ATI Technologies PROFINET DL12 User manual

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
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Table of Contents
Glossary........................................................................................................................................C-3
C. Control and Signal Modules ...................................................................................................C-5
DL12—PROFINET®Control/Signal Module ...............................................................................C-5
1. Product Overview..................................................................................................................C-5
1.1 Master Module........................................................................................................................... C-5
1.2 Tool Module ............................................................................................................................... C-6
2. Product Information..............................................................................................................C-7
2.1 Master Module .......................................................................................................................... C-7
2.1.1 PROFINET Interface Information ................................................................................... C-7
2.1.2 Integrated Ethernet Switch............................................................................................. C-7
2.1.3 System Failure and Bus Failure LEDs ......................................................................... C-13
2.1.4 Ethernet 1 and Ethernet 2 LEDs .................................................................................. C-14
2.1.5 Reset To Factory Push Button...................................................................................... C-15
2.2 Arc Prevention Circuit ............................................................................................................ C-15
2.2.1 Arc Prevention Circuit Behavior during Coupling......................................................... C-15
2.2.2 Arc Prevention Circuit Behavior during Uncoupling ..................................................... C-16
2.3 Tool Module ............................................................................................................................ C-17
2.4 Safety System.......................................................................................................................... C-18
3. Installation ...........................................................................................................................C-20
3.1 Master Module Installation..................................................................................................... C-20
3.2 Master Module Removal......................................................................................................... C-21
3.3 Tool Module Installation ......................................................................................................... C-21
3.4 Tool Module Removal ............................................................................................................. C-22
3.5 PROFINET Interface................................................................................................................ C-22
3.6 Utility Schematic ..................................................................................................................... C-22
3.7 Electrical Connections............................................................................................................ C-22
3.8 Setting the Tool-ID................................................................................................................... C-23
4. Operation .............................................................................................................................C-24
4.1 Lock, Unlock, and RTL Sensor Cable LED Behavior........................................................... C-24
4.2 Inputs........................................................................................................................................ C-25
4.2.1 EVERYTHING IS OK.................................................................................................... C-25
4.2.2 Locked.......................................................................................................................... C-25
4.2.3 Latch Enabled .............................................................................................................. C-25
4.2.4 RTL1 and RTL2............................................................................................................ C-25
4.2.5 SSO 1 and SSO 2........................................................................................................ C-25
4.2.6 SS Pulse Missing ......................................................................................................... C-25

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
C-2
4.2.7 Tool Power Is On.......................................................................................................... C-25
4.2.8 Tool Present ................................................................................................................. C-25
4.2.9 Unlatch Enabled........................................................................................................... C-26
4.2.10 Unlocked ...................................................................................................................... C-26
4.2.11 US1 Power Present...................................................................................................... C-26
4.2.12 US2 Power Present...................................................................................................... C-26
4.2.13 V1 Relay and V2 Relay................................................................................................ C-26
4.3 Error Conditions...................................................................................................................... C-26
4.3.1 AP2 COMM ERROR.................................................................................................... C-26
4.3.2 CROSS MONITORING ERROR.................................................................................. C-26
4.3.3 ERROR ON LATCH...................................................................................................... C-26
4.3.4 ERROR ON UNLATCH1 .............................................................................................. C-27
4.3.5 ERROR ON UNLATCH2 .............................................................................................. C-27
4.3.6 Lock/Unlock Sensor Fault ............................................................................................ C-27
4.3.7 PRESSURE DISCONNECTED.................................................................................... C-27
4.3.8 Pressure Too High........................................................................................................ C-27
4.3.9 Pressure Too Low......................................................................................................... C-27
4.3.10 SYSTEM IS UNSAFE................................................................................................... C-27
4.3.11 TOOL-ID ERROR......................................................................................................... C-27
4.3.12 UNSAFE LATCH .......................................................................................................... C-27
4.3.13 UNSAFE UNLATCH..................................................................................................... C-28
4.3.14 VALVE ERROR ............................................................................................................ C-28
4.3.15 Error Recovery Sequence............................................................................................ C-29
4.4 Recommended Sequence of Operation................................................................................ C-30
5. Maintenance.........................................................................................................................C-36
5.1 Pin Block Inspection and Cleaning ....................................................................................... C-37
6. Troubleshooting and Service Procedures........................................................................C-38
6.1 Troubleshooting...................................................................................................................... C-38
6.2 Service Procedures................................................................................................................. C-39
6.2.1 Seal Replacement........................................................................................................ C-39
6.2.2 DL12 Device Replacement Procedures....................................................................... C-40
7. Serviceable Parts ................................................................................................................C-42
7.1 Master Module Mounting Fasteners...................................................................................... C-42
7.2 Tool Module Mounting Fasteners .......................................................................................... C-42
7.3 Accessories............................................................................................................................. C-42
8. Specications ......................................................................................................................C-43
9. Drawings ..............................................................................................................................C-45

