Novanta ATI QC-161 User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
QC‑161
Custom Tool Changer
Manual
Document #: 9610‑20‑4446

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
2
Foreword
This manual contains basic information applicable to all ATI robotic Tool Changers. Certain 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.
Copyright© 2023 by ATI Industrial Automation. All rights reserved.
How to reach us:
Sale, Service and Information about ATI products:
ATI Industrial Automation
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati‑ia.com
Tel: [phone]
Fax: [phone]
Application Engineering
Tel: [phone]
Fax: [phone]
E‑mail: [email protected]
24/7 Support: +1 855 ATI-IA 00 ([phone])

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
3
Table of Contents
Foreword .......................................................................................................................................... 2
Glossary ........................................................................................................................................... 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
3. Installation .............................................................................................................................. 10
3.1 MasterInterface........................................................................................................................... 11
3.2 Master Plate Installation ............................................................................................................. 12
3.3 MasterPlateRemoval ................................................................................................................. 13
3.4 ToolInterface ............................................................................................................................... 14
3.5 Tool Plate Installation ................................................................................................................. 15
3.6 ToolPlateRemoval ..................................................................................................................... 15
3.7 Optional Module .......................................................................................................................... 16
3.7.1 Optional Module Installation ............................................................................................. 16
3.7.2 Optional Module Removal ................................................................................................ 17
3.8 PneumaticConnections ............................................................................................................. 17
3.8.1 Valve Requirements and Connections for the Locking Mechanism ................................. 17
3.9 ElectricalConnections................................................................................................................ 18
3.9.1 PNP Type Lock and Unlock Sensors ............................................................................... 18
3.9.2 M12 4‑Pin Male Connector............................................................................................... 18
4. Operation ................................................................................................................................ 19
4.1 Conditions for Coupling ............................................................................................................. 20
4.2 Fail‑Safe Operation ..................................................................................................................... 20
4.3 ConditionsforUncoupling ......................................................................................................... 21
4.4 ToolIdentication........................................................................................................................ 21
4.5 Tool Storage Considerations ..................................................................................................... 22
5. Maintenance............................................................................................................................ 23
5.1 PreventiveMaintenance ............................................................................................................. 23
5.2 CleaningandLubricationoftheLockingMechanismandAlignmentPins........................... 24
5.3 PinBlockInspectionandCleaning ........................................................................................... 26
6. TroubleshootingandServiceProcedures ........................................................................... 27

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
4
6.1 Troubleshooting .......................................................................................................................... 27
6.2 ServiceProcedures..................................................................................................................... 28
6.2.1 Lock and Unlock Sensor Replacement ............................................................................ 28
6.2.2 M12 Connector Assembly Replacement .......................................................................... 30
6.2.3 V‑ring Seal Inspection and Replacement ......................................................................... 31
6.2.4 Alignment Pin Replacement ............................................................................................. 32
7. ServiceableParts ................................................................................................................... 33
7.1 Master Plate ................................................................................................................................ 33
7.1.1 Lock and Unlock Sensor Assembly .................................................................................. 34
7.2 Tool Plate ..................................................................................................................................... 34
8. Specications ......................................................................................................................... 35
9. Drawings ................................................................................................................................. 36
10. Terms and Conditions of Sale............................................................................................... 40

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
5
Glossary
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.
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.
Electrical Module Utility modules that pass electrical power and signals through the Master and
Tool modules to the end‑effector.
EOAT End of the Arm Tooling – An object attached to the Tool plate that serves a
function.
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 (IP) An optional customized component that is used to adapt a Tool Changer to the
user’s robot or tooling.
Lock
The lock air pressure that is provided to the Master plate locking mechanism to
force the cam to press the locking balls against the bearing race and lock the
Master and Tool plates together.
Lock Port A 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 position.
Locked An output signal provided by a proximity sensor that indicates 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
A manual, pneumatic or electrical driven device that draws the Master and
Tool plates together and secures 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 a lever, pneumatic cylinder, or an
electric motor.
L/U Lock/Unlock sensing capability that 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.
No‑Touch™ A design feature of all ATI Tool Changer products that allows the Master plate
and Tool plate to couple without physical contact prior to locking.
Piston A cylinder located in the Master plate that actuates the locking mechanism.
Tool plate The half of the Tool Changer to which various tools or end‑effectors are mounted.
Unlock Sensor A proximity sensor that detects the position of the pneumatically actuated piston
when it is in the unlocked position.

