9610-60-1004

9610-60-1004
Protector
™
Robotic Collision Sensor
SR-81, SR-101, SR-131, SR-176, SR-221
U.S. Patent Nos. 6069415 and 6690208
Installation and Operation Manual
Document #9610-60-1004
January 2016
Engineered Products for Robotic Productivity
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Protector Installation & Operation Manual
Document #9610-60-1004-29
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
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 reflect and incorporate changes made to the product.
The information contained herein is CONFIDENTIAL 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 fitness 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
Sales, Service and Information about other ATI products:
ATI Industrial Automation
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati-ia.com
Tel:
919.772.0115
Fax:
919.772.8259
E-mail: info@ati-ia.com
Technical support and questions:
Application Engineering
Tel:
919.772.0115, Option 2, then option 2
Fax:
919.772.8259
E-mail: mech_support@ati-ia.com
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Table of Contents
Page
1.
Product Overview ............................................................................................................................... 5
2.
1.1 Introduction ................................................................................................................................... 5
1.2 Safety Considerations ................................................................................................................... 5
Description .......................................................................................................................................... 6
3.
Installation ........................................................................................................................................... 7
4.
3.1 Operating Requirements ............................................................................................................... 7
3.2 Mechanical .................................................................................................................................... 7
3.3 Electrical........................................................................................................................................ 8
3.3.1 Switch Adjustment ........................................................................................................... 9
3.3.2 Cable Replacement ....................................................................................................... 12
Operation ........................................................................................................................................... 12
5.
Maintenance ...................................................................................................................................... 13
6.
5.1 General ....................................................................................................................................... 13
5.2 Protectors with the Spring Assist Option ..................................................................................... 14
5.3 Replacement of Connector Block Assembly............................................................................... 14
5.3.1 Removal ......................................................................................................................... 14
5.3.2 Replacement .................................................................................................................. 15
5.4 Re-lubrication .............................................................................................................................. 16
5.4.1 Disassembly................................................................................................................... 16
5.4.2 Re-assembly .................................................................................................................. 18
5.5 Switch Replacement ................................................................................................................... 19
5.6 Coolant Protection Boots (C5) .................................................................................................... 19
5.7 Other Repairs .............................................................................................................................. 19
Troubleshooting ................................................................................................................................ 20
7.
Specifications and Drawings ........................................................................................................... 21
8.
7.1 SR-81 Replacement Parts - General .......................................................................................... 21
7.2 SR-81 Replacement Parts – Boots and Shields ......................................................................... 22
7.3 SR-101 Replacement Parts - General ........................................................................................ 23
7.4 SR-101 Replacement Parts – Boots and Shields ....................................................................... 24
7.5 SR-131 Replacement Parts—General ........................................................................................ 25
7.6 SR-131 Replacement Parts—Boots and Shields........................................................................ 26
7.7 SR-176 Replacement Parts—General ........................................................................................ 27
7.8 SR-176 Replacement Parts—Boots and Shields........................................................................ 28
7.9 SR-221 Replacement Parts—General ........................................................................................ 29
7.10 SR-221 Replacement Parts—Boots ........................................................................................... 30
7.11 Collision Sensor Interface Plate Dowel Pin Insertion .................................................................. 31
Terms and Conditions of Sale ......................................................................................................... 32
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Document #9610-60-1004-29
Glossary of Terms
Term
Definition
Body
Cylindrical aluminum housing and air pressure chamber. An interface plate to
the user’s robot is usually attached here.
Cam
A hardened steel ring mounted inside the cover on which the hardened steel
balls mounted to the stem are nested.
Collision
The accidental impact between the end of arm tooling and some obstruction in
its path.
Cover Plate
Disk-shaped aluminum cover for Protector Body.
Crash
The result of a disturbance that displaces the Protector components from their
standard, working position.
Interface Plate
Optional component used to adapt the Protector Body or Stem to the user’s
robot or tooling.
Nano Connector 8mm electrical connector mounted in block attached to the side of the Body.
Reset
The ability of the Protector to return to its working position when a disturbing
force or displacement is removed.
Stem
Round tapered post containing tapped holes and dowel pins. An interface plate
to the user’s tooling is usually attached here.
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Protector Installation & Operation Manual
Document #9610-60-1004-29
1. Product Overview
1.1
Introduction
The Protector is a pneumatically pressurized device offering protection to industrial
robots and tooling in the event of accidental impacts and unanticipated loads. The
Protector works by “breaking away” from its working geometry in the event of
excessive torsional, moment, or compressive axial forces, or any combination of
these. The Protector cannot respond to pure axial tension, which is an unlikely mode
of loading. Removal of the upsetting force or moment allows the Protector to return
to its normal working geometry.
As a collision occurs, internal motion of the Protector components cause a normallyclosed dry contact switch to open. The switch circuit may be monitored by robotic
controllers to stop operations before damage to the robot or tooling occurs. The load
threshold at which the Protector breaks away is adjustable by controlling the air
pressure supplied to the unit. The amount of compliance (travel) provided by the
Protector before the switch circuit opens is adjustable by turning a switch adjustment
screw.
