ATI Technologies QC-210 User manual

Engineered Products for Robotic Productivity
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
QC-210
Robotic Tool Changer
(Application-specific Drawing Available upon Request)
Product Manual
Includes:
Part Number Description
9121-210AM-0-0-0-0 Tool Changer—Master
9121-210CT-0-0-0-0 Tool Changer—Tool
9121-Jxx-M Air Adapter (incl JA2-M,JA3-M,JB2-M,JB3-M,
JB4-M,JB8-M,JP2-M,JP3-M)
9121-SA2/SA3-M/T Control & Signal Module—Master & Tool
9121-JJ43-M/T Mounting Adapter Module—Master & Tool
9121-AH2-M/AHx-T Air Module—Master & Tool
9121-ED15-M/T Servo Module—Master & Tool
9120-REP6-M/T Servo Module—Master & Tool
9120-RF8-M/T Electrical Module—Master & Tool
9121-UAA-T Protective Cover Module—Tool
Some 3-D Model Downloads are available on our website. Contact your Account Representative for more information.
Manual #: 9610-20-3474

Quick Change Installation and Operation Manual
Document #9620-20-A-General TOC and Introduction-08
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
A-1
Table of Contents
A. Introduction..............................................................................................................................A-2
1. Glossary of Terms..................................................................................................................... A-3
2. Safety.......................................................................................................................................... A-6
2.1 ExplanationofNotications .............................................................................................A-6
2.2 General Safety Guidelines ..............................................................................................A-6
2.3 SafetyPrecautions ..........................................................................................................A-7
3. Product Overview...................................................................................................................... A-8
3.1 Tool Changers.................................................................................................................A-8
3.1.1 ManuallyActuatedToolChangers ...................................................................A-8
3.1.2 Quick-Change(RoundBodystyle) ..................................................................A-8
3.1.3 Heavy Automation............................................................................................A-8
3.2 Utility Couplers................................................................................................................A-8
4. Terms and Conditions of Sale.................................................................................................. A-9
B. Base Tool Changer or Utility Coupler
C. Control/Signal Module and Air/Valve Adapters
D. Pneumatic and Fluid Modules
E. Electrical Modules
F. High Current Modules
G. Interface Plates
H. Other

Quick Change Installation and Operation Manual
Document #9620-20-A-General TOC and Introduction-08
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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A. Introduction
Please contact ATI IndustrialAutomation with any questions concerning your particular model.
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. Users’critical evaluation of this
document is welcomed.
Copyright 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]
E-mail: [email protected]
Technical support and questions:
Application Engineering
Tel: [phone], Option 2, Option 2
Fax: [phone]
E-mail: [email protected]

Quick Change Installation and Operation Manual
Document #9620-20-A-General TOC and Introduction-08
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
A-3
1. Glossary of Terms
More specic terms pertaining to the Control and Signal modules can be found in the Control and Signal Module
section of this manual.
Table 1.1—Tool Changer/Utility Coupler and Module Glossary
Term Denition
ArcPrevention
Arcingisthedischargeofcurrentwhenastrongcurrentjumpsgapina
circuitorbetweentwoelectrodes.Arcingcandamageandshortenthelifeof
theelectricalpowercontacts.ATI’sexclusiveArcPreventionfeaturemakes
itpossibletocouple/uncouple“modules”withoutswitchingoffelectrical
powercontacts.Thisextendsthelifeofallelectricalpowercontactsby
eliminatingarcingcausedbyinductiveloadsandhighinrushcurrentduring
couplingandupcouplingoftheToolChanger.
BearingRace AsteelringintheToolplatethatisengagedbythelockingballsduringthe
couplingoftheToolChangerorUtilityCoupler.
Cam Amultitaperedslidingcylinderattachedtothepistonthatforcesthelocking
ballsoutwardduringthelockingprocess.
Control/SignalModule
Awidevarietyofmodulesthatpassautomationprotocolsthroughthe
MasterandToolmodulestotheend-effector.Somecontrolmodulesalso
providetheabilitytocontroltheToolChangerbyproviding“Latch”and
“Unlatch”signalstoanintegratedvalvethatlocksandunlockstheTool
Changer.
Coupling ThephysicalactionofthelockingtheMasterandToolplatestogether.See
Lock
Cover Plate AprotectiveclosureplateonstandardQuick-ChangeMasterassemblies
whichclosesthepneumaticchamber.
DetectionShaft Threadedsteminsertedintotherobotsideofthepiston,functionsasa
targettoactuatetheLock/Unlocksensors.
DeviceNet™
Aeldbuscommunicationnetworkusedmostlybydevicesinindustrial
environment,whichcommunicatesusingacontrollerareanetwork(CAN).
DeviceNetisatrademarkofODVA.
EIP End-effectorInterfacePlate–interfaceplatebetweentheToolplateandthe customer’send-effector(tooling).Allowscustomizedmountingtotheend-
effector.
ElectricalModule Anyofawidevarietyofutilitymodulesthatpasselectricalpowerand
signalsthroughtheMasterandToolmodulestotheend-effector.
End-Effector Toolusedbytherobottoperformaparticularoperationorfunction.
EtherNet/IP™
EtherNet/IP(EthernetIndustrialProtocol)isaeldbuscommunication
network,usedmostlybydevicesinindustrialenvironment,that
communicatesusingEthernet.EtherNet/IPisatrademarkofControlNet
InternationalLtd.usedunderlicensebyODVA.
EthernetSwitch AnEthernetnetworkcomponentconnectingmultiplecommunication
partnerswitheachother.
Fieldbus Agenerictermreferringtoanyoneofanumberofindustrialcomputer
networkingstandards.Examplesinclude:CAN,Modbus,andPROFINET.
Fluid Module AnyofawidevarietyofutilitymodulesthatpassuidsthroughtheMaster
andToolmodulestotheend-effector.

