ATI Technologies UA8 User manual

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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Table of Contents
H. Other Modules ........................................................................................2
UA—Stud Welding (Utility) Modules..........................................................2
1. Product Overview .......................................................................................................... 2
1.1 Electrical Modules .....................................................................................3
1.1.1 J16 Pattern mounted electrical modules ................................................. 3
2. Installation ..................................................................................................................... 3
2.1 Module Installation.....................................................................................3
2.2 Module Removal........................................................................................4
2.3 Master Module Swivel Installation .............................................................4
2.4 Master Module Swivel Removal ................................................................5
2.5 Tool Module Swivel Installation .................................................................5
2.6 Tool Module Swivel Removal ....................................................................6
3. Operation....................................................................................................................... 6
4. Maintenance .................................................................................................................. 6
4.1 O-Ring Seal Replacement.........................................................................8
4.2 Swivel Joint Inspection, cleaning, lubrication and Replacement................8
4.2.1 Master Swivel removal and installation ................................................... 8
4.2.2 Tool Swivel removal and installation ....................................................... 8
4.3 Compression Spring Inspection, cleaning, and Replacement ...................8
4.3.1 Compression Spring removal and installation ......................................... 8
4.4 Electrical module Pin Block Inspection and Cleaning................................9
4.5 Electrical Module Seal Replacement.........................................................9
5. Troubleshooting........................................................................................................... 11
6. Recommended Spare Parts......................................................................................... 11
7. Specifications .............................................................................................................. 12
8. Drawings ..................................................................................................................... 13
8.1 UA8 Utility Stud Feed Module, Service Parts Drawing ............................13
8.2 UA11 Master and Tool Utility Module Drawings ......................................14

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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H. Other Modules
UA—Stud Welding (Utility) Modules
1. Product Overview
The utility module described here is used in robotic applications where blow fed fasteners or studs are welded
to panels. Modules on the tool changer allow the transfer of fasteners, weld power, electric signal circuits, and
blow fed fasteners between the two halves. By incorporating such a tool change system, the same robot arm
can be used with various guns required for different stud sizes. The tool changer itself is pneumatically driven
into coupled or uncoupled positions and the various utilities for the gun are attached to the modules on it.
Electrical Modules can attach to the Utility Module Extension Arm. Refer to Section 1.1—Electrical Module
for further detail.
Table 1.1—Utility Module Interface Details
Model Feed Tube Connection I.D. Electrical Modules
UA8 1/4-Turn Feed Connection .573 Short chamfer RB26-M/R26R180-T
UA11 1/4-Turn Feed Connection .313 Short chamfer RB26-M/R26R180-T
Additional UA Modules are available. See Section 8—Drawings and contact ATI if further details are required.
Figure 1.1—Utility Stud Feed Modules

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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1.1 Electrical Modules
Utility modules provide J16 pattern, rail, and ledge mountings for electrical modules. Refer to Table 1.1
for the option electrical module available for a specific utility module.
1.1.1 J16 Pattern mounted electrical modules
Some utility modules provide J16 pattern mounting for the RB26-M R26R180-T Electrical
modules, for more details on this electrical module refer to the 9620-20-E-RB26-M R26R180-T
section of your manual.
Figure 1.2—J16 Pattern Mounted Electrical Modules
2. Installation
The UA modules have one or two pneumatic stud feed tube connections. Threaded adapters and electrical
modules may be specified at the time of order to support customer-supplied tubes and signal requirements. The
module can be removed from the tool changer for ease of tube attachment.
The Utility Stud Feed Tube modules are typically installed by ATI prior to shipment. The steps below outline
field installation or removal as required.
2.1 Module Installation
1. It may be necessary to clean the mounting surface on the tool changer prior to installing the module in
order to remove any debris that may be present.
2. Using the ledge feature as a guide place the module into the appropriate location on the Tool Changer
body. Align the module with the Tool Changer using the dowels in the bottom of the ledge feature.
Refer to Figure 2.1.
3. If fasteners do not have pre-applied adhesive, apply Loctite 242®to the supplied M6 SHCS fasteners.
Install the two (2) M6 socket head screws securing the module to the Tool Changer and tighten to 40–
70 in-lbs.
4. Cables can be connected to the module after attaching the module to the Tool Changer body. Ensure
that the connectors are cleaned prior to being secured as appropriate
5. Connect customer stud feed tubes to the module.
WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the
tool is safely supported or docked in the tool stand and all energized circuits (e.g. electrical,
air, water, etc.) have been turned off. Injury or equipment damage can occur with tool not
docked and energized circuits on. Dock the tool safely in the tool stand and turn off all
energized circuits before performing maintenance or repair on Tool Changer or modules.