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
6
1. Safety
The safety section describes general safety guidelines to be followed with this product, explanations of the
notications found in this manual, and safety precautions that apply to the product. Product specic notications
are imbedded within the sections of this manual (where they apply).
1.1 ExplanationofNotications
These notications are used in all ATI manuals and are not specic to this product. The user should heed
all notications from the robot manufacturer and/or the manufacturers of other components used in the
installation.
DANGER: Notication of information or instructions that if not followed will result in
death or serious injury. The notication provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
WARNING: Notication of information or instructions that if not followed could result
in death or serious injury. The notication provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
CAUTION: Notication of information or instructions that if not followed could result
in moderate injury or will cause damage to equipment. The notication provides
information about the nature of the hazardous situation, the consequences of not
avoiding the hazard, and the method for avoiding the situation.
NOTICE: Notication of specic information or instructions about maintaining, operating,
installing, or setting up the product that if not followed could result in damage to equipment. The
notication can emphasize, but is not limited to: specic grease types, best operating practices,
and maintenance tips.
1.2 General Safety Guidelines
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 the product specications section in
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 the static forces in the 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 the 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) 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 the electrical and pneumatic lines must minimize the possibility of stress/
strain, kinking, rupture, etc. Failure of the 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‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
7
1.3 SafetyPrecautions
WARNING: Remove all temporary protective materials (caps, plugs, tape, etc.) on the
locking face of the 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 the 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 the applications
other than intended will result in damage to Tool Changer, modules, or end‑of‑arm
tooling and could cause injury to personnel.

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
8
2. ProductOverview
ATI Tool Changers enhance the versatility of a robot by enabling the use of multiple customer tools, such as:
grippers, vacuum cup tooling, pneumatic and electric motors, weld guns, and more. The QC‑161 is a custom Tool
Changer for a washdown environment in a food application. The QC‑161 has ingress seals at the primary customer
interfaces, more corrosion‑resistant parts, and less surfaces where food could become caught.
The Tool Changer consists of a Master plate, which is attached to the robot arm, and a Tool plate, which is
attached to customer tooling. When the robot picks up the customer tooling, a pneumatically‑driven locking
mechanism couples the two plates. The patented, fail-safe locking mechanism utilizes a multi-tapered cam with
ball locking technology to ensure the Tool Changer does not uncouple if the air pressure falls below 4.1 bar (60 psi)
during operation.
The robot can be programmed to select the desired customer tooling by coupling the Master plate to the Tool
plate. Electricity, uid, and other forces of energy transfer to the customer tooling through optional modules that
are attached to the Master and Tool plates. For assistance in selecting compatible modules, contact an ATI sales
representative.
2.1 Master Plate Assembly
The Master plate assembly includes the following features:
• A stainless steel body
• A hardened stainless steel locking mechanism (cam, male coupling, and tungsten carbide ball bearings)
• Hardened steel alignment pins that mate with bushings on the Tool plate
• (2) ats for mounting optional modules or protective cover platescover plates
• Proximity sensor assemblies used to verify the lock/unlock position of the piston and cam
• An ISO 9409-1-125-10-M10 mounting pattern for a robot arm or an interface plate
Non-toxic food grade grease is applied to the cam, male coupling, ball bearings, and pins to enhance
performance and maximize the life of the Master plate.
Figure 2.1—Master Plate Assembly
Mounting Flat for
Optional Module
Mounting Flat for Optional
Module (Not Visible)
1/8" BSPP Lock Air Port
M12 4-Pin Male Lock and
Unlock Signal for a Cable
Enclosure for Lock and
Unlock Sensor Assemblies
(2) Alignment Pins
Cam
1/8" BSPP Unlock Air Port
Male Coupling and
(12) Ball Bearings

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
9
2.2 Tool Plate Assembly
The Tool plate includes a stainless steel body and a hardened stainless steel bearing race (refer to
Figure 2.2). Alignment bushings are integrated in the Tool body to ensure proper, repeatable orientation with
the Master plate.
The Tool plate assembly includes the following features:
• A stainless steel body
• A hardened stainless steel bearing race
• Alignment bushings that mate with pins on the Master plate
• (2) ats for mounting an optional modules or protective cover plates
• An ISO 9409-1-125-10-M10 mounting pattern for customer tooling or a tooling interface plate
Figure 2.2—Tool Plate Assembly
Bearing Race
Mounting Flat for
Optional Module
Mounting Flat for
Optional Module
(2) Integrated
Alignment Bushings

