ATI Technologies SR-82 Operating and safety instructions

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
Robotic Collision Sensor
SR‑82 Switch Replacement Manual
U.S. Patent Nos. 6069415 and 6690208
Document #: 9610‑60‑1017

Manual, Collision Sensor Switch Replacement, SR‑82
Document #9610‑60‑1017‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
2
Table of Contents
1. Safety......................................................................................................................................... 3
1.1 ExplanationofNotications......................................................................................................... 3
1.2 General Safety Guidelines............................................................................................................ 3
1.3 Safety Precautions ........................................................................................................................ 4
1.4 Electrical Connection.................................................................................................................... 5
1.4.1 Test Switch Functionality .................................................................................................... 6
1.4.2 Replacement of Original Style Switch/Connector Block Assembly .................................... 6
1.4.3 Replacement of Current Style Switch/Connector Block Assembly..................................... 8
1.5 Switch Adjustment ........................................................................................................................ 9
1.5.1 Original Style Switch Adjustment........................................................................................ 9
1.5.2 Current Style Switch Adjustment ...................................................................................... 10

Manual, Collision Sensor Switch Replacement, SR‑82
Document #9610‑60‑1017‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
3
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 maintenance, operation,
installation, or setup of the product that if not followed could result in damage to equipment. The
notication can emphasize specic grease types, good operating practices, or maintenance tips.
1.2 General Safety Guidelines
The Collision Sensor is not designed for, nor should it be used in, situations involving the safety of humans
or animals. The Collision Sensor is designed as a safety device to protect industrial components and
machinery from damage resulting from collisions and impacts. In all situations the user is responsible for
insuring that applicable safety practices are followed as outlined by the manufacturer of the equipment on
which the Collision Sensor is used.
The routing of electrical and pneumatic lines must minimize the possibility of stress, pullout, kinking,
rupture, etc. Failure of critical electrical and/or pneumatic lines to function properly may result in injury to
personnel and damage to equipment.
CAUTION: The customer should lock out and discharge all energy to the work cell prior
to working on any Collision Sensor system. Failure to do so may result in damage to
equipment or injury to personnel.

Manual, Collision Sensor Switch Replacement, SR‑82
Document #9610‑60‑1017‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
4
1.3 Safety Precautions
WARNING: Do not perform maintenance or repair on the Collision Sensor with air
pressure applied, current supplied to the sensor, or the robot not in a safe condition.
Injury or equipment damage can occur if this is not observed. Always ensure that air
pressure has been vented from the unit, that electrical current is not supplied to the
Collision Sensor’s signal circuit, and that the robot is in a safe, locked‑out condition
consistent with local and national safety standards before performing maintenance or
repair on the Collision Sensor.
WARNING: The Collision Sensor is only to be used for intended applications and
applications approved by the manufacturer. Using the Collision Sensor in applications
other than intended will result in damage to Collision Sensor or end‑of‑arm tooling and
could cause injury to personnel.
CAUTION: Do not adjust or remove either of the (2) set screws installed in the wall of
the body. Doing so may result in damage to the unit or failure of the switch to operate.

Manual, Collision Sensor Switch Replacement, SR‑82
Document #9610‑60‑1017‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
5
1.4 Electrical Connection
The Collision Sensor is connected to the user’s control wiring as a normally‑open PNP or NPN proximity
switch. The following sketch details the connections between the internal switch and the pins in the
connector block assembly. Optional mating cables, available from ATI, utilize the brown‑black‑blue color
code indicated.
CAUTION: The user is responsible for connecting the collision sensor to their controls
and providing an “electrical load” in series with the collision sensing switch. The switch
is rated for instrument level signals of 100mA (max.) at 10–30VDC.
Figure 1.1—Switch Wiring

