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)

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-11
2.7 Pneumatic Connections
The air supply used for coupling and uncoupling the Tool Changer should be clean, dry, and non‑lubricated.
A supply pressure in the range of 70 to 100 psi is acceptable for operation of the locking mechanism, with a
setting of 80 psi suggested. The air should be ltered 40 micron or better.
CAUTION: Do not use the Tool Changer in the fail-safe condition for extended periods
of time. Do not transport the Tool Changer in the fail-safe condition. Possible damage
to the locking mechanism could occur.
2.7.1 Valve Requirements and Connections for the Locking Mechanism
If utilizing an air adapter module that does not contain an integrated solenoid valve, the customer
is required to supply a 2‑position 4‑way or 5‑way valve to actuate the locking mechanisms in the
Master plate. When air is supplied to the Lock or Unlock Port on the Master plate, the opposite port
must be vented to the atmosphere (for example: when air is supplied to the Lock Port, the Unlock
Port must be open to the atmosphere). Failure to vent trapped air or vacuum on the inactive port
may hinder proper shuttling of the valve and prevent coupling and/or uncoupling from occurring.
CAUTION: The locking mechanism will not function properly when connected
to a 3-way valve; a 3-way valve is incapable of venting trapped air pressure
from within the Tool Changer. Trapped air pressure could result in injury of
personnel or damage to the product and attached tooling. Connect the Lock
and Unlock supply air to a 2-position 4-way or 5-way valve.
Figure 3.3—Lock and Unlock Pneumatic Connections
4or 5-wayValve
SupplyClean,Dry,
Non-lubricatedAir
70 – 100psi(4.8–6.9 Bar
)
Exhaust
OpentoAtmosphere
LockPort
UnlockPort
Air Adapter without
integrated valve

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-12
2.8 Electrical Connections
A Tool Changer is available with integrated Lock/Unlock sensors. If sensors are not used, plugs will be
provided to seal the locking mechanism. If a Control/Signal module is to be utilized on Flat A when ordered,
the sensors will be connected to the module prior to shipping.
2.8.1 PNP Type Lock, Unlock and RTL Sensors (-SL sensor designations)
These sensors are used on 9121‑1210AM‑0‑0‑0‑0‑SL.
Table 3.2—PNP (Current Sourcing)
Description Value
Voltage Supply Range 10-30VDC
Output Current < 150 mA
Output Circuit PNP make function (NO)
Figure 3.4—PNP Type Lock, Unlock and RTL Sensors
(3) Blue Brown (1)
(4) Black
Brown (1)
Black (4)
Blue (3)
+Vs
Output
0 V
PNP
Z
Connector
PNP (Current Sourcing)
2.8.2 NPN Type Lock, Unlock and RTL Sensors (-SE sensor designations)
These sensors are used on 9121‑1210AM‑0‑0‑0‑0‑SE.
Table 3.3—NPN (Current Sinking)
Description Value
Voltage Supply Range 10-30VDC
Output Current < 150 mA
Output Circuit NPN make function (NO)
Figure 3.5—NPN Type Lock, Unlock and RTL Sensors
(3) Blue Brown (1)
(4) Black
Brown (1)
Black (4)
Blue (3)
+Vs
Output
0 V
NPN
Z
Connector
NPN (Current Sinking)

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-13
3. Operation
The Master locking mechanism is pneumatically driven to couple and uncouple with the bearing race on the Tool
plate. The Master plate utilizes air ports from an air or air/valve adapter module to provide lock and unlock pressure
to the locking mechanism.
CAUTION: Safe, reliable operation of the Tool Changer is dependent on a continuous supply
of compressed air at a pressure of 70 to 100 psi. Robot motion should be halted if the air
supply pressure drops below 70 psi for any reason.
The robot should be programmed to minimize misalignment during coupling and uncoupling. Additionally, the tool
stand should be durable and not allow deection under uncoupled Tool weight; should that occur, alignment of the
Tool Changer plates will be taken outside of accepted offsets. For recommended maximum allowable offsets prior
to coupling, see the following Figure 4.1 and Table 4.1. In some cases, offsets greater than what is shown in Table
4.1 can be accommodated by the Master and Tool plates; however, this will increase wear.
Lock‑up should occur with the Master plate in the No‑Touch™ locking zone (see Table 4.1) but without the Master
plate physically in contact with the Tool plate. As locking occurs, the Master plate should draw the Tool plate into
the locked position.
Figure 4.1—OffsetDenitions
Twisting
Z
Tool Plate
Master Plate
Cocking
Offset
(About X
and Y)
Y
X
X, Y, and Z Offset
Table 4.1—Maximum Recommended Offsets Prior to Coupling
Model No-Touch Zone Z
Offset
(Max)1
X and Y Offset
(Max) 2Cocking Offset (Max) Twisting Offset (Max)
QC-1210 0.04”
(1 mm) ±0.08” (2 mm) ±0.7° ±1°
Notes:
1. Maximum values shown. Decreasing actual values will minimize wear during coupling/uncoupling.
2. Actual allowable values may be higher in some cases but higher offsets will increase wear during coupling.