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
10
3. Installation
All fasteners used to mount the Tool Changer to the robot and customer’s tooling should be tightened to the torque
values indicated in Table 3.1——Fastener Size, Class, and Torque Specications.Additionally, Loctite 7649
primer and removable Loctite 242 must be used on these fasteners.
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 specic 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.
CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners
might become loose and cause equipment damage. Always apply new thread locker when
reusing fasteners.
CAUTION: For stainless steel socket screws, use a at hex broach (not a ball end) to tighten
the fasteners. Always tighten to the specied torque.
Table 3.1—FastenerSize,Class,andTorqueSpecications
Mounting Conditions
Fastener Size
& Property
Class (MIN)
Recommended
Torque
Thread
Locker
Master plate to Interface plate (6061‑T6 aluminum). Minimum thread
engagement of 15 mm (0.59”) [1.5X fastener Ø].
M10‑1.5
A2‑70 / A4‑70*
(stainless steel)
33 Nm
(24 ft‑lb)
Loctite® 7649,
Loctite ® 242
Master plate to Robot (steel; USS ≥ 90KSI). Minimum thread
engagement of 10 mm (0.39”) [1.0X fastener Ø]. Conrm available
engagement with robot manufacturer.
M10‑1.5
A2‑70 / A4‑70*
(stainless steel)
33 Nm
(24 ft‑lb)
Tool interface plate to Tool plate (304 SS). Minimum thread engagement
of 15 mm (0.59”) [1.5X fastener Ø]. Do not exceed maximum available
thread depth of 17.5 mm as shown in Section 9—Drawings.
M10‑1.5
A2‑70 / A4‑70*
(stainless steel)
33 Nm
(24 ft‑lb)
Optional Module or Adapter Plate to Master or Tool Plate.
M4‑0.7 Socket
Head Cap
A2‑50 / A4‑50
(stainless steel)
1.69 Nm
(15 in‑lb)
Loctite® 7649,
Loctite® 222
M4‑0.7 Socket
Flat Head Cap
A2‑50 / A4‑50
(stainless steel)
1.13 Nm
(10 in‑lb)
* Using less than 10 fasteners will reduce QC Moment X & Y rating. Refer to Section 9—Drawings.

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
11
3.1 MasterInterface
The Master plate is typically attached to the robot arm. The QC‑161 is designed to mount directly to ISO
9409-1-125-10-M10 robot wrists to minimize stack height. An interface plate can adapt the Master plate
to differing specic robot arm mounting patterns. Alignment features (dowel holes and bosses) accurately
position and bolt holes secure the Master plate to the robot arm or an interface plate.
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 the Master body’s boss 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’s boss causing
damage to the equipment. Use the proper size dowel pins that will not extend further
than allowed by the Master body.
Interface Plate
Dowel pins that are too long
can cause a gap between
the interface plate and
boss in the Master plate.
A boss and (2) dowel pins
can be difficult to align and
cause damage to the
Master Plate
Incorrect Mounting of the Master Plate
equipment.
Correct size dowel pin(s)
allows the interface plate
and the boss in the
Master plate to mount flush.
Interface Plate
Master Plate
Boss
Flush
A gap is between the
interface plate
and the flange
of the Master plate.
Note: A dowel pin and a boss/recess
or ((2) dowel pins) are used as
alignment features.
Correct Mounting of the 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 (2) dowel pins or (1) 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 farther than the depth of the dowel
holes in the boss of 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 the 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‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
12
3.2 Master Plate Installation
Refer to Figure 3.1.
Tools required: 8 mm at hex key (not a ball end), torque wrench
Supplies required: Clean rag, Loctite® 7649 and 242
1. Wipe down the mounting surfaces with a clean rag.
CAUTION: The (10) M10 socket at head cap screws are stainless steel. Use a at hex
broach (not a ball end) to tighten the fasteners. Always tighten to the specied torque.
2. If the customer-supplied (10) M10 socket head cap screws do not have a pre-applied adhesive, rst apply
Loctite 7649 primer, then apply Loctite 242 to the threads of the screws.
3. Align the robot wrist (or interface plate if required) with the customer‑supplied dowel pins on
the Master plate.
4. Install the O‑ring into the QC‑161 Master plate mounting face groove, ensuring the O‑ring is fully seated
to prevent pinching.
5. Secure the Master plate to the robot wrist with (10) M10 socket head cap screws using a 8 mm at hex
key (not a ball end). See Table 3.1 for proper torque specications.
6. Connect the lock and unlock air to the connections on the Master plate. For details on the lock and
unlock air refer to Section 3.8.1—Valve Requirements and Connections for the Locking Mechanism.
7. Connect the lock and unlock sensor cable:
a. Attach a cable to the M12 4‑pin male connector. For connector information, refer to Section 3.9—
Electrical Connections.
8. If equipped, connect other utilities to the optional modules on the Master plate.
Figure 3.1—Standard Master Plate Installation
Robot Arm
QC-161 Master Plate
(2) 10mm Dowel Pins
(Customer Supplied)
O-Ring
(10) M10 Socket Head Cap
Screws (Customer Supplied)
Mounting Face Groove

