ATI Technologies 9150-CGV-900 User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com
ATI Pneumatic Angle Grinder
(Model 9150‑CGV‑900)
Product Manual
Document #: 9610-50-1056

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
2
Foreword
CAUTION: This manual describes the function, application, and safety considerations of this
product. This manual must be read and understood before any attempt is made to install or
operate the product, otherwise damage to the product or unsafe conditions may occur.
Information contained in this document is the property of ATI Industrial Automation, Inc (ATI) and shall not be
reproduced in whole or in part without prior written approval of ATI. The information herein is subject to change without
notice. This manual is periodically revised to reect and incorporate changes made to the product.
The information contained herein is condential and reserved exclusively for the customers and authorized agents of ATI
Industrial Automation and may not be divulged to any third party without prior written consent from ATI. No warranty
including implied warranties is made with regard to accuracy of this document or tness of this device for a particular
application. ATI Industrial Automation shall not be liable for any errors contained in this document or for any incidental
or consequential damages caused thereby. ATI Industrial Automation also reserves the right to make changes to this
manual at any time without prior notice.
ATI assumes no responsibility for any errors or omissions in this document.
Copyright © (2023) by ATI Industrial Automation. All rights reserved.
How to reach us:
Sale, Service and Information about ATI products:
ATI Industrial Automation
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati‑ia.com
Tel: [phone]
Fax: [phone]
Application Engineering
Tel: [phone]
Fax: [phone]
E-mail: ATI‑[email protected]
24/7 Support:
+1 855 ATI-IA 00 ([phone])

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
3
Table of Contents
Glossary........................................................................................................................................... 5
1. Safety......................................................................................................................................... 6
1.1 ExplanationofNotications.........................................................................................................6
1.2 General Safety Guidelines............................................................................................................6
1.3 Safety Precautions........................................................................................................................6
2. Product Overview..................................................................................................................... 7
2.1 Technical Description ...................................................................................................................8
2.1.1 Environmental Considerations ...........................................................................................8
2.1.1.1 Operation............................................................................................................8
2.1.1.2 Storage...............................................................................................................8
2.2 Compliance Unit Performance.....................................................................................................9
3. Guidelines for Transporting, Unpacking, and Storing the CGV......................................... 10
3.1 Protection During Transportation..............................................................................................10
3.2 Inspect the Product Condition When Delivered.......................................................................10
3.3 Unpacking and Handling............................................................................................................10
3.4 Storage and Preventive Maintenance During Storage.............................................................10
4. Installation ...............................................................................................................................11
4.1 General Guidelines: .................................................................................................................... 11
4.2 Robot Mounting Options............................................................................................................ 11
4.3 Installation Procedure.................................................................................................................13
4.4 Optional Installation of Accessories .........................................................................................14
4.4.1 Exhaust Assembly (ATI P/N 9005‑50‑6273).....................................................................14
4.4.2 Position Sensing...............................................................................................................15
4.4.3 90° Mounting Bracket (ATI P/N 9005‑50‑6274)................................................................16
4.5 Pneumatic Connections .............................................................................................................18
4.6 M8 Sensor Connection ...............................................................................................................19
4.7 Sensor Assembly Cable (P/N 9105-C-ZC27-ZC28) ...................................................................20
4.8 Set-up of the RS485 Communication Interface........................................................................20
5. Operation ................................................................................................................................ 23
5.1 Tool Working Environment.........................................................................................................23
5.2 Safety Precautions......................................................................................................................23
5.3 Normal Operation........................................................................................................................24
5.3.1 Air Quality.........................................................................................................................24
5.3.2 Lubrication........................................................................................................................24
5.3.3 Media Selection................................................................................................................24
5.3.4 CGV Approach Path Should Be Slow and at anAngle.....................................................24