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
C-3
Glossary
Term Denition
Application Processor 1
A board inside the module which controls solenoid outputs, monitors
function of the unlatch valves for pressure and position, safety checking
and diagnostics, reports sensor status, protects outputs against short circuit
overload, detects and reports status of the 24 V power supply, and provides
cross monitoring of the pressure processor board.
Application Processor 2 A board inside the module which controls Unlatch Valve 2, reports the pressure inside the valve module, and provides cross monitoring of the
Application Processor 1.
BF LED BUS Failure LED; this is a standard Probus status LED, similar to the
DeviceNet Network Status LED.
Clear Errors An output supplied to the ATI Master DeviceNet node to clear all applicable
error conditions
CL-RPC Connection Less Remote Procedure Call.
DCP PROFINET Discovery and Conguration Protocol.
EOAT End Of Arm Tool (end effector).
Error on Latch Output An input indicating a short circuit overload condition exists with the Latch
Output.
Error on Unlatch Output An input indicating a short circuit overload condition exists with the Unlatch
Output.
Ethernet Switch An Ethernet network component connecting multiple communication partners
with each other.
FE Functional Earth
GSDML File Aspecial kind of XML-based Device Description File used by PROFINET to
automatically obtain the device characteristics.
Latch (Lock) The output supplied to the ATI Master module to couple the Tool Changer.
LLDP Link Layer Discovery Protocol
Lock/Unlock Sensor Fault An input indicating that the Locked and Unlocked inputs are high at the same
time.
Locked
A proximity sensor input indicating that the coupling mechanism is in the
Locked position.The “LOCKED” bit in the PROFINET bitmap will only be set
high if the following conditions are on:
• LOCKED sensor input is high
• UNLOCKED sensor input is low
• TOOL PRESENT input is high
PROFINET A communication system for Industrial Ethernet designed and developed by
PROFIBUS International.
It uses some mechanisms similar to those of the PROFIBUS eld bus
RTL (Ready To Lock) A proximity sensor input that senses when theATI Tool is in close proximity.
SF LED System Failure LED; this is a standard Probus status LED, similar to the
DeviceNet Module Status LED;it has a red part and a green part.
SNMP Simple Network Management Protocol
SSO1 and SSO2 Inputs from a safety switch, which are high when the Tool Changer is in the
stand.

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
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Term Denition
US2 Power Present An input indicating the presence of Output Power (US2) at the ATI Master
module.
Tool Power is On The “Tool Power is ON” bit is set high when the Arc Prevention Circuit has activated power on the Tool side. If this bit is low there will be neither Input/
Logic Power nor Output power available on the Tool.
Tool Present A hard connect input (sourced from the Tool) indicating the Master and Tool
are electrically connected to each other.
Tool-ID An input from the Master node reporting the values from the Tool-ID switch on
the Tool module.
Unlatch (Unlock) The output supplied to the ATI Master module to uncouple the Tool Changer.
Unlatch Enable Indicates it is safe to proceed with an unlatch request.
Unlocked
A proximity sensor input indicating that the coupling mechanism is in the
Unlocked position. The “UNLOCKED” bit in the PROFINET bitmap will only be
set high if the following conditions are on:
• UNLOCKED sensor input is high
• LOCKED sensor input is low
Unsafe Unlatch An input indicating that an Unlatch command was received which would result
in an unsafe Tool release and was therefore not processed.
US1 Power Present An input indicating the presence of Input and Logic Power (US1) at the ATI
Master module.
V1Relay and V2Relay Inputs from relays which should mirror the status of SSO1 and SSO2.

