9610 20 2255

Quick-Change
High-Precision Robotic Tool Changer

QC-40 through QC-100
Installation and Operation Manual
Document #: 9610-20-2255
June 2015
Engineered Products for Robotic Productivity
Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 USA Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: info@ati-ia.com
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
Foreword
This manual contains basic information applicable to all ATI Quick-Change robotic Tool Changers. Certain QuickChange models have their own manuals that contain more detailed information. Also, additional information about
electrical, pneumatic, fluid, high-power and high-current modules and other options is 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 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
Sale, Service and Information about 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, Option 2
Fax: 919.772.8259
E-mail: mech_support@ati-ia.com
Document #9610-20-2255-02
Table of Contents
1. Safety.......................................................................................................................................... 6
1.1
Explanation of Notifications.......................................................................................................... 6
1.2
General Safety Guidelines............................................................................................................. 6
1.3
Safety Precautions......................................................................................................................... 7
2. Product Overview...................................................................................................................... 8
2.1
Master Plate Assembly................................................................................................................ 10
2.2
Tool Plate Assembly..................................................................................................................... 11
2.3
Master Plate/Tool Plate Locking Mechanism............................................................................. 11
2.4
Optional Sensor Interface Plate (SIP)......................................................................................... 12
2.5
Optional Modules......................................................................................................................... 12
3. Installation............................................................................................................................... 13
3.1
Robot Interface Plates (RIP)........................................................................................................ 14
3.2
Master Plate Installation.............................................................................................................. 15
3.3
Master Plate Removal.................................................................................................................. 16
3.4
Tool Interface Plate...................................................................................................................... 17
3.5
Tool Plate Installation.................................................................................................................. 18
3.6
Tool Plate Removal...................................................................................................................... 18
3.7
Optional Module Installation....................................................................................................... 19
3.8
3.9
3.7.1
QC-60 Flat A Optional K Series Module Installation.......................................................... 19
3.7.2
QC-60 Flat A Optional K Series Module Removal............................................................. 19
3.7.3
QC-60 Flat B Optional Module Installation........................................................................ 20
3.7.4
QC-60 Flat B Optional Module Removal........................................................................... 20
3.7.5
QC-40. QC-41, QC-43, QC-71, and QC-100 Optional Module Installation....................... 21
3.7.6
QC-40, QC-41, QC-43, QC-71, and QC-100 Optional Module Removal.......................... 21
Lock/Unlock Pneumatic Connections and Valving................................................................... 22

3.8.1
Air Requirements............................................................................................................... 22
3.8.2
Valve Requirements and Connections.............................................................................. 22
Electrical Connections................................................................................................................. 24
3.9.1
PNP Type Lock and Unlock Sensors................................................................................. 24
3.9.2
NPN Type Lock and Unlock Sensors................................................................................ 24
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4. Operation................................................................................................................................. 25
4.1
Coupling Sequence...................................................................................................................... 26
4.2
Fail-Safe Operation...................................................................................................................... 26
4.3
Uncoupling Sequence.................................................................................................................. 26
4.4
Tool Identification......................................................................................................................... 27
4.5
Tool Storage Considerations...................................................................................................... 27
5. Maintenance............................................................................................................................. 28
5.1
Preventive Maintenance.............................................................................................................. 28
5.2
Cleaning and Lubrication of the Locking Mechanism and Alignment Pins............................ 29
5.3
Optional Electrical Module Pin Block Inspection and Cleaning.............................................. 31
6. Troubleshooting and Service Procedures............................................................................ 32