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
4
5.3.5 No Radial Loads...............................................................................................................24
5.3.6 Program the Robot to Incorporate 50% Compliance Travel of the Tool...........................24
5.4 Gravity Compensation................................................................................................................24
5.5 LEDs Normal Operation..............................................................................................................25
6. RS485 Serial Console Interface ............................................................................................ 26
6.1 Serial Console Commands.........................................................................................................26
6.2 Help Command: “help”, “h”, or “?”...........................................................................................27
6.3 MANCAL Command ....................................................................................................................28
6.4 FASTCAL Command ...................................................................................................................28
6.5 Save All Command: “saveall”....................................................................................................28
6.6 FlowCommand:“ow”...............................................................................................................29
6.7 Status Command: “status” ........................................................................................................30
6.8 Reset Command: “reset”............................................................................................................31
6.9 Stream Command: "stream [HDBXYZTP%OR]".......................................................................32
6.10 Set/Cal Commands......................................................................................................................33
6.11 Filter"lTC"Parameters.............................................................................................................34
6.12 Baud Rate Command: “set baud...............................................................................................35
7. Maintenance............................................................................................................................ 36
7.1 Routine Operational Maintenance.............................................................................................36
7.1.1 Gearhead Assembly Maintenance ..................................................................................36
7.2 Media Replacement.....................................................................................................................36
7.3 Utilities .........................................................................................................................................36
8. Troubleshooting and Service Procedures ........................................................................... 37
8.1 Troubleshooting for Material Finishing.....................................................................................37
8.2 Troubleshooting for the Sensor Assembly...............................................................................37
8.3 Service Procedures.....................................................................................................................37
8.3.1 Media Installation .............................................................................................................38
8.3.2 Media Removal ................................................................................................................38
9. Parts and Accessories........................................................................................................... 39
9.1 Replacement Parts......................................................................................................................39
10. Specications ......................................................................................................................... 40
11. Drawings ................................................................................................................................. 40
12. Terms and Conditions of Sale............................................................................................... 41
12.1 Motor Life and Service Interval Statement................................................................................42
12.1.1 Vane Motor Products........................................................................................................42

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
5
Glossary
Term Denition
Air Filter Device for removing contamination from air supply lines. Typically refers to removal
of particulates.
Baud Rate A number that is related to the speed of data transmission in a system. The data indicates the number of electrical oscillations per second that occurs within a
data transmission.
Coalescing Filter Device that removes liquid aerosols from the supply air lines.
Compliance The ability of the motor to passively move in response to protrusions on or
deviations of the work piece.
Compliance Assembly The upper body of the unit which includes the mounting features
Communication
Interface Version The software standard that the customer device uses to apply features to the sensor and for the sensor to report data, for example: RS485.
Float A data type: IEEE 754-2008 binary32 (or ‘single’) oating point number.
Gearhead Tool subcomponent used for transferring output shaft 90°to media.
Hall Effect
The production of a potential difference across an electrical conductor
when a magnetic eld is applied in a direction perpendicular
to that of the ow of current. An optional sensor assembly in the CGV uses
a hall effect sensor to detect the tool position during gravity compensation.
IIR Innite Impulse Response is a digital signal lter that uses a feedback mechanism
based on current and output data.
IP67 Ingress protection rating “67” designates protection against dust and submersion under 1 m
of fresh water. This IP rating only applies to the optional sensor assembly cable.
Interface Plate Device for attaching the tool to robots or work surfaces.
Main Housing The main body of the unit which includes the motor and gearhead.
MCU Microcontroller unit. A part of the software and electronics of the sensor. The MCU contains a
computer processing unit that includes memory.
Media Term referring to tools and/or abrasives held by the tool during the completion of a
manufacturing process.
Motor The rotating device of the tool assembly.
N/A Not/Applicable
NVM Non‑Volatile Memory. Storage of information or device memory that can be retrieved even
after the device goes through a power cycle (turned off and then back on).
Qty Quantity
Regulator Device used to set and control the supplied air pressure to lower acceptable levels.
Solenoid Valve Electrically controlled device for switching air supplies on and off.
STRINGnString of ncharacters
STRING(20) A data type representing (20) characters, using (20) bytes.
STRING(32) A data type representing (32) characters, using (32) bytes.
STRING(40) A data type representing (40) characters, using (40) bytes.
STRING(100) A data type representing (100) characters, using (100) bytes.
uint8 A data type that is an 8‑bit unsigned integer.
uint16 A data type that is a 16‑bit unsigned integer.
uint32 A data type that is a 32‑bit unsigned integer.