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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Figure 2.1—Module Installation
2.2 Module Removal
1. Prior to removing the module use a marker pen to scribe a line or indication between the Tool
Changer and module body as a reminder where the module is to be re-installed.
2. All customer tube connections to the module need to be purged and disconnected.
3. Depending upon the service or repair being done cable connections up to the module may or may
not need to be disconnected.
4. Remove the socket head cap screws and remove the module from the Tool Changer. Refer to
Figure 2.1.
2.3 Master Module Swivel Installation
1. Make sure housing is clean of debris, insert compression spring into housing.
2. Insert the race into housing so that the spherical inner contour that mates with the swivel faces
outward. Note: the race should slide up and down (when compressing the spring) freely.
3. Apply a thin coat of MobilGrease®XHP222 Special grease on the spherical inner contour of the
race.
4. Insert the swivel into the race, apply pressure to compress the spring and secure from opposite side
with the retaining ring. Note: If retaining ring is a snap type ring use snap ring pliers to install the
retaining ring.
5. Insert the O-ring into the groove in the face of the Swivel and lightly lubricate.
DANGER: For electrical modules using > 60VDC or 42VAC, NO contact should
be attempted before removing power. This includes attaching and disconnecting
cables to mating connectors or any contact with the Tool Changer or its
components. Arcing and damage will occur if this is not observed. Remove power
before attaching, disconnecting any cables or attempting any maintenance of Tool
Changer.

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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Figure 2.2—Master Module Swivel Installation
2.4 Master Module Swivel Removal
1. Apply pressure to the swivel to compress the spring and remove the retaining ring from the back
of the swivel. Refer to Figure 2.2. Note: If retaining ring is a snap type ring use snap ring pliers to
remove the retaining ring.
2. Remove the swivel from the housing.
3. Pull the race out of the housing.
4. Remove the compression spring from the housing.
2.5 Tool Module Swivel Installation
1. Make sure housing is clean of debris.
2. Apply a thin coat of MobilGrease®XHP222 Special grease on the spherical inner contour of the
race.
3. Insert the swivel into the race and secure from opposite side with the retaining ring. Note: If
retaining ring is a snap type ring use snap ring pliers to install the retaining ring.
Figure 2.3—Tool Module Swivel Installation

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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2.6 Tool Module Swivel Removal
1. Remove the retaining ring from the swivel. Note: If retaining ring is a snap type ring use snap ring
pliers to remove the retaining ring.
2. Remove the swivel from the housing.
3. Operation
The Utility Stud Feed modules are designed to pass studs/air from the Master to the Tool for use by the
customer’s tooling. A unique, patented stud feed-through mechanism has been developed by ATI for this
application. A spring-loaded ball joint mechanism is used to transfer solid studs between the mating halves.
This produces self-alignment between the Master and Tool sides, while simultaneously allowing axial and
rotational degrees of freedom to the feed tube. Traditionally, the feed tube looses its flexibility at the joint to
the tool changer and therefore this location is prone to premature failure from excessive strain. Using a large
tube bend radius at this joint only somewhat alleviates the problem. ATI’s method allows the joint to maintain
its flexibility and therefore completely eliminates any strain on the tube. After passing through the tool
changer, the Master and Tool halves of the tube behave as one integral unit.
To provide a large bend radius to the tube, the feed-through attachment is offset from the center of the tool
changer, thereby providing ample clearance from the robot wrist. Extension arms of various lengths are
available from ATI to provide this offset.
Electrical Modules can attach to the Utility Module Extension Arm. Refer to the corresponding specific
electrical module section of the modular manual for further detail.
4. Maintenance
Once installed, the operation of the Utility Stud Feed modules is generally trouble-free. Periodically, the
condition of the spherical joints should be checked. Replace any damaged or degraded components as
necessary.
Electrical Modules can attach to the Utility Module Extension Arm. Refer to the corresponding specific
electrical maintenance instructions for further detail.
Under normal conditions, no special maintenance is necessary, however it is recommended that periodic
inspections be performed to assure long-lasting performance and to assure that unexpected damage has not
occurred. Perform the following visual inspection monthly:
Inspect mounting fasteners to verify they are tight and if loose, then tighten to the proper torque.
Cable connections should be inspected during maintenance periods to ensure they are secure. Loose
connections should be cleaned and re-tightened as appropriate. Inspect cable sheathing for damage, repair or
replace damaged cabling. Loose connections or damaged cabling are not expected and may indicate improper
routing and/or strain relieving.
Inspect the O-ring seal on the swivel for wear or damage. If worn or damaged, replace. Refer to Section 4.1—
O-Ring Seal Replacement.
WARNING: Do not perform maintenance or repair on Tool Changer or modules unless
the tool is safely supported or docked in the tool stand and all energized circuits (e.g.
electrical, air, water, etc.) have been turned off. Injury or equipment damage can occur
with tool not docked and energized circuits on. Dock the tool safely in the tool stand and
turn off all energized circuits before performing maintenance or repair on Tool Changer
or modules.
DANGER: For electrical modules using > 60VDC or 42VAC, NO contact should be
attempted before removing power. This includes attaching and disconnecting cables or
any contact with the Tool Changer or its components. Arcing and damage will occur if
this is not observed. Remove power before attaching, disconnecting any cables or
attempting any maintenance of Tool Changer.