6.1 Troubleshooting........................................................................................................................... 32
6.2
Service Procedures...................................................................................................................... 33
6.2.1 1/8 and 1/4 Rubber Bushing Inspection & Replacement............................................... 33
6.2.2 3/8 Rubber Bushing Replacement................................................................................... 33
6.2.3
Optional Electrical Module Seal Inspection and Replacement.......................................... 34
6.2.4
QC-100 Alignment Pin Replacement................................................................................. 35
6.2.5
Proximity Sensor Adjustment, Test, or Replacement........................................................ 35
7. Serviceable Parts.................................................................................................................... 37
7.1
Models QC-40............................................................................................................................... 37
7.2
Models QC-41............................................................................................................................... 38
7.3
Models QC-43............................................................................................................................... 39
7.4
Models QC-60............................................................................................................................... 40
7.5
Models QC-71............................................................................................................................... 41
7.6
Models QC-100............................................................................................................................. 42
8. Drawings.................................................................................................................................. 43
8.1
QC-40 Tool Changer with J16 Module........................................................................................ 43
8.2
QC-41 Tool Changer with R19 Module....................................................................................... 44
8.3
QC-43 Tool Changer..................................................................................................................... 45
8.4
QC-60 Tool Changer with K19 Module....................................................................................... 46
8.5
QC-71 Tool Changer with G19 Module....................................................................................... 47
8.6
QC-100 Tool Changer with T19 and F02 Modules..................................................................... 48
9. Terms and Conditions of Sale................................................................................................ 50
Document #9610-20-2255-02
Glossary of Terms
Term
Definition
Master Plate
The half of the Tool Changer that is mounted to a robot. The Master Plate contains the
locking mechanism.
Tool Plate
The half of the Tool Changer to which various tools or end-effectors are mounted.
Cover Plate
Simple, blank closure plate on standard Quick-Change Master Plates that closes the
pneumatic chamber.
Piston
Piston located in the Master Plate that actuates the locking mechanism.
Cam
Circular cam attached to the piston that forces the locking balls outward during the
locking process.
Bearing Race
Hardened steel ring in the Tool Plate that is engaged by the locking balls during the
locking process.
End-Effector
Tool used by the robot to perform a particular function.
Tool Stand
Stand that holds Tools not being used by the robot. This is usually supplied by the
customer and is specific to the application.
RIP
Robot Interface Plate interface plate between the robot flange and Master Plate.
Electrical Module
Any of a wide variety of modules that pass electrical power through the Master Plate to
the Tool Plate and to the end-effector.
Pneumatic Module
Any of a wide variety of modules that pass pneumatic power through the Master Plate to
the Tool Plate and to the end-effector.
Detection Shaft
Threaded stem inserted into the back side (top) of the Piston, functions as a target to
actuate the Lock/Unlock switches.
Sensor Plate
Cover plate for the back side of the Master plate, seals the pneumatic chamber and
provides mounting points for the Lock/Unlock switches.
Lock Port
Pneumatic port on the Master Plate to which air is supplied to Lock the Master Plate to
the Tool Plate.
Unlock Port
Pneumatic port on the Master Plate to which air is supplied to Unlock the Master Plate
from the Tool Plate.
No-Touch
Design feature of all ATI Quick-Change products that allows coupling the Master Plate
and Tool Plate without physical contact prior to locking.
Document #9610-20-2255-02
1. Safety
The safety section describes general safety guidelines to be followed with this product, explanation of the
notification found in this manual, and safety precaution that apply to the product. More specific notification are
imbedded within the sections of the manual were they apply.
1.1 Explanation of Notifications
The notifications included here are specific to the product(s) covered by this manual. It is expected that the
user heed all notifications from the robot manufacturer and/or the manufacturers of other components used
in the installation.
DANGER: Notification of information or instructions that if not followed will result in
death or serious injury. The notification provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
WARNING: Notification of information or instructions that if not followed could result
in death or serious injury. The notification provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
CAUTION: Notification of information or instructions that if not followed could result
in moderate injury or will cause damage to equipment. The notification provides
information about the nature of the hazardous situation, the consequences of not
avoiding the hazard, and the method for avoiding the situation.
NOTICE: Notification of specific information or instructions about maintaining, operating,
installation, or setup of the product that if not followed could result in damage to equipment. The
notification can emphasize but is not limited to specific grease types, good operating practices,
or maintenance tips.
1.2 General Safety Guidelines

Prior to purchase and installation, the customer should verify that the Tool Changer selected is rated for the
maximum loads and moments expected during operation. Refer to product specifications section in each
module of this manual or contact ATI for assistance. Particular attention should be paid to dynamic loads
caused by robot acceleration and deceleration. These forces can be many times the value of static forces in
high acceleration or deceleration situations.
The customer is responsible for ensuring that the area between the Master and Tool sides is clear of foreign
objects during mating and subsequent coupling. Failure to do so may result in serious injury to personnel.
DANGER: The gap between the Master and Tool sides is a pinch point. All personnel
should be prevented from placing any part of their body or clothing in the gap,
especially during actuation of the locking mechanism.
The customer is responsible for understanding the function of the Tool Changer and implementing the
proper hardware and/or software to operate the Tool Changer safely. The Tool Changer should be controlled
such that there is no chance of locking or unlocking in a position that would endanger personnel and/or
equipment. If the Tool Changer is specified with Lock/Unlock (L/U) and Ready-to-Lock (RTL) sensing
capability, the status should be monitored and proper interlocks applied to prevent injury to personnel and
equipment.
Document #9610-20-2255-02
All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the application
without failing. The routing of electrical and pneumatic lines must minimize the possibility of stress/strain,
kinking, rupture, etc. Failure of critical electrical or pneumatic lines to function properly may result in injury
to personnel and equipment.
All electrical power, pneumatic and fluid circuits should be disconnected during servicing.
1.3 Safety Precautions

