ATI Technologies QC-1210 Series User manual

Manual, Tool Changer, QC‑1210
Document #9620‑20‑B‑1210 Series Base Tool Changer‑11
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-1
Table of Contents
B. Base Tool Changer ................................................................................................................B-3
QC-1210 Series—Robotic Tool Changer....................................................................................B-3
1. Product Overview..................................................................................................................B-3
1.1 Master Plate Assembly ............................................................................................................. B-4
1.2 Tool Plate Assembly.................................................................................................................. B-5
1.3 Optional Modules...................................................................................................................... B-5
2. Installation .............................................................................................................................B-6
2.1 Master Interface......................................................................................................................... B-7
2.2 Master Plate Installation........................................................................................................... B-8
2.3 Master Plate Removal............................................................................................................... B-8
2.4 Tool Interface............................................................................................................................. B-9
2.5 Tool Plate Installation ............................................................................................................. B-10
2.6 Tool Plate Removal ................................................................................................................. B-10
2.7 Pneumatic Connections ..........................................................................................................B-11
2.7.1 Valve Requirements and Connections for the Locking Mechanism ..............................B-11
2.8 Electrical Connections............................................................................................................ B-12
2.8.1 PNP Type Lock, Unlock and RTL Sensors (-SL sensor designations)..........................B-12
2.8.2 NPN Type Lock, Unlock and RTL Sensors (-SE sensor designations).........................B-12
3. Operation .............................................................................................................................B-13
3.1 Conditions for Coupling......................................................................................................... B-14
3.2 Fail-Safe Operation ................................................................................................................. B-15
3.3 Conditions for Uncoupling..................................................................................................... B-16
3.4 ToolIdentication.................................................................................................................... B-16
3.5 Tool Storage Considerations ................................................................................................. B-17
4. Maintenance.........................................................................................................................B-18
4.1 Preventive Maintenance ......................................................................................................... B-18
4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins....................... B-19
4.3 Pin Block Inspection and Cleaning ....................................................................................... B-21
5. Troubleshooting and Service Procedures........................................................................B-22
5.1 Troubleshooting Procedures ................................................................................................. B-22

Manual, Tool Changer, QC‑1210
Document #9620‑20‑B‑1210 Series Base Tool Changer‑11
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-2
5.2 Service Procedures................................................................................................................. B-23
5.2.1 Lock and Unlock Sensor and Sensor Cable Replacement ...........................................B-23
5.2.2 Ready-to-Lock Sensor and Cable Replacement...........................................................B-34
5.2.3 Seal Inspection and Replacement.................................................................................B-44
6. Serviceable Parts ................................................................................................................B-45
6.1 Common Master Parts............................................................................................................ B-45
6.2 Cables for Models 9121-1210AM-0-0-0-0-0-0-SL and
9121-1210AM-0-0-0-0-0-0-SE .................................................................................................. B-46
6.3 Tool Plate ................................................................................................................................. B-47
7. Specications ......................................................................................................................B-48
8. Drawings ..............................................................................................................................B-49
8.1 QC-1210 Tool Changer............................................................................................................ B-49

Manual, Tool Changer, QC‑1210
Document #9620‑20‑B‑1210 Series Base Tool Changer‑11
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-3
B. Base Tool Changer
QC-1210 Series—Robotic Tool Changer
1. Product Overview
The QC 1210 Robotic Tool Changer enhances the exibility and reliability of a robotic cell by enabling a robot to
change tooling automatically. Various tooling, such as grippers, weld guns, pneumatic and electric motors etc., can
be selected and connected to a robot arm.
The QC‑1210’s main components are a Master and Tool plate. The Master plate attaches to the robot; the Tool plate
attaches to selected end‑effectors. When installed on the robot arm, the Master plate locks to the Tool plate using
(3) pneumatic locking mechanisms. Each locking mechanism uses a patented, multi‑tapered cam with ball‑locking
technology and a patented fail‑safe mechanism. With the Master plate coupled to the Tool plate, the passage of
utilities from Master to tooling is enabled. Electrical signals, pneumatic signals, power, and uids can be transferred
to the customer tooling through additional modules and ports. Refer to the respective manuals of each module for
details on operation.
The Tool Changer is applicable in both automated and manual tool change processes, providing a method for quick
tool change in maintenance operations.
For the most current product information and specications on the QC‑1210 Series of Tool Changers, please click
the following link: QC‑1210 Series.

