ATI Technologies MC-16 User manual

Installation and Operation Manual
Document #9620-20-b-mc-16 base tool changer-07
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
B. Base Tool Changer......................................................................................................2
MC-16—Manual Tool Changer ........................................................................................2
1. Product Overview..........................................................................................................2
1.1 Master Plate Assembly.........................................................................................2
1.1.1 Optional Ratchet Knob..............................................................................2
1.2 Tool Plate .............................................................................................................3
1.3 Optional Modules..................................................................................................3
2. Installation .....................................................................................................................3
2.1 Master Interface....................................................................................................4
2.2 Tool Interface........................................................................................................4
2.3 Optional Module Installation .................................................................................5
2.3.1 Installing Optional Modules.......................................................................5
2.3.2 Removing Optional Modules.....................................................................5
2.4 Tool Stand Design ................................................................................................5
2.4.1 Tool Locating Features .............................................................................5
3. Operation .......................................................................................................................7
3.1 Coupling Sequence ..............................................................................................7
3.2 Fail-Safe Operation ..............................................................................................9
3.3 Uncoupling............................................................................................................9
4. Maintenance ................................................................................................................10
4.1 Preventive Maintenance .....................................................................................10
4.2 Locking Mechanism, Alignment Pins Cleaning and Lubrication .........................11
4.2.1 Cleaning and Lubrication of the Locking Mechanism and Alignment
Pins (Master Plate). ................................................................................11
4.2.2 Cleaning the Locking Mechanism and Alignment Pin Bushings
(Tool Plate). ............................................................................................11
4.3 Alignment Pin Replacement ...............................................................................11
4.4 Electrical Module Pin Block Contact Inspection and cleaning ............................12
4.5 Electrical Module Seal Inspection and Replacement .........................................12
5. Troubleshooting..........................................................................................................13
6. Recommended Spare Parts .......................................................................................14
7. Specifications..............................................................................................................14
8. Drawings ......................................................................................................................15
8.1 MC-16 Manual Tool Changer Drawing ...............................................................15
8.2 MC-16 Manual Coupler Outer Dimensions.........................................................17
8.1 MC-16 with Quick Action Screw Lock – Euro – Ports Removed ........................18
8.2 Manual Coupler Ratchet Knob ...........................................................................20

Installation and Operation Manual
Document #9620-20-b-mc-16 base tool changer-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
B - 2
B. Base Tool Changer
MC-16—Manual Tool Changer
1. Product Overview
1.1 Master Plate Assembly
The Master base assembly includes an anodized aluminum body, a hardened stainless-steel
locking mechanism, and hardened steel alignment pins (see Figure 1.1).
The Master plate assembly is equipped with four pass through air ports, 1/8” NPT port are
provided in the body for the pneumatic connections. The body or Master plate has one flat
side for mounting of optional modules.
The locking mechanism consists of a tapered cam, a set of hardened steel ball bearings, a
steel threaded rod, and a spring-loaded quick-action rod release mechanism. The surfaces on
the cam are tapered and contact balls as the rod is pushed in or tightened. When the Master
and Tool are brought together, the user pushes the button to release the cam toward the lock
position. Then the user applies the final tightening torque by twisting the knob. This final
tightening is required to ensure the unit has full locking force applied. The ball bearings slide
on the tapered surfaces of the Tool-side to apply the lock. Tapered pins located on the Master
body mate with holes in the Tool body to ensure repeatable alignment during the coupling
process. An extreme pressure grease is applied to the cam and pins to enhance performance
and maximize the life of the Master assembly.
Figure 1.1—Master Plate Assembly
1.1.1 Optional Ratchet Knob
An optional ratchet knob is available to provide additional protection in application
where extreme vibrations can cause the actuation to become loose. The ratchet knob
locks in the closed position preventing it from coming loose during operation.