WARNING: Remove all temporary protective materials (caps, plugs, tape, etc.) on
locking face of Tool Changer and modules prior to operation. Failure to do so will result
in damage to Tool Changers, modules, and end-of-arm tooling and could cause injury
to personnel.
WARNING: Do not perform maintenance or repair on Tool Changer or modules unless

the tool is safely supported or docked in the tool stand and all energized circuits (e.g.
electrical, air, water, etc.) have been turned off. Injury or equipment damage can occur
with tool not docked and energized circuits on. Dock the tool safely in the tool stand
and turn off all energized circuits before performing maintenance or repair on 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 endof-arm tooling and could cause injury to personnel.
WARNING: The Tool Changer is only to be used for intended applications and
applications approved by the manufacturer. Using the Tool Changer in applications
other than intended will result in damage to Tool Changer, modules, or end-of-arm
tooling and could cause injury to personnel.
CAUTION: The Master Plate locking mechanism must not be actuated without being
mounted to the robot interface plate. Damage to the Cover Plate and O-ring may result.
Always attach the Master Plate to the Robot interface plate prior to attempting any
operations.
Document #9610-20-2255-02
2. Product Overview
QC models are available with different anodizing, pneumatic port sizes and quantities, refer to Table 2.1 for specific
part numbers.
The Quick-Change Tool Changer provides flexibility to robot applications by allowing the robot to change endeffectors (e.g., grippers, vacuum cup tooling, pneumatic and electric motors, weld guns, etc.) automatically. The
Quick-Change consists of a Master plate and a Tool plate.
The Master plate is installed on the robot arm and locks to the Tool plate with a pneumatically-driven locking
mechanism. This locking mechanism uses a patented, multi-tapered cam with ball locking technology and a
patented fail-safe mechanism. The Master allows for the passage of pneumatic and electrical connections to the
Tool plate. End-effectors such as grippers, material handlers, etc. are attached to one or more Tool Plates.
In operation, the robot can be programmed to select the desired end-effector by coupling the Master Plate to the
Tool Plate. Electrical signals, pneumatic power, and fluids can be transferred to the end-effector(s) through the
Master Plate and Tool Plate by optional modules and ports. See the respective manuals for these options for more
details on their operation.
A Tool Changer enhances the flexibility and reliability of a robotic cell. Robotic Tool Changers are used in
automated Tool-change applications, as well as manual Tool-change operations. Robotic Tool Changers also
provide a method for quick Tool change for maintenance purposes.
Model
Payload
QC-40
110 lbs
QC-41
110 lbs
QC-43
110 lbs
Table 2.1Standard QC Tool Changer Models and Features

Flats
Plate
Pneumatic Ports
Part No.
(8) 1/8 NPT Pass-through ports
9120-040M-000-000
Master
(2) 1/8 NPT Lock/Unlock air ports
9120-040M-000-000-B
9120-040T-000-000
Tool
9120-040T-000-000-B
(8) 1/8-28 BSPP Pass-through ports 9120-040M-000-000-E
Master
(2) Flat
(2) 1/8-28 BSPP Lock/Unlock air ports
Tool
(8) 1/8-28 BSPP Pass-through ports 9120-040T-000-000-E
(8) 1/8 BSPT Pass-through ports
9120-040M-000-000-R
Master
(2) 1/8 BSPT Lock/Unlock air ports
Tool
9120-040T-000-000-R
9120-041M-000-000
Master
9120-041M-000-000-B
9120-041T-000-000
Tool
9120-041T-000-000-B
(1) Flat
Master (4) 1/8-28 BSPP Pass-through ports
(2) 1/8-28 BSPP Pass-through ports
Tool
(4) 1/8-28 BSPP Pass-through ports
9120-043M-000-000
Master
Tool
9120-043T-000-000
(2) Flat
Master
Tool
Notes
1. QC Tool Changer Master and Tool Plate Assemblies with (-B and -E) part numbers have black anodized bodies
2. Additional options are available upon request.
Document #9610-20-2255-02
Table 2.1Standard QC Tool Changer Models and Features
Model Payload
Flats
Plate
Pneumatic Ports
Part No.
9120-060M-000-000
Master
9120-060M-000-000-B
9120-060T-000-000
Tool
9120-060T-000-000-B
(2) Flat
(1) J16 pattern
Master
QC-60 160 lbs
and
(1) K series
Tool
9120-060M-000-000-R
Master
Tool
9120-060T-000-000-R
9120-071M-000-000
Master
9120-071M-000-000-B
9120-071T-000-000
Tool
9120-071T-000-000-B
(8) 1/4 BSPP Pass-through ports
9120-071M-000-000-E
Master
QC-71 180 lbs
(2) Flats
(2) 1/8 BSPP Lock/Unlock air ports
(8) 1/4 BSPP Pass-through ports
9120-071T-000-000-E
Tool
(8) 1/4 BSPT(R) Pass-through ports 9120-071M-000-000-R
Master
Tool
(8) 1/4 BSPT(R) Pass-through ports
9120-071T-000-000-R
9120-100M-000-000
Master
Tool
9120-100T-000-000
QC-100 330 lbs
(2) Flats
(8) G 3/8 BSPP Pass-through ports
9120-100M-000-000-E
Master
(2) G 1/8 BSPP Lock/Unlock air ports
Tool
(8) G 3/8 BSPP Pass-through ports
9120-100T-000-000-E
Notes
1. QC Tool Changer Master and Tool Plate Assemblies with (-B and -E) part numbers have black anodized bodies
2. Additional options are available upon request.
Document #9610-20-2255-02
2.1 Master Plate Assembly