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-14
3.1 Conditions for Coupling
The following conditions should be considered when operating the Tool Changer. For more details about
programming the robot, refer to the Operation section of the Control/Signal Module Manual.
CAUTION: Do not attempt to couple the Tool Changer when in locked position. The
locking mechanism must be in the unlock position when attempting to couple the Tool
Changer. Failure to adhere to this condition may result in damage to the unit and/or the
robot. Always unlock the Master prior to coupling to a Tool.
1. Unlock the Tool Changer by removing air pressure from the lock port and supplying air pressure to the
unlock port (if equipped, the unlock sensor indicates the Tool Changer is unlocked).
NOTICE: For Tool Changers with a control/signal module and air/valve adapters with a double
solenoid valve, turn the Unlatch output ON and turn the Latch output OFF. For Tool Changers
with a control/signal module and air/valve adapters with a single solenoid valve, turn the Unlatch
output ON. Some control/signal modules prevent the Tool Changer from being unlocked unless
the Master and Tool are coupled and nested properly in the tool stand, a manual override
procedure is required to unlock the Tool Changer. Refer to your Control/Signal Module Manual
for instructions.
2. Position the Master above the Tool and move the Master into ready to lock position. The mating surfaces
of the Master and Tool should be parallel and not touching. Make sure that the tapered alignment
pins from the Master enter the alignment holes on the Tool. The alignment pins should be relatively
concentric with the alignment bushings with no contact between the two.
3. It is recommended that the mating faces of the Master and Tool not be touching but be within the
No‑Touch distance of each other when coupling to minimize stress and wear on the locking mechanism.
The locking mechanism allows the Master to “pull up” the Tool with gaps between the two sides.
CAUTION: Direct contact of the Master and Tool mating surfaces is not suggested
or required just prior to coupling. Contact may result in damage to the unit and/or the
robot. No-Touch locking technology allows the unit to couple with a separation distance
between the Master and Tool.
4. The RTL (Ready‑To‑Lock) sensor and target that are built into the Tool Changer must be positioned
within approximately 0.05” (1.5 mm) of each other for the sensors to detect Tool presence. RTL signals
are not required to couple the Tool Changer but are recommended as a conrmation of coupling prior to
removing the Tool from the tool stand.
NOTICE: At this point, communication is initiated with the ATI Tool and downstream nodes.
If equipped, Tool-ID and communications become available. Depending on the type of
control/signal module, additional notications such as RTLV, TSRV, TSIV, Tool Present,
Unlatch Enabled, and other notications can provide verication of properly functioning
system components.
5. Couple the Tool Changer by releasing the air pressure from the unlock port and supplying air pressure
to the lock port. Air must be maintained on the lock port during operation to assure rigid coupling (if
equipped, the lock sensor indicates the Tool Changer is in the locked position).
NOTICE: For Tool Changers with a control/signal module and air/valve adapters with a double
solenoid valve, turn the Unlatch output OFF and turn the Latch output ON. For Tool Changers
with a control/signal module and air/valve adapters with a single solenoid valve, turn the
Unlatch output OFF.

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
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6. A sufcient delay must be programmed between locking valve actuation and robot motion so that the
locking process is complete before moving the robot. If equipped with Lock and Unlock sensors, the
Lock signal should read “ON” (true) and the Unlock signal should read “OFF” (false).
NOTICE: If the locking mechanism has been actuated and both the Lock and Unlock signals are
OFF, then a “missed tool” condition has occurred (for example, the Tool is not in the stand or is
not positioned properly). In this case an error should be generated and the robot program
halted. The situation requires manual inspection to determine the cause of the problem. Some
congurations will require a manual unlock of the Master plate before attempting coupling, refer
to the Control/Signal Module Manual for instructions.
NOTICE: The locking mechanism must be in the unlock state before another attempt is made to
couple or damage could occur to the robot and/or the Tool Changer.
3.2 Fail-Safe Operation
A fail‑safe condition occurs when there is an unintended loss of lock air pressure to the Master plate. When
air pressure is lost, the Tool Changer relaxes and there may be a slight separation between the Master
and Tool plates. The lock sensor may indicate that the unit is not locked. ATI’s patented fail‑safe feature
utilizes a multi‑tapered cam to trap the ball bearings and prevent an unintended release of the Tool plate.
Positional accuracy of the tooling is not maintained during this fail‑safe condition. Do not operate the
Tool Changer in the fail‑safe condition. If source air is lost to the unit, movement should be halted until air
pressure is restored.
After air pressure is re‑established to the Master plate, the locking mechanism will energize and securely
lock the Master and Tool plates together. In some cases when the load on the tool changer is signicantly
off center, it may be necessary to position the load underneath the tool changer or return the tool to the tool
storage location to ensure a secure lock condition. If equipped, make sure the lock sensor indicates the Tool
Changer is in the locked position before resuming normal operations. Consult your Control/Signal Module
Manual for specic error recovery information.
CAUTION: Do not use the Tool Changer in a fail-safe condition. Damage to the locking
mechanism could occur. Re-establish air pressure and ensure the Tool Changer is in a
secure lock position before returning to normal operations.

