ATI Technologies QC-150 User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
QC-150 Robotic Tool Changer
Manual
Document #: 9610-20-2256

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
2
Foreword
This manual contains basic information applicable to all ATI Tool Changer robotic Tool Changers. Certain Tool Changer
models have their own manuals that contain more detailed information. Also, additional information about electrical,
pneumatic, uid, high-power and high-current modules and other options are available in other manuals and documents.
Please contact ATI Industrial Automation 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]

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
3
Table of Contents
Foreword.......................................................................................................................................... 2
Glossary of Terms........................................................................................................................... 5
1. Safety......................................................................................................................................... 6
1.1 ExplanationofNotications.........................................................................................................6
1.2 General Safety Guidelines............................................................................................................6
1.3 Safety Precautions........................................................................................................................7
2. Product Overview..................................................................................................................... 8
2.1 Master Plate Assembly .................................................................................................................8
2.2 Tool Plate Assembly......................................................................................................................9
2.3 Master Plate/Tool Plate Locking Mechanism..............................................................................9
2.4 Optional Sensor Interface Plate (SIP)........................................................................................10
2.5 Optional Modules........................................................................................................................10
3. Installation ...............................................................................................................................11
3.1 Robot Side Interface Plates........................................................................................................13
3.2 Master Plate Installation.............................................................................................................14
3.3 Master Plate Removal.................................................................................................................15
3.4 Tool Interface Plate .....................................................................................................................16
3.5 Tool Plate Installation .................................................................................................................17
3.6 Tool Plate Removal .....................................................................................................................17
3.7 Optional Module Installation......................................................................................................18
3.8 Optional Module Removal..........................................................................................................18
3.9 Installing an Optional (SIP) Sensor Interface Plate Assembly................................................19
3.10 Pneumatic Requirements...........................................................................................................22
3.10.1 Valve Requirements .........................................................................................................22
3.11 Electrical Connections................................................................................................................23
3.11.1 PNP Type Lock and Unlock Sensors................................................................................23
3.11.2 NPN Type Lock and Unlock Sensors ...............................................................................23
4. Operation ................................................................................................................................ 24
4.1 Conditions for Coupling.............................................................................................................25
4.2 Fail-Safe Operation .....................................................................................................................25
4.3 Uncoupling Sequence.................................................................................................................26
4.4 ToolIdentication........................................................................................................................26
4.5 Tool Storage Considerations .....................................................................................................26

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
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5. Maintenance............................................................................................................................ 27
5.1 Preventive Maintenance .............................................................................................................27
5.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins...........................28
5.3 Optional Electrical Module Pin Block Inspection and Cleaning.............................................30
6. Troubleshooting and Service Procedures ........................................................................... 31
6.1 Troubleshooting Procedures .....................................................................................................31
6.2 Service Procedures.....................................................................................................................32
6.2.1 Proximity Sensor Adjustment, Test, or Replacement .......................................................32
6.2.2 Optional Electrical Module Seal Inspection and Replacement.........................................34
6.2.3 3/8”Rubber Bushing Replacement..................................................................................35
6.2.4 Alignment Pin Replacement.............................................................................................36
7. Specications ......................................................................................................................... 38
8. Serviceable Parts ................................................................................................................... 39
8.1 Models QC-150 ............................................................................................................................39
9. Drawings ................................................................................................................................. 41
9.1 QC-150 Tool Changer with G19 and FN2 Modules...................................................................41
10. Terms and Conditions of Sale............................................................................................... 42