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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Inspect stud feed swivel joints for proper movement and lubrication. Refer to Section 4.2—Swivel Joint
Inspection, cleaning, lubrication and Replacement.
Inspect the compression spring for proper operation. Refer to Section 4.3—Compression Spring Inspection,
cleaning, and Replacement.
Inspect the Master and Tool pin blocks for any pin damage, debris or darkened pins. Refer to Section 4.4—
Electrical module Pin Block Inspection and Cleaning.
Inspect V-Ring seals for wear, abrasion, and cuts. If worn or damaged, replace. Refer to Section 4.5—
Electrical Module Seal Replacement.
The modules may be field serviced as needed. The following section describes how to perform various
operations.

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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4.1 O-Ring Seal Replacement
1. To replace the o-ring seals, use a small screwdriver or similar tool to gently pry the seal away
from the swivel block on the Master side, and then pull the o-ring off the swivel.
2. To install a new seal, stretch it around the groove in the block and use a small screwdriver to push
the ring down fully against the recess in the insulator block.
3. Lightly lubricate the o-ring.
Figure 2.4—O-ring Seal Replacement
4.2 Swivel Joint Inspection, cleaning, lubrication and Replacement
Inspect both the Master and Tool swivel joint components, make sure swivels rotate freely. If not
remove swivel, clean and lubricate components and reinstall. If components are worn or damaged
replace.
4.2.1 Master Swivel removal and installation
To remove the existing Master swivel use the procedure in Section 2.4—Master Module Swivel
Removal.
To install the new Master swivel use the procedure in Section 2.3—Master Module Swivel
Installation.
4.2.2 Tool Swivel removal and installation
To remove the existing Tool swivel use the procedure in Section 2.6—Tool Module Swivel
Removal .
To install the new Tool swivel use the procedure in Section 2.5—Tool Module Swivel
Installation.
4.3 Compression Spring Inspection, cleaning, and Replacement
The Master side swivel joints provide axial compliance using compression springs.
Inspect master swivel joint, press on the swivel to make sure the swivel and race move up and down
freely in the housing. If not remove the Swivel, race, and spring and clean the components and housing,
then reinstall.
The spring should maintain pressure on the race and swivel so that the retaining ring on the back is held
tight against the housing. If not, the compression spring should be replaced.
4.3.1 Compression Spring removal and installation
To remove the existing compression spring use the procedure in Section 2.4—Master Module
Swivel Removal.
To install the new compression spring use the procedure in Section 2.3—Master Module Swivel
Installation.

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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4.4 Electrical module Pin Block Inspection and Cleaning
Inspect the Master and Tool pin blocks for any debris or darkened pins.
Figure 4.1—Inspect Master and Tool Pin Blocks
If debris or darkened pins exist, remove debris using a vacuum, and clean using a nylon brush (ATI part
number 3690-0000064-60).
Inspect the Master and Tool pin blocks for stuck pins or severe pin block damage.
Figure 4.2—Stuck Pin and Pin Block Damage
If stuck pins or severe pin block damage exists, contact ATI for possible pin replacement procedures or
module replacement.
4.5 Electrical Module Seal Replacement
Replace the V-Ring seal:
To remove the existing seal, pinch edge of seal with fingers and gently pull the seal away from the pin
block on the Master.
Pull the seal off the pin block.
NOTICE: Do not use an abrasive media, cleaners, or solvents to clean the contact pins.
Using abrasive media, cleaners, or solvents will cause erosion to the contact surface.
Clean contact surfaces with a vacuum or non-abrasive media such as a nylon brush
(ATI part number 3690-0000064-60).