Manual, Tool Changer, QC‑1210
Document #9620‑20‑B‑1210 Series Base Tool Changer‑11
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-4
1.1 Master Plate Assembly
The Master base assembly (Master plate) includes an anodized aluminum body, a set of hardened
stainless‑steel locking mechanisms, and hardened steel alignment pins (see Figure 1.1).
The Master plate has (9) at sides for mounting optional modules. Flat A is designated for integrated valve
assembly and Control module or air adapter and signal module. Flats C, D, E, F, G, H, and J are fully
interchangeable; optional modules suited to the application requirements can be installed on interchangeable
ats or moved around to what best suits robot dress package. All models come with Lock and Unlock (L/U)
sensors which include a master junction box module mounted to Flat B.
The Master plate has (3) locking mechanisms. Each locking mechanism consists of a cam, male coupling,
and chrome‑steel balls. The tapered alignment pins on the Master plate mate with bushings in the Tool
plate to ensure alignment during the coupling process. Extreme pressure grease is applied to the cams, male
couplings, ball bearings, and pins to enhance performance and maximize the life of the entire assembly.
The Master plate body contains (6) proximity sensors to verify the lock/unlock position of each locking
mechanism. The proximity sensors are arranged such that (3) sensors correspond to ‘lock’ and the other
(3) correspond to ‘unlock’. The lock/unlock signal at each locking mechanism is routed to the junction box
module. The junction box module informs the control/signal module of the Master plate’s lock/unlock state.
For further details on relationships between the sensors, junction box module, and control/signal module,
refer to Section 5.2.1—Lock and Unlock Sensor and Sensor Cable Replacement.
The Master plate also contains (2) proximity sensors mounted to its body to verify Tool plate presence and
provide (2) Ready‑To‑Lock (RTL) signals to the control/signal module. To accomplish a dual RTL signal,
the (2) sensors are wired in series. Refer to Section 5.2.2—Ready‑to‑Lock Sensor and Cable Replacement for
a further explanation on the RTL layout.
Figure 1.1—Master Plate Assembly
Cable Retaining
Tabs
Internal Proximity
Sensors Location
(Lock/Unlock)
Internal Proximity
Sensors Location
(Lock/Unlock)
Internal Proximity
Sensors Location
(Lock/Unlock)
Master
Junction
Module
RTL Proximity
Sensors Location
(Ready-to-Lock)
RTL Proximity
Sensors Location
(Ready-to-Lock)
RTL Proximity
Sensors Location
(Ready-to-Lock)
(2) Alignment
Pins
(3) Male Couplings (3x 12) Ball Bearings
Common Ledge
for Modules
mounted to
Flats B, C, D, and F
(3) Cams
Sensors Cables
to Control Module

Manual, Tool Changer, QC‑1210
Document #9620‑20‑B‑1210 Series Base Tool Changer‑11
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-5
1.2 Tool Plate Assembly
The Tool plate assembly includes an anodized aluminum body and hardened stainless steel bearing races.
Flat A of the Tool plate is reserved for the tool‑side Control/Signal module and a valve spacer. The Tool
plate has (6) at sides for mounting additional modules (optional).
Proximity sensor targets are mounted to the body of the Tool plate. The targets are used by the Master plate’s
proximity sensors to verify Tool plate presence when coupled and provide a Ready‑To‑Lock (RTL) signal.
A mounting pattern is machined into the Tool plate for mounting customer tooling or a tooling interface
plate. Refer to Section 8—Drawings for details.
Figure 1.2—Tool Plate Assembly
Alignment Pin Bushing (2)
(3) Bearing Race
Proximity Sensor Assembly
Target (RTL)
Proximity Sensor Assembly
Target (RTL)
Common Ledge Feature for
Module mounted to Flat A,
B, C, D, E and F
Proximity Sensor Assembly
Target (RTL)
Tool Junction Module
1.3 Optional Modules
The (6) ats available are for mounting optional modules. Modules can support various utility pass through,
such as: signal, uid/air, and power.
Flat A is reserved for an integrated valve/air adapter and Control/Signal module on both the Master
and Tool‑side. Modules mounted to ats C, D, E, F, G, H, or J are interchangeable to suit the specic
robot application.
The optional modules are mounted to the Master or Tool plate using a common ledge mounting feature.
Detaching modules from the Master/Tool plate requires removing the (2) M6 socket head cap screws
securing each module to the Tool Changer body.
Visit the ATI website (www.ati‑ia.com) to see what modules are available or contact an ATI Sales
Representative for assistance in choosing modules specic to particular applications.