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
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5
Glossary of Terms
Term Denition
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.
Coupling The physical action of the locking the Master and Tool plates together. See Lock
Cover Plate A protective closure plate on standard 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.
Electrical Module 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.
Fluid Module Utility modules that pass uids through the Master and Tool modules to the end-effector.
High Current
Module Utility modules that pass electrical power through the Master and Tool modules to the end-effector.
Interface Plate Component that adapts a Tool Changer or Utility Coupler to the user’s robot or tooling.
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.
Locked An output signal provided by a proximity sensor, indicating that the coupling mechanism is in the Locked
position.
Locking
Mechanism
Manual, pneumatic, or electrical driven device that draws the Master and Tool plates together securing
them in a fail-safe or 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 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.
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 Utility modules that pass air or vacuum through the Master and Tool modules to the end-effector.
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 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 robot. The SIP is an interface plate
that contains sensors that determine the state (Locked/Unlocked/No Tool) of the Master plate.
Tool plate The half of the Tool Changer to which tools or end-effectors are mounted.
Tool Stand Stand that holds Tools not being used by the robot.
Trip Dog A physical device used to activate a mechanical switch, use in the tool stand Interlock circuit.
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.

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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1. Safety
The safety section describes general safety guidelines to be followed with this product, explanation of the
notications found in this manual, and safety precautions that apply to the product. More specic notications are
imbedded within the sections of the manual where they apply.
1.1 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.
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,
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.
1.2 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 interlocks applied to prevent injury to personnel and
equipment.
All pneumatic ttings and tubing must be capable of withstanding the repetitive motions of the application
without failing. The routing of electrical and pneumatic lines must minimize the possibility of stress/strain,
kinking, rupture, etc. Failure of critical electrical 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.

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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1.3 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(s) on the Tool Changer or modules
unless the Tool is safely supported or placed in the tool stand, all energized circuits
(e.g. electrical, air, water, etc.) are turned off, pressurized connections are purged and
power is discharged from circuits in accordance with the customer 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: 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 interface plate. Damage to the Cover Plate and O-ring may result.
Always attach the Master plate to the Interface plate prior to attempting any operations.

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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2. Product Overview
The Tool Changer provides exibility to robot applications by allowing 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.
Table 2.1—Standard QC Tool Changer Models and Features
Model Payload Flats Plate Pneumatic Ports Part No.
QC-150 440 lbs
(200 kg) (2) Flat
Master (10) 3/8” NPT Pass through ports
(2) 1/8” NPT Lock/Unlock air ports 9120-150M-000-000
9120-150M-000-000-B
Tool (10) 3/8” NPT Pass through ports 9120-150T-000-000
9120-150T-000-000-B
Master (10) 3/8”-19 BSPP Pass through ports
(2) 1/8”-28 BSPP Lock/Unlock air ports 9120-150M-000-000-E
Tool (10) 3/8”-19 BSPP Pass through ports 9120-150T-000-000-E
Master (10) R 3/8” BSPT Pass through ports
(2) R 1/8” BSPT Lock/Unlock air ports 9120-150M-000-000-R
Tool (10) R 3/8” BSPT Pass through ports 9120-150T-000-000-R
Notes: QC-150 Tool Changer Master and Tool plate assemblies with (-B and -E) part numbers have black anodized bodies
2.1 Master Plate Assembly
The Master plate assembly includes an anodized aluminum body, a hardened stainless-steel locking
mechanism, and hardened steel alignment pins. The locking mechanism consists of a cam, a male coupling,
and chrome-steel ball bearings. The Master plate provides (2) ats for mounting optional modules.
Figure 2.1—Master Plate Assemblies (9120-150M-000-000 Shown)
Cover Plate
Optional Module
Flat A
Optional Module
Flat B
1/8"NPT Lock Air Connection
(12) Ball Bearing
Male Coupling
(10) Pass-Through
Air Port
(10) 3/8" NPT Customer Connection
(2) Alignment Pin
1/8"NPT Unlock
Optional Module
Flat B
Master Plate
Assembly
Optional Module Flat A
Air Connection
The air port provides lock and unlock air for the locking mechanism and pass through air for the end of arm
tooling.
Alignment pins on the Master mate with bushings on the Tool to ensure repeatable alignment during the
coupling process. An extreme pressure grease is applied to the cam, male coupling, ball bearings, and pins to
maximize the life of the Master plate assembly.
A cover plate attaches to the Master to protect the internal locking mechanism during shipment. This cover
plate can be removed during installation, if replaced by an interface plate or Sensor interface plate. Refer to
Section 3—Installation for details.