Installation and Operation Manual
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Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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1.2 Tool Plate
The hardened steel body of the Tool plate has one flat side for the mounting of optional
modules. The Tool plate is equipped with four pass through air ports, 1/8” NPT port are
provided in the body for the pneumatic connections.
Figure 1.2—Tool Plate
1.3 Optional Modules
There is one flat available for the mounting of the optional modules for support of various
utility pass-through, such as electrical signals.
For assistance in choosing the right modules for your particular application, visit our website
to see what is available or contact an ATI Sales Representative directly.
The optional modules are mounted to the Master or Tool Plate using a common side
mounting feature. Only (2) socket head cap screws need to be unscrewed in order to remove
the module from the Master/Tool Plate.
Figure 1.3—Optional Modules
2. Installation

Installation and Operation Manual
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All fasteners used to mount the Tool Changer to the robot and to user Tools should be tightened to a
torque value as indicated below. Furthermore, removable Loctite 222® must be used on M4 and M5
fasteners.
Mounting conditions Fastener Size and
Property Class
Maximum
Recommended
Torque
Master Plate to interface plate (6061-T6 aluminum)
Minimum thread engagement of 6mm (0.24”) [1.5X fastener Ø]
M4–0.7
Class 12.9
12 in-lbs
Master Plate to Robot (steel; USS ≥ 90KSI)
Minimum thread engagement of 6mm (0.24”) [1.5X fastener Ø]
M4–0.7
Class 12.9
25 in-lbs
IP to Master Plate (6061-T6 aluminum) M5 threads into body
Minimum thread engagement of 7.5mm (0.30”) [1.5X fastener Ø]
M5–.8
Class 12.9
25 in-lbs
Tool Plate to TIP (6061-T6 aluminum)
Minimum thread engagement of 9mm (0.35”) [1.5X fastener Ø]
M4–0.7
Class 12.9
12 in-lbs
Tool Plate to TIP (steel; USS ≥ 90KSI)
Minimum thread engagement of 9mm (0.35”) [1.5X fastener Ø]
M4–0.7
Class 12.9
25 in-lbs
TIP to Tool Plate (steel) M5 threads into body
Minimum thread engagement of 7.5mm (0.30”) [1.5X fastener Ø]
M5–.8
Class 12.9
25 in-lbs
2.1 Master Interface
The Master assembly is attached to the robot arm. The Master Plate is designed with bolt
holes and dowel holes as mounting features. These features are used to accurately position
and secure the Master to the robot. An interface plate is utilized to adapt the Master Plate to a
specific robot flange that is not compatible with the Master Plate mounting features. Custom
interface plates are available upon request. (Refer to Section 8—Drawings for technical
information on mounting features.)
If the customer chooses to design and build a robot interface plate, the following should be
considered:
•The interface plate should be designed to include bolt holes for mounting, and dowel
pins for accurate positioning on the robot and Master Plate.
•The thickness of the interface plate must be great enough to provide the necessary
thread engagement for the mounting bolts.
•The interface plate must be properly designed to provide rigid mounting to the
Master Plate boss area.
•The plate design should take into account clearances required for Tool Changer
module attachments and accessories.
2.2 Tool Interface
The Tool Plate is attached to customer-supplied tooling. The Tool Plate is designed with bolt
and dowel holes as mounting features. These features are used to accurately position and
secure the end-effector. Most often an End-effector Interface Plate (EIP) is utilized to adapt
the Tool Plate to an end-effector that is not compatible with the Tool Plate mounting features.
CAUTION: Care should be taken to select fasteners for mounting that are not too long,
such that a gap is formed at the interface

Installation and Operation Manual
Document #9620-20-b-mc-16 base tool changer-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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Custom EIPs can be supplied by ATI to meet customer requirements (Refer to Section 8—
Drawings for technical information on mounting features.).
When the customer chooses to design and build an End-effector Interface Plate, the following
should be considered:
•The interface plate should be designed to include bolt holes for mounting, and dowel
pins for accurate positioning.
•The thickness of the interface plate must be great enough to provide the necessary
thread engagement for the mounting bolts.
•The plate design should take into account clearances required for Tool Changer
module attachments and accessories.
2.3 Optional Module Installation
The optional modules are typically installed by ATI prior to shipment. The following the steps
outlining the field installation and removal of optional modules.
2.3.1 Installing Optional Modules
1. Clean the mounting surfaces.
2. Align the module to the mounting flat as shown in Figure 1.3.
3. If fasteners do not have pre-applied adhesive, apply Loctite 222®to the supplied
M3 Socket head cap screws. Install the (2) M3 socket head screws securing the
module to the Master or Tool plate and tighten to 7–10 in-lbs.
2.3.2 Removing Optional Modules
1. Depending upon the service or repair being done, customer connections up to
the module may or may not need to be disconnected.
2. Remove the M3 socket head cap screws and lift the module from the Master or
Tool plate. Refer to Figure 1.3
2.4 Tool Stand Design
In most cases, the Tools are stored in a Tool Stand when not being used by the robot. During
coupling and lock-up, the Tool Stand must allow for movement (float) in a plane parallel with
the mating surfaces of the Master Plate and Tool Plates (X and Y). This will help reduce wear
on alignment pin features and help to extend the life of the product.
Ideally, the Tool should be hanging vertically in the Tool Stand so that gravity helps to
uncouple the Tool Plate from the Master Plate during unlocking. It is possible to design Tool
Stands that hold tools in the horizontal position, but care must be taken that the necessary
compliance is provided during coupling and uncoupling. In general, “horizontal-position”
tool stands will cause more wear on the locking mechanism and locating features of the Tool
and Tool Stand.
Tool Stands may also need to incorporate means for covering Tools and electrical modules to
protect them in dirty environments, such as grinding or welding. Alternatively, locating Tool
Stands in areas shielded from weld spatter, fluids, adhesives, or other debris would eliminate
the need for Tool covers.
2.4.1 Tool Locating Features
The Tool should be positively and repeatably located in the Tool Stand. A variety
of methods may be used to accomplish this. A common method is to use tapered