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
C-5
C. Control and Signal Modules
DL12—PROFINET®Control/Signal Module
1. Product Overview
The modules enable the customer to control and communicate with the Tool Changer through a network using a
PROFINET interface.A PROFINET node is established on the Master module, but not on the Tool. Control of the
Tool Changer is realized through the Master node along with the reporting of various Tool Changer I/O. The Tool
module supports Tool‑ID reported through the Master module and functions as a pass‑through for PROFINET
network and power to downstream equipment.
The Master module is used in combination with a valve adapter with dual double solenoid valves, for Latch/
Unlatch control of the Tool Changer. When used in combination with a dual double solenoid valve adapter, the
modules achieves PLd safety reliability in accordance with ISO standard 13849‑1. The user is required to provide
a pneumatic supply source to the valve adapter. Refer to the appropriate valve adapter or Tool Changer manual for
requirements.
In addition to supporting the standard Tool Changer input signals (Locked, Unlocked, etc.) the modules also
support advanced diagnostic and fault reporting. Refer to Section 4.3—Error Conditions.
A minifast connector is provided on the Master and Tool modules for interfacing with power. The power source for
input and output power must be capable of outputting an operating voltage (reverse polarity protected, regulated)
of 20.4 to 28.8 VDC.A M12 D‑coded connector is provided on the Master and Tool modules for interfacing with
PROFINET. When the Tool Changer is coupled, the Master and Tool modules pass signals via spring loaded
pin blocks. Flexible V‑ring seals surround the pin blocks and are water resistant but not water proof. Refer to
Figure 1.1.
To avoid unintentional Tool release, the power for the Unlatch valve is routed through a safety switch connector. A
safety switch must be connected to support this function. Refer to Section 2.4—Safety System.
1.1 Master Module
The module has the following connectors:
• (1) integrated 4‑pin valve signal pin block for the Latch and Unlatch signals to the solenoid valves
• (4) 3‑pin female M8 RTL sensors (R1 and R2), Lock (L), and Unlock (U) sensor connectors
• (1) 3‑pin female M8 valve adapter proximity sensor connector
• (1) 4‑pin female M8 valve adapter pressure sensor connector
• (1) 4‑pin female M12 D‑coded PROFINET connector
• (1) 4‑pin male minifast power connector
The module also incorporates ATI’s exclusive Arc Prevention Circuit which extends the life of electrical
power contacts by eliminating arcing caused by inductive loads and high inrush current during coupling/
uncoupling. Refer to Section 2.2—Arc Prevention Circuit.
The module provides status LED’s to visually indicate its operation. A reset button provides the ability to
return to default settings. Refer to Section 2.1.3—System Failure and Bus Failure LEDs and Section 2.1.4—
Ethernet 1 and Ethernet 2 LEDs.
An electrical interface is provided on the module for support of two integrated double solenoid valves (DC
Voltage, sourcing type). The integrated valve is supplied from ATI as part of a dual double solenoid valve
adapter. Refer to the Valve Adapter Manual for more information (9620‑20‑C‑Jxx Valve Adapters with Dual
Double Solenoid, Valve Pass Through, Proximity and Pressure Sensors). Electrical interface drawings and
connector details are provided in drawings in Section 9—Drawings.
PROFINET requires a FE ground, the Master module provides a M8 threaded hole for FE ground terminal
that is passes FE ground to the Tool Module through the 7‑Pin contact block. The M8 set screw must be
removed prior to FE ground connection.

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
C-6
Figure 1.1—Modules
19-Pin Signal Contact
19-Pin Spring Signal Contact
and Rubber V-ring Seal
4-Pin Female D-coded
PROFINET Connector
4-Pin Female D-coded
PROFINET Connector
5-Pin Female M12
TSI Connector
(4) 3-Pin Female M8
RTL, Lock, and Unlock Connector
5-Pin Male Minifast
Power Connector
FE Ground Terminal Connection
5-Pin Female Minifast
Power Connector
Tool-ID
SF, Ethernet 2, BF,
Ethernet 1 LED's,
and Reset Switch
7-Pin Power Spring Contact
and Rubber V-ring Seal
7-Pin Power Contact
Valve Adapter Pressure Sensor Connector
4-Pin Female M8
Valve Signal Pin Block
FE Ground Terminal Connection
Valve Adapter Proximity Sensor Connector
3-Pin Female M8
Common Ledge
Mounting Feature
DL12 Tool Module
DL12 Master Module
1.2 Tool Module
The module has the following connectors:
• (1) 5‑pin female M12 safety switch connector
• (1) 4‑pin female M12 D‑coded PROFINET connector
• (1) 4‑pin male minifast power connector
The module requires a JR4‑T tool adapter to align the Master and Tool modules, and mounts to the Tool
plate of the Tool Changer or Utility Coupler. PROFINET requires a FE ground, the Tool module provides a
M5 threaded hole that is passes FE ground to the customer tooling. The M5 set screw must be removed prior
to FE ground connection.
The module has a series of push button switches for setting of the Tool‑ID input. This allows the customer
to distinguish between the different tools that are being used in a robotic cell or on a production line. The
Tool‑ID is reported through the Master module bitmap. Refer to Section 2.1.1—PROFINET Interface
Information