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
6
1. Safety
The safety section describes general safety guidelines to be followed with this product, explanations of the
notications found in this manual, and safety precautions that apply to the product. More specic notications are
embedded within the sections of the manual (where they apply).
1.1 ExplanationofNotications
These notications are used in all of ATI manuals and are not specic to this product. The user should heed
all notications from the robot manufacturer and/or the manufacturers of other components used in
the installation.
DANGER: Notication of information or instructions that if not followed will result in
death or serious injury. The notication provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
WARNING: Notication of information or instructions that if not followed could result
in death or serious injury. The notication provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
CAUTION: Notication of information or instructions that if not followed could result
in moderate injury or will cause damage to equipment. The notication provides
information about the nature of the hazardous situation, the consequences of not
avoiding the hazard, and the method for avoiding the situation.
NOTICE: Notication of specic information or instructions about maintaining, operating,
installing, or setting up the product that if not followed could result in damage to equipment. The
notication can emphasize, but is not limited to: specic grease types, best operating practices,
and maintenance tips.
1.2 General Safety Guidelines
Before installation or operation of the CGV, rst read and understand the operating procedures and
information described in this manual. Never use the CGV for any purpose not explicitly described in this
manual. Follow installation instructions and pneumatic connections as described in this manual.
All pneumatic ttings, tubing, and electrical lines must be capable of withstanding the repetitive motions of
the application without failing. The routing of pneumatic and electrical lines must minimize the possibility
of stress/strain, kinking, rupture, etc. Failure of critical pneumatic lines to function properly may result in
equipment damage.
1.3 Safety Precautions
CAUTION: Do not use serviceable parts other than original ATI serviceable parts. Use
of serviceable parts not supplied by ATI can damage equipment and void the warranty.
Always use original ATI serviceable parts.
CAUTION: Do not perform maintenance or repair on the CGV product unless the tool
is safely supported or placed in the tool stand and air has been turned off. Injury or
equipment damage can occur with tool not placed in a tool stand and air remaining
on. Place the tool safely in the tool stand and turn off the air before performing
maintenance or repair on the CGV product.

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
7
2. Product Overview
ATI's Compliant Pneumatic Robotic Angle Grinder (CGV) is a compliant tool that is best for nishing, blending,
and light grinding operations. The CGV can be a replacement for handheld grinders and is compatible with
industry-standard grinding media such as ap wheels, sanding discs, and wire brushes. The CGV has a strong
pneumatic vane motor with high-torque performance and has minimal noise and vibration. Here are other important
features and benets of the CGV:
• Can mount to a robot arm with a bolt-up or bolt-down pattern, or 30-degree angled mounting pattern
(for mounting pattern geometry, refer to Section 11—Drawings)
• Has an optional 90° mounting bracket that rotates the main housing for applications such as a cut-off
wheel (refer to Section 4.4.3—90° Mounting Bracket (ATI P/N 9005‑50‑6274))
• Has built-in compliance that reduces robot programming
• Has compliance travel position sensing, through RS485 communication, that monitors media wear and
part differences
• Has gravity compensation that provides consistent force in any orientation
The CGV's adjustable compliance force maintains a constant force along surface irregularities and gives on-
demand adjustments that achieve the desired surface nish.
The CGV assembly has two main components. The compliance assembly bolts to a robot/bench and controls
the CGV's motion. The grinding tool component attaches to the bottom part of the assembly. ATI can also
provide an exhaust assembly that collects oil from the motor exhaust slots into a mufer or can be adapted
to a customer-supplied oil recovery system.
Figure 2.1—Overview
Compliance assembly
Main housing
LEDs indicate
tool travel position
Top mounting surface
(bolt‑up or bolt‑down pattern)
Angled mounting surface
(ISO50 bolt‑down pattern)
Motor air inlet
Retract compliance air port and fitting
Extend compliance air port and fitting
(current position)
M8 8‑pin connector
on sensor assembly
(available on ‑S1 models)
Motor exhaust slots
Angle grinder
vane motor
Gearhead and
arbor shaft for
media

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
8
2.1 Technical Description
A technical overview of the product is provided in the following tables and graphs. For additional technical
specications, refer to Section 10—Specications.
2.1.1 Environmental Considerations
2.1.1.1 Operation
Table 2.1—Operation
Installation position Mounted to robot or xed post/bench by various
means, customer‑supplied tool holders/adapters.
Temperature range 41 °F – 95 °F
5 °C – 35 °C
Utilities
The tool requires the following:
• Clean, dry, ltered, and lubricated air
• A coalescing lter and lter elements that are
rated 5 micron or better.
• The axial force/compliance air supplied from a
regulated source and must not exceed 40 psi
(2.75 bar).
2.1.1.2 Storage
Table 2.2—Storage
Conditions
The tool should be stored in its crate located in a
cool, dry place.
When not in use, keep the unit in its crate, if
possible. Consult Section 3.4—Storage and
Preventive Maintenance During Storage of this
manual.