All Protector devices provide axial (compression only), torsional, and moment
compliance.
1.2
Safety Considerations
The Protector has not been designed for, nor should it be used in, situations
involving the safety of humans or animals. The Protector was 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 Protector will be used.
The routing of electrical and pneumatic lines must minimize the possibility of stress,
pullout, kinking, rupture, etc. Failure of some critical electrical and/or pneumatic
lines to function properly may result in injury to personnel and equipment.
CAUTION: The customer should lock out and discharge all energy to the work
cell prior to working on any Protector system.
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2. Description
The Protector consists of a piston housing (body) closed with a cover plate assembly. A
stem assembly protrudes through the cover plate assembly. The cover plate assembly
incorporates a cam to accurately and repeatably position the stem assembly. The stem
assembly is forced into position against the cam by a piston. The piston is supported by
user supplied compressed air and an optional assist spring. The stem provides a mounting
surface for customized interface plates. Tapped and through holes on the back surface of
the body allow direct bolting of the body to user tooling. All load-bearing components and
those with wear surfaces are made of hard-coat anodized aluminum, hardened bearing
steel, or hardened tool steel.
A collision sensing switch is positioned in the center of the body. A connector block
assembly containing a Nano connector is mounted on the side of the Protector body. The
user connects to the switch using the Nano connector for which a variety of cables are
available. The user must also supply the Protector with dry, regulated, compressed air
through a port on the side of the Protector body. The size and location of these connections
are shown in the drawing provided at the end of this manual.
Optional Blank
Interface Plate
(Stem)
Stem
Cover Plate
Body
Connector Block Assembly
Nano Connector
Optional Blank
Interface Plate
(Body)
Figure 2.1—Protector Collision Sensor
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Protector Installation & Operation Manual
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3. Installation
3.1
Operating Requirements
The Protector requires clean, dry, non-lubricated air delivered from a user-supplied,
self-relieving regulator. The Protector is certified for accurate, repeatable operation
when supplied with air at 25–90psi (1.7–6.2 bar ) of pressure operated in an
environment with an ambient temperature range of 40 to 120°F (5–50°C). For
connection to the user’s controls, the Protector is equipped with a normally closed
(NC) collision sensing switch. When the Protector is in the collision mode or the
electrical cable to the switch is disconnected an open circuit is generated.
CAUTION: The user is responsible for connecting the Protector to their
controls and providing an “electrical load” in series with the collision sensing
switch. The switch is rated for instrument level signals of 125mA (max.) at 28V
(max.) AC or DC.
Proper sizing of the Protector is imperative for the safe and reliable operation of the
unit. Contact ATI for assistance in selecting the proper unit.
Equivalent spring assist options of 5psi, 10psi, and 15psi are available.
3.2
Mechanical
The Protector is commonly mounted with its body toward the robot and its stem
toward the user tooling, however, this is strictly up to the user. The Protector can be
mounted directly to the robot or to the user tooling using the dowel pin holes and the
clearance / tapped holes in the Protector body. Should this not be possible, an
interface plate must be fabricated.
CAUTION: The surface to which the Protector body is mounted must be flat
and smooth, and provide support for the entire surface of the body.
A second interface plate is often required for mounting to the Protector stem. Such
interface plates may be ordered from ATI as blank plates or machined as necessary
for specific applications. Another option is for the user to fabricate their own
interface plates.
Once any required machining of the interface plates is complete, mount the Protector
using hardware appropriately sized for the application. Connect an appropriately
sized air line and fitting to the Protector. Do not supply air pressure at this time.
Dowel Pins should be used at all interfaces to minimize movement between
components. Interface Plates, supplied by ATI, come with Dowel Pins and mounting
bolts for attachment to the Protector. The Dowel Pins are press fit into the Interface
Plates and slip fit into the Protector. They are not typically installed prior to
shipment. See drawing 9230-60-1150 in Section 7—Specifications and Drawings for
the proper depths to press these Dowel Pins into the Interface Plates.
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All mounting hardware should be tightened. The use of an industrial thread-locking
compound is recommended for all fasteners.
M5-0.8 Cap Screw
45–60 in-lbs.
M6-1.0 Cap Screw
80–105 in-lbs.
M8-1.25 Cap Screw
190 – 250 in-lbs.
M10-1.50 Cap Screw
390 – 520 in-lbs.
M12-1.75 Cap Screw
55 – 75 ft-lbs.
Table 3.1—Recommended torques for ATI supplied fasteners
CAUTION: Before connecting or disconnecting the air supply to the Protector,
insure that the air supply is turned off and that all trapped air has been vented.
3.3
Electrical
The Protector is connected to the user’s control wiring as a normally-closed, drycontact 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 (see Table 3.4), utilize the brown-black-blue color code
indicated.