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
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2.2 Tool Plate Assembly
The Tool plate assembly includes an anodized aluminum body and hardened stainless-steel bearing race. The
Tool plate provides (2) ats for mounting optional modules. The Tool plate is equipped with pass through air
ports to supply air to the end of arm tooling.
Figure 2.2—Tool Plate Assembly
(2) Integrated Alignment Hole
(10) 3/8" NPT Customer Connection Optional Module Flat A
Optional Module Flat B
(10) Pass Through Air Port
Tool Plate Assembly
Harden Stainless Steel
Bearing Race
2.3 Master Plate/Tool Plate Locking Mechanism
The coupling of the Master plate and the Tool plate is achieved through a patented, high-strength, and
stainless steel mechanism. During locking, steel balls in the Master plate are driven outward by a circular
cam attached to a pneumatically actuated piston. The cam prole has (3) features: A lead-in angle (conical),
a at (cylindrical) area, and a secondary angle (conical). The lead-in angle initiates the coupling process,
the at area assures the coupling will not be compromised in case of air loss (fail-safe feature), and the
secondary angle provides rigid coupling during normal operation. The balls engage a bearing race (or
“locking ring”) in the Tool plate and lock the Master plate and Tool plate tightly together.
Figure 2.3—Locking Mechanism
Piston
Bearing Race
Circular Cam
Ball Cage
Ball Bearing

Manual, Robotic Tool Changer, QC-150
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2.4 Optional Sensor Interface Plate (SIP)
The sensor interface plate (SIP) system provides locking mechanism position signals to the customer
process controller. These signals indicate (2) possible conditions for the Tool Changer Master plate:
unlocked or locked.
The SIP system utilizes sensors to detect the position of the pneumatically-actuated piston in the Master
plate. These sensors are available in PNP, NPN, and other options upon request, contact ATI for more
information.
The SIP system consists of a SIP plate, a detection shaft, a sensor plate, proximity switches, and an O-ring.
The sensor plate (which is the interface plate between the Master plate and the robot) will replace the
cover plate on the back of the Tool Changer Master. The sensor plate provides mounting locations for the
proximity sensors and closes the pneumatic chamber of the Master. The SIP provides mounting holes for
attaching the Master to the customer application and retains the sensor plate.
Figure 2.4—Optional Sensor Interface Plate
Detection Shaft
(Sensor Target)
Unlock Sensor
Lock Sensor
Sensor Interface Plate (SIP)
O-ring
Sensor Plate
2.5 Optional Modules
Tool Changers have (1) or (2) ats depending on the model. Optional modules support the pass through of
various utilities such as signal, uid/air, and power. Some modules require an adapter plate.
For assistance in choosing the right modules for your application, visit the specic QC-150 model webpage
by clicking on the link QC-150 Web Page and select the Compatible Modules tab to see what is available or
contact an ATI Sales Representative.

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
11
3. Installation
WARNING: Do not perform maintenance or repair(s) on the Tool Changer or modules
unless the Tool is safely supported or placed in the tool stand, all energized circuits (e.g.
electrical, air, water, etc.) are turned off, pressurized connections are purged and power is
discharged from circuits in accordance with the customer 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: All pneumatic ttings and tubing must be capable of withstanding the repetitive
motions of the application without failing. The routing of electrical and pneumatic lines must
minimize the possibility of over stressing, pullout, or kinking the lines. Failure to do so can
cause critical electrical and/or pneumatic lines not to function properly and may result in injury
to personnel or damage to equipment.
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.
Allowing 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 apply Lock or Unlock air pressure to the Tool Changer prior to installing an
interface plate or sensor interface plate (SIP). Applying air pressure can damage the cover
plate, O-ring or may cause injury to personnel from ying debris. Always install an interface
plate or SIP and have the Tool Changer mounted securely to the robot before applying air
pressure. Refer to Section 3.1—Robot Side Interface Plates and Section 3.2—Master Plate
Installation for more information.
CAUTION: Failure to follow the interface plate or tool interface plate design consideration in
Section 3.1—Robot Side Interface Plates and Section 3.4—Tool Interface Plate may result
in cover plate O-ring damage or loosening of the interface during operation. Follow the
guidelines provided when designing an interface plate for the Tool Changer.
CAUTION: Do not use fasteners that exceed the thread depth in the Tool Changer. Refer to
Section 9—Drawings for details on mounting hole thread depth. Secure the Tool Changer with
the proper length fasteners. This is true for both robot and tool interfaces.
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.