Quick Change Installation and Operation Manual
Document #9620-20-A-General TOC and Introduction-08
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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Table 1.1—Tool Changer/Utility Coupler and Module Glossary
Term Denition
GigabitEthernet
AtermdescribingvarioustechnologiesfortransmittingEthernetframesat
arateofagigabitpersecondasdenedbytheIEEE802.3-2008standard
generallywithRJ45,X-codedM12,orA-codedM12connectorsoverCAT6
cabling.Typicallyusedinvisionapplications(GigEVision).
High Current Module Anyofawidevarietyofutilitymodulesthatpasselectricalpowerthrough
theMasterandToolmodulestotheend-effector.
InterfacePlate(IP) OptionalcustomizedcomponentusedtoadaptaToolChangerorUtility
Couplertotheuser’srobotortooling.
Latch TheoutputcommandsuppliedtotheATIMastermoduletocoupletheTool
Changer.
Lock
ThelockairpressureprovidedtotheMasterplatelockingmechanism
forcingthecamtopressthelockingballsagainstthebearingrace.This
lockstheMasterandToolPlatestogether.
LockPort PneumaticportontheMasterplatethroughwhichairpressureissuppliedto
LocktheMasterplatetotheToolplate.
LockSensor Aproximitysensorthatdetectsthepositionofthepneumaticallyactuated
pistonwhenitisinthelockedormissedtoolposition.
Locked Anoutputsignalprovidedbyaproximitysensor,indicatingthatthecoupling
mechanismisintheLockedposition.
LockingBalls
Hardenedsteelballbearingsusedinthefail-safelockingmechanism.The
lockingballsareforcedoutwardbythecamagainstthebearingracetopull
the Master and Tool plates together.
LockingMechanism
Manual,pneumaticorelectricaldrivendevicethatdrawstheMasterand
Toolplatestogethersecuringtheminafail-safelockedconditionuntilthe
mechanismisunlocked.Thelockingmechanismconsistsoflockingballs,
cam,ballcage,bearingrace,andeitheranlever,pneumaticcylinderoran
electricmotor.
L/U Lock/Unlocksensingcapabilityallowsthecustomertodeterminethestate
ofthemasterassemblylockingmechanism.
Master Plate ThehalfoftheToolChangerthatismountedtoarobot.TheMasterplate
containsthelockingmechanism.
Moment Theappliedforcemultipliedbythedistanceitisfromapoint.
Multibus
Anadvancedcomputerbusarchitecturestandardusedinindustrial
applications.MultibusIisaIEEE-79616-bitstandard,andMultibusIIisa
IEEE-129632-bit/10MHzbus,at40Mbyte/sstandard.
No-Touch™ DesignfeatureofallATIToolChangerproductsthatallowscouplingthe
MasterplateandToolplatewithoutphysicalcontactpriortolocking.
Piston CylinderlocatedintheMasterplatethatactuatesthelockingmechanism.
PneumaticModule Anyofawidevarietyofutilitymodulesthatpassairorvacuumthroughthe
MasterandToolmodulestotheend-effector.
PROFINET®AnEthernet-basedeldbususedinindustrialautomation.
RIP RobotInterfacePlate–interfaceplatebetweentherobotangeandMaster
plate.
RTL
ProximitysensorsthatdetectwhentheMasterandToolplatesareclose
enoughtoeachotherthatitissafetoinitiatethealatchcommandandlock
the Master and Tool together.