STANDARD WIRING
ALTERNATE WIRING
(DISTINGUISHED BY SILVER DECAL
ON TOP OF CONNECTOR BLOCK)
NC Switch Inside Protector
BLUE
INTERNAL
JUMPER
NC Switch Inside Protector
BROWN
BLUE
BLACK
BROWN
BLACK
FRONT VIEW OF CONNECTOR
(PIN SIDE)
FRONT VIEW OF CONNECTOR
(PIN SIDE)
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CAUTION: The user is responsible for connecting the Protector to their
controls and providing an “electrical load” in series with the collision sensing
switch. The switch is rated for instrument level signals of 125mA (max.) at 28V
(max.) AC or DC.
CAUTION: The level of the desired or required air pressure will vary according
to the weight, loading, and motion of the user’s tooling. Exercise caution while
increasing the air pressure supplied to the Protector. When the pneumaticallysupplied forces are sufficient to re-seat the Protector, the tooling will move to
its working position.
Once the Protector has been installed and connected as described in the preceding
paragraphs proper electrical operation of the unit may be confirmed.
Supply the Protector with approximately 15psi (1bar) and insure that the unit is
electrically connected to the user’s control circuit or to a volt-ohm meter. The switch
should appear closed.
Manually push the Protector to simulate a collision while observing the switch
output. When the collision occurs the switch will open and continuity will be lost.
Release the Protector and it will return to its working position. Continuity across the
switch should be restored.
3.3.1 Switch Adjustment
Note: The switch is factory adjusted to open after the stem has traveled 0.02”
(0.5 mm) in the axial direction. Adjustments should only be made
after it has been determined that the Protector should open sooner or
later after the start of a collision. Adjusting the switch to open sooner
may result in nuisance signals.
1. De-energize all electrical and pneumatic power supplied to the
Protector. 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 Protector.
3. Remove the user-installed mounting hardware from the Protector and
remove the unit. Take the unit to a test bench equipped with a clean
working surface and compressed air.
4. Insure that the Protector 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.
5. Set a volt-ohm meter to ohms or continuity and connect it between the
black and brown wires of the cord (see wiring diagrams on previous
page) connected to the Nano connector on the switch housing.
6. Peel back the gasket at the bottom center of the Protector body and
locate the switch adjustment screw. Determine which switch version
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Protector Installation & Operation Manual
Document #9610-60-1004-29
the unit contains using Figure 3.2. (The adjustment procedure differs
slightly depending on the version.).
Hex
Socket Set
Screw
Phillips or
Slotted
Head
Older Style Switch
Newer Style Switch
Figure 3.2—Determining Switch Style
Figure 3.3—Checking Switch Height Adjustment
7. Attach an interface plate to the stem of the Protector.
8. Center the Protector under the press ram of an arbor press (see Figure
3.3).
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 0.06” (1.5mm) 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.
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11. Units with older style switch: If the distance traveled before the
switch turns off is greater than desired turn the adjusting screw
counterclockwise. If the distance traveled is less turn the adjusting
screw clockwise.
CAUTION: Adjusting the switch to the limits of its travel on a
SR-81 or SR-101 may cause the switch to short to ground.
Check for continuity between each leg of the circuit and ground
after adjusting the switch on a SR-81 or SR-101.
12. Units with newer style switch: If the distance traveled before the
switch turns off is greater than desired, turn the adjusting screw
clockwise. If the distance traveled is less turn the adjusting screw
counterclockwise. (Use a 1.5mm hex key.)
CAUTION: The newer style switch can be adjusted to open
between 0.01” and 0.05” (0.3 mm and 1.3 mm) of axial stem
displacement. Setting the switch to open beyond the maximum
value of 0.05” (1.3 mm) may result in failure of the switch to
detect a crash condition. Setting the switch to open under the
minimum value of 0.01” (0.3 mm) may result in damage to the
switch and eventual failure of the switch to detect a crash
condition.
13. After turning the adjusting screw, confirm that the switch is
functioning properly by pushing down on the interface plate until the
switch circuit opens. Verify that the switch setting is within the
adjustment range of 0.01” to 0.05” (0.3 mm to 1.3 mm).
CAUTION: Before putting the Protector back into operation,
confirm that the switch is functioning properly and is set within
the adjustment range of 0.01” to 0.05 “ (0.3 mm to 1.3 mm).
See Section 3.3—Electrical.
14. Re-install the Protector using the user-installed mounting hardware.
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3.3.2 Cable Replacement
If the cable attached to your Protector becomes broken or worn, replacement
cables may be purchased as follows:
Protector Model Number: 9610-xxx-xxx-XX-x-x-x.