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The Master plate of the Tool Changer mounts to the robot arm using an interface plate or a SIP. Custom interface
plates are available from ATI. Refer to Section 3.1—Robot Side Interface Plates or Section 2.4—Optional Sensor
Interface Plate (SIP) for more information.
The end-effector typically attaches to the Tool plate with an interface plate, standard and custom interface plates are
available from ATI upon request. Refer to Section 3.4—Tool Interface Plate for more information.
All fasteners used to mount the Tool Changer to the robot and to customer tooling should be tightened to a torque
value as indicated, refer to Table 3.1.
Pneumatic lines and electrical cables are attached, bundled, and must be strain-relieved to allows for movement
during operation.
Table 3.1—FastenerSize,Class,andTorqueSpecications
Mounting Conditions Fastener Size and
Property Class Recommended Torque Thread
Locker
QC-150 Master plate to Interface plate or Sensor
Interface plate, Supplied Fasteners M10 x 1.5 Class 12.9
Pre-applied
Adhesive or
Loctite 242
Socket head cap 55 ft-lbs (75 Nm)
Tool Interface Plate to QC-150 Tool plate Minimum thread
engagement of 15 mm [1.5X fastener Ø]. Do not exceed
maximum available thread depth as shown in Section 9—
Drawings
M10 x 1.5 Class 12.9
Socket head cap 55 ft-lbs (75 Nm)
Optional Module or adapter plate to Master or Tool plate,
Supplied Fasteners
M4 x 0.7 Class 12.9 Pre-applied
Adhesive or
Loctite 222
Socket head cap 15 in-lbs (1.69 Nm)
Socket at head cap 10 in-lbs (1.13 Nm)

Manual, Robotic Tool Changer, QC-150
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3.1 Robot Side Interface Plates
The interface plate is used to adapt the Master plate to a specic robot arm. The interface plate is designed
with mounting features such as a boss and/or bolt and dowel holes. These features are used to accurately
position and secure the Master plate to the robot arm. Custom interface plates are available from ATI upon
request.
If the customer chooses to design and build an interface plate, the following points should be considered:
CAUTION: Do not use more than two alignment features when securing a Master plate
to a robot 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 robot interface plate.
CAUTION: Do not use dowel pins that are too long that will not allow the interface plate
and Master body to mate ush with each other. Using dowel pins that are too long will
cause a gap between the interface plate and the Master body causing damage to the
equipment. Use the proper size dowel pins that will not extend further than allowed by
the Master body.
Master Plate
Interface Plate
Dowel pins which are
proper size allowing
interface plate and Master
Plate to mount flush.
Two dowel pins
(or a single dowel
pin along
with a boss/recess) being
used as alignment features.
Flush
Correct Mounting of Master Plate
Master Plate
Interface Plate
Dowel pins which are
too long can cause a
plate and Master Plate.
gap between interface
Optional Boss
GapGap
A boss and two dowel pins
as alignment features can
as difficult to align and can
cause damage to equipment.
Incorrect Mounting of Master Plate
• The interface plate must include bolt holes for mounting, dowel pins, and a boss for positioning on the
robot and Master plate. (Refer to robot manual). (The dowel and boss features prevent rotation).
• A piston cover plate is provided with the Tool Changer Master plate. If the interface plate provides
sealing for the piston cylinder, then the cover plate can be removed.
• The interface plate must be designed to provide rigid mounting on the boss surfaces. The interface
plate must not contact the Master body outside of the boss. The recommended dimensions for the
interface plate bore, with and without the cover plate, are provided in Section 9—Drawings. The
mating diameters must provide sufcient clearance so that mating corner radii do not interfere.
• The thickness of the interface plate must be enough to provide the necessary thread engagement for the
mounting bolts.
• Mounting bolts must not be too long that a gap is formed at the interface.