Quick Change Installation and Operation Manual
Document #9620-20-A-General TOC and Introduction-08
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
A-5
Table 1.1—Tool Changer/Utility Coupler and Module Glossary
Term Denition
RTLRelay
AelectricalcircuitpresentontheATIMastermodulethatisdrivenbythe
RTLsensorandallowstheToolChangerlockingmechanismtoretractwhen
there is no Tool present.
Sensor Plate CoverplateforthebacksideoftheMasterplate,sealsthepneumatic
chamberandprovidesmountingpointsfortheLock/Unlockswitches.
Servo Module Anyofawidevarietyofutilitymodulesthatpasselectricalpowerandservo signalsthroughtheMasterandToolmodulestotheend-effectorequipped
withaservomotor.
SIP
Sensor InterfacePlate used to adapt the Tool Changer Master to the
customer-suppliedrobot.TheSIPisessentiallyaRobotInterfacePlatethat
containssensorsthatdeterminethestate(Locked/Unlocked/NoTool)ofthe
Master plate.
Soft Start
IsanATIexclusivefeaturethatpulsesthepowerongraduallytopreventthe
largecurrentspikesthatwouldotherwiseoccurduringthecouplingofthe
MasterandTool.Thisresultsinaseriesofmuchsmallercurrentspikesand
preventssignicantvoltagedropsonthenetworkpower.
TeachPlug Adeviceusedduringtheset-upandintegrationoftherobottooverridethe
TSIcircuit.
Tool-ID
Anindividualorsetofpush-buttonordialswitchesonthecontrol/signal
ToolmodulethatprovidesanuniqueidenticationnumberforeachTool
whenusingmultipleTools.TheTool-IDalsoprovidestheToolnotpresent
indication.
Tool Plate ThehalfoftheToolChangertowhichvarioustoolsorend-effectorsare
mounted.
Tool Stand StandthatholdsToolsnotbeingusedbytherobot.
Tool Present Ahard-connectinput(sourcedfromtheTool)indicatingtheMasterandTool
areelectricallyconnectedtoeachother.
Trip Dog Aphysicaldeviceusedtoactivateamechanicalswitch,useintheTool
StandInterlockcircuit.
TSI TheToolStandInterlockfeatureisacustomATIsafetysolutionandcircuit designedtoonlyallowToolChangerreleasewhileinthestandorstorage
location.
TSIRelay
AelectricalcircuitpresentontheATIToolmodulethatisdrivenbyatool
standlimitswitchinordertoclosetheTSIcircuitandallowToolChanger
release.
Uncoupling ThephysicalactionoftheunlockingtheMasterandToolPlates.SeeUnlock
Unlatch TheoutputsuppliedtotheATIMastermoduletouncoupletheToolChanger.
Unlock
TheunlockairpressureprovidedtotheMasterplatelockingmechanism
forcingthecamtoreleasethelockingballsfromthebearingrace.Allowing
theMasterandToolPlatestobeseparated.
Unlocked Anoutputsignalprovidedbyaproximitysensor,indicatingthatthecoupling
mechanismisintheUnlockedposition.
UnlockPort PneumaticportontheMasterplatethroughwhichairpressureissuppliedto
UnlocktheMasterplatefromtheToolplate.
UnlockSensor Aproximitysensorthatdetectsthepositionofthepneumaticallyactuated
pistonwhenitisintheunlockedposition.
VLAN VirtualLocalAreaNetwork

Quick Change Installation and Operation Manual
Document #9620-20-A-General TOC and Introduction-08
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
A-6
2. Safety
The safety section describes general safety guidelines to be followed with this product, explanation of the
notication found in this manual, and safety precaution that apply to the product. More specic notication are
imbedded within the sections of the manual where they apply.
2.1 Explanation of Notications
The notications included here are specic to the product(s) covered by this manual. It is expected that the
user heed all notications from the robot manufacturer and/or the manufacturers of other components used
in the installation.
or
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.
ATTENTION, NOTE, or NOTICE: Noticationofspecicinformationorinstructionsabout
maintaining,operating,installation,orsetupof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,
goodoperatingpractices,ormaintenancetips.
2.2 General Safety Guidelines
Prior to purchase and installation, the customer should verify that the Tool Changer selected is rated for the
maximum loads and moments expected during operation. Refer to product specications section in each
module of this manual or contact ATI for assistance. Particular attention should be paid to dynamic loads
caused by robot acceleration and deceleration. These forces can be many times the value of static forces in
high acceleration or deceleration situations.
The customer is responsible for ensuring that the area between the Master and Tool sides is clear of foreign
objects during mating and subsequent coupling. Failure to do so may result in serious injury to personnel.
DANGER:ThegapbetweentheMasterandToolsidesisapinchpoint.Allpersonnel
shouldbepreventedfromplacinganypartoftheirbodyorclothinginthegap,
especiallyduringactuationofthelockingmechanism.
The customer is responsible for understanding the function of the Tool Changer and implementing the
proper fasteners and/or software to operate the Tool Changer safely. The Tool Changer should be controlled
such that there is no chance of locking or unlocking in a position that would endanger personnel and/or
equipment. If the Tool Changer is specied with Lock/Unlock (L/U) and Ready-to-Lock (RTL) sensing
capability, the status should be monitored and proper interlocks applied to prevent injury to personnel and
equipment.