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
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2. Product Information
A PROFINET node is established on the Master module but not on the Tool. Control of the Tool Changer is realized
through the Master node along with the reporting of various Tool Changer I/O. The Tool module supports Tool‑ID
reported through the Master and functions as a pass‑through for PROFINET network and power to downstream
equipment.
2.1 Master Module
2.1.1 PROFINET Interface Information
Table 2.1 lists the PROFINET interface parameters applied to the Master module.
Table 2.1—PROFINET Interface Parameters
Parameter Description
DCP supported
Fast Startup supported
Used Protocols (subset) UDP, IP,ARP, ICMP (Ping)
Topology recognition LLDP, SNMP V1, MIB2, physical device
VLAN- and priority tagging yes
Context Management by CL-RPC
Minimum cycle time 2 ms
Baud rate 100 MBit/s
Data transport layer Ethernet II, IEEE 802.3
A GSDML le for the Master node is available from our website:
(www.ati‑ia.com/download/edsles) or by email.
Reference the Part Number: Master node GSDML le 9031‑20‑1071
Bitmaps for the Master node are provided in Table 2.2 and Table 2.3.
2.1.2 Integrated Ethernet Switch
The Master module provides an integrated 2 port Ethernet switch which supports the following:
• Transmission rate 100 MBit/s
• Interface type 100 BASE‑TX, isolated
• Half duplex/Full duplex supported
• Auto Negotiation supported
• Auto Crossover supported.

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
C-8
Table 2.2—I/O Bit map, Robot Inputs from 9121-DL12-M
Byte Bit# Name Description/Function
0
0 Locked Tool Changer is locked
1 Unlocked Tool Changer is unlocked
2 Latch Enabled Tool Changer is ready to Latch
3 Unlatch Enabled Tool Changer is ready to Unlatch
4 RTL1 Ready to Lock Prox1 I/P
5 RTL2 Ready to Lock Prox2 I/P
6 TOOL_PRESENT Bit indicating Master and Tool are in electrical contact.
7 Tool Power Is On Indicates that Arc Prevention Circuit is turned ON and power
is provided to the Tool
1
0 US1_Power_Present US1 supply voltage on robot side within the allowable range of
20.4 to 28.8 V
1 US2_Power_Present US2 supply voltage on robot side within the allowable range of
20.4 to 28.8 V
2 SSO_1 Input from safety switch that indicates it is safe to unlatch the
Tool. Should always agree with SSO_2
3 SSO_2 Input from safety switch that indicates it is safe to unlatch the
Tool. Should always agree with SSO_1
4 SS Pulse Missing Is high if the SSO inputs are jumpered or shorted.
5 UNSAFE_LATCH User attempted to latch when unsafe.
6 Unsafe Unlatch Unlatch Rejected Due to Unsafe Condition Present
7SYSTEM_IS_
UNSAFE Any APx_COMM_ERROR, APx_MISMATCH_ERROR, APx_ SAFETY_ERROR sets this bit.
2
0 V1RELAY Indicates that safety switch has activated safety relay 1.
Should agree with SSO_1.
1 V2RELAY Indicates that safety switch has activated safety relay 2.
Should agree with SSO_2.
2Lock/Unlock Sensor
Fault
Locked and Unlocked sensor inputs are ON at the same time
or swapped. Indicative of failed sensors or no latch/unlatch
motion.
3ERROR_ON_
LATCH Overload or short circuit on Latch Output
4ERROR_ON_
UNLATCH1 Overload or short circuit on Unlatch1 Output
5ERROR_ON_
UNLATCH2 Overload or short circuit on Unlatch2 Output
6TOOL-ID_ERROR Tool-ID Communication Timeout
7EVERYTHING IS
OK Any APx_COMM_ERROR, APx_MISMATCH_ERROR, APx_ SAFETY_ERROR sets this bit.
Notes:
These bits should be mapped for customer use.
These bits should be mapped forATI diagnostic use.