Manual, Tool Changer, QC‑1210
Document #9620‑20‑B‑1210 Series Base Tool Changer‑11
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-6
2. Installation
All fasteners used to mount the Tool Changer to the robot and to customer’s tooling should be tightened to a
torque value as indicated. Refer to Table 3.1. Furthermore, removable (blue) Loctite 242 must be used on these
fasteners. The following table contains recommended values based on engineering standards.
WARNING: Do not use lock washer under the head of the mounting fasteners or allow the
mounting fasteners to protrude above the mating surfaces of the Master and Tool plates.
Allowing fasteners to protrude above the mating surface will create a gap between the Master
and Tool plates, preventing the locking mechanism from fully engaging. This can lead to
personal injury or equipment damage. Make sure the mounting fasteners are ush or below
the mating surfaces of the Master and Tool plates.
Head of Mounting Fastener Must Be Flush or
Below Mating Surface. (Do Not Use Lock
Washer under Head of Mounting Fastener).
Mating Surface
WARNING: Do not perform maintenance or repair(s) on the Tool Changer or modules unless
the Tool is safely supported or placed in the tool stand, all energized circuits (e.g. electrical,
air, water, etc.) are turned off, pressurized connections are purged and power is discharged
from circuits in accordance with the customer specic safety practices and policies. Injury
or equipment damage can occur with the Tool not placed and energized circuits on. Place
the Tool in the tool stand, turn off and discharge all energized circuits, purge all pressurized
connections, and verify all circuits are de-energized before performing maintenance or
repair(s) on the Tool Changer or modules.
CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners
might become loose and cause equipment damage. Always apply new thread locker when
reusing fasteners.
Table 3.1—FastenerSize,Class,andTorqueSpecications
Mounting Conditions Fastener Size
and Property Class Recommended Torque
Master plate to Interface plate (6061-T6 aluminum)
Minimum thread engagement of 0.59” (15 mm)
[1.5X fastener Ø].
M10-1.5
Class 12.9 55 ft-lbs (75 Nm)
Master plate to Interface plate (steel; USS ≥ 90KSI)
Minimum thread engagement of 0.59” (15 mm)
[1.5X fastener Ø].
Conrm available engagement with Robot Manufacturer
M10-1.5
Class 12.9 55 ft-lbs (75 Nm)
Tool plate (aluminum) to Tool Interface Plate
(6061-T6 aluminum)
Minimum thread engagement of 0.59” (15 mm)
[1.5X fastener Ø]
M10-1.5
Class 12.9 38 ft-lbs (52 Nm)
Tool plate (aluminum) to Tool Interface Plate
(7075-T6 aluminum)
Minimum thread engagement of 0.59” (15 mm)
[1.5X fastener Ø].
M10-1.5
Class 12.9 38 ft-lbs (52 Nm)