Quick Change Installation and Operation Manual
Document #9620-20-A-General TOC and Introduction-08
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
A-7
All pneumatic and uid components (i.e. ttings, tubing) must be capable of withstanding the repetitive
motions of the application without failing. The routing of electrical, uid, and pneumatic lines must
minimize the possibility of stress/strain, kinking, rupture, etc. Failure of critical electrical, uid, or
pneumatic lines to function properly may result in injury to personnel and equipment.
All electrical power, pneumatic and uid circuits should be disconnected during servicing.
2.3 Safety Precautions
WARNING: Removealltemporaryprotectivematerials(caps,plugs,tape,etc.)on
lockingfaceofToolChangerandmodulespriortooperation.Failuretodosowillresult
indamagetoToolChangers,modules,andend-of-armtoolingandcouldcauseinjury
to personnel.
WARNING: DonotperformmaintenanceorrepaironToolChangerormodulesunless
theToolissafelysupportedordockedinthetoolstand,allenergizedcircuits(e.g.
electrical,air,water,etc.)areturnedoff,pressurizedconnectionspurgedandpower
dischargedfromcircuitsinaccordancewiththecustomer’ssafetypracticesand
policies.InjuryorequipmentdamagecanoccurwithToolnotdockedandenergized
circuitson.DocktheToolsafelyinthetoolstand,turnoffanddischargeallenergized
circuits,purgeallpressurizedconnections,verifyallenergizedcircuitsarede-energized
beforeperformingmaintenanceorrepaironToolChangerormodules.
WARNING: Duringoperation,theareabetweentheMasterandToolmustbekept
clear.FailuretokeepareaclearwillresultindamagetoToolChanger,modules,orend-
of-armtoolingandcouldcauseinjurytopersonnel.
WARNING: TheToolChangerisonlytobeusedforintendedapplicationsand
applicationsapprovedbythemanufacturer.UsingtheToolChangerinapplications
otherthanintendedwillresultindamagetoToolChanger,modules,orend-of-arm
toolingandcouldcauseinjurytopersonnel.
CAUTION:TheMasterplatelockingmechanismmustnotbeactuatedwithoutbeing
mountedtotherobotinterfaceplate.DamagetotheCoverplateandO-ringmayresult.
AlwaysattachtheMasterplatetotherobotinterfaceplatepriortoattemptingany
operations.

Quick Change Installation and Operation Manual
Document #9620-20-A-General TOC and Introduction-08
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
A-8
3. Product Overview
3.1 Tool Changers
There are many different types of Tool Changers, Manual, Heavy Automation, Rail, Hollow Wrist, etc,
which are specically suited for the application they are designed for. A Tool Changer enhances the
exibility and reliability of a robotic cell. Robotic Tool Changers are used in automated Tool change
applications as well as manual Tool change operations. Robotic Tool Changers also provide a method for
quick Tool change for maintenance purposes.
Automatic Tool Changers provide added exibility to robot applications by allowing one robot to change
end-effectors, such as grippers and vacuum tooling. The Quick-Change products are pneumatically or
electrically operated devices consisting of a Master Plate and Tool Plate using a patented stainless steel
locking mechanism. Add-on utility modules provide electrical pass-through of, DeviceNet™, Ethernet,
PROFINET™ or PROFIBUS™ bus network signals, high current and servo signals, as well as air, vacuum,
and uid pass-through.
Tool Changers can be equipped with sensors to detect when the Tool Changer is in the locked/unlocked
positions and if the Tool plate is present. Some models require an optional Sensor Interface Plate (SIP) plate
to mount the lock and unlock sensors. If required, the use of a SIP is highly recommended for achieving the
highest level of safety and reliability.
The ATI Tool Changer has been designed to provide extremely long life with little maintenance.
3.1.1 Manually Actuated
ATI’s Manual Tool Changers provide a cost effective solution for quickly changing tools by hand.
They feature a unique design that combines high strength, excellent repeatability and a lever or
screw-cam locking mechanism with multiple fail-safe features, which resists vibration and prevents
loosening. The Manual Tool Changers also feature quick-action locking for manual operation.
These robust and compact Manual Tool Changers can handle payloads up to 80 pounds (36 kg) as
well as pass pneumatics and electrical signals.
3.1.2 Quick-Change (Round Body style)
The Quick-Change robotic Tool Changer has been designed to incorporate high strength in a small,
low-weight package. The Tool change system consists of two primary parts: the Master plate and
the Tool plate. The Master plate is mounted to a robot while the customer supplied end-effector
is typically attached to the Tool plate. The Master plate is typically mounted to the robot with an
optional interface plate. Many models have integrated pass-through air ports.
3.1.3 Heavy Automation
The Heavy Automation Robotic Tool Changer line has been developed for resistance welding and
medium-duty to heavy-duty material handling. Because a Tool Changer uses specic modules
to pass utilities such as uids, electrical, and pneumatics, it can be custom congured to handle
numerous applications.
3.2 Utility Couplers
The Utility Coupler from ATI was developed for heavy-duty, automated industrial applications where there
is a need to change tools that pass utilities such as air and electrical signals. Unlike other traditional manual
methods of connecting multiple lines, the ATI Utility Coupler is especially congured for coupling lines and
restoring operations more quickly. The modular body design is capable of mounting any of ATI’s standard
add-on utility modules and is designed to improve cycle time as well as add exibility to any production
cell. The Master-side connection can feature an unique compliance mechanism that allows for large tooling
misalignments. The Utility Coupler can be provided with anATI locking mechanism or a drive cylinder.