Installation and Operation Manual
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Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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dowel pins in holes. As the Tool Plate approaches during locking, the taper lets the
Tool float into its locked position even with small deviations in position.
Other Tool locating feature methods include balls and detents, dowel pins in
notched V-grooves, etc. Please consult ATI for recommendations or assistance with
locating feature design for your particular tooling.
Straight cylindrical dowel pins should not be used as they provide too much
surface engagement. During coupling and uncoupling, the Tool can bind on these
pins due to misalignment of the Master and Tool Plates.

Installation and Operation Manual
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3. Operation
The Master locking mechanism is manually-driven to couple and uncouple with the Tool Plate. The
Master Plate utilizes mechanical leverage from the actuation screw to provide lock and unlock force
to the locking mechanism.
3.1 Coupling Sequence
Position the Master above the Tool and move the Master into locking position. The mating
surfaces of the Master and Tool should be parallel upon approach. Make sure that the tapered
alignment pins from the Master enter the alignment holes on the Tool. The alignment pins
should be relatively concentric with the alignment holes such that they do not rub against the
edge. Note: In Figure 3.1 through Figure 3.3 the MC036 is shown for reference.
Figure 3.1—Bring Tool to Master
CAUTION: The locking mechanism must be in the unlock position when
attempting to couple the Tool Changer. Failure to adhere to this condition may
result in damage to the unit and/or the tooling.
NOTICE: All Tool Changers are initially lubricated using MobilGrease® XHP222 Special
grease. The end user must apply additional lubricant to the locking mechanism
components and alignment pins prior to start of service (See Section 4.2—Locking
Mechanism, Alignment Pins Cleaning and Lubrication). Tubes of lubricant for this
purpose are shipped with every Tool Changer. Note: MobilGrease® XHP222 Special is
a NLGI #2 lithium complex grease with molybdenum disulfide.

Installation and Operation Manual
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Push the quick action rod release button on the Master body. Be sure the Tool is engaged
with the Master. There should be no gap between the Master and Tool at this time.
Figure 3.2—Push Button for Quick Locking
Then apply the tightening torque to the knob to provide the final clamping force. In lab
testing, 25 in-lbs of tightening torque was determined to provide the optimal clamping force,
but anywhere between 10 in-lbs and 25 in-lbs is adequate. This tightening force range equates
to the average human tightening a knob by hand. Do not use a tool and over-tighten or
excessive wear on components will occur and the product lifespan will be shortened.
Figure 3.3—Tighten Knob for Full Lock
Tighten clockwise by
hand to provide the
lock force