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
9
2.2 Compliance Unit Performance
The force from the compliance mechanism varies linearly with air pressure as shown in Figure 2.2. This
shown compliance force does not include the friction or weight of the attached tooling. Therefore, when
calculating this force, customers should include the weight of the motor assembly (5.1 lbs or 2.3 kg),
additional accessories, and the tool's orientation.
If the CGV is pointed upward, this weight reduces the net compliance force. Therefore, to achieve the
desired compliance force, the CGV needs a higher operating pressure. But if the CGV is pointed downward,
this weight increases the total compliance force. Therefore, to achieve the desired compliance force, the
CGV needs a lower operating pressure (or a higher pressure applied to the retract compliance tting).
Figure 2.2—Compliance Force Curves
0.00 0.34 0.69 1.03 1.38 1.72 2.07 2.41 2.76 3.10
0
9
18
27
36
44
53
62
0
2
4
6
8
10
12
14
16
0 5 10 15 20 25 30 35 40 45
Compliance Air Pressure (Bar)
Compliance Force (N)
Compliance Force (lbs)
Compliance Air Pressure (PSI)

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
10
3. Guidelines for Transporting, Unpacking, and Storing the CGV
3.1 Protection During Transportation
The CGV arrives in packaging that secures and protects the tool during transportation.Always use this
packaging to safely transport the CGV.
3.2 Inspect the Product Condition When Delivered
Upon receipt, verify the following:
• The product is delivered in accordance with freight documents.
• The product's packaging is in good condition.
If there is damage to any of the packaging, or if any of the goods have been exposed to abnormal handling,
thoroughly inspect and verify that the products are not damaged. Contact ATI for assistance.
3.3 Unpacking and Handling
Always place the CGV inside the provided packaging, while transporting, storing, and handling the product.
3.4 Storage and Preventive Maintenance During Storage
For short-term storage, place the tool in its provided packaging and store in a dry place.
For long-term storage, clean the CGV thoroughly for any dust or debris before storing the product. The
unit should not be disassembled. Place the tool inside a sealed, plastic bag and place the bagged tool
inside the crate.

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
11
4. Installation
4.1 General Guidelines:
• Mount the tool onto a rigid xture, prior to use.
• Do not use the unit for handheld operations.
• Supply the unit with clean air ltered (5) micron or better. The use of a coalescing lter is
recommended to remove trace moisture from the air supply. Lubrication is required for the
motor supply air.
4.2 Robot Mounting Options
When used with a robot, the CGV has three available mounting patterns:
• An ISO50 bolt-down pattern, which is located on an angled surface on the rear of the tool
• A bolt-up pattern, which is located on the top of the tool (refer to Figure 4.2)
• A bolt-down pattern, which is located on the top of the tool
For more information on the mounting patterns, refer to Section 11—Drawings.
Figure 4.1—Tool Mounting Patterns
ISO50 bolt‑down pattern
on the angled surface
A bolt‑down or bold‑up pattern
on the top surface.
Interface plate ATI P/N 9005‑50‑6267
is for a bolt‑up configuration.

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
12
Figure 4.2—Bolt-up Top Surface (ATI Interface Plate Kit P/N 9005-50-6267)
(4) M5 socket head cap screws
(4) M6 socket head cap screws*
Interface plate
ATI P/N 3700‑50‑9282
(2) M6 dowel pin*
(2) M6 dowel pin
Compliance assembly
*These dowel pins and screws are for mounting
to a ISO50 bolt pattern on the robot or customer device.
Table 4.1—ATI Interface Plate Kit For ISO50 Bolt Pattern (P/N 9005-50-6267)
Part Number Quantity Description
3500‑1064035‑15A 4 M5‑0.8 x 35 mm socket head cap screw, CPC,
pre‑applied threadlocker
3500‑1066012‑15A 4 M6‑1 x 12mm socket head cap screw, Blue, pre‑applied
threadlocker
3540‑0106012‑11 4 6 mm x 12 mm dowel pin, alloy steel
3700‑50‑9282 1 Interface plate, CGx compliance to these customer congurations: 50 mm bolt circle, 31.5 bolt circle, or ATI
QC‑22 Tool Changer