Quick Change Installation and Operation Manual
Document #9620-20-A-General TOC and Introduction-08
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
A-9
4. Terms and Conditions of Sale
The following Terms and Conditions are a supplement to and include a portion of ATI’s Standard Terms and
Conditions, which are on le at ATI and available upon request.
ATI warrants to Purchaser that robotic Tool Changer products purchased hereunder will be free from defects
in material and workmanship under normal use for a period of three (3) years from the date of shipment. This
warranty does not cover components subject to wear and tear under normal usage or those requiring periodic
replacement. ATI will have no liability under this warranty unless: (a) ATI is given written notice of the claimed
defect and a description thereof within thirty (30) days after Purchaser discovers the defect and in any event not
later than the last day of the warranty period; and (b) the defective item is received by ATI not later ten (10) days
after the last day of the warranty period. ATI’s entire liability and Purchaser’s sole remedy under this warranty is
limited to repair or replacement, at ATI’s election, of the defective part or item or, at ATI’s election, refund of the
price paid for the item. The foregoing warranty does not apply to any defect or failure resulting from improper
installation, operation, maintenance or repair by anyone other than ATI.
ATI will in no event be liable for incidental, consequential or special damages of any kind, even if ATI has been
advised of the possibility of such damages. ATI’s aggregate liability will in no event exceed the amount paid by
purchaser for the item which is the subject of claim or dispute. ATI will have no liability of any kind for failure of
any equipment or other items not supplied by ATI.
No action against ATI, regardless of form, arising out of or in any way connected with products or services supplied
hereunder may be brought more than one (1) year after the cause of action accrued.
No representation or agreement varying or extending the warranty and limitation of remedy provisions contained
herein is authorized by ATI, and may not be relied upon as having been authorized by ATI, unless in writing and
signed by an executive ofcer of ATI.
Unless otherwise agreed in writing by ATI, all designs, drawings, data, inventions, software and other technology
made or developed by ATI in the course of providing products and services hereunder, and all rights therein under
any patent, copyright or other law protecting intellectual property, shall be and remain ATI’s property. The sale of
products or services hereunder does not convey any express or implied license under any patent, copyright or other
intellectual property right owned or controlled by ATI, whether relating to the products sold or any other matter
except for the license expressly granted below.
In the course of supplying products and services hereunder, ATI may provide or disclose to Purchaser condential
and proprietary information of ATI relating to the design, operation or other aspects of ATI’s products. As between
ATI and Purchaser, ownership of such information, including without limitation any computer software provided
to Purchaser by ATI, shall remain in ATI and such information is licensed to Purchaser only for Purchaser’s use in
operating the products supplied by ATI hereunder in Purchaser’s internal business operations.
Without ATI’s prior written permission, Purchaser will not use such information for any other purpose or provide or
otherwise make such information available to any third party. Purchaser agrees to take all reasonable precautions to
prevent any unauthorized use or disclosure of such information.
Purchaser will not be liable hereunder with respect to disclosure or use of information which: (a) is in the public
domain when received from ATI; (b) is thereafter published or otherwise enters the public domain through no fault
of Purchaser; (c) is in Purchaser’s possession prior to receipt from ATI; (d) is lawfully obtained by Purchaser from a
third party entitled to disclose it; or (f) is required to be disclosed by judicial order or other governmental authority,
provided that, with respect to such required disclosures, Purchaser gives ATI prior notice thereof and uses all legally
available means to maintain the condentiality of such information.

Manual, Robotic Tool Changer, QC-210
Document #9620-20-B-210 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-1
Table of Contents
B. Base Tool Changer ..................................................................................................................B-3
QC-210 Series—Robotic Tool Changer......................................................................................B-3
1. Product Overview..................................................................................................................B-3
1.1 Master Plate Assembly ............................................................................................................. B-4
1.2 Tool Plate Assembly.................................................................................................................. B-5
1.3 Optional Modules...................................................................................................................... B-5
2. Installation .............................................................................................................................B-6
2.1 Master Interface......................................................................................................................... B-7
2.2 Master Plate Installation........................................................................................................... B-8
2.3 Master Plate Removal............................................................................................................... B-8
2.4 Tool Interface............................................................................................................................. B-9
2.5 Tool Plate Installation (includes Bolt-Down Plate)............................................................... B-10
2.6 Tool Plate Removal (includes Bolt-Down Plate)....................................................................B-11
2.7 Pneumatic Requirements....................................................................................................... B-12
2.7.1 Valve Requirements for Air Adapter Modules................................................................B-12
2.8 Electrical Connections............................................................................................................ B-13
2.8.1 PNP Type Lock, Unlock and RTL Sensors (-SM, -SR, -SL, -ST sensor designations) .B-13
2.8.2 NPN Type Lock, Unlock and RTL Sensors (-SP, -SE, -SU sensor designations)..........B-13
3. Operation .............................................................................................................................B-14
3.1 Conditions for Coupling......................................................................................................... B-15
3.2 Fail-Safe Operation ................................................................................................................. B-16
3.3 Conditions for Uncoupling..................................................................................................... B-17
3.4 ToolIdentication.................................................................................................................... B-17
3.5 Tool Storage Considerations ................................................................................................. B-18
4. Maintenance.........................................................................................................................B-19
4.1 Preventive Maintenance ......................................................................................................... B-19
4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins....................... B-20
4.3 Pin Block Inspection and Cleaning ....................................................................................... B-22
5. Troubleshooting and Service Procedures ........................................................................B-23
5.1 Troubleshooting Procedures ................................................................................................. B-23
5.2 Service Procedures................................................................................................................. B-24
5.2.1 Sensor Replacement Procedures .................................................................................B-24
5.2.2 V-ring Seal Replacement...............................................................................................B-34
5.2.3 Alignment Pin Replacement..........................................................................................B-35