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
13
3.3 MasterPlateRemoval
Tools required: 8 mm at 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 (for example: electrical, pneumatic, and hydraulic).
4. If equipped, disconnect all utilities (for example: electrical, pneumatic, hydraulic).
5. Disconnect the lock and unlock sensor cable.
6. Use a 8 mm at hex key to loosen the (10) M10 socket head cap screws from the Master plate, and
remove Master plate from interface plate or robot. Note: Interface plate is not required to be removed
from the robot.

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
14
3.4 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.
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 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 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 contaminating
the locking mechanism.

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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3.5 Tool Plate Installation
Tools required: 8 mm hex key, torque wrench
Supplies required: Clean rag, Loctite® 7649 and 242
1. Wipe down the mounting surfaces with a clean rag.
2. If required, install the tooling interface plate to the customer tooling, align using the recess and dowel
pin(s). Secure with customer‑supplied fasteners.
3. Install the O‑rings into the QC‑161 Tool plate mounting face grooves, ensuring O‑rings are fully seated
to prevent pinching.
4. Align the customer‑supplied dowel pins in the tool interface plate or customer tooling to the
corresponding holes in the Tool plate.
5. First apply Loctite® 7649 primer, then apply Loctite® 242 to the threads of the customer‑supplied
fasteners, (10) M10 screws.
6. Secure the Tool plate to the tool interface plate or customer tooling with (10) M10 screws using the 8
mm hex key. See Table 3.1 for proper torque specications
7. Connect utilities to the optional modules on the Tool plate.
8. Safely resume normal operation.
Figure 3.2—Standard Tool Plate Installation
(10) M10 Socket
Head Cap Screws
(Customer-Supplied)
Tool Interface Plate
(Customer-Supplied)
(If Required)
O-Ring
O-Ring
(2) 10mm Dowel Pins
(Customer-Supplied)
Inner Mounting
Face Groove
Outer Mounting
Face Groove
QC-161 Tool Plate
Flat A
Flat B
(Not Visible)
3.6 ToolPlateRemoval
Tools required: 8 mm hex key
1. Place the Tool in a secure location.
2. If equipped, disconnect all utilities (for example: electrical, pneumatic, hydraulic).
3. Using the 8 mm hex key, remove the (10) M10 fasteners, connecting the Tool plate to the tool
interface plate.
4. Remove the Tool plate.

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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3.7 Optional Module
The optional modules are typically installed on the Tool Changers by ATI prior to shipment. The following
steps outline eld installation or removal as required. Tool Changers are compatible with many different
types of modules. Some modules will require an adapter plate to be installed to the Tool Changer.
NOTICE: It is recommended to use the JPC1 cover plate if a module is not used to protect
exposed fastener holes. Refer to JPC1 manual for more information: 9620‑20‑H‑JPC1.
3.7.1 Optional Module Installation
Tools required: 2.5 mm or 3 mm hex key, torque wrench
Supplies required: Loctite® 7649 and 222
1. Place the Tool in a secure location.
2. Uncouple the Master and Tool plates.
3. Turn off and de-energize all energized circuits (for example: electrical, pneumatic, and
hydraulic circuits).
4. Place the silicone gasket between the optional module and Tool Changer plate.
5. Align the (2) dowel pins, if equipped, on each module to the corresponding holes on the Flat of
the Master or Tool plate as shown in Figure 3.3.
6. If not using fasteners with pre-applied adhesive, rst apply Loctite 7649 then apply Loctite 222
to the (4) mounting fasteners on each module.
7. Secure the optional modules to the Tool Changer with mounting fasteners. See Table 3.1 for
proper torque specications.
8. Remove all protective caps, plugs, tape, etc. from the module prior to operation.
9. Connect any cables, air line, etc. (if required)
10. Safely resume normal operation.
Figure 3.3—Optional Module Installation
QC-161 Master Plate
Silicone Gasket
(Supplied with QC)
Optional Master Module
(FR2ZF5G3-M Shown)
(4) M4 Socket
Head Cap Screw
(4) M4 Socket
Head Cap Screw
Optional Tool Module
(FR2ZF5G3-T Shown)
Silicone Gasket
(Supplied with QC)
QC-161 Tool Plate