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
13
4.3 Installation Procedure
Parts required: Refer to Section 9—Parts and Accessories
Supplies required: Loctite®242, M5 or M6 socket head cap screws
Tools required: 4 or 5 mm hex key wrench, torque wrench
The CGV can be installed to a robot/interface plate using one of the three mounting patterns: bolt-up or
bolt-down on the top of the compliance assembly; or bolt-down on the angled surface on the rear of the
compliance assembly.
If using the interface plate kit (P/N 9005-50-6267), rst install the interface plate to the robot or customer
device with the (4) M6 socket head cap screws. Then install the CGV.
For installation instructions of the 90° mounting bracket for a cutoff wheel application, refer to
Section 4.4.3—90° Mounting Bracket (ATI P/N 9005‑50‑6274).
The following procedure outlines the standard installation process for the CGV:
1. Apply Loctite 242 to the mounting fasteners for the CGV.
2. Install the appropriate screws to the CGV for the chosen mounting pattern (refer to Figure 4.1):
a. For the bolt-down/ angle mounting pattern, install M6 socket head cap screws.
b. For the bolt-up pattern, install M5 socket head cap screws.
3. Secure the CGV to the robot/interface plate:
a. For the bolt-down or angle pattern, use a 5 mm hex key to tighten the M6 screws to
89 in-lbs (10.1 Nm).
b. For the bolt-up pattern, use a 4 mm hex key to tighten the M5 screws to 52 in-lbs (5.9 Nm).
4. Connect the compliance air supply to the air ttings on the side of the compliance assembly (refer
to Figure 2.1).
5. Install media to the gearhead shaft; for instructions, refer to Section 8.3.1—Media Installation.
6. (Optional) Install the exhaust mufer assembly. Refer to Section 4.4.1—Exhaust Assembly (ATI
P/N 9005‑50‑6273).
7. Connect the motor air supply to the air tting on the rear of the CGV (refer to Figure 2.1).
8. (Optional for position sensing) Connect the 8-pin M8 connection on the cable to the sensor assembly.
Refer to Section 4.4.2—Position Sensing.
9. Safely start normal operation.

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
14
4.4 Optional Installation of Accessories
4.4.1 Exhaust Assembly (ATI P/N 9005-50-6273)
Parts required: Refer to Section 9—Parts and Accessories
Tools required: 2 mm hex key, spanner wrench or box wrench
Supplies required: Magnalube
1. Apply a thin layer of Magnalube to the O-rings inside the exhaust assembly.
2. Slide the exhaust assembly over the motor exhaust slots.
NOTICE: When installing the exhaust mufer, orient the mufer so that the compliance
mechanism has full range of motion.
3. Install the snap ring to prevent the assembly from sliding along the motor.
4. Rotate the mufer to the desired orientation.
5. Use a 2 mm hex key to install (2) M4 set screws that prevent the assembly from rotating.
6. Install the exhaust mufer or connect a hose to the G 1/2 (BSPP) port that routes to a customer-
supplied oil recovery system.
Figure 4.3—Optional Exhaust Assembly Installation
Motor air inlet
Motor exhaust slots
(2) M4 set screw
Snap ring
Exhaust assembly
Muffler
G 1/2 (BSPP) port
for either a muffler or for routing a hose
to a customer‑supplied oil recovery system
Apply magnalube
to the O‑rings in the
exhaust assembly.