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
C-9
Table 2.2—I/O Bit map, Robot Inputs from 9121-DL12-M
Byte Bit# Name Description/Function
3
0 VALVE_ERROR Valve or pressure sensor defect. Logical OR of APx_VALVE_
ERROR bits.
1CROSS_ MONITORING_
ERROR
Safety System detected mismatch. Logical OR of the APx_
INP_MISMATCH, APx_OUTP_MISMATCH, and AP2_COMM_
ERROR bits.
2PRESSURE_TOO_
HIGH Pressure sensor reports an unlatch pressure higher than the maximum system rating.
3PRESSURE_TOO_
LOW Pressure sensor report an unlatch pressure lower than the minimum system rating
4Tool-ID Switch1 Bit1
N/A
5Tool-ID Switch1 Bit2
6 Tool-ID Switch1 Bit4
7 Tool-ID Switch1 Bit8
4
0Tool-ID Switch2 Bit1
1 Tool-ID Switch2 Bit2
2 Tool-ID Switch2 Bit4
3 Tool-ID Switch2 Bit8
4 Tool-ID Switch3 Bit1
5 Tool-ID Switch3 Bit2
6 Tool-ID Switch3 Bit4
7 Tool-ID Switch3 Bit8
5
0Tool-ID Switch4 Bit1
1 Tool-ID Switch4 Bit2
2 Tool-ID Switch4 Bit4
3 Tool-ID Switch4 Bit8
4 Tool-ID Switch5 Bit1
5 Tool-ID Switch5 Bit2
6 Tool-ID Switch5 Bit4
7 Tool-ID Switch5 Bit8
6
0 Minor Revision Bit0
uC rmware revision
1 Minor Revision Bit1
2 Minor Revision Bit2
3 Minor Revision Bit3
4 Major Revision Bit0
5 Major Revision Bit1
6 Major Revision Bit2
7 Major Revision Bit3
Notes:
These bits should be mapped for customer use.
These bits should be mapped forATI diagnostic use.

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
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Table 2.2—I/O Bit map, Robot Inputs from 9121-DL12-M
Byte Bit# Name Description/Function
7
0 Raw Locked Sensor Direct mirror of locked proximity sensor.
1Raw Unlocked
Sensor Direct mirror of unlocked proximity sensor.
2Valve Proximity
Sensor Shows status of valve position.
3 AP2_Comm_Error AP1 lost communication toAP2
4AP1_VALVE_
ERROR Valve 2 opening or closing at the wrong time.
5AP1_OUTP_
MISMATCH
AP1 detects that AP2 has come to a different decision than
AP1 regarding a safety-critical motion, or AP1 sees Unlatch_
valve_control_2 is different than expected.
6AP1_INP_
MISMATCH AP1 detects that AP2 reports different input values than AP1 sees.
7 MEMORY_FAILURE
N/A
8
0 Reserved
1 Reserved
2 Reserved
3 Reserved
4Firmware Version
Mismatch
5 Reserved
6 Reserved
7 Reserved
9
0AP2_Mismatch_
Error
1 AP2_Comm_Error AP1 lost communication toAP2
2AP2_Memory_
Failure N/A
3AP2_VALVE_
ERROR Position sensor does not meet expectations
4ERROR_ON_
UNLATCH2 Overload on Unlatch 2 output was detected.
5PRESSURE_ SENSOR_
DISCONNECTED
Internal bit indicating that the pressure sensor is disconnected
and/or that there are broken wires in the sensor cable
6Memory_Tests_
Complete N/A
7Safe_to_Unlatch_
AP2
Notes:
These bits should be mapped for customer use.
These bits should be mapped forATI diagnostic use.

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
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Table 2.2—I/O Bit map, Robot Inputs from 9121-DL12-M
Byte Bit# Name Description/Function
10
0 AP2_SSO_2
N/A
1 V1Relay
2 V2Relay
3 AP2_SSFAULT
4Unlatch_Valve_
Control_2
5 Valve_Position
6 AP2_Version_Error
7 AP2_Safety_Error
11
0Pressure Reading
Bit 8
1Pressure Reading
Bit 9
2
Unused
3
4
5
6
7
12
0Pressure Reading
Bit 0
1Pressure Reading
Bit 1
2Pressure Reading
Bit 2
3Pressure Reading
Bit 3
4Pressure Reading
Bit 4
5Pressure Reading
Bit 5
6Pressure Reading
Bit 6
7Pressure Reading
Bit 7
Notes:
These bits should be mapped for customer use.
These bits should be mapped forATI diagnostic use.