Manual, Collision Sensor Switch Replacement, SR‑82
Document #9610‑60‑1017‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
6
1.4.1 Test Switch Functionality
Once the Collision Sensor has been installed and connected as described in the preceding
paragraphs, proper electrical operation of the unit may be conrmed.
Supply the Collision Sensor with approximately 15 psi (1 bar) and ensure that the unit is
electrically connected to the user’s control circuit or to a test box per Figure 1.1. The switch
should appear closed.
Manually push the Collision Sensor to simulate a collision while observing the switch output.
When the collision occurs the switch will open and the test light will turn off.
Release the Collision Sensor and it will return to its working position. The test light will illuminate.
1.4.2 Replacement of Connector Block Assembly
1. Remove the mounting screw using a 2.5 mm hex key (see Figure 1.2).
2. Pull the connector block away from the Collision Sensor just enough to ensure that the gasket is
free from the body.
3. Unplug the PCB Header from the proximity switch connector in the body of the
Collision Sensor.
Figure 1.2—Removal of Connector Block Assembly from the Collision Sensor
4. Hold the proximity switch connector protruding from the Body with needle nose pliers while
plugging it into the PCB Header of the Connector Block Assembly. Position the Connector
Block Assembly so that the dowel pin in the Connector Block Assembly is aligned with its
mating hole in the Body.
Figure 1.3—Removal of Connector Block Assembly from the Collision Sensor
5. Carefully push the Connector Block Assembly into position. Check to see that the connector
parts have properly mated by letting the Connector Block Assembly fall away from the
Collision Sensor body.

Manual, Collision Sensor Switch Replacement, SR‑82
Document #9610‑60‑1017‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
7
6. Reposition the Connector Block Assembly for nal attachment.
7. Slide the plastic at washer onto the mounting screw and apply a drop of Loctite 222MS to the
end of the threads.
8. Install the mounting screw and plastic at washer.
9. Press the Connector Block Assembly rmly against the body of the Collision Sensor while
tightening the screw. When tightened securely, the Connector Block Assembly should rest
parallel to its mounting surface.
10. Conrm the integrity of the circuit between the 3‑pole Nano connector and the internal switch
by following the instructions in Section 1.4—Electrical Connection.

Manual, Collision Sensor Switch Replacement, SR‑82
Document #9610‑60‑1017‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
8
1.5 Switch Adjustment
There are (2) styles of switch/connector block assemblies for the SR‑82 Collision Sensor. The original style
has a larger connector body than the current style. The current style has an adjustment set screw in the side
of the connector body, refer to Figure 1.6.
Figure 1.4—Determine the Switch/Connector Block Assemblies Style
If adjusting an original style switch, it is necessary to return the unit to ATI for servicing.
If adjusting a current style switch, refer to Section 1.5.1—Current Style Switch Adjustment
1.5.1 Current Style Switch Adjustment
Note: The switch is factory adjusted to open after the stem has traveled .025” in the axial direction.
Adjustments should only be made if replacing the switch.
1. De‑energize all electrical and pneumatic power supplied to the Collision Sensor. Drain all stored
air and electric power in compliance with standard (OSHA) safety practices and standards.
2. Disconnect the air lines and signal wires connected to the Collision Sensor.

Manual, Collision Sensor Switch Replacement, SR‑82
Document #9610‑60‑1017‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
9
3. Remove the user‑installed mounting hardware from the Collision Sensor and remove the unit.
Take the unit to a test bench equipped with a clean working surface and compressed air.
4. Ensure that the Collision Sensor returns to its reset or working position with the stem fully
extended and the alignment mark on the stem in line with the alignment mark on the cover plate
(Temporarily supply approximately 15 psi (1 bars) to the unit.
5. Peel back the gasket at the bottom center of the Collision Sensor body and locate the switch
adjustment screw.
Figure 1.5—Switch Adjustment Screw Location
6. Connect a test box per Figure 1.1.
7. Attach an interface plate to the stem of the Collision Sensor.
8. Center the Collision Sensor under the press ram (see Figure 1.6).
9. Set a dial indicator in contact with the interface plate and adjust it so that the probe is
vertical. Set the dial indicator height so that it can read at least .06” (1.5 mm) stroke. Set the
dial ring to zero.
10. Push on the press handle until the switch circuit opens and check the distance traveled on the
dial indicator.
11. If the distance traveled is greater than desired turn the adjustment screw counterclockwise. If
the distance traveled is less turn the adjustment screw clockwise.
12. Repeat steps (10) and (11) as necessary to obtain the desired switch setting.

Manual, Collision Sensor Switch Replacement, SR‑82
Document #9610‑60‑1017‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
10
Figure 1.6—Checking Switch Height Adjustment
13. Re‑install the Collision Sensor using the user‑installed mounting hardware.
CAUTION: Before putting the Collision Sensor back into operation, conrm that
the switch is functioning properly. See Section 1.4.1—Test Switch Functionality.
14. Connect the air lines and signal wires connected to the Collision Sensor.
15. Energize all electrical and pneumatic power supplied to the Collision Sensor.