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
15
4.4.2 Position Sensing
1. Connect a sensor cable such as ATI P/N 9105-C-ZC27-ZC28 to the M8 connector on the
compliance housing. For connector pinouts, refer to Section 4.6—M8 Sensor Connection and
Section 4.7—Sensor Assembly Cable (P/N 9105‑C‑ZC27‑ZC28).
2. To connect power and either an analog or serial connection, refer to the connection pinout
descriptions in Section 4.6—M8 Sensor Connection or Section 4.7—Sensor Assembly Cable
(P/N 9105‑C‑ZC27‑ZC28).
a. For setting up a serial interface, refer to Section 4.8—Set‑up of the RS485
Communication Interface.
Figure 4.4—CGV Electrical Connection for Position Sensing
M8 8‑pin male connector
for position sensing

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
16
4.4.3 90° Mounting Bracket (ATI P/N 9005-50-6274)
Parts required: Refer to Section 9—Parts and Accessories
Tools required: 2.5 mm, 5 mm hex key, T20 Torx®bit, torque wrench
Supplies required: Locite®222, 242, and 7649
1. Remove the lower crossbar:
a. Use a 2.5 mm hex key to unscrew the (4) M3 socket head cap screws.
b. Lift the lower crossbar from the compliance assembly.
2. Remove the upper crossbar:
a. Use a T20 Torx bit to unscrew the (4) M4 socket at head cap screws.
b. Lift the upper crossbar from the compliance assembly.
3. Remove the compliance assembly from the main housing:
a. Use a 5 mm hex key to unscrew the (4) M6 socket head cap screws.
b. Lift the compliance assembly from the main housing.
Figure 4.5—Remove the Compliance Assembly
(4) M6 socket head cap screws
Main housing
Compliance assembly
(4) M3 socket head
cap screws
Lower crossbar
Upper crossbar
(4) M4 socket flat head cap screws
Pivot the compliance assembly
to remove the M4 socket flat
head cap screws.

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
17
NOTICE: The 90° mounting bracket and main housing have a 50 mm bolt pattern for
(4) M6 socket head cap screws and (2) M6 dowel pins. The bracket can be installed as
shown or rotated 180°.
4. Install the 90° mounting bracket to the main housing:
a. Apply Loctite 242 to the threads of the (4) M6 socket head cap screws that are part of the
mounting bracket kit.
b. Secure the bracket to the main housing with the (4) M6 socket head cap screws. Use a 5
mm hex key to tighten the screws 89 in-lbs (10.06 Nm).
5. Install the compliance assembly to the 90° mounting bracket:
a. Apply Loctite 242 to the threads of the (4) M6 socket head cap screws.
b. Secure the compliance assembly to the mounting bracket with the (4) M6 socket head cap
screws. Use a 5 mm hex key to tighten the screws 89 in-lbs (10.06 Nm).
6. Install the lower crossbar to the compliance assembly:
a. Apply Loctite 222 to the threads of the (4) M3 socket head cap screws.
b. Secure lower crossbar to the compliance assembly with the (4) M3 socket head cap screws.
Use a 2.5 mm hex key to tighten the screws 12 in-lbs (1.4 Nm).
7. Install the upper crossbar to the compliance assembly:
a. Apply Loctite 7649 as a primer to the threads of the (4) M4 socket at head cap screws.
b. Apply Loctite 222 to the threads of the (4) M4 socket at head cap screws.
c. Secure the upper crossbar to the compliance assembly with the (4) M6 socket head cap
screws. Use a T20 torx bit to tighten the screws 50 in-lbs (5.6 Nm).
Figure 4.6—Install the 90° Mounting Bracket
90° bracket
(part of ATI Kit P/N 9005‑50‑6274)
Compliance assembly
(4) M6 socket head cap screws
(part of ATI Kit P/N 9005‑50‑6274)
(4) M6 socket head cap screws
Main housing
(4) M3 socket head cap screws
(to install the lower crossbar)
(4) M4 socket flat head cap screws
(to install the upper crossbar)