Manual, Robotic Tool Changer, QC-210
Document #9620-20-B-210 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-3
6. Serviceable Parts ................................................................................................................B-36
6.1 Models 9121-210xM-0-0-0-0-S0 .............................................................................................. B-36
6.2 Models 9121-210xM-0-0-0-0-SL and 9121-210xM-0-0-0-0-SE............................................... B-37
6.3 Models 9121-210xM-0-0-0-0-SM, 9121-210xM-0-0-0-0-SP and 9121-210xM-0-0-0-0-SR..... B-38
6.4 Models 9121-210xM-0-0-0-0-ST and 9121-210xM-0-0-0-0-SU............................................... B-39
6.5 Standard Tool Plate ................................................................................................................ B-40
6.6 Bolt-Down Tool Plate ............................................................................................................. B-41
7. Specications ......................................................................................................................B-42
8. Drawings ..............................................................................................................................B-43
8.1 QC-210 Tool Changer.............................................................................................................. B-43
8.2 Bolt-Down Tool Plate ............................................................................................................. B-46

Manual, Robotic Tool Changer, QC-210
Document #9620-20-B-210 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-3
B. Base Tool Changer
QC-210 Series—Robotic Tool Changer
1. Product Overview
The Tool Changer provides exibility to robot applications by that allow the robot to change customer tooling (e.g.,
grippers, vacuum cup tooling, pneumatic and electric motors, weld guns, etc.) automatically. The Tool Changer
consists of a Master plate and a Tool plate. The Master plate is attached to a robot, while end-effectors such as
grippers, material handlers, etc. are attached to one or more Tool plates.
The Master plate locks to the Tool plate with a pneumatically driven locking mechanism. This locking mechanism
uses a patented, multi-tapered cam with ball locking technology and a patented fail-safe mechanism.
The robot can be programmed to select the desired customer tooling by coupling the Master plate to the Tool plate
attached to the tooling. Electrical signals, pneumatic power, and uids can be transferred to the customer tooling
through the Master plate and Tool plate by optional modules. See the respective manuals for these options for more
details.
For the most current product information and specications on the QC-210 Series of Tool Changers, please click
the following link: http://www.ati-ia.com/products/toolchanger/QC.aspx?ID=QC-210

Manual, Robotic Tool Changer, QC-210
Document #9620-20-B-210 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-4
1.1 Master Plate Assembly
The Master plate assembly includes the following features:
• An anodized aluminum body.
• A hardened stainless steel locking mechanism (a cam, male coupling, and chrome steel ball bearings).
• Hardened steel alignment pins that mate with bushings on the Tool plate.
• (4) ats for mounting optional modules. Flat an is dedicated for mounting an air adapter or a valve
adapter and control/signal module combination. Flats B, C, and D are for optional modules.
• Proximity sensor assemblies used to verify the lock/unlock position of the piston and cam.
• Proximity sensors used to verify Tool plate presence when coupled.
• A mounting pattern for a robot arm or an interface plate.
• Routing channels for the RTL, Lock, and Unlock sensor cables.
Extreme pressure grease is applied to the cam, male coupling, ball bearings, and pins to enhance
performance and maximize the life of the Master plate.
Figure 1.1—Master Plate Assembly
RTL (R1) Proximity Sensor
Assembly
(12) Ball Bearing
Cam
Male Coupling
(2) Alignment pin
Lock/Unlock Air supplied
through Air/Valve Adapter
mounted to Flat A
Cable Retaining Tab
Common Ledge
Feature for Module
mounted to Flat B, C,
and D
Internal Proximity Sensors
(Lock/Unlock) [Not Visible]
RTL (R2) Proximity Sensor
Assembly

Manual, Robotic Tool Changer, QC-210
Document #9620-20-B-210 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-5
1.2 Tool Plate Assembly
The Tool plate assembly includes the following features:
• An anodized aluminum body.
• A hardened stainless steel bearing race.
• Alignment bushings that mate with pins on the Master plate.
• (4) ats for mounting optional modules. Flat A requires a tool adapter assembly that is compatible with
the air or valve adapter used on the Master Plate. Flats B, C, and D are for optional modules.
• Ferrous metal proximity sensor targets.
• A mounting pattern for customer tooling or a tooling interface plate.
Figure 1.2—Tool Plate Assembly
(2) Alignment Pin
Bushing
Bearing Race
Proximity Sensor
Assembly Target (RTL)
Proximity Sensor
Assembly Target (RTL)
Common Ledge Feature for
Module mounted to Flat A,
B, C, and D
1.3 Optional Modules
The optional modules are mounted to the Master and Tool plate using a common ledge mounting feature and
pass utilities to customer tooling.
For assistance in the choosing the right modules for your particular application, visit our website (http://
www.ati-ia.com/products/toolchanger/QC.aspx?ID=QC-210) to see what is available or contact an ATI sales
representative.