XX
Cable Number
Description
BN
---
No cable purchased with Protector – choose
one of the following replacement cables
BB
8590-9909999-15
High-flex cable with straight screw-on
connector, 5M (16.4 ft.) long with flying leads
BC
8590-9909999-06
o
High-flex cable with 90 snap-on connector,
5M (16.4 ft.) long with flying leads
BD
8590-9909999-89
o
High-flex cable with 90 screw-on connector,
10M (32.8 ft.) long with flying leads
BE
8590-9909999-116
High-flex cable with 90 straight screw-on
connector, 5M (16.4 ft.) long with flying leads
BT
8590-9909999-48
High-flex cable with straight snap-on
connector, 10M (32.8 ft.) long with flying leads
BU
8590-9909999-07
High-flex cable with straight snap-on
connector, 5M (16.4 ft.) long with flying leads
o
Table 3.4—Available Cables
4. Operation
With the Protector mounted and connected pneumatically and electrically the unit may be
placed into operation. If possible, for safety and convenience, position the Protector and
the tooling vertically so that the load is suspended below the Protector. Apply lowpressure air [2–15psi (0.15–1bar)] to the unit. Gradually increase the air pressure until the
desired working pressure is applied.
In operation, the Protector should be supplied with the minimum air pressure necessary to
allow continuous, un-interrupted operation of the unit. Nuisance collision detections
caused by high accelerations and unanticipated loads will occur if the air pressure is too
low. The magnitude of overhung loads, robot accelerations, and applied loads prevent ATI
from recommending air pressure settings. Where high robot accelerations are anticipated
the user may wish to supply the Protector with electronically variable or multiple,
switchable air supplies. Alternatively, where working loads are small the Protector may be
outfitted with auxiliary springs and supplied with high-pressure air only during robot
moves. Using these techniques, the Protector may be supplied with higher air pressure
when higher loads or accelerations are anticipated.
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5. Maintenance
CAUTION: Do not adjust or remove any of the three (3) set screws installed in the wall of
the Body. Doing so may result in personal injury and/or damage to the unit. See Figure 5.1
below.
Dog point set
screw, 3 places
Figure 5.1—Location of Dog Point Set Screws
5.1
General
The Protector is a reliable device fabricated using heavy-duty components. In normal
operation, the unit requires no maintenance if proper air quality and pressures are
maintained. Service kits are available in the event that the Nano connector or
collision sensing switch become damaged or worn.
Proper collision sensing should be verified on a regular basis. This can be scheduled
twice a year or as a part of any robot or work cell preventative maintenance
activities.
In applications where a high number of collisions occur on a regular basis, the life of
the Protector can be extended with periodic maintenance. Partial disassembly allows
the unit to be cleaned, re-greased, and reassembled without special tools or
adjustment procedures. Such maintenance work should be conducted every 5,000 or
fewer collisions.
Check the control wiring for shorts.
Perform switch adjustment per Section 3.3.1—Switch Adjustment.
CAUTION: In all instances where the Protector is to be examined, installed,
or removed from service, insure that air pressure has been vented from the
unit, that electrical current is not supplied to the Protector’s signal circuit,
and that the robot is in a safe, locked-out condition consistent with local and
national safety standards.
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5.2
Protectors with the Spring Assist Option
CAUTION: Protectors equipped with the spring assist option contain a
significant amount of stored energy and present an increased level of
hazard if not handled properly. Do not attempt to disassemble or repair
these units beyond what is described in the following sections: Section
3.3.1—Switch Adjustment and Section 5.3—Replacement of Connector
Block Assembly. All additional repair work requires the use of special tools
and procedures necessary to prevent personal injury and/or damage to the
unit.
5.3
Replacement of Connector Block Assembly
5.3.1 Removal
1. Remove the mounting screw using a 2.5mm Allen wrench.
2. Pull the Connector Block Assembly away from the Protector just enough
to ensure that the gasket is free from the body. Be careful not to strain
the wires inside (older versions only).
3. If the Connector Board pulls away from the Connector Block perform
step 4 otherwise perform step 5.
4. Pivot the connector block up and away from the Protector and firmly
grasp the circuit board on either side of the PCB Header (see Figure 5.1).
Pull the circuit board away from the Protector, bringing the connector
block along with it. This will unplug the PCB Header from its mate in
the body of the Protector.
Figure 5.1—Removal of Connector Block Assembly from the Protector (Older versions)
5. Unplug the PCB Header from its mate in the body of the Protector. (See
Figure 5.2) (Newer versions have the Connector Boards attached to the
Connector Block.)
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Figure 5.2—Removal of Connector Block Assembly from the Protector (Newer versions)
5.3.2 Replacement
1. Hold the Micro Header Socket protruding from the Body with needle
nose pliers while plugging it into the PCB Header of the Connector
Block Assembly (see Figure 5.3). Position the Connector Block
Assembly so that the dowel pin in the Connector Block Assembly is
aligned with its mating hole in the Body.
2. 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 Protector body.
3. Reposition the Connector Block Assembly for final attachment and
check that the 3 wire loops are not pinched between the Connector Block
Assembly and the body of the Protector. (Newer versions do not contain
wire loops.)