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
18
4.5 Pneumatic Connections
Connect the CGV as outlined in Section 4.3—Installation Procedure.
WARNING: All pneumatic ttings and tubing must be capable of withstanding the
repetitive motions of the application without failing. The routing of pneumatic lines must
minimize the possibility of over stressing, pullout, or kinking the lines. Failure to do
so can cause some critical pneumatic lines not to function properly and may result in
damage to the equipment.
NOTICE: It is recommended that the customer use a coalescing lter and lter elements rated 5
micron or better to remove trace moisture. Water damage of the air motor or damage associated
with debris in the air lines is not covered under warranty.
The end user may need a regulator for the extend and retract compliance. Minimal airow is required for the
compliance mechanism. The compliance force is applied axially and is adjusted until the desired nishing
result is achieved.
CAUTION: Pneumatic components used for the motor drive circuit must be capable
of meeting the air consumption requirements (See Section10—Specications). Poor
performance will result if the correct components are not used. Lubricators must be
located as close to the unit as possible with performance rapidly deteriorating when the
distance exceeds 15 feet (5 meters).
Table 4.2—Pneumatic Connections
Function Connection Type Pressure
Motor Inlet 1/2" (12 mm) Tube 90 psi (6.2 bar)
Compliance (Axial) Force Inlet (2) 5/32" (4 mm) Tube 0 to 40 psi
(0 to 2.75 bar)
The CGV must be plumbed using exible tubing. The compliance force air supply pressure regulator should
be adjusted up to 40 psi (2.75 bar). The minimum force air supply pressure to overcome friction depends
upon the orientation of the device and the customer's application. When testing for the proper contact force,
start with a very low pressure and increase slowly until the desired process result is achieved.

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
19
4.6 M8 Sensor Connection
Electrical connection pinouts and ratings are listed in the following table. Cable shielding is required.
Figure 4.7—M8 8-Pin Connector Wiring (Face View Shown)
(see also Figure 4.4)
Table 4.3—M8 8-Pin Male Connector Wiring
Pin
Number Signal name Description Voltage/Current Rating
1 V + Power (Positive) 24 VDC+/‑20%
2VO ‑ /IO ‑ Analog Output Reference 0 V
3VO/IO_POS + Analog output (Position) 0‑5 V, 0‑10 V, 4‑20 mA1
4VO/IO_REG + Analog output (Regulator) 0‑5 V, 0‑10 V, 4‑20 mA1
5RS485+ Serial Data N/A
6 Reserved
7V ‑ Power (Negative) / Ground (GND) 0 V
8RS485 ‑ Serial Data N/A
Note:
1. Default value for a new unit is 0‑5 V.

Manual, Pneumatic Angle Grinder (CGV)
Document #9610-50-1056-02
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919‑772‑0115 • Fax: +1 919‑772‑8259 • www.ati‑ia.com
20
4.7 Sensor Assembly Cable (P/N 9105-C-ZC27-ZC28)
NOTICE: ATI can provide a sensor assembly cable to install from the position sensor connector
on the CGV (ZC27 connector) to the customer interface (ZC28 connector).
For cable electrical specications, refer to Section 10—Specications.
Table 4.4—ZC27 Connector, M8, 8-pin, Female
Connector Schematic Pin Number Signal Description
1
2
34
5
7
8
6
1 V + Power (Positive)
2 VO ‑ / IO ‑ Analog Output Reference
3 VO/IO_Pos + Analog Output Position
4 VO/IO_Reg + Analog Output Regulator
5 RS485 + Serial Data
6 Reserved
7 V ‑ Power (Negative) / Ground (GND)
8 RS485 ‑ Serial Data
Shell Shield
Table 4.5—ZC28 Connector, M12, 8-pin, Male
Connector Schematic Pin Number Signal Description or Rating
1
2
3
456
7
8
1 V + Power (Positive)
2 VO ‑ / IO ‑ Analog Output Reference
3 VO/IO_Pos + Analog Output Position
4 VO/IO_Reg + Analog Output Regulator
5 RS485 + Serial Data
6 Reserved
7 V ‑ Power (Negative) / Ground (GND)
8 RS485 ‑ Serial Data
Shell Shield
4.8 Set-up of the RS485 Communication Interface
The optional sensor assembly in the CGV is a serial device that can be used programmatically with the
user’s application.
When the sensor is attached via cable to the customer’s device such as a personal computer or robot,
the computer assigns the sensor a COM port. Then by using a console on the computer, the user can
communicate with the sensor. Free console software, such as PuTTY, is available online. Commands are
covered in Section 6—RS485 Serial Console Interface.
For additional instructions on setting up a console like PuTTY, refer to the following procedure:
1. If an RS485 serial port is not on the customer device, use a third party serial device to add the port, for
example: a high-speed USB to an RS485 adapter module.
2. Connect the customer-supplied RS485 cable from the CGV or optional sensor assembly cable to the
RS485 serial port.
3. Find the COM port that is assigned to the CGV sensor assembly device.
• In Windows®, from the Control Panel go to the Device Manager > ports > USB Serial Port. The
sensor is assigned COM6 in the following gure.