Table of Contents

Table of Contents
Quick-Change Installation and Operation Manual
Document #9620-20-F-PG0-06
Table of Contents
F. High-Power Modules ...................................................................................................2
PG0—High-Current Modules...........................................................................................2
1. Product Overview.................................................................................................2
1.1 High-Current Modules ...............................................................................2
2. Installation ............................................................................................................3
3. Operation .............................................................................................................4
4. Maintenance.........................................................................................................4
5. Troubleshooting ...................................................................................................6
6. Recommended Spare Parts .................................................................................7
7. Specifications .......................................................................................................7
8. Drawings ..............................................................................................................8
8.1 High-Current Module (PG0).......................................................................8
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com
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Quick-Change Installation and Operation Manual
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F. High-Power Modules
PG0—High-Current Modules
1. Product Overview
1.1
High-Current Modules
The High-Current Modules used by the spot-welding tool changer are designed to carry High-Current
from a power supply to customer tooling. They consist of two silver-plated copper contacts, each
capable of carrying 600 Amps when coupled. The voltage should not exceed 800 Volts. To avoid
arcing, never uncouple the Tool Changer without first turning off the power supply to the
Master. Power must be off when coupling and uncoupling. In addition, the installation of over-current
protection in the primary power supply circuit is recommended.
Figure 1.1—High-Current Module—Master (PG0)
Figure 1.2—High-Current Module—Tool (PG0)
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com
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Quick-Change Installation and Operation Manual
Document #9620-20-F-PG0-06
The High-Current modules use advanced, patented, cone-mating technology to transfer current from the
Master to the Tool. The mating conical surfaces provide a large contact area, excellent misalignment
capability and allow efficient coupling/uncoupling without high spring forces or excessive wear. If
required, the contact tip on either the Master or Tool can be easily replaced without removing the
wiring.
Additional safety features have been designed into the PG0 modules shown here. The contact tip on the
Master side are recessed well below the surface and contain a central insulated post. The modules were
designed so that the finger of an average human adult cannot touch the metallic parts. The interior of
the module housings are insulated electrically with a thick, hard anodized coating and high-dielectric
paper.
2. Installation
Cable Installation
For cable installation, the power module cover plates are removed from the module bodies by unscrewing
the (4) M5 flat-head screws. This exposes a dielectric paper insulator that protects the insulator block and
the contact base. The power cable is then passed through the cable entrance and its conductors are attached
to the individual contact base by tightening the split-bolt nuts. Each contact can accept up to #4/0 AWG
stranded conductor. The cable is then attached to the module enclosure through a cord grip. Optional
flanges on this enclosure allow the attachment of ¾ NPT, strain relief connectors. After attaching the
cables, the dielectric paper is replaced and the covers are re-installed on the module bodies.
DANGER: Power and air should always be removed prior to maintenance or repair.
The High-Current modules are typically installed by ATI prior to shipment. The steps below outline field
installation or removal as required.
Tool
1.
Remove the flat head screws attaching the cover plate to the top of the Tool module.
2.
Disconnect the electrical wires from the contact base by loosening the split-bolt nuts.
3.
Remove the four (4) M6 socket head cap screws securing the fixture plate, then remove the plate and
cables.
4.
Locate the screws attaching the module to the tool changer.
5.
Remove the screws and pull the module off the tool changer.
6.
To refit the Tool module, reverse the steps above.
Master
1.
Remove the flat head screws attaching the cover plate to the top of the Master module.
2.
Disconnect the electrical wires from the contact base by loosening the split-bolt nuts.
3.
Remove the four (4) M6 socket head cap screws securing the fixture plate, then remove the plate and
cables.
4.
Remove the screws securing the module and pull the module off the tool changer.
5.
To refit the Master module, reverse the steps above.
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com
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Quick-Change Installation and Operation Manual
Document #9620-20-F-PG0-06
3. Operation
The High-Current modules are designed to carry large currents to various industrial devices, providing a
separable joint in the power wiring. To maximize the service life of these components the following points
should be observed:
1.
Do not couple or uncouple the modules unless electrical power has been disconnected and discharged
both upstream and downstream from the modules. Arcing and contact damage will occur if this is not
observed.
2.
Properly route and secure all cables, particularly on the Master. Failure to observe this point may result
in premature failure of the industrial electrical connectors. Poor cable routing can also result in wires
and cable being pinched in the joint between the tool changer halves.
3.
Always protect the un-used Tool modules when not coupled to a Master module. Dust, debris, and
weld spatter can contaminate the contact tip resulting in arcing and a significant decrease in contact
life.
4. Maintenance
Once installed the operation of the primary current modules is generally trouble free. Periodically the
condition of the contacts should be checked. Any contamination should be removed with industrial contact
cleaner. During inspection insure that the fasteners attaching the modules to the Quick-Change bodies are still
secure.
DANGER: Power and air should always be removed prior to maintenance or repair.
The modules may be field serviced as needed. The following list describes how to perform various operations.
V-Ring Seal
1.
To replace the V-Ring seal, use a small screwdriver or similar to gently pry the seal away from the
insulator block on the master side then pull the seal off the block.
2.
To install a new seal, stretch it over the shoulder on the block and use a small screwdriver to push the
seal’s hub down fully against the recess in the insulator block.