Manual, Robotic Tool Changer, QC-150
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14
Figure 3.1—InterfacePlateandSIPwithMasterPlateCongurations
Interface Plate
Master Plate Body
Maintain a Gap
Cover Plate Left in Place
O-ring
Dowel Pin
Boss
Mounting Fastener
(Supplied by Customer)
Master Plate Boss
Sensor Interface plate (SIP)
Master Plate Body
Sensor Plate (Cover Plate Removed)
O-ring
Detection shaft
O-ring
Dowel Pin
Mounting Fastener
(Supplied by Customer)
Master Plate Boss
Interface Plate
Master Plate Body
O-ring
Boss Dowel Pin
Mounting Fastener
(Supplied by Customer)
Maintain a Gap
Master Plate Boss
Cover Plate Removed
3.2 Master Plate Installation
Tools required: 2.5 mm and 8 mm Allen®wrench, torque wrench
Supplies required: Clean rag, Loctite 242
The Tool Changer Master plate mounts to the robot ange using an SIP or interface plate. A cover plate
attaches to the Master plate to protect the internal locking mechanism during shipment. The cover plate must
be removed if an SIP is being used, and may have to be removed if an interface plate is being used. The
interface plate can be designed to accommodate the cover plate.
1. Clean the mating surfaces.
2. Align the dowel pin in the interface plate or SIP to the corresponding holes in the robot arm and secure
with supplied or customer supplied fasteners, refer to Figure 3.1. Refer to Table 3.1 for fasteners and
torque.
3. What type of interface plate is being installed?
If an interface plate that replaces the cover plate is being installed, go to step 4.
If an SIP or an interface plate that incorporates the cover plate, go to step 6.
4. Using a 2.5 mm Allen wrench, remove the (2) M3 socket at head screws and discard.
5. Remove the cover plate.
CAUTION: Make sure the O-ring is seated in the groove in the Master plate. If the
O-ring is not seated in the groove it can be cut or damaged, resulting in a leaking seal.
Seat O-ring into groove in Master body.
6. Align the dowel pin in the interface plate or SIP to the corresponding holes in the Master plate and
secure with supplied (6) M10 socket head cap screws using an 8 mm Allen wrench, refer to Figure 3.2.
Refer to Table 3.1 for fasteners and torque.
7. Connect all lock / unlock and pass through air connections to the connections on the Master plate. For
lock and unlock air refer to Section 3.10—Pneumatic Requirements.
8. If equipped connected the lock and unlock sensor cables.
9. If equipped connect other utilities to the optional modules on the Master plate.
10. After the procedure is complete, resume normal operation.

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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3.3 Master Plate Removal
Tools required: 8 mm Allen wrench
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.).
5. If equipped, disconnect the lock and unlock sensor cables.
NOTICE: Support the Master plate while removing the fasteners.
6. Using an 8 mm Allen wrench, remove the (6) M10 socket head cap screws securing the Master plate to
the interface plate or SIP.
7. Remove the Master plate.
Figure 3.2—Typical Master Plate Installation
Sensor Interface Plate
Master Plate Assembly
(QC-150 with RF19 and
FN2 modules Shown)
(6) M10 Socket Head
Cap Screw
(Customer Supplied)
(6) M10 Socket Head
Cap Screw
Dowel Pin
(Customer Supplied)
Sensor Plate
(Replaces Cover Plate)
Robot Arm
(6) M10 Socket Head
Cap Screw
Robot Arm
Robot Interface Plate
(Customer Supplied)
The Cover Plate can remain
in place if the interface plate is
designed to accomodate the plate
(2) M3 Socket Flat Head
Screw to temporaraly
hold cover plate in place
Dowel Pin
(Customer Supplied)
Socket Head Cap Screw
(Customer Supplied)
Master Plate Assembly
(QC-150 with RF19 and
FN2 modules Shown)