Manual, Robotic Tool Changer, QC-210
Document #9620-20-B-210 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-6
2. Installation
All fasteners used to mount the Tool Changer to the robot and to customer’s tooling should be tightened to a
torque value as indicated. Refer to Table 2.1. Furthermore, removable (blue) Loctite 242 must be used on these
fasteners. Table 2.1 contains recommended values based on the engineering standards.
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 the circuits in accordance with the customer’s 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.
WARNING: Do not use lock washers under the head of the mounting fasteners or allow the
mounting fasteners to protrude above the mating surfaces of the Master and Tool plates. That
allow fasteners to protrude above the mating surface will create a gap between the Master
and Tool plates and not allow the locking mechanism to fully engage, this can cause damage
to equipment or personal injury. The mounting fasteners must be ush or below the mating
surfaces of the Master and Tool plates.
Head of Mounting Fastener Must Be Flush or
Below Mating Surface. (Do Not Use Lock
Washer under Head of Mounting Fastener.)
Mating Surface
CAUTION: Do not use fasteners with pre-applied adhesive more than once. Fasteners might
become loose and cause equipment damage. Always apply new thread locker when reusing
fasteners.
CAUTION: Do not use fasteners that exceed the thread depth in the Tool Changer. Refer to
Section 8—Drawings for details on the mounting hole thread depth. Secure the Tool Changer
with the proper length fasteners. This is true for both robot and tool interfaces.
Table 2.1—FastenerSize,Class,andTorqueSpecications
Mounting Conditions Fastener Size and Property
Class
Recommended
Torque
Master plate to Interface plate and
Interface plate to Robot (6061-T6 aluminum)
Minimum thread engagement of 0.59” (15 mm) [1.5X fastener Ø].
Conrm available engagement with Robot Manufacturer
M10-1.5
Class 12.9 38 ft-lbs (52 Nm)
Interface plate to Robot (steel; USS ≥ 90KSI)
Minimum thread engagement of 0.39” (10 mm) [1.0X fastener Ø].
Conrm available engagement with Robot Manufacturer
M10-1.5
Class 12.9 55 ft-lbs (75 Nm)
Tool plate (aluminum) to Tool interface plate (aluminum)
Minimum thread engagement of 0.47” (12 mm) [1.5X fastener Ø]. M8-1.25 Class 12.9 20 ft-lbs (27 Nm)
Tool interface plate (aluminum) to Tool plate (aluminum)
Minimum thread engagement of 0.59” (15 mm) [1.5X fastener Ø]. M10-1.5 Class 12.9 38 ft-lbs (52 Nm)
Tool interface plate (aluminum) to Tool plate (aluminum)
Minimum thread engagement of 0.71” (18 mm) [1.5X fastener Ø]. M12-1.75 Class 12.9 70 ft-lbs (94 Nm)

Manual, Robotic Tool Changer, QC-210
Document #9620-20-B-210 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-7
2.1 Master Interface
The Master plate is typically attached to the robot arm. An interface plate can adapt the Master plate to a
specic robot arm. Alignment features (dowel holes and bosses) accurately position and bolt holes secure
the Master plate to the robot arm or an interface plate. Custom interface plates are available from ATI upon
request. (Refer to the Drawing Section for technical information on the mounting features.)
CAUTION: Do not use more than two alignment features when that secure a Master
plate to an interface plate. Using more than two alignment features can cause damage
to equipment. Use either two dowel pins or a single dowel pin along with a boss/recess
feature to align the Master plate with the interface plate.
CAUTION: Do not use dowel pins that are too long or do not allow the interface plate
and Master body to mate ush. Using dowel pins that are too long will cause a gap
between the interface plate and Master body and damage to the equipment. Use dowel
pins that will not extend further than allowed by the Master body.
Master Plate
Interface Plate
Correct size dowel
pins allow the interface
plate and Master
plate to mount flush.
Two dowel pins
(or a single dowel
pin along
with a boss/recess)
used as alignment features.
Flush
Correct Mounting of Master Plate
Master Plate
Interface Plate
Dowel pins that are
too long can cause a
plate and Master Plate.
gap between interface
Optional Boss
GapGap
A boss and two dowel pins can
be difficult to align and can
cause damage to equipment.
Incorrect Mounting of Master Plate
If the customer chooses to design and build an interface plate, consider the following points:
• The interface plate should include bolt holes for mounting and either two dowel pins or a dowel pin
and a boss for accurate positioning on the robot and Master plate. The dowel and boss features prevent
unwanted rotation. Refer to the robot manual for robot mounting features.
• The thickness of the interface plate must be sufcient to provide the necessary thread engagement for
the mounting bolts.
• Dowel pins must not extend out from the surface of the interface plate farther than the depth of the
dowel holes in the Master plate.
• If a boss is used on the Master plate, a recess of proper depth and diameter must be machined into the
interface plate to correspond with the boss on the Master plate.
• Mounting bolts that are too long can create a gap between the interface plate and the Master plate,
which can damage equipment.
• The interface plate must provide rigid mounting to the Master plate.
• The interface plate design must account for clearances required for Tool Changer module attachments
and accessories.