4. Slide the plastic flat washer onto the mounting screw and apply a drop of
Loctite® 222MS to the end of the threads.
5. Install the mounting screw and plastic flat washer.
6. Press the Connector Block Assembly firmly against the body of the
Protector while tightening the screw. When tightened securely, the
Connector Block Assembly should rest parallel to its mounting surface.
7. Confirm the integrity of the circuit between the 3-pole Nano connector
and the internal switch by following the instructions in Section 3.3—
Electrical.
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Figure 5.3—Connector Block Assembly Replacement
5.4
Re-lubrication
5.4.1 Disassembly
Note: Cleaning may be accomplished with a clean, dry rag. For more
thorough cleaning, use isopropyl alcohol.
1. Remove the four (4) socket head cap screws securing the Cover Plate
assembly to the Body. Note: During factory assembly, Loctite is applied
to the screws to prevent them from coming loose in operation. As a
result, it may be necessary to use a hot air gun to individually heat the
screws (and the immediate areas of the Body) in order to soften the
Loctite and allow the screws to be removed.
CAUTION: Do not attempt to pry or wedge the Cover Plate
assembly and Body apart. Doing so can damage the mating
surfaces and may render the parts unusable.
2. Remove the Cover Plate assembly by carefully pulling it straight up and
off of the Body. This may be difficult due to the close fit of the dowel
pins used to align the parts. It may be necessary to hold the unit up by
the Cover Plate and lightly tap on the Stem with a rubber or plastic
mallet. Note: The dowel pins are pressed into the Cover Plate and are a
slip fit into the Body.
CAUTION: The Cover Plate assemblies and Stem assemblies are
factory-assembled as matched parts. Do not allow either of these
assemblies to be mixed with those from other units.
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Cam surfaces to be cleaned and
re-lubricated: entire vee-groove, 3
places.
Clearance Ring surface to be
cleaned and re-lubricated:
entire rounded edge.
Figure 5.4—Cleaning and Relubricating the Cover Plate Assembly
Surface of ball segment to be cleaned and
re-lubricated: entire polished surface, 3
places.
Surface of Stem
to be cleaned
and re-lubricated:
entire flat
Surface of Stem to be cleaned and relubricated: rounded edge between ball
segments, 3 places.
Figure 5.5—Cleaning and Re-lubricating the Stem
3. Clean the lubricant from the working surfaces of the Cam and the
Clearance Ring. Set the Cover Plate assembly aside for later re-use.
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17
Protector Installation & Operation Manual
Document #9610-60-1004-29
4. Remove the Stem assembly and clean the lubricant from the working
surfaces of the ball segments and the Stem. Set the Stem assembly aside
for later re-use.
5. Clean the lubricant from the working surfaces of the Piston Cap. Push
the Piston assembly to the bottom of the Body.
5.4.2 Re-assembly
1. Apply a generous coating of CRC Extreme Pressure Moly C.V. Joint
Grease (Moly Grease) to the top of the Piston Cap and to the rounded
edges.
2. Apply a generous coat of Moly Grease to each of the three (3) ball
segments on the Stem Assembly and to the rounded edge of the
shoulders between the ball segments. Apply a layer of Moly Grease to
the flat underneath surface of the Stem (see Figure 5.5).
3. Apply a generous coat of Moly Grease to each of the three (3) v-grooves
in the Cam and to the rounded edge of the Clearance Ring (see Figure
5.4).
4. (This step applies only to SR-131s, SR-176s, and SR-221s) Apply
Magnalube to the Cover Seal and assemble to the groove in the Cover
Plate.
5. With the Stem assembly upright, set the Cover Plate assembly onto it.
Make certain that the alignment grooves are lined up.
6. Place the Stem and Cover Plate together onto the Body. Make certain
that the dowel pins in the Plate and the Stem are still lined up. See figure
below.
Alignment groove in
Stem.
Alignment grooves
in Cover Plate.
Dog point set
screw, 3 places
Figure 5.6—Cover Plate and Stem Alignment
7. Press the Cover Plate down onto the Body.
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18
Protector Installation & Operation Manual
Document #9610-60-1004-29
8. Apply Loctite 222MS to the four (4) socket head cap screws and thread
them into the Body. (Note: On units with the Spring Assist Option it is
necessary to use two opposing screws to evenly pull the Cover Plate
down against the Body.) Tighten the screws per the following table:
Protector Model
Screw Size / Type
Recommended
Torque
SR-081 and SR-101
M5 x 20 Socket Flat Head Cap Screw
55 in-lbs
SR-131
M6 x 25 Socket Flat Head Cap Screw
70 in-lbs
SR-176
M8 x 40 Socket Flat Head Cap Screw
175 in-lbs
SR-221
M10 x 30 Socket Head Cap Screw
420 in-lbs
Table 5.7—Recommended Tightening Torques for Cover Screws
CAUTION: Before putting the Protector back into operation,
confirm that the switch is functioning properly. See Section 3.3.