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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To install a new seal, stretch the new seal over the shoulder of the pin block.
Push the seal’s hub down against the pin block using finger tip.
Figure 4.3—V-Ring seal Replacement

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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5. Troubleshooting
The Utility Stud Feed modules provide a separable joint in the tube connection between various stud feed supply sources.
Symptom
Possible Cause
Correction
Stud feed fails
to operate
Pinched, torn, or fatigued
stud feed tube
Inspect stud feed tubes and replace tubes as needed
Air leaking – Object
trapped between modules
Remove object, then re-attempt coupling.
Air leaking – Swivel Joint
O-ring seals worn,
damaged, or debris
between
Clean in and around swivel joint components. Ensure air stream
is free of large particulates, filter as necessary.
Inspect O-ring seals if worn or damaged, replace O-rings, refer
to Section 4.1—O-Ring Seal Replacement.
Air leaking – Swivel Joint
components worn, not
moving freely, or damaged
Inspect swivel joint components, make sure swivel rotates freely,
if not remove swivel clean and lubricate components and
reinstall. If components are worn or damaged replace. Refer to
Section 4.2—Swivel Joint Inspection, cleaning, lubrication and
Replacement.
Air leaking – Swivel Joint
compression spring not
maintaining tight pressure
between modules
Inspect master swivel joint, press on the swivel to make sure the
swivel and race move up and down freely in the housing. If not
remove the Swivel, race, and spring and clean the components
and housing, refer to Section 2.4—Master Module Swivel
Removal.Replace and lubricate components, refer to Section
2.3—Master Module Swivel Installation.
The compression spring provides axial compliance. The spring
should maintain pressure on the race and swivel so that the
retaining ring on the back is held tight against the housing. If not,
the compression spring should be replaced, refer to Section
4.3—Compression Spring .
Loss of
Communication
or Servo Motor
intermittently
functioning or
not functioning
at all
Electrical/Servo Module
Contact Pin Contamination
or damaged
Ensure that the spring pins on the Master-side can move freely
and are not bound by debris. Clean the spring pins. Clean Tool-
side module contacts refer to Section 4.4—Electrical module Pin
Block Inspection and Cleaning. Inspect seal, replace if damaged
refer to Section 4.5—Electrical Module Seal Replacement.
Contact Pin Separation due
to air supply to Tool
Changer
Ensure that the Tool Changer has proper pneumatic connections
and air is supplied to proper specification. Refer to Tool changer
section of this manual for air supply requirements.
Coupling/Uncoupling Tool
Changer under load.
Revise operating procedures to only couple/uncouple with power
disconnected and discharged. Field replacement of module
contacts is not possible.
Cable Damage: Pinched,
torn, or fatigued cables
Examine cables for damage, perform a continuity test on cables
and replace any bad cables.
Servo Module damaged Refer to Servo module manual troubleshooting section.
Drive or Motor damaged Refer to Servo module manual troubleshooting section.
6. Recommended Spare Parts
For your specific module refer to Section 8—Drawings.

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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7. Specifications
Utility Stud Feed Module
UA Modules
Weights
(Weights include the
Electrical or Servo
modules)
3.53 lbs. (1.6 kg.)
2.33 lbs. (1.1 kg.)
UA8-M
UA8-T
5.06 lbs. (2.30 kg.)
3.75 lbs. (1.70 kg.)
UA11-M
UA11-T
Materials of Construction Various Hardened stainless steel swivel joints and
adapters, T6 aluminum extension arm
and swivel housings
Tube Sizes Supported 3/4 BSPP
(Others, Contact ATI)
Threaded adapters can be used to attach
the feed tubes to the pass-through ports.
1/4-Turn Feed Connection 1/4 –Turn feed adapters can be used to
attach the feed tubes to the pass-through
ports.
Stud Size 13 mm max. diameter Stud feed-through up to 16mm maximum
head diameter and smaller is stocked.
Contact ATI for other sizes.
Tube Flexibility 5° Off Normal 360° Rotation The tube retains its flexibility to move with
robots motions, so experience no strain at
the joint.

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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8. Drawings
8.1 UA8 Utility Stud Feed Module, Service Parts Drawing

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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8.2 UA11 Master and Tool Utility Module Drawings

Quick-Change Installation and Operation Manual
Document #9620-20-H-UAx-13
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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