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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3.7.2 OptionalModuleRemoval
Refer to Figure 3.3
Tools required: 2.5 mm or 3 mm 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 (for example: electrical, pneumatic, and
hydraulic circuits).
4. Disconnect any cables, air line, etc.
5. Supporting the module, remove the (4) M4 mounting fasteners from the each module.
6. Remove the module and gasket from the Tool Changer plate.
3.8 PneumaticConnections
The air supply used for coupling and uncoupling the Tool Changer should be at 60 to 100 psi (4.1 - 6.9 Bar),
with a setting of 80 psi suggested. The air should be ltered to ISO 8573-1:2010 [7:4:4].
CAUTION: Do not use the Tool Changer in a fail‑safe condition. Do not transport the
Tool Changer in a fail‑safe condition. Possible damage to the locking mechanism
could occur. Re‑establish air pressure to the Tool Changer before returning to
normal operations.
3.8.1 ValveRequirementsandConnectionsfortheLockingMechanism
It is required that a customer-supplied 2-position 4-way or 5-way valve be used to actuate the
locking mechanism in the Master plate. It is imperative that when air is supplied to the lock or
unlock port on the Master plate, that the opposite port be vented to atmosphere (for example: when
air is supplied to the lock port, the unlock port must be open to the atmosphere.) Failure to vent
trapped air or vacuum on the inactive port may inhibit proper shuttling of the valve and prevent
coupling/uncoupling from the occurring.
CAUTION: The locking mechanism will not function properly when connected
to a single 3‑way valve as this type of valve is incapable of venting trapped air
pressure from the within the Tool Changer. This could result in damage to the
product, attached tooling, or personnel. Connect the lock and unlock supply air
to a 2‑position 4‑way or 5‑way valve.
Figure 3.4—LockandUnlockPneumaticConnections
4 or 5 -way Valve
Supply Clean, Dry,
Non -lubricated Air
60 – 100 psi (4.1 – 6.9 Bar)
Exhaust
Open to Atmosphere
Lock Port
Unlock Port

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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3.9 ElectricalConnections
Integrated lock/unlock sensors are available. The sensor assemblies are protected within an enclosure
attached to the Master plate. For the pinout and wire call‑outs of the M12 4‑pin connector, refer to
Section 3.9.2—M12 4-Pin Male Connector.
3.9.1 PNPTypeLockandUnlockSensors
Table 3.2—PNP(CurrentSourcing)
Description Value
Voltage Supply Range 10‑30VDC
Output Circuit PNP make function (NO)
Figure 3.5—PNPTypeLockandUnlockSensors
Brown
Black
Blue
+Vs
Output
0 V
PNP
Load
PNP (Current Sourcing)
3.9.2 M124-PinMaleConnector
Table 3.3—Pin Numbers, Wire Colors, and Signals
Pin Number Signal Wire Color
1 + Vs Brown
2 Output Circuit ‑ Lock White
3 Output Circuit ‑ Unlock Blue
4 0 V (Ground) Black
Figure 3.6—M124-PinMaleConnector
4-Pin Male Connector
Face View
Key
1
4
2
3
4-Pin Male Connector
Wire View
Key
1 (Brown)
4 (Black)
3 (Blue)
2 (White)