5.5
Switch Replacement
Should the switch become damaged (usually the result of a wiring error) and require
replacement, first determine the switch style (See Figure 3.2). If the switch is of the
older style return the unit to ATI for servicing. If the switch is of the newer style you
have the option of returning it to ATI for servicing or ordering a replacement switch.
Instructions for replacing newer style switches will be shipped with the switch.
5.6
Coolant Protection Boots (C5)
These boots are easily field-replaceable per 9610-60-1008 Installation Instructions
for Coolant Protection Boots.
5.7
Other Repairs
Units damaged due to high impact crashes or that have sustained sufficient wear to
prevent their proper operation should be returned to ATI for evaluation and repair.
Our high quality, precision assemblies require special tools and procedures to return
them to proper working order.
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19
Protector Installation & Operation Manual
Document #9610-60-1004-29
6. Troubleshooting
The Protector will offer exceptional performance in normal operation. However, the
Protector is not a compliance device and frequent collisions should be avoided to
maximize performance and life. The Protector is designed to automatically return to its
working position once the disturbing force is removed. Should this fail to happen the
following examinations should be performed to verify proper operation of the unit:
Check the supply air pressure. Insure that the supply air pressure is sufficient to support
the loads placed upon the unit. If the supply pressure is too low the Protector will
experience excessive nuisance collision sensing and fail to reset.
Once proper air supply pressure has been verified, check the self-relieving function of the
pressure regulator. Do so by deflecting the tooling while listening for the regulator to
exhaust air in response to compression of the air trapped within the Protector. If the
regulator does not properly relieve the air pressure, it may need to be cleaned or replaced.
Check the control wiring. Disconnect the cable from the Protector and use a volt-ohm
meter on the Nano connector to confirm that the switch is closed when the Protector is in
the working position. (The scribe lines on the Protector cover plate and stem must be
aligned and the mounting surfaces of the body and stem must be parallel. Remove tooling
or increase air pressure if necessary to allow the unit to move to its working position.) If
the switch does not close adjustment or replacement may be necessary. See Section 3.3.1—
Switch Adjustment for adjustment procedure. If the switch is closed under this condition
examine the system for control wiring and logic problems.
Check for mechanical obstructions. The Protector will not be free to rotate back to its
working position if obstructions prevent its free motion. Insure that there are no
obstructions either on or around the tooling or the stem of the Protector. Pay particular
attention to cables and tubing that may become trapped or snagged.
If the Protector still fails to reset or if the switch fails to close after adjustment when the
unloaded unit is in its working condition, contact ATI.
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20
Protector Installation & Operation Manual
Document #9610-60-1004-29
7. Specifications and Drawings
7.1
SR-81 Replacement Parts - General
Specifications
Angular
Displacement
Torsional
+/- 13o max.
+/- 25o max.
Axial
Moment
Load Limit
Axial
0.34 in.
(8.6mm) max.
521 in-lbs.
(59 N-m)
385 lb.
(1713 N)
Torsional
540 in-lbs.
(61 N-m)
Weight
1.28 lb.
(0.58 Kg)
Operating
Pressure
Temp.
(25–90 psi)
(1.7–6.2bar)
40–120oF
(5–50oC)
Connector Type
Switch Rating
3-pole “Nano”
connector 125 mA
28V AC/DC
Sensitivity
(Adjustable)
.02 in.
(.5mm)
axial
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21
Spring Assist
Option
5, 10,15psi
equivalents
available
Protector Installation & Operation Manual
Document #9610-60-1004-29
7.2
SR-81 Replacement Parts – Boots and Shields
Specifications
Angular
Displacement
Torsional
+/- 13o max.
+/- 25o max.
Axial
Moment
Load Limit
Axial
0.34 in.
(8.6mm) max.
521 in-lbs.
(59 N-m)
385 lb.
(1713 N)
Torsional
540 in-lbs.
(61 N-m)
Weight
1.28 lb.
(0.58 Kg)
Operating
Pressure
Temp.
(25–90 psi)
(1.7–6.2bar)
40–120oF
(5–50oC)
Connector Type
Switch Rating
3-pole “Nano”
connector 125 mA
28V AC/DC
Sensitivity
(Adjustable)
.02 in.
(.5mm)
axial
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22
Spring Assist
Option
5, 10,15psi
equivalents
available
Protector Installation & Operation Manual
Document #9610-60-1004-29
7.3
SR-101 Replacement Parts - General
Specifications
Angular
Displacement
Torsional
+/- 12o max.
+/- 25o max.
Axial
0.40 in.
(10.2 mm)
max.
Moment
Load Limit
Axial
Torsional
1060 in-lbs.
(120 N-m)
600 lb.
(2670 N)
1145 in-lbs.
(130 N-m)
Weight
2.6 lb.
(1.2 Kg)
Operating
Pressure
Temp.
(25–90 psi)
(1.7–6.2bar)
40–120oF
(5–50oC)
Connector Type
Switch Rating
Sensitivity
(Adjustable)
.02 in.