Manual, Robotic Tool Changer, QC-210
Document #9620-20-B-210 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-8
2.2 Master Plate Installation
Tools required: 8 mm Allen®wrench (hex key), torque wrench
Supplies required: Clean rag, Loctite®242
1. Clean the mounting surfaces.
2. If required, install the interface plate to the robot arm, align using the boss or dowel pins and secure with
customer supplied fasteners.
3. Align the dowel pins to the corresponding holes in the Master plate and secure the Master plate to the
robot arm or interface plate with customer supplied (10) M10-1.5 socket head cap screws using an 8 mm
Allen wrench. Refer to Section 8—Drawings for mounting pattern. Apply Loctite 242 to threads (see
Table 2.1 for proper fasteners and torque).
NOTICE: If an ATI interface plate is used, fasteners to mount the Master plate is supplied with
the interface plate.
4. Connect utilities to the appropriate module and Master plate connections. For pneumatic lock and unlock
connection refer to Section 2.7—Pneumatic Requirements.
5. After the procedure is complete, resume normal operation.
Figure 2.1—Typical Master Plate Installation
Robot Arm
Robot Interface Plate
(Customer Supplied)
(If required, custom RIP’s
(10) M10-1.5 Socket Head Cap Screw
(Refer to Table 2.1)
(Customer Supplied)
Master Plate
Dowel Pin (Customer Supplied)
Socket Head Cap Screw
(Customer Supplied)
Dowel Pin (Customer Supplied)
are available from ATI.)
2.3 Master Plate Removal
Tools required: 8 mm Allen wrench (hex key)
1. Place the Tool in a secure location.
2. Uncouple the Master and Tool plates.
3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).
4. Disconnect all utilities (e.g. electrical, air, water, etc.).
NOTICE: Support the Master plate while removing the fasteners.
5. Remove the (10) M10 socket head cap screws connecting the Master plate to the robot arm or interface
plate using an 8 mm Allen wrench.

Manual, Robotic Tool Changer, QC-210
Document #9620-20-B-210 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-9
2.4 Tool Interface
The Tool plate is attached to the customer’s tooling. An interface plate can adapt the Tool plate to customer
tooling. Alignment features (dowel holes and a recess) accurately position and bolt holes secure the Tool
plate to customer tooling. Custom interface plates can be supplied by ATI (Refer to the application drawing).
CAUTION: Do not use more than two alignment features when that secure a Tool plate
to an interface plate. Using more than two alignment features can cause damage to
equipment. Use either two dowel pins or a single dowel pin along with a boss/recess
feature to align the Tool plate with the interface plate.
CAUTION: Do not use dowel pins that are too long or do not allow the interface plate
and Tool body to mate ush. Using dowel pins that are too long will cause a gap
between the interface plate and Tool body and damage to the equipment. Use dowel
pins that will not extend further than allowed by the Tool body.
Tool Plate
Interface Plate
Dowel pins are
proper size allowing
interface plate and Tool
Plate to mount flush.
Two dowel pins (or a
boss/recess) used as
alignment features.
Correct Mounting of Tool Plate
Tool Plate
Interface Plate
Dowel pins
are too long and
cause a gap between
interface plate and Tool.
Boss and two dowel pins
as alignment features can be
difficult to align and can
damage equipment.
Gap
Incorrect Mounting of Tool Plate
single dowel pin along with a
If the customer chooses to design and build a tool interface plate, consider the following points:
• The interface plate should include bolt holes for mounting and either two dowel pins or a dowel
pin and a boss for accurate positioning on the customer tooling and Tool plate. The dowel and boss
features prevent unwanted rotation.
• Dowel pins must not extend out from the surface of the interface plate farther than the depth of the
dowel holes in the Tool plate.
• The thickness of the interface plate must be sufcient to provide the necessary thread engagement for
the mounting bolts. Fasteners should meet minimum recommended engagement lengths while not
exceeding the maximum available thread depth. Use of bolts that are too long can cause damage to the
tool side changer.
• The plate design must account for clearances required for Tool Changer module attachments and
accessories.
• If a boss is to be used on the interface plate, a boss of proper height and diameter must be machined
into the interface plate to correspond with the recess in the Tool plate.
• The interface plate must have a hole in its center for manually returning the locking mechanism to
the unlocked position under adverse conditions (i.e. unintended loss of power and/or air pressure).
The center access hole with a minimum diameter of the 1” (25.4 mm) prevents debris from the
contaminating the locking mechanism. Greater protection is provided by leaving the race cover and
grommet in place.

Manual, Robotic Tool Changer, QC-210
Document #9620-20-B-210 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-10
2.5 Tool Plate Installation (includes Bolt-Down Plate)
Tools required: 8 mm, 10 mm, or 12 mm Allen wrench (hex key), torque wrench
Supplies required: Clean rag, Loctite 242
1. Clean the mounting surfaces.
2. If required, install the tool interface plate to the customer tooling, align using the boss or dowel pins and
secure with customer supplied fasteners.
3. Align the dowel pins to the corresponding holes in the Tool plate and secure the Tool plate to the tool
interface plate or customer tooling with customer supplied fasteners. Refer to Section 8—Drawings for
mounting pattern. Apply Loctite 242 to threads (see Table 2.1).
NOTICE: If an ATI interface plate is used, fasteners to mount the Tool plate is supplied with the
interface plate.
4. Connect utilities to the appropriate module and Tool plate connections.
5. After the procedure is complete, resume normal operation.
Figure 2.2—Standard Tool Plate Installation (210CT Shown)
Tool Plate
Dowel Pin (Customer Supplied)
Tool Interface Plate
(Customer Supplied)
(6) M10-1.5 Socket Head Cap Screw
Torque to 52 N-m (38 ft-lbs)
(Customer Supplied)