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
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Table 2.2—I/O Bit map, Robot Inputs from 9121-DL12-M
Byte Bit# Name Description/Function
13
0
Unused Unused
1
2
3
4
5
6
7
14
0Major Version
Number of AP2 [0:4]
AP2 Firmware Revision Number
1
2
3
4Minor Version
Number of AP2 [0:4]
5
6
7
15 0 to 7 Reserved
Notes:
These bits should be mapped for customer use.
These bits should be mapped forATI diagnostic use.
Table 2.3—I/O Bitmap, Robot Outputs to 9121-DL12-M
Byte Bit# Name Description/Function
0
0 Latch Request Lock
1 Unlatch Request Unlock
2(Unused - Does not need to be mapped)
3 Clear Errors Reset errors, allow affected I/O to be reactivated
4 Reserved
5(Unused - Does not need to be mapped)
6 Direct Power Control Enable Arc Prevention Override
7(Unused - Does not need to be mapped)
1 to 7 (Unused - Does not need to be mapped)
Notes:
These bits should be mapped for customer use.

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
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2.1.3 System Failure and Bus Failure LEDs
When the modules are coupled and communicating properly on the network, the LEDs should
When the modules are coupled and communicating properly on the network, the LEDs should
display as shown in Figure 2.1,with the E1 and E2 LEDs RED (solid) and Green (solid) based on
the PROFINET communication.
Figure 2.1—LED Display of Properly Functioning Coupled Modules
SF LED is Green
E2 LED is Red/Green
BF LED is Off
E1 LED is Red/Green
The System Failure (SF) status LED is identied on the module as “SF”. It provides device status
for power and proper operation. Refer to Table 2.4 for an outline of this LED’s operation.
The Bus Failure (BF) status LED is identied on the module as “BF”. It provides PROFINET
status information. Refer to Table 2.5 for an outline of this LED’s operation.
Table 2.4—SF status LED
Status LED Function Note
No Power Off No power applied. Check if the voltage is
between 20.4 and 28.8 VDC.
Operational1Green (solid) Normal operation.
Fault Red (solid) The fault Internal Diagnostic Error has occurred.
Fault Red (ashing)
Reset To Factory Push Button was pressed or
one of the following faults has occurred:
- Communication error with tool module
- Input power failure
Note:
1. The LED will be green even if no network connection is established.
Table 2.5—BF status LED
Status LED Function Note
Operational1Off1No error (Normal operation).
Not OK
Green (solid) Watchdog timeout; channel, generic or
extended diagnosis present; system error.
Green (ashing) DCP signal service is initiated via the bus.
Red (solid) No conguration.
Red (ashing) No data exchange.
Note:
1. If the LED is off it may also indicate the device may be powered off.

Manual, Control Module, PROFINET, DL12
Document #9620-20-C-DL12-06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
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2.1.4 Ethernet 1 and Ethernet 2 LEDs
The Ethernet LEDs provide information about link status and activity on the ports of the integrated
Ethernet switch.
The Ethernet 1 (E1) LED will display the status of the robot side Ethernet port. The Ethernet 2 (E2)
LED will display the status of the Tool side Ethernet port. The module status listed in Table 2.6 and
Table 2.7 will be indicated by the specied LED color and state.
Table 2.6—Ethernet 1 (E1) Robot Side LED
Status LED Function Note
No Link Off The Master module has no connection
to the Ethernet.
Link Green (solid) The Master module is connected to the
Ethernet but there is currently no data
exchange activity.
Active RX/TX Red (ashing)
Green (solid) There is sporatic data exchange activity with the Ethernet.
PROFINET connection
established Red (solid)
Green (solid) There is continuous data exchange activity with the Ethernet.
Table 2.7—Ethernet 2 (E2) Tool Side LED
Status LED Function Note
No Link Off The Tool module has no connection to
the Ethernet.
Link Green (solid) The Tool module is connected to the
Ethernet but there is currently no data
exchange activity.
Active RX/TX Red (ashing)
Green (solid) There is sporatic data exchange activity with the Ethernet.
PROFINET connection
established Red (solid)
Green (solid) There is continuous data exchange activity with the Ethernet.
Figure 2.2 —Master Module LED and Reset Button
Bus Failure (BF) LED
Ethernet (E1) LED
Master Side Ethernet Port
Ethernet (E2) LED
Tool Side Ethernet Port
System Failure (SF) LED
Reset Button
(Reset to Factory Settings)
(2) M3 Captive Head Screw
Window

