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NOTICE: The robot interface plate can be purchased from ATI or manufactured, refer
to Section 9—Drawings. The use of a robot interface plate supplied byATI is strongly
recommended.
2. Attach, locate using the dowel pin, the Collision Sensor to the robot interface plate using the (4)
mounting fasteners. All mounting hardware should be tightened. The use of thread locking compound is
recommended for all fasteners. Refer to Table 3.1 for torque.
Figure 3.2—Install the Collision Sensor to the Robot Interface Plate
Mounting Fasteners (Customer Supplied)
(ATI Supplied with Custom Interface Plate)
Collision Sensor
Robot Interface Plate
3. Attach, locate using the dowel pin, the tooling or tooling interface plate to the Collision Sensor using the
(4) mounting fasteners. All mounting hardware should be tightened. The use of thread locking compound
is recommended for all fasteners. Refer to Table 3.1 for torque.
Figure 3.3—Install the Tooling Interface Plate to the Collision Sensor Stem
Mounting Fasteners (Customer Supplied)
(ATI Supplied with Custom Interface Plate)
Collision Sensor
Optional Interface Plate (Stem)
(Custom Interface Plates Available from ATI)
Stem

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Document #9610‑60‑1004‑32
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4. Connect the pneumatic supply hose to the Collision Sensor and apply 10‑20 psi to raise the stem. Note:
This step is not required for Collision Sensors that are spring loaded.
NOTICE: SR‑81 and SR‑101 models are equipped with a #10‑32 or M5 x 0.8 air port
connection. SR‑131, SR‑176, and SR‑221 models are equipped with a 1/8” NPT air port
connection
Figure 3.4—Install the Pneumatic Supply Hose to the Collision Sensor
Pneumatic Connection
Collision Sensor

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
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3.1 Electrical Connection
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 125 mA (max.) at 28 V (max.) AC or DC.
The Collision Sensor is connected to the user’s control wiring as a normally‑closed mechanical 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 8.1), utilize the brown‑black‑blue color
code indicated.
Figure 3.5—Switch Wiring
All Models Produced 1/1/2018
and After
Models Produced prior to 1/1/2018
(Unless Otherwise Marked)
3.1.1 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 3.5. 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 o.
Release the Collision Sensor and it will return to its working position. The test light will illuminate.

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
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3.2 Pneumatic Connection
Compressed air is to be supplied to the port marked “P” in the range of 20‑90 psi (1.4–6.2 bar ). 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 3.2.2—Calculating Estimated Pressure Setting The
exact pressure required must be determined through testing using the procedure outlined in Section 3.2.3—
Determining Exact Pressure Required.
3.2.1 Operating Requirements
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 125 mA(max.) at
28 V (max.) AC or DC.
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 su󰀩cient to re‑seat the Collision Sensor the
tooling will move to its working position.
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 ) 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. The
15 psi (P15) spring is not available for the SR‑131 Collision Sensor.
3.2.2 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‑eector 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:
3.2.2.1 Calculate Applied Loads
Figure 3.6 can be used to convert the forces acting on the end‑eector tooling into
the resulting moment, torque, and axial loads applied to the Collision Sensor. Use
the diagram shown in Figure 3.6 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 di󰀨erent times
in the program.

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
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Figure 3.6—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‑81/SR‑101/SR‑131/SR‑176/SR‑221
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3.2.2.2 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.
3.2.3 Determining Exact Pressure Required
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.
1. Set the pressure approximately 5 psi (0.3 Bar) higher than the pressure calculated in
Section 3.2.2—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.

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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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 (2–15 psi, 0.15–1 bar) 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,
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 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.
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.
CAUTION: Do not adjust or remove any of the three (3) set screws installed in the wall of the
Body. Doing so may result in personal injury and/or damage to the unit. See Figure 5.1 below.
Figure 5.1—Set Screws
(3) Set Screw
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.

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
17
5.1 Periodic Lubrication Instructions
Note: Cleaning may be accomplished with a clean, dry rag. For more thorough cleaning, use isopropyl
alcohol.
Tools required: 3 mm Allen wrench (hex key)
Supplies required: Clean rag, Loctite 222, CRC Extreme Pressure Moly C.V. Joint Grease
CAUTION: Collision Sensors equipped with the spring assist option contain a
signicant amount of stored energy and present an increased level of hazard if not
handled properly. Do not attempt to disassemble or repair these units beyond all
procedures described in this manual. All additional repair work requires the use of
special tools and procedures necessary to prevent personal injury and/or damage to
the unit.
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: 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.
Table 5.1—Recommended torques for ATI supplied fasteners
Model Fastener Size Torque Allen Wrench
(Hex Key) Thread Locker
SR‑081 and
SR‑101 M5x20 mm Socket Flat
Head Cap Screw 55 in‑lbs. 3 mm Loctite 222 or equivalent
SR‑131 M6x25 mm Socket Flat
Head Cap Screw 70 in‑lbs. 4 mm
Loctite 242 or
equivalent
SR‑176 M8x40 mm Socket Flat
Head Cap Screw 175 in‑lbs. 5 mm
SR‑221 M10‑1.5x30 mm Socket
Head Cap Screw 420 in‑lbs. 8 mm
1. Remove the Collision Sensor from the interface plate or mounting location.
2. Remove the cover fasteners (refer to Table 5.1) securing the cover plate assembly to the body using the
proper Allen wrench.
3. Remove the cover plate assembly by carefully pulling it straight up and o of the body. This may be
di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.
Figure 5.2—Disassembly of Cover Plate
Cover Fasteners

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
18
4. 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 5.3).
Figure 5.3—Cleaning and Re‑lubricating the Cover Plate Assembly
(3) Cam Surface to be Cleaned and
Re-lubricated (Entire V-groove)
Clearance Ring Surface to be
Cleaned and Re-lubricated
(Entire Rounded Edge)
5. Remove the stem assembly and clean the lubricant from the working surfaces of the ball segments and
the stem.
Figure 5.4—Cleaning and Re‑lubricating the Stem
6. Clean the lubricant from the top surface of the piston.
Figure 5.5—Cleaning and Re‑lubricating Top Surface of Piston

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
19
7. Apply a generous coating of CRC Extreme Pressure Moly C.V. Joint Grease (moly grease) to the top
surface of the piston (see Figure 5.5).
8. 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 (see Figure 5.4).
9. 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 (see Figure 5.3).
10. For the SR‑131, SR‑176, and SR‑221: Apply Magnalube to the cover seal and assemble to the groove in
the cover plate.
11. 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).
12. 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).
13. If the Collision Sensor is being exposed to moisture, apply Loctite 548 Gasket Eliminator to the
underside of the cover.
Figure 5.6—Apply Gasket Eliminator

Manual, Collision Sensor, SR‑81/SR‑101/SR‑131/SR‑176/SR‑221
Document #9610‑60‑1004‑32
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
20
14. Apply thread locker to the cover fasteners (refer to Table 5.1) and thread them into the body.
15. Process for tightening the cover fasteners.
a. Align the dowels with the dowel holes.
b. Press down on the cover plate.
c. Install (2) opposing fasteners.
d. Use the (2) opposing fasteners to evenly pull the cover plate down until the cover contacts the body.
(This is to prevent binding against the dowels.)
e. Install the remaining cover fasteners.
f. Tighten all the cover fasteners to torque. Refer to Table 5.1.
Figure 5.7—Cover Plate and Stem Alignment
Cover Fasteners
Align Grooves in the Cover Plate and Stem