Manual, Tool Changer, QC‑1210
Document #9620‑20‑B‑1210 Series Base Tool Changer‑11
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-7
2.1 Master Interface
The Master plate is typically attached to the robot arm. An interface plate can adapt the Master plate to a
specic robot arm. Alignment features (dowel holes and bosses) accurately position and bolt holes secure
the Master plate to the robot arm or an interface plate. Custom interface plates are available from ATI upon
request (refer to the drawings for technical information on mounting features.)
CAUTION: Do not use more than two alignment features when securing a Master plate
to an interface plate. Using more than two alignment features can cause damage to
equipment. Use either two dowel pins or a single dowel pin, along with a boss/recess
feature to align the Master plate with the interface plate.
CAUTION: Do not use dowel pins that are too long or do not allow the interface plate
and Master body to mate ush. Using dowel pins that are too long will cause a gap
between the interface plate and Master body and damage the equipment. Use dowel
pins that will not extend further than allowed by the Master body.
Master Plate
Interface Plate
Correct size dowel
pins allow the interface
plate and Master
plate to mount flush.
Two dowel pins
(or a single dowel
pin along
with a boss/recess)
used as alignment features.
Flush
Correct Mounting of Master Plate
Master Plate
Interface Plate
Dowel pins that are
too long can cause a
plate and Master Plate.
gap between interface
Optional Boss
GapGap
A boss and two dowel pins can
be difficult to align and can
cause damage to equipment.
Incorrect Mounting of Master Plate
If the customer chooses to design and build an interface plate, consider the following points:
• The interface plate should include bolt holes for mounting and either two dowel pins or a dowel pin
and a boss for accurate positioning on the robot and Master plate. The dowel and boss features prevent
unwanted rotation. Refer to the robot manual for robot mounting features.
• The thickness of the interface plate must be sufcient to provide the necessary thread engagement for
the mounting bolts.
• Dowel pins must not extend out from the surface of the interface plate farther than the depth of the
dowel holes in the Master plate.
• If a boss is used on the Master plate, a recess of proper depth and diameter must be machined into the
interface plate to correspond with the boss on the Master plate.
• Mounting bolts that are too long can create a gap between the interface plate and the Master plate,
which can damage equipment.
• The interface plate must provide rigid mounting to the Master plate.
• The interface plate design must account for clearances required for Tool Changer module attachments
and accessories.

Manual, Tool Changer, QC‑1210
Document #9620‑20‑B‑1210 Series Base Tool Changer‑11
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-8
2.2 Master Plate Installation
Tools required: 8 mm hex key
Supplies required: Clean rag, Loctite®242
1. Make sure mounting surface of the Master plate and robot arm or interface plate are clean and
free of debris.
2. Align the dowel pins to the corresponding holes in the Master plate and secure the Master plate to the
robot arm or interface plate with customer supplied (36) M10 socket head cap screws using an 8 mm hex
key. Apply Loctite 242 to threads (see Table 3.1 for proper fasteners and torque).
NOTICE: If an ATI interface plate is used, fasteners to mount the Master plate are supplied with
the interface plate.
3. Connect utilities to appropriate modules and Master plate connections.
4. When installation is complete, safely resume normal operations.
2.3 Master Plate Removal
Tools required: 8 mm hex key
1. Place the Tool in a secure location.
2. Uncouple the Master and Tool plates.
3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, and
hydraulic circuits).
4. If necessary, disconnect all utilities (for example: electrical, pneumatic, hydraulic). Note: support the
Master plate while removing the fasteners.
5. Using an 8 mm hex key, remove the (36) M10 socket head cap screws connecting the Master plate to the
robot arm or interface plate.
6. Remove the Master plate.
Figure 3.1—Typical Master Plate Installation
Robot Arm
Interface Plate,
ATI or Customer Supplied
(If required)
(36) M10 Socket Head Cap Screws
(See Table 2.1)
(Customer Supplied
or supplied with ATI Interface Plate)
Master Plate
Dowel Pin (Customer Supplied
or supplied with ATI Interface Plate)
Mounting Hardware
(Customer Supplied)
Dowel Pin
(Customer Supplied)