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2.1.5 Reset To Factory Push Button
A push button, located under the LED window cover between the E2 and BF LED allows the
user to perform a “Reset To Factory” function which clears the PROFINET Name Of Station
and the module’s IP address. This is useful when already congured devices get swapped or a
broken device gets replaced by an already congured device. See Section 6.2.2—DL12 Device
Replacement Procedures for a detailed device replacement procedure.
After the push button was pressed the SF LED will blink red, indicating that with the next power
cycle the Name of Station and IP address will be cleared.
Make sure to re‑apply the LED window cover after access to the push button is not needed
anymore.
2.2 Arc Prevention Circuit
The DL12 module incorporates ATI’s exclusive Arc Prevention Circuit. The Arc Prevention Circuit extends
the life of electrical power contacts by eliminating arcing caused by inductive loads and high inrush current
during coupling/uncoupling. TheArc Prevention Circuit makes it possible to couple/uncouple without
switching power off and prevents damage to the contacts.
In the DL12 module, the Arc Prevention Circuit controls the ON/OFF status of the following two power
signals:
‑Input and Logic power US1+
‑Output power US2+
2.2.1 Arc Prevention Circuit Behavior during Coupling
The behavior of the Arc Prevention circuit during coupling can be more clearly understood by
referring to Figure 2.3, which shows the power on timing diagram for the Arc Prevention Circuit.
Starting at the top of the diagram, the LATCH command is issued thus initiating locking of the Tool
Changer.
When the robot and Master approach the Tool for pick up, electrical contact between the Master
and Tool pin contacts occurs. Soon after the LATCH command is turned ON, the Arc Prevention
Circuit will turn on US1 and US2 power. The time delay between when the LATCH output is
turned ON to when power is actually available to the EOAT (time T1in the diagram) is less than 20
ms.
Important: TheArc Prevention Circuit will only allow power to pass to the Tool after the LATCH
command has been issued and the Master and Tool module’s electrical contacts are fully engaged.
Figure 2.3—Power-On Timing
PROFINET US1 and
US2 Power
to Tool
Electrical Contact
between Master and Tool
LATCH Output
ON
OFF
ON
OFF
ON
OFF
T1
T1 = Power Switch ON-delay

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2.2.2 Arc Prevention Circuit Behavior during Uncoupling
The behavior of the Arc Prevention Circuit during uncoupling can be more clearly understood by
referring to Figure 2.4, which shows the power‑off timing diagram for theArc Prevention Circuit.
Starting at the top of the diagram, the UNLATCH command is issued thus initiating uncoupling of
the Master and Tool.
Immediately after the UNLATCH command is issued, the Arc Prevention Circuit will turn off US1
and US2 power. The power‑off time delay between the UNLATCH command and the switching off
of power (designated T3in the diagram) is less than 100 ms.
Some time after power is turned off and the Master and Tool begin to separate, electrical contact
between Master and Tool Pin Contacts will be lost. This occurs with a delay, designated T4in the
diagram, after the UNLATCH command is issued. The magnitude of time T4is a function of many
factors, including the weight of the EOAT, the friction between Master and Tool alignment pins,
etc. but is usually not shorter than 300 ms.
Figure 2.4—Power-Off Timing
PROFINET US1 and
US2 Power
to Tool
Electrical Contact
between Master and Tool
UNLATCH Output
ON
OFF
ON
OFF
ON
OFF
T2
T2 = Power Switch OFF-delay
T3 = Tool Changer Unlock Time
T3

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2.3 Tool Module
The Tool module utilizes a rapid communication method to report the Tool‑ID information from the push
button switches to the Master module as soon as the Tool Changer or Utility Coupler is coupled. Typically
the Tool‑ID information is available to the Master within 150 ms from the time the Tool Changer or Utility
Coupler is coupled.
(5) push button switches are provided on the Tool module for setting of a Tool‑ID number.
If the plastic window and seal above the Tool‑ID switches are removed, ensure the seal and window are
re‑positioned correctly to prevent a leakage path to the module inside.
The Tool‑ID is available to the Master within 250 ms from the time the changer is coupled; otherwise a
Tool‑ID_Error shall be set in the bit map. If a Tool is not present the Tool‑ID is set to FFFFF. If the Master
and Tool are coupled and the Tool‑ID fails to be reported, a Tool‑ID_Error shall be set.
Figure 2.5—Tool-ID Switch Settings
Decrease (-) Digit
Increase (+) Digit
Set Tool-ID to an
Unique 1-Digit Number
for each Tool
Window
(4) M3 Captive
Head Screw
SW5 SW1
SW5 SW1