Contact Tip
1.
To replace a Master contact tip locate the socket head cap screw in its center insulator post. Remove
this screw to extract the contact and insulator.
2.
To fit or re-fit a Master contact apply a thin film of non-hardening, conductive, silver bearing grease
with a volume resistivity of 0.001 ohm-cm or better to the mounting surface of the contact. Replace the
®
contact in the FR-4 block and refit the center insulator and socket head cap screw. Apply Loctite-222
(or similar) to the screw prior to installation.
3.
To replace the Tool contact tip follow the instructions above noting there is no center insulator post.
Contact Base
1.
To remove the contact base refer to the installation section and remove the module(s) from the tool
changer.
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com
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Quick-Change Installation and Operation Manual
Document #9620-20-F-PG0-06
2.
With the modules open and on a workbench, use snap-ring pliers to remove the circlip from the back
side of the contact base.
3.
Remove the contact base by pushing it out of the insulator block. Replace as necessary.
4.
To refit the contact base reverse the steps above and apply conductive, silver bearing grease to the
interface with the contact tip. (NOTE: The Tool contact is supported by a wave spring. Do not omit
this spring during reassembly.)
Spring
1.
The Tool contacts provide axial compliance using wave springs. To remove or replace this spring,
remove the Tool contact base as described above.
2.
Remove the old spring from the contact base and fit new spring.
3.
To reassemble, reverse the steps above. When compressing the spring to fit the circlip to the contact
base, place the contact tip on a clean hardwood block and apply downward pressure. (DO NOT use
metal objects to push on the contact tip or contact base.)
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com
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Quick-Change Installation and Operation Manual
Document #9620-20-F-PG0-06
5. Troubleshooting
The High-Current modules provide a separable joint in the cabling between various power sources and loads.
Failure of the load to operate for any reason must be diagnosed electrically.
Load Fails to Operate
Possible Problem
Cause
Remedy
Cable Damage
Pinched, torn, or
fatigued cables.
Replace Cables
Obstruction
Object trapped
between modules
Remove object and re-attempt coupling.
Module Contact Damage
Coupling/Uncoupling
under load.
Revise operating procedures to only
couple/uncouple with power disconnected and
discharged.
Replace module contacts
Contact Contamination
Environment
Clean master and tool side module contacts
with contact cleaner.
The following sequence is recommended for troubleshooting primary current problems.
1.
First examine all the cables, cable connectors, and power sources for problems and correct as
necessary.
2.
Use a known good cable to bypass the modules and directly connect the supply to the load.
3.
If the load does not operate properly with known good cables the problem is in the supply or load.
Troubleshoot these components using that manufacturer’s procedures.
4.
If the load operates properly, use the known good cables from step 2 to connect between the supply
and Master module. Use a second set of known good cables to connect the Tool module to the load.
5.
If the load operates properly the problem is in the old cables, which must be repaired or replaced.
6.
If the load does not operate properly the problem is in the High-Current modules.
7.
Externally, examine the modules for loose, missing, or damaged contacts replacing and tightening as
necessary.
8.
Remove the cover plates from the modules and insure that the cables have not come loose from the
contact base. Re-secure the cables as necessary.
9.
Use a hardwood dowel or other non-metallic, soft rod to push axially on the tool side contacts to verify
free axial motion. If the spring under these contacts do not allow axial motion of the contacts replace
the spring accordingly as outlined above in the maintenance section.
If the above steps fail to restore proper operation contact ATI for service.
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com
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Quick-Change Installation and Operation Manual
Document #9620-20-F-PG0-06
6. Recommended Spare Parts
Assembly
High-Current Master
High-Current Tool
Part Number
Description
9120-PG0-M
Master High-Current Module
3500-1062016-12
3690-7500001-11
3700-20-2582
3700-20-2583
3700-20-2584
3700-20-3408
3700-20-2594
4010-0000046-01
M4 x 16mm SHCS Zinc
Retaining Ring 1” Alloy
Center Insulator
Master Contact
Master Contact Base
Insulator Paper
Split-Bolt Cable Nut, 7/8-14
V-Ring, V-50A
9120-PG0-T
Tool High-Current Module
3500-1062012-12
3610-8801301-21
3690-7500001-11
3700-20-3408
3700-20-2592
3700-20-2593
3700-20-2594
3690-7500001-11
M4 x 12mm SHCS Zinc
Wave Spring, 1.5 OD x 1.15 ID
Retaining Ring 1” Alloy
Insulator Paper
Tool Contact
Tool Contact Base
Split-Bolt Cable Nut, 7/8-14
Retaining Ring, 1” Alloy
7. Specifications
High-Current Module
PG0
Weight (coupled)
3.1 lbs. (1.4 kg)
(Contact) Current & Voltage
Specification
@ 600A, 800V Max.
Silver-plated, conical contacts
No-Touch on Master side.
Cable Sizes Supported
#1/0 Thru #4/0 AWG
Split-bolt terminals are used to attach the
conductor to the contact post.
Connection Options
Optional Flanges
Custom fitting plates available.
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com
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Quick-Change Installation and Operation Manual
Document #9620-20-F-PG0-06
8. Drawings
8.1
High-Current Module (PG0)
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com
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