Manual, Tool Changer, QC‑1210
Document #9620‑20‑B‑1210 Series Base Tool Changer‑11
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-9
2.4 Tool Interface
The Tool plate is attached to the customer’s tooling. An interface plate can adapt the Tool plate to customer
tooling. Alignment features (dowel holes and a recess) accurately position and bolt holes to secure the Tool
plate to customer tooling. Custom interface plates can be supplied by ATI (refer to the application drawing).
CAUTION: Do not use more than two alignment features when securing a Tool plate
to an interface plate. Using more than two alignment features can cause damage to
equipment. Use either two dowel pins or a single dowel pin, along with a boss/recess
feature to align the Tool plate with the interface plate.
CAUTION: Do not use dowel pins that are too long or do not allow the interface plate
and Tool body to mate ush. Using dowel pins that are too long will cause a gap
between the interface plate and Tool body and damage the equipment. Use dowel pins
that will not extend further than allowed by the Tool body.
Tool Plate
Interface Plate
Dowel pins are
proper size allowing
interface plate and Tool
Plate to mount flush.
Two dowel pins (or a
boss/recess) used as
alignment features.
Correct Mounting of Tool Plate
Tool Plate
Interface Plate
Dowel pins
are too long and
cause a gap between
interface plate and Tool.
Boss and two dowel pins
as alignment features can be
difficult to align and can
damage equipment.
Gap
Incorrect Mounting of Tool Plate
single dowel pin along with a
If the customer chooses to design and build a tool interface plate, consider the following points:
• The interface plate should include bolt holes for mounting and either two dowel pins or a dowel
pin and a boss for accurate positioning on the customer tooling and Tool plate. The dowel and boss
features prevent unwanted rotation.
• Dowel pins must not extend out from the surface of the interface plate farther than the depth of the
dowel holes in the Tool plate.
• The thickness of the interface plate must be sufcient to provide the necessary thread engagement for
the mounting bolts. Fasteners should meet minimum recommended engagement lengths while not
exceeding the maximum available thread depth. Use of bolts that are too long can cause damage to the
tool side changer.
• The plate design must account for clearances required for Tool Changer module attachments
and accessories.
• If a boss is to be used on the interface plate, a boss of proper height and diameter must be machined
into the interface plate to correspond with the recess in the Tool plate.
• The interface plate must have a hole in its center for manually returning the locking mechanism to the
unlocked position under adverse conditions (i.e. unintended loss of power and/or air pressure). The
center access hole with a minimum diameter of 1” (25.4 mm) prevents debris from contaminating the
locking mechanism. Greater protection is provided by leaving the race cover and grommet in place.

Manual, Tool Changer, QC‑1210
Document #9620‑20‑B‑1210 Series Base Tool Changer‑11
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-10
2.5 Tool Plate Installation
Tools required: 8 mm hex key
Supplies required: Clean rag, Loctite 242
1. Make sure mounting surface of the Master plate and robot arm or interface plate are clean and
free of debris.
2. Align the dowel pins to the corresponding holes in the Tool plate and secure the Tool plate to the tool
interface plate or customer tooling with customer supplied (36) M10 socket head cap screws using an
8 mm hex key. Apply Loctite 242 to threads (see Table 3.1 for proper fasteners and torque).
NOTICE: If an ATI interface plate is used, fasteners to mount the Tool plate are supplied with the
interface plate.
3. Connect utilities to the appropriate module and Master plate connections.
4. When installation is complete, safely resume normal operations.
2.6 Tool Plate Removal
Tools required: 8 mm hex key
1. Place the Tool in a secure location.
2. Uncouple the Master and Tool plates.
3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, and
hydraulic circuits).
4. If needed, disconnect all utilities (for example: electrical, pneumatic, hydraulic).
5. Remove the customer supplied (36) M10 socket head cap screws connecting the Tool plate to the tooling
or tool interface plate using an 8 mm hex key.
6. Remove the Tool plate.
Figure 3.2—Tool Plate Installation
Tool Plate
Dowel Pins
(Customer Supplied or supplied with
ATI Tool Interface Plate)
Tool Stand/Tool Interface Plate
(Customer Supplied)
(if required)
(36) M10 Socket Head Cap Screws
(See Table 2.1)
(Customer Supplied or supplied with
ATI Tool Interface Plate)