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2.4 Safety System
The safety system is designed to avoid unintentional Tool release, by integrating a non‑contact safety switch,
(2) pneumatically interconnected solenoid valves, dual relays, and (2) cross monitoring processors into the
safety circuit.
The (2) cross monitoring processors in the Master module determine, based on the status of all the safety
related inputs and outputs, when it is safe to execute an Unlatch command. The processors are linked by
hardwired I/O. If one processor detects a condition that differs from the other processor, its control logic
declares a fault preventing the Unlatch output. When the Tool is positioned safely in the tool stand or storage
location, the safety switch outputs close the V1 and V2 Relays that allows the Unlatch command to pass
from the Application Processors to the solenoid valves.
A second set of contacts on the V1 and V2 Relays also provide diagnostics to the Application Processors.
The valve adapter is equipped with (2) double solenoid valves. Valve adapter pressure and proximity sensor
outputs are evaluated by the Application Processors for diagnostic purposes.
Figure 2.6—Safety Circuit Diagram

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The safety switch (not included with module) is mounted on Tool side of the module. The actuator is
mounted to the tool stand. The safety switch is connected to the Tool module by a ve conductor M12 cable.
Refer to the dual double solenoid valve adapter manual (9620‑20‑C‑Jxx ValveAdapters with Dual Double
Solenoid, Valve Pass Through, Proximity and Pressure Sensors) for detailed information on the dual double
solenoid valve functionality.
CAUTION: It is required to use a PLe rated non-contact safety switch such as the
Euchner CES-AP with the module. Use of unapproved switches will void the PLd safety
rating. Contact ATI before using another safety rated switch.
Figure 2.7—Safety Switch (Modules Shown for Reference Only)
Non-Contact
Safety Switch
Switch
Actuator
Valve Module Spacer
9121-JR4-T Shown
Valve Module
9121-JR4-M Shown
Master Module
Tool Module
Non-Contact Switch
Interconnecting Cable
Tool Stand

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3. Installation
The modules are typically installed by ATI prior to shipment. The steps below outline the eld installation or
removal as required. For wiring information refer to Section 9—Drawings.
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.
3.1 Master Module Installation
NOTICE: If module being installed is not new “out of the box” and has been previously
commissioned refer to Section 6.2.2—DL12 Device Replacement Procedures for instructions.
Refer to Figure 3.1
Tools required: 5 mm Allen wrench (hex key)
Supplies required: Clean rag, Loctite®242
1. Place the Tool in a secure location.
2. Uncouple the Master and Tool plates.
3. Turn off and de‑energize all energized circuits (e.g. electrical, air, water, etc.).
4. Clean the mounting surfaces.
5. Place the module into the appropriate location on the valve adapter. Align the module with the valve
adapter using the dowels in the bottom of the ledge feature.
6. Apply Loctite 242 to the supplied (2) M6 socket head cap screws. Install the (2) M6 socket head screws
securing the module to the valve adapter using a 5 mm Allen wrench. Tighten to 70 in‑lbs (7.9 Nm).
7. If fasteners do not have pre‑applied adhesive, apply Loctite 242 to the supplied M6 socket head cap
screws. Install the (2) M6 socket head cap screws securing the module to the valve adapter and tighten to
70 in‑lbs (7.9 Nm).
8. Connect the valve adapter proximity sensor cable to (S1) and valve adapter pressure sensor cable to (S2)
connections on the module.
9. Connect the (L) Lock, (U) Unlock, and (R1 and R2) RTL sensor cable connectors to the module.
10. Connect the 5‑pin power cable and PROFINET cable connectors to the module.
11. Remove the 8 mm set screw from the FE ground terminal using a 5 mm hex key.
12. Connect the ground to the FE grounding terminal using a M8 customer supplied fastener.
13. The module will automatically get the name and IP address assigned.
14. After a few seconds, it should be operating on the network.
15. After the procedure is complete, resume normal operation.