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
16
3.4 Tool Interface Plate
The end-effector typically attaches to the Tool plate with an interface plate. The interface plate is designed
with mounting features such as a recess and/or bolt and dowel holes. These features are used to position
and secure the customer tooling. An interface plate adapts the Tool plate to customer tooling that is not
compatible with the Tool plate mounting features. Custom interface plates can be supplied by ATI (see
Figure 3.3). Refer to Section 9—Drawings for specic mounting features for your model.
If the customer chooses to design and build a tool interface plate, the following should be considered:
CAUTION: Do not use more than two alignment features when securing 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 that will not allow the interface
plate and Tool body to mate ush with each other. Using dowel pins that are too long
will cause a gap between the interface plate and the Tool body causing damage to the
equipment. Use the proper size dowel pins that will not extend further than allowed by
the Tool body.
Tool Plate
Interface Plate
Dowel pins which are
proper size allowing
interface plate and Tool
Plate to mount flush.
Two dowel pins (or a
boss/recess) being used as
alignment features.
Correct Mounting of Tool Plate
Tool Plate
Interface Plate
Dowel pins which
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
cause damage to equipment.
Gap
Incorrect Mounting of Tool Plate
single dowel pin along with a
• The interface plate must be designed to include bolt holes for mounting, dowel pins, and a boss that
mates with the Tool plate recess for positioning. (The dowel and boss features prevent rotation).
• The locating boss height should not exceed the customer interface depth specied on the drawing.
• 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 Changer.
• The plate design must account for clearances required for Tool Changer module attachments and
accessories.
• The interface plate should be designed with a hole in its center to allow 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 should be kept small [minimum recommended hole
diameter: 1” (25.4 mm)] to prevent debris from contaminating the locking mechanism while operating
in dirty environments.

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
17
3.5 Tool Plate Installation
Refer to Figure 3.3.
Tools required: 8 mm Allen wrench, torque wrench
Supplies required: Clean rag, Loctite 242
1. Clean the mating surfaces.
2. If not using fasteners with pre-applied adhesive, apply Loctite 242 to supplied fasteners. (Note:
Mounting fasteners are supplied with ATI custom interface plates).
3. Align the dowel pins in the interface plate or customer tooling to the corresponding holes in the Tool
plate and secure with customer supplied (6) M10 socket head cap screws using an 8 mm Allen wrench.
4. Connect utilities to the modules and Tool plate connections.
5. After the procedure is complete, resume normal operation.
Figure 3.3—Typical Tool Plate Installation
(6) M10 Socket Head Cap Screw
(Customer Supplied)
Tool Plate Assembly
(QC-150 with RF19 and
FN2 Module Shown)
Interface Plate
(Customer Supplied)
Dowel Pin
(Customer Supplied)
Note: Mounting Fasteners
and Dowel Pins included
with ATI Interface Plates
3.6 Tool Plate Removal
Tools required: 8 mm Allen wrench
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.).
5. Using an 8 mm Allen wrench, remove the (6) socket head cap screws securing the Tool plate to the
interface plate or customer tooling. Refer to Figure 3.3.
6. Remove the Tool plate.

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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3.7 Optional Module Installation
Tools required: 2.5 mm and 3 mm Allen wrench, torque wrench
Supplies required: Clean rag, Loctite 222
The optional modules are typically installed on Tool Changers prior to shipment. The following steps outline
installation or removal as required. Tool Changers are compatible with many different types of modules.
Some modules require an adapter plate to be installed to the Tool Changer.
1. Place the Tool in a secure location.
2. Uncouple the Master and Tool plates.
3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).
4. Clean the mating surfaces.
5. Align optional module on the Master or Tool plate as shown in Figure 3.4.
6. If not using fasteners with pre-applied adhesive, apply Loctite 222 to supplied fasteners.
7. Using an Allen wrench, secure the module with (4) M4 mounting fasteners. Refer to Table 3.1 for torque
for your specic mounting fasteners.
8. Remove all protective caps, plugs, tape, etc from the module prior to operation.
9. After the procedure is complete, resume normal operation.
Figure 3.4—Optional Module Installation
Tool Plate
Assembly
Master Plate
Assembly
(4) M4 Socket Head
Cap Screw
Fluid/Air Module
(9120-FN2-T Shown)
(4) M4 Socket Head
Cap Screw
Fluid/Air Module
(9120-FN2-M Shown)
(4) M4 Socket Flat
Head Cap Screw
(4) M4 Socket Flat
Head Cap Screw
Electrical Module
(9120-RF19-M Shown)
Electrical Module
(9120-RF19-T Shown)
3.8 Optional Module Removal
Tools required: 2.5 mm and 3 mm Allen wrench
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 any cables, air line, etc. if required.
5. Supporting the module and using an Allen wrench, remove the M4 mounting fasteners.
6. Remove the module from the Master or Tool plate.