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
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3.3 Conditions for Uncoupling
Refer to your Air/Valve Adapter and/or Control/Signal Module Manual’s Operation section for operation
during coupling/uncoupling.
1. Move the robot to position the Tool plate in the tool stand. The position for coupling and
uncoupling are the same.
NOTICE: Depending on the type of control/signal module, additional notications such as TSRV,
TSIV, and other notications can provide verication of properly functioning system components.
2. Unlock the Tool Changer by releasing the air pressure from the lock port and supplying air pressure to
the unlock port. The Tool Changer locking mechanism moves to the unlocked position and the Tool plate
releases from the Master plate (If equipped, the unlock sensor indicates the Tool Changer is unlocked).
NOTICE: For Tool Changers with a control/signal module and air/valve adapters with a double
solenoid valve, turn the Unlatch output ON and turn the Latch output OFF. For Tool Changers
with a control/signal module and air/valve adapters with a single solenoid valve, turn the
Unlatch output ON.
CAUTION: This Tool Changer may be equipped with a tool stand Interlock (TSI) feature
that physically breaks the Unlatch solenoid circuit. Proper use of the TSI prevents
unwanted Unlock software commands from being recognized until the circuit is made.
Make sure the Tool Changer is positioned properly to trip actuate the TSI switch when
the Tool is in the tool stand.
3. A sufcient delay must be programmed between unlocking valve actuation and robot motion so
that the unlocking process is complete before moving the robot. If equipped with lock and unlock
sensors, the Unlock signal should read “on” (true) and the Lock signal should read “off” (false). Any
other condition indicates a problem and the robot program should be halted. Once the Lock and
Unlock signals in the proper state, the Master plate may be moved away from the Tool plate in the
axial direction.
The robot and Master plate can now proceed to another Tool plate for coupling and subsequent operations.
3.4 ToolIdentication
When using multiple Tools, it is good practice to implement a Tool‑ID system that identies each Tool with
a unique code. This can be used to verify that the robot has picked up the proper Tool. Modules with Tool‑ID
are available from ATI, refer to our Web site http://www.ati‑ia.com/products/toolchanger/tool_changer_
modules.aspx for products available or your specic application or contact ATI for recommendations
and assistance.

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
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3.5 Tool Storage Considerations
NOTICE: Tool stand design is critical to the operation of the Tool Changer. Improperly designed
tool stands can cause jamming and excessive wear of the Tool Changer components.
Tool plates with customer tooling attached may be stored in a tool stand. ATI provides compatible tool
stands designed for durability, longevity, and maximum adaptability to t most customers’ applications. The
ATI TSL (Tool Stand Large) system is compatible with ATI Tool Changer sizes QC‑150 and larger. The TSL
systems can be equipped with horizontal modules, clamp modules, and different types of tool sensing. Visit
the ATI Web Site http://www.ati‑ia.com/products/toolchanger/toolstand/large/LargeStand.aspx for products
available or contact ATI for assistance.
If the customer is supplying the tool stand, it must provide a xed, repeatable, level, and stable position
for tool pick‑up and drop‑off. The tool stand must support the weight of the Tool Changer Tool plate, tool
interface plate, optional modules, cables, hoses, and customer tooling without allowing deection in excess
of the offsets specied.
Ideally, the Tool should be hanging vertically in the tool stand so that gravity assists to uncouple the Tool
plate from the Master plate during unlocking. It is possible to design tool stands that hold tools in the
horizontal position, but the necessary compliance must be provided during coupling and uncoupling. In
general, “horizontal‑position” tool stands cause more wear on the locking mechanism and locating features
of the Tool Changer and tool stand.
A variety of methods may be used to position the Tool in the tool stand. A common method is to use
tapered alignment pins and bushings. Robot programming and positional repeatability are vital in Tool
pick‑up and drop‑off.
A sensor that detects the presence of the Tool in the tool stand is recommended. The sensor may be used
prior to coupling to ensure the Tool is seated in the stand. Sensors may also be used as the robot starts to
move away after uncoupling. Sensors provide a safety measure if a Tool becomes jammed in the stand or if
the Tool fails to release from the robot.
Proximity sensors should be positioned so that the sensing face is vertical to prevent metal shavings, weld
spatter, or other debris from falling on the sensor and creating false readings.
Tool stands debris shields can cover Tools and modules to protect them in dirty environments, such as
grinding or welding. Alternatively, positioning tool stands in areas shielded from weld spatter, uids,
adhesives, or other debris would eliminate the need for debris shields.