3-pole “Nano”
(.5mm)
125 mA 28V AC/DC
axial
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23
Spring Assist
Option
5, 10,15psi
equivalents
available
Protector Installation & Operation Manual
Document #9610-60-1004-29
7.4
SR-101 Replacement Parts – Boots and Shields
Specifications
Angular
Displacement
Torsional
+/- 12o max.
+/- 25o max.
Axial
0.40 in.
(10.2 mm)
max.
Moment
Load Limit
Axial
Torsional
1060 in-lbs.
(120 N-m)
600 lb.
(2670 N)
1145 in-lbs.
(130 N-m)
Weight
2.6 lb.
(1.2 Kg)
Operating
Pressure
Temp.
(25–90 psi)
(1.7–6.2bar)
40–120oF
(5–50oC)
Connector Type
Switch Rating
Sensitivity
(Adjustable)
.02 in.
3-pole “Nano”
(.5mm)
125 mA 28V AC/DC
axial
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24
Spring Assist
Option
5, 10,15psi
equivalents
available
Protector Installation & Operation Manual
Document #9610-60-1004-29
7.5
SR-131 Replacement Parts—General
Specifications
Angular
Displacement
Torsional
+/- 10o max.
+/- 20o max.
Axial
0.46 in.
(11.7mm)
max.
Moment
Load Limit
Axial
Torsional
2520 in-lbs.
(285 N-m)
1060 lb.
(4715 N)
2555 in-lbs.
(290 N-m)
Weight
5.0 lb.
(2.3 Kg)
Operating
Pressure
Temp.
(25–90 psi)
(1.7–6.2bar)
40–120oF
(5–50oC)
Connector Type
Switch Rating
Sensitivity
(Adjustable)
.02 in.
3-pole “Nano”
(.5mm)
125 mA 28V AC/DC
axial
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25
Spring Assist
Option
5, 10,15psi
equivalents
available
Protector Installation & Operation Manual
Document #9610-60-1004-29
7.6
SR-131 Replacement Parts—Boots and Shields
Specifications
Angular
Displacement
Torsional
+/- 10o max.
+/- 20o max.
Axial
0.46 in.
(11.7mm)
max.
Moment
Load Limit
Axial
Torsional
2520 in-lbs.
(285 N-m)
1060 lb.
(4715 N)
2555 in-lbs.
(290 N-m)
Weight
5.0 lb.
(2.3 Kg)
Operating
Pressure
Temp.
(25–90 psi)
(1.7–6.2bar)
40–120oF
(5–50oC)
Connector Type
Switch Rating
Sensitivity
(Adjustable)
.02 in.
3-pole “Nano”
(.5mm)
125 mA 28V AC/DC
axial
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26
Spring Assist
Option
5, 10,15psi
equivalents
available
Protector Installation & Operation Manual
Document #9610-60-1004-29
7.7
SR-176 Replacement Parts—General
Specifications
Angular
Displacement
Torsional
+/- 10o max.
+/- 20o max.
Axial
0.63 in.
(16.0 mm)
max.
Moment
Load Limit
Axial
Torsional
7130 in-lbs.
(806 N-m)
2000 lb.
(8900 N)
7530 in-lbs.
(851 N-m)
Weight
12.0 lb.
(5.4 kg)
Operating
Pressure
Temp.
(20–90 psi)
(1.4–6.2bar)
40–120oF
(5–50oC)
Connector Type
Switch Rating
Sensitivity
(Adjustable)
.02 in.
3-pole “Nano”
(.5mm)
125 mA 28V AC/DC
axial
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27
Spring Assist
Option
5, 10,15psi
equivalents
available
Protector Installation & Operation Manual
Document #9610-60-1004-29
7.8
SR-176 Replacement Parts—Boots and Shields
Specifications
Angular
Displacement
Torsional
+/- 10o max.
+/- 20o max.
Axial
0.63 in.
(16.0 mm)
max.
Moment
Load Limit
Axial
Torsional
7130 in-lbs.
(806 N-m)
2000 lb.
(8900 N)
7530 in-lbs.
(851 N-m)
Weight
12.0 lb.
(5.4 kg)
Operating
Pressure
Temp.
(20–90 psi)
(1.4–6.2bar)
40–120oF
(5–50oC)
Connector Type
Switch Rating
Sensitivity
(Adjustable)
.02 in.
3-pole “Nano”
(.5mm)
125 mA 28V AC/DC
axial
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28
Spring Assist
Option
5, 10,15psi
equivalents
available
Protector Installation & Operation Manual
Document #9610-60-1004-29
7.9
SR-221 Replacement Parts—General
Specifications
Angular
+/- 8o max.
Displacement
Torsional
+/- 20o max.
Axial
0.63 in.
(16.0 mm)
max.
Moment
17,390 in-lbs.
(1965 N-m)
Load Limit
Axial
3100 lb.