The Master Plate assembly includes an anodized aluminum body, a hardened stainless-steel locking
mechanism, and hardened steel alignment pins. The locking mechanism consists of a cam, a male coupling,
and chrome-steel ball bearings. The Master Plate provides one or two flat sides for mounting of optional
modules, depending on the model. Optional modules can be arranged to suit the application.
Figure2.1Master Plate Assemblies
Master Plate Assembly
(QC-71 Shown)
Cover Plate

(QC-40 Shown)
Cover Plate
Optional Module
Flat B
Optional Module
Flat A
1/8"NPT Lock,
Unlock Air Ports
Ball Bearings
1/8"NPT Lock,
Unlock Air Ports
Optional Module Flat B
Ball Bearings
Male Coupling
Male Coupling
(2) Alignment Bushings
Optional Module
Flat A
(2) Alignment
Bushings
Pass-Through
Air Ports
Pass-Through Air Ports

(8) 1/8" NPT Pass-Through Air Ports
The air port provides Lock and Unlock air for the locking mechanism and pass through air for the end of
arm tooling. An Adapter Plate Assembly provides a standoff for the air ports and a mounting pattern to
attach to the robot arm.
Alignment pins mate with bushings to ensure repeatable alignment during the coupling process. An extreme
pressure grease is applied to the cam, male coupling, ball bearings, and pins to enhance performance and
maximize the life of the Master Plate assembly. In some models the Master plate is equipped with tapered
alignment pins, other models such as the QC-43 Mater Plate have hardened stainless steel alignment
bushings.
A cover plate is attached to the master to protect the internal locking mechanism during shipment. This
cover plate can be removed during installation if replaced by a robot interface plate or Sensor interface plate.
Refer to Section3Installation for details.
10
Document #9610-20-2255-02
2.2 Tool Plate Assembly

The Tool Plate assembly includes an anodized aluminum body and hardened stainless-steel bearing race.
The Tool Plate provides one or two flat sides for mounting of optional modules, depending on the model.
Optional modules can be arranged to suit the application. In some models the bearing race or Tool plate
body has integrated alignment holes or bushings, other models such as the QC-43 Tool Plate have hardened
steel alignment pins.
The Tool Plate is equipped with pass through air ports to supply end of arm tooling.
Figure2.2Tool Plate Assemblies
Tool Plate Assembly
(QC-71 Shown)
Optional Module
Flat A
Pass Through Air Ports

(2) Integrated Alignment Holes
(2) Integrated Alignment Holes
Tool Plate Assembly