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
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4. Maintenance
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.
NOTICE: The cleanliness of the work environment strongly inuences the trouble free operation of
the Tool Changer. The dirtier the environment, the greater the need for protection against debris.
Protection of the entire EOAT, the Master, the Tool and all of the modules may be necessary. Protective
measures include the following:
Placement of the tool stands away from the debris generators.
• Covers incorporated into the tool stands.
• Guards, deectors, air curtains, and similar devices built into the EOAT and the tool stand.
4.1 Preventive Maintenance
The Tool Changer and optional modules are designed for long‑term functionality, provided regular
maintenance is performed. A visual inspection and preventive maintenance schedule, depending on the
application, is supplied in the following table. Detailed assembly drawings are provided in Section 8—
Drawings . Refer to module sections for detailed preventive maintenance steps for all utility modules.
Table 5.1—Maintenance
Application(s) Tool Change Frequency Inspection Schedule
General Usage Material Handling Docking Station > 1 per minute Weekly
< 1 per minute Monthly
Welding/Servo/Deburring, Foundry Operations (Dirty Environments) All Weekly
Checklist
Mounting Fasteners
гInspect fasteners for proper torque, interferences, and wear. Tighten and correct as required. Refer to Table 3.1 —
Fastener Size, Class, and Torque Specications.
Ball Bearings/Alignment Pins/Bushings/Bearing Race
гInspect for wear and proper lubrication. MobilGrease XHP222 Special a NLGI #2 lithium complex grease with
molybdenum disulde additive is suggested for locking mechanism and alignment pin lubrication. Over time,
lubricants can become contaminated with debris; therefore, it is recommended to thoroughly clean the existing
grease and replace with new as needed. See Section 4.2—Cleaning and Lubrication of the Locking Mechanism and
Alignment Pins.
гInspect for excessive alignment pin/bushing wear—possibly an indication of misaligned robot position during
pickup/drop-off. Check tool stand for wear and alignment problems. To replace worn alignment pins, refer to
Section 5.2.2.4—Alignment Pin Replacement.
гInspect for wear on the ball bearings/bearing race—possibly an indication of excessive loading.
Sensors and Cables
гInspect sensor cable connectors for tightness. If loose, tighten connections.
гInspect sensor cables for any damage, cuts, and abrasion. Replace as necessary. Refer to Section 5.2.1—Lock and
Unlock Sensor and Sensor Cable Replacement.
Hoses
гInspect hose connection for tightness and leaks. If leaking or loose, secure hose connection.
гInspect hoses for interferences, abrasions, cuts, and leaks. Replace as necessary.
Electrical Contacts/Pin Block (Modules)
гInspect for damage, debris, and stuck/burnt pins. Clean pin blocks as necessary, Refer to Section 4.3—Pin Block
Inspection and Cleaning.
Seals (Modules)
гInspect for wear, abrasion, and cuts. Refer to Section 5.2.3—Seal Inspection and Replacement

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
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4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins
Supplies required: Clean rag, MobilGrease®XHP222 Special Grease
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. Use a clean rag to thoroughly remove any lubricant and debris from the ball bearings, male coupling,
cam, and alignment pins.
Figure 5.1—Cleaning Ball Bearings and Outer Surfaces of Male Coupling
5. Use a clean rag to thoroughly remove any lubricant and debris from the inner surface of the male
coupling and cam.
Figure 5.2—Cleaning Ball Bearings, Cam and Inner Surfaces of Male Coupling

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
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6. Check each ball bearing to make sure it moves freely in the male coupling. Additional cleaning may be
necessary to free up any ball bearings that are sticking in place.
Figure 5.3—Check Ball Bearing Movement
7. Apply a liberal coating of lubricant to the ball bearings, the male coupling (inside and out), and the
alignment pins.
Figure 5.4—Apply Lubricant to Locking Mechanism
Apply Lubricant on Inner
Surface of Male Coupling (3)
Apply Lubricant on Alignment Pins (2)
and Outer Surface of Male Coupling (3)
8. Use a clean rag to thoroughly remove any lubricant and debris from the Tool plate bearing
race and bushings.
NOTICE: No application of lubrication is necessary on the Tool plate components.
9. Safely resume normal operation.
Figure 5.5—Clean Tool Plate Surfaces of locking Mechanism
Clean Bushing Surfaces
Clean Bearing Race
Surfaces