Manual, Robotic Tool Changer, QC‑161
Document #9610‑20‑4446‑03
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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4. Operation
The Master plate locking mechanism is pneumatically driven to couple and uncouple with the Tool
plate bearing race.
CAUTION: Operation of the Tool Changer is dependent on the maintaining an air pressure
of 60 to 100 psi (4.1–6.9 bar). Damage to the locking mechanism could occur. Robot motion
must be halted if the air supply pressure drops below 60 psi (4.1 bar).
NOTICE: All Tool Changers are lubricated prior to shipment. The customer must apply additional
lubricant to the locking mechanism components and alignment pins prior to operation. This Tool
Changer requires food grade grease.
Coupling should occur with the Master plate in the No-Touch™ locking zone. As coupling occurs, the Master plate
should pull the Tool plate into the locked position.
Program the robot to minimize misalignment during coupling and uncoupling. Greater offsets can be
accommodated by the Master and Tool plates but will increase wear. Misalignments can be caused by improper tool
stand design. Refer to Section 4.5—Tool Storage Considerations.
Figure 4.1—OffsetDenitions
X, Y, and Z Offset
X
Y
Z
Twisting Offset
(About Z)
Master Plate
Tool Plate
Cocking Offset
(About X and Y)
Table 4.1—MaximumRecommendedOffsetsPriortoCoupling
Model
No‑Touch™ Zone
Z Offset (Max)1
(mm)
X and Y Offset (Max)2
(mm)
Cocking Offset (Max)
(degrees)
Twisting Offset (Max)
(degrees)
QC‑161 2 (0.08 in) ± 2 (0.08 in) ± 0.7 ± 1
Notes:
1. Maximum values shown. Decreasing actual values will minimize wear during coupling/uncoupling.
2. Actual allowable values may be higher in some cases but higher offsets will increase wear during coupling.

Manual, Robotic Tool Changer, QC‑161
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4.1 Conditions for Coupling
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 robot.
1. Position the Master plate above the Tool plate with the air supplied to the Unlock Port (if equipped, the
Unlock sensor indicates the Tool Changer is Unlocked).
2. Move the Master plate toward the Tool plate so that the (2) alignment pins enter the alignment holes on
the opposite plate. Program the robot so that the Master plate and Tool plate are aligned axially and are
parallel to each other (as closely as possible). This will minimize Tool movement and subsequent wear
during lock‑up.
CAUTION: No‑Touch™ locking technology allows the unit to couple with a separation
distance between the Master and Tool. Direct contact of the Master and Tool mating
surfaces is not suggested or required prior to coupling. Contact may result in damage
to the unit and/or the robot.
3. When the (2) faces are within the specied No-Touch™ distance, release the pressure from the Unlock
port and supply air to the Lock port. The Tool plate is drawn toward the Master plate and coupled. Air
must be maintained on the Lock port during operation to assure rigid coupling (if equipped, the Lock
sensor indicates the Tool Changer is in the Locked position).
4. A sufcient delay must be programmed between locking valve actuation and robot motion so that the
locking process is complete before moving the robot.
CAUTION: If air pressure is lost during operation, ATI’s patented fail‑safe design
prevents the Tool plate from being released. Do not use the Tool Changer in a fail‑safe
condition. Re‑establish air pressure and ensure the Tool Changer is in a secure lock
position before returning to normal operations.
NOTICE: If the locking mechanism has been actuated and both the Lock and Unlock signals
are OFF, then a “missed tool” condition has occurred (for example, the Tool is not in the
stand or is not positioned properly). Inthiscaseanerrorshouldbegeneratedandthe
robotprogramhalted.The situation requires manual inspection to determine the cause
of the problem.
NOTICE: The locking mechanism must be in the unlock state before another attempt is made
to couple or damage could occur to the robot and/or the Tool Changer.
4.2 Fail‑Safe Operation
A fail‑safe condition occurs when there is an unintended loss of lock air pressure to the Master plate. When
air pressure is lost, the Tool Changer relaxes and there may be a slight separation between the Master
and Tool plates. The lock sensor may indicate that the unit is not locked. ATI’s patented fail‑safe feature
utilizes a multi-tapered cam to trap the ball bearings and prevent an unintended release of the Tool plate.
Positional accuracy of the tooling is not maintained during this fail‑safe condition. Do not operate the Tool
Changer in the fail‑safe condition. If the source air is lost to the unit, movement should be halted until air
pressure is restored.
After air pressure is re-established to the Master plate, the locking mechanism will energize and securely
lock the Master and Tool plates together. In some cases when the load on the Tool Changer is signicantly
off center, it may be necessary to position load underneath the Tool Changer or return the Tool to the tool
storage location to ensure a secure lock condition. If equipped, make sure the lock sensor indicates the Tool
Changer is in the locked position before resuming normal operations.
CAUTION: Do not use the Tool Changer in a fail‑safe condition. Damage to the locking
mechanism could occur. Re‑establish air pressure and ensure the Tool Changer is in a
secure lock position before returning to normal operations.