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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3.9 Installing an Optional (SIP) Sensor Interface Plate Assembly
The optional sensor interface plate is typically installed on Tool Changers by ATI prior to shipment. The
following steps outline installation. The sensor interface plate assembly includes a custom interface plate.
This may replace the existing interface plate. For interface plate installation refer to Section 3.2—Master
Plate Installation.
The SIP assembly comes partially assembled, the Lock and Unlock sensors are assembled to the proper
position in the sensor plate. There is no need to remove the sensors or adjust the position. The small
detection shaft O-ring is lubricated and installed in the sensor plate.
Parts required: 9120-150M-SIP-yyyy, (where yyyy is the custom SIP interface plate)
Tools required: 2 mm, 2.5 mm, 3 mm, and 5 mm Allen®wrenches (hex key), torque wrench
Supplies required: Loctite®222 and Loctite®Primer 7649 (if fasteners do not have pre-applied adhesive),
MagnaLube, tape
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. Remove the Tool Changer Master plate from the robot and the interface plate , refer to Section 3.3—
Master Plate Removal.
5. If the Tool Changer has a cover plate, remove the (2) M3 socket at head screws securing the cover plate
to the Tool Changer Master plate using a 2 mm Allen wrench. Refer to Figure 3.5.
6. Lift the cover plate off the Master plate.
7. Make sure the O-ring in the Master plate is present and in good condition, lubricate with Magnalube.
Figure 3.5—Cover Plate Removal
Cover Plate
O-ring
Master Plate
(2) M3 Socket Flat Head Screw
NOTICE: The sensor plate assembly comes assembled with the lock and unlock sensor
installed. Do not remove the sensors, the sensors have been position properly from the factory.
The sensor plate assembly has the detection shaft O-ring installed and lubricated, make sure it
is present as shown in Figure 3.6.

Manual, Robotic Tool Changer, QC-150
Document #9610-20-2256-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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Figure 3.6— Sensor Plate Assembly with Lock/Unlock sensors and O-ring
O-ring
Sensor Plate Assembly
8. Apply tape over the threads of the detection shaft to protect the threads from grease contamination
during assembly.
9. Lightly lubricate the detection shaft with Magnalube.
10. Carefully insert the taped detection shaft through the sensor plate assembly pushing it through until it
stops.
11. Remove the tape from the detection shaft and apply Loctite primer 7649 to the threads of the detection
shaft and the internal threads of the piston. Allow the primer to dry.
12. Apply Loctite 242 to the threads of the detection shaft and the internal threads of the piston.
13. Assemble the sensor plate assembly to the Master plate using the dowel pin to align the sensor plate
assembly.
14. Secure the sensor plate to the Master plate with the (2) M3 socket at head screws using a 2 mm Allen
wrench. Tighten to 6 in lbs (0.68 Nm).
Figure 3.7—Sensor Interface Plate Installation
Sensor Plate Assembly
Master Plate
Dowel Pin
Detection Shaft
Piston
O-ring
M3 Socket Flat Head Screws
15. Use a 5 mm Allen wrench to hold the cam screw as shown in Figure 3.8.
16. Use a 3 mm Allen wrench to tighten the detection shaft. Tighten to 60 in lbs. (6.78 Nm).