(QC-40 Shown)
Pass Through
Air Ports
Harden Stainless Steel

Bearing Race
Harden Stainless Steel
Bearing Race

Optional Module Flat A
(8) 1/8" NPT

Pass-Through
Air Ports
2.3 Master Plate/Tool Plate Locking Mechanism

The coupling of the Master Plate and the Tool Plate is achieved through a patented, high-strength, highrepeatability, stainless steel mechanism. During locking, steel balls in the Master Plate are driven outward
by a circular cam attached to a pneumatically actuated piston. The cam profile has three features: A lead-in
angle (conical), a fail-safe surface (cylindrical) area, and a secondary angle (conical). The lead-in angle
initiates the coupling process, the fail-safe surface assures the coupling will not be compromised in case of
air loss (fail-safe feature), and the secondary angle provides rigid coupling during normal operation. The
balls engage a bearing race (or locking ring) in the Tool Plate and lock the Master Plate and Tool Plate
tightly together.
Figure2.3Locking Mechanism
Piston
Ball Bearings
Bearing Race
Circular Cam
Ball Cage
11
Document #9610-20-2255-02
2.4 Optional Sensor Interface Plate (SIP)

The Sensor Interface Plate (SIP) system provides locking mechanism position signals to the customers
process controller. These signals will indicate two possible conditions for the Quick-Change Master Plate:
Unlocked or Locked.
The SIP system utilizes sensors to detect the position of the pneumatically-actuated piston in the Master
Plate. These sensors are available in PNP, or NPN other option are available, contact ATI for more
information. Quick-Change model, and sensor availability.
The SIP system consists of a SIP Plate (which is actually the interface plate between the Master Plate and
the robot), a Detection Shaft, a Sensor Plate, Proximity Switches, and an O-Ring.
The Sensor Plate will replace the simple Cover Plate on the backside of the Quick-Change Master. The
Sensor Plate provides mounting locations for the Proximity Sensors and closes the pneumatic chamber of
the Master. The SIP provides mounting holes for attaching the Master to the customers application and
retains the Sensor Plate.
Figure2.4Optional Sensor Interface Plate
Detection Shaft
(Sensor Target)
Lock Sensor
Unlock Sensor
Sensor Interface Plate (SIP)
Sensor Plate
O-ring
2.5 Optional Modules

Tool Changers have one or two flats depending on the model. Optional modules support the pass-through of
various utilities such as signal, fluid/air, and power. Refer to Table 2.2 for more information. Some module
may require an adapter plate.
For assistance in choosing the right modules for your particular application, visit the specific QC
model webpages by clicking on the links in Table 2.2 to see what is available or contact an ATI Sales
Representative directly.
Model
QC-40
QC-41
QC-43
QC-60
QC-71
QC-100
Table 2.2Tool Changer Models and Features

For the most current list, information, and specifications for compatible
Optional Modules click the link below
QC-40 Web Page and select the Compatible modules tab
Note: The ATI website provides information on the Standard compatible modules additional custom
modules are available, contact an ATI Sales Representative directly
12
Document #9610-20-2255-02
3. Installation
The Master Plate of the Tool Changer mounts to the robot arm using a robot Interface Plate (RIP) or a Sensor
Interface Plate (SIP). Custom interface plates are available from ATI upon request. Refer to Section3.1Robot
Interface Plates (RIP) or Section2.4Optional Sensor Interface Plate (SIP) for more information.
The end-effector is typically attached to the Tool Plate with a tool interface plate, standard and custom tool interface
plates are available from ATI upon request. Refer to Section3.4Tool Interface Plate for more information.
All fasteners used to mount the Tool Changer to the robot and to customers tooling should be tightened to a torque
value as indicated. Refer to Table 3.1. Furthermore, fasteners should have pre-applied adhesive or be applied
with removable (blue) Loctite 222. Table 3.1 contains recommended values based on engineering standards.
Pneumatic lines and electrical cables are attached, bundled, and must be strain-relieved in a manner that allows for
freedom of movement during operation.
WARNING: All pneumatic fittings and tubing must be capable of withstanding the repetitive
motions of the application without failing. The routing of electrical and pneumatic lines must
minimize the possibility of over stressing, pullout, or kinking the lines. Failure to do so can
cause some critical electrical and/or pneumatic lines not to function properly and may result in
injury to personnel or damage to equipment.
WARNING: Do not use lock washer under the head of the mounting fasteners or allow the
mounting fasteners to protrude above the mating surfaces of the Master and Tool Plates.
Allowing fasteners to protrude above the mating surface will create a gap between the Master
and Tool Plates and not allow the locking mechanism to fully engage, this can cause damage
to equipment or personal injury. Make sure the mounting fasteners are flush or below the
mating surfaces of the Master and Tool Plates.
Head of Mounting Fastener Must Be Flush or

Below Mating Surface. (Do Not Use Lock
Washer under Head of Mounting Fastener).
Mating Surface
CAUTION: Do not apply Lock or Unlock air pressure to the Tool Changer prior to installing a
robot interface plate (RIP) or sensor interface plate (SIP). Applying