(13,800 N)
Torsional
13,250 in-lbs.
(1497 N-m)
Weight
25.1 lb.
(11.4 Kg)
Operating
Pressure
Temp.
(20–90 psi)
40–120oF
(1.4–6.2bar)
(5–50oC)
Connector Type
Sensitivity
Switch Rating
(Adjustable)
3-pole “Nano”
.02 in.
125 mA 28V AC/DC
(.5mm)
axial
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29
Spring Assist
Option
5, 10,15psi
equivalents
available
Protector Installation & Operation Manual
Document #9610-60-1004-29
7.10 SR-221 Replacement Parts—Boots
Specifications
Displacement
Angular
Torsional
+/- 8o max. +/- 20o max.
Axial
0.63 in.
(16.0 mm)
max.
Moment
17,390 in-lbs.
(1965 N-m)
Load Limit
Axial
3100 lb.
(13,800 N)
Torsional
13,250 in-lbs.
(1497 N-m)
Weight
25.1 lb.
(11.4 Kg)
Operating
Pressure
Temp.
(20–90 psi)
40–120oF
(1.4–6.2bar)
(5–50oC)
Connector Type
Sensitivity
Switch Rating
(Adjustable)
3-pole “Nano”
.02 in.
125 mA 28V AC/DC
(.5mm)
axial
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30
Spring Assist
Option
5, 10,15psi
equivalents
available
Protector Installation & Operation Manual
Document #9610-60-1004-29
7.11 Collision Sensor Interface Plate Dowel Pin Insertion
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31
Protector Installation & Operation Manual
Document #9610-60-1004-29
8. Terms and Conditions of Sale
The following Terms and Conditions are a supplement to and include a portion of ATI’s Standard Terms and
Conditions, which are on file at ATI and available upon request.
ATI warrants to Purchaser that Protector products purchased hereunder will be free from defects in material
and workmanship under normal use for a period of one (1) years from the date of shipment. This warranty
does not cover components subject to wear and tear under normal usage or those requiring periodic
replacement. ATI will have no liability under this warranty unless: (a) ATI is given written notice of the
claimed defect and a description thereof within thirty (30) days after Purchaser discovers the defect and in
any event not later than the last day of the warranty period; and (b) the defective item is received by ATI not
later ten (10) days after the last day of the warranty period. ATI’s entire liability and Purchaser’s sole remedy
under this warranty is limited to repair or replacement, at ATI’s election, of the defective part or item or, at
ATI’s election, refund of the price paid for the item. The foregoing warranty does not apply to any defect or
failure resulting from improper installation, operation, maintenance or repair by anyone other than ATI.
ATI will in no event be liable for incidental, consequential or special damages of any kind, even if ATI has
been advised of the possibility of such damages. ATI’s aggregate liability will in no event exceed the amount
paid by purchaser for the item which is the subject of claim or dispute. ATI will have no liability of any kind
for failure of any equipment or other items not supplied by ATI.
No action against ATI, regardless of form, arising out of or in any way connected with products or services
supplied hereunder may be brought more than one (1) year after the cause of action occurred.
No representation or agreement varying or extending the warranty and limitation of remedy provisions
contained herein is authorized by ATI, and may not be relied upon as having been authorized by ATI, unless
in writing and signed by an executive officer of ATI.
Unless otherwise agreed in writing by ATI, all designs, drawings, data, inventions, software and other
technology made or developed by ATI in the course of providing products and services hereunder, and all
rights therein under any patent, copyright or other law protecting intellectual property, shall be and remain
ATI’s property. The sale of products or services hereunder does not convey any express or implied license
under any patent, copyright or other intellectual property right owned or controlled by ATI, whether relating
to the products sold or any other matter, except for the license expressly granted below.
In the course of supplying products and services hereunder, ATI may provide or disclose to Purchaser
confidential and proprietary information of ATI relating to the design, operation or other aspects of ATI’s
products. As between ATI and Purchaser, ownership of such information, including without limitation any
computer software provided to Purchaser by ATI, shall remain in ATI and such information is licensed to
Purchaser only for Purchaser’s use in operating the products supplied by ATI hereunder in Purchaser’s
internal business operations.
Without ATI’s prior written permission, Purchaser will not use such information for any other purpose or
provide or otherwise make such information available to any third party. Purchaser agrees to take all
reasonable precautions to prevent any unauthorized use or disclosure of such information.
Purchaser will not be liable hereunder with respect to disclosure or use of information which: (a) is in the
public domain when received from ATI; (b) is thereafter published or otherwise enters the public domain
through no fault of Purchaser; (c) is in Purchaser’s possession prior to receipt from ATI; (d) is lawfully
obtained by Purchaser from a third party entitled to disclose it; or (f) is required to be disclosed by judicial
order or other governmental authority, provided that, with respect to such required disclosures, Purchaser
gives ATI prior notice thereof and uses all legally available means to maintain the confidentiality of such
information.
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32
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