Installation and Operation Manual
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3.2 Fail-Safe Operation
The manual Tool Changer features two fail-safe features. The first feature is the cam spring
feature. When the Master is locked, the cam is spring-loaded to bias it to keep it locked. This
spring prevents the cam from vibrating to the unlock position as well as allows for a quick
action lock movement when the button is pushed (see Figure 3.4).
Figure 3.4—Fail Safe Operation (MC-36 shown)
The second fail-safe feature is the fail-safe tapered surface on the cam. As the cam is screwed
in towards lock position, the balls roll along the first taper. The first taper simply provides the
travel necessary to move towards lock. Then the balls roll past the intermediate tapered
surface and onto the final tapered surface called the lock angle. This lock angle, combined
with the tightening torque from the cam shaft, results in a high mechanical advantage and
reliable locking force. In the event that the cam shaft is accidentally loosened, the cam may
want to back out toward unlock position. If this happens, the balls will contact the
intermediate “fail-safe” taper on the cam profile, and become trapped, as the forces on the
Tool pull against the Master, the effect of this fail-safe taper strengthens. Both the cam spring
and the fail-safe cam tapered surface act together to provide a high assurance and high level
of safety.
3.3 Uncoupling
The Tool Changer should be positioned in the Tool Stand in the same location as that when
coupling took place.
Unscrew the cam all the way out of the lock position. Take precautions to ensure the Tool
will not fall on your fingers. The unit will not fully disengage the Tool until the cam is all the
way unscrewed. It is safe to remove the Master from the Tool only when the cam is in the
fully unlocked position.
NOTICE: :If the unit is equipped with an optional ratchet knob pull out on the knob and
unscrew until the ratchet knob is past the ratcheting device on the Tool Changer body .

Installation and Operation Manual
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4. Maintenance
4.1 Preventive Maintenance
The Tool Changer and optional modules are designed to provide a long life with regular
maintenance.
A visual inspection and preventative maintenance schedule is provided in the table below
depending upon the application. Details are provided in Section 8—Drawings.
Table 5.1—Preventative Maintenance Checklist
Application(s)
Tool Change Frequency
Inspection Schedule
General Usage, Material Handling, Docking Station
More than 1 per minute
Weekly
Less than 1 per minute
Monthly
Wet or Humid Environments
All
Weekly
Welding/Servo/Deburring, Foundry Operations
(Dirty Environments)
All
Weekly
Locking Mechanism Cam and Alignment Pins
□Inspect for lubrication and wear. A NLGI #2, lithium-based grease with molybdenum disulfide additive is suggested
for locking mechanism and alignment pin lubrication. Over time, lubricants can become contaminated with process
debris. Therefore, it is recommended to thoroughly clean the existing grease and replace with new as needed.
Refer to Section 4.2—Locking Mechanism, Alignment Pins Cleaning and Lubrication.
□Excessive alignment pin/bushing wear may be an indication of poor robot position during pickup/drop-off. Adjust
robot position as needed. Check Tool Stand for wear and alignment problems. Refer to Section 4.3—Alignment
Pin Replacement.
Mounting Fasteners and Interface Connections
□Inspect for proper torque and interference or wear, abrasions, cuts of hoses, and electrical cables. Tighten and
correct as required.
O-rings and Rubber Bushings
□Exposed o-rings and rubber bushings may be subject to damage during normal operation. Inspect for wear,
abrasion, and cuts. Replace damaged o-rings and rubber bushings as needed.
Electrical Module
□Clear debris from area of the contact using compressed air. Do not directly clean contacts as abrasion may occur
and the performance of the contact may be compromised. Inspect Electrical Contacts for wear or damage. Refer
to Section 4.4—Electrical Module Pin Block Contact Inspection and cleaning.
□Inspect V-Ring Seal for wear, abrasion, and cuts. Refer to Section 4.5—Electrical Module Seal Inspection and
Replacement.
NOTICE: All Tool Changers are initially lubricated using MobilGrease® XHP222 Special
grease. The end user must apply additional lubricant to the locking mechanism
components and alignment pins prior to start of service (See Section 4.2). Tubes of
lubricant for this purpose are shipped with every Tool Changer. Note: MobilGrease®
XHP222 Special is a NLGI #2 lithium complex grease with molybdenum disulfide.
NOTICE: The cleanliness of the work environment strongly influences the trouble-free operation
of the changer. The dirtier the environment, the greater the need is for protection against debris.
Protection of the entire EOAT, the Master, the Tool, and all of the modules may be necessary.
Protective measures include the following: 1) placement of Tools Stands away from debris
generators, 2) covers incorporated into the Tool Stands [see Section 2.3] and 3) guards,
deflectors, air curtains, and similar devices built into the EOAT and the Tool Stand.

Installation and Operation Manual
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4.2 Locking Mechanism, Alignment Pins Cleaning and Lubrication
4.2.1 Cleaning and Lubrication of the Locking Mechanism and Alignment
Pins (Master Plate).
1. The locking mechanism must be in the unlock state before cleaning.
2. Use a clean rag to thoroughly remove the existing lubricant and debris from
the cam, locking balls, and the alignment pins.
Figure 4.1—Clean and Lubricate Locking Mechanism and Alignment Pins
3. Apply a liberal coating of lubricant to the cam, locking balls, and the
alignment pins.
4.2.2 Cleaning the Locking Mechanism and Alignment Pin Bushings (Tool
Plate).
1. Use a clean rag to thoroughly remove any lubricant and debris from the
engagement surfaces and the alignment holes.
2. No re-lubrication is necessary on the Tool Plate components.
4.3 Alignment Pin Replacement
1. Alignment pins can be removed via pliers or by pushing the pins out from the back of the
Master housing.
2. Install the new alignment pin into the body via an arbor press. Verify the pin is fully
seated into the body. The pin heads should seat fully against the Master body.
3. Also be sure the diamond head is oriented as shown.
Figure 4.2—Alignment Pin Replacement

Installation and Operation Manual
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4.4 Electrical Module Pin Block Contact Inspection and cleaning
1. Inspect the Master and Tool pin blocks for any debris or darkened pins.
Figure 4.3—Inspect Master and Tool Pin Blocks
2. If debris or darkened pins exist, remove debris using a vacuum, and clean using a nylon brush
(ATI part number 3690-0000064-60).
3. Inspect the Master and Tool pin blocks for stuck pins or severe pin block damage.
Figure 4.4—Stuck Pin and Pin Block Damage
4. If stuck pins or severe pin block damage exists, contact ATI for possible pin replacement
procedures or module replacement.
4.5 Electrical Module Seal Inspection and Replacement
The seal protect the electrical connection between the Master and Tool module. If the seal
becomes worn or damaged it needs to be replaced.
1. To remove the existing seal, pinch edge of seal with fingers and gently pull the seal away from the
pin block on the Master.
2. 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).

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3. To install a new seal, stretch the new seal over the shoulder of the pin block.
4. Push the seal’s hub down against the pin block using finger tip.
Figure 4.5—V-Ring seal Replacement
5. Troubleshooting
Check these conditions for all symptoms prior to troubleshooting:
•Proper pneumatic and electrical connections have been made to the Manual Coupler.
•Mounting screws are properly installed.
•Locking Cam Screw is fully tightened (to approximately 25 in-lbs).
Symptom Cause Resolution
Unit will not lock or
unlock
The locking mechanism
cam is jammed.
Clean and lubricate as needed to restore smooth
operation (see Section 4—Maintenance).
The cam screw is not
moving.
Check for debris in the handle area of the locking
mechanism, and clean if necessary.
The Master and Tool are
not touching prior to lock.
Check that the Tool is properly seated in the
Tool Stand.
Verify that there is no debris between the Master
and Tool prior to locking.

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6. Recommended Spare Parts
Assembly Part Number Description
Master Plate 9122-016M-000 Complete MC-16 Master Assembly, with Air Ports
3690-5800803-10 Round Alignment Pin, Steel
3690-5800804-10 Diamond Alignment Pin, Steel
3410-0001291-01 O-rings – Air ports
For Other Components see Section 8—Drawings
Tool Plate 9122-016T-000 Complete MC-16 Tool Plate, No Options
For Other Components Section 8—Drawings
Optional Ratchet
Knob
9005-20-1814 Complete MC Ratchet Knob Assembly
For Other Components Section 8—Drawings
7. Specifications
Master and Tool Plates
Suggested Payload Limit 35 lbs.
(16 kg)
The mass attached to the tool Changer.
Operating Temperature Range -20–150oF
(-30–66oC)
Static Moment Capacity (x, y) 220 in-lb
(25 Nm)
Maximum recommended working load for optimum
performance of the Tool Changer.
Weight (coupled, no access.) 1.35 lbs
(.54 kg)
Master 0.75 lbs (0.34 kg)
Tool 0.60 lbs (0.27 kg)
Mounting/Customer Interface
Master Plate Custom Rectangular Pattern See Section 8—Drawings
Tool Plate Custom Rectangular Pattern See Section 8—Drawings
Pneumatic Pass-through Ports (4) 1/8” NPT Optional. Specify –NP for version with No Ports

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8. Drawings
8.1 MC-16 Manual Tool Changer Drawing

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8.2 MC-16 Manual Coupler Outer Dimensions

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8.1 MC-16 with Quick Action Screw Lock – Euro – Ports Removed

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Installation and Operation Manual
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8.2 Manual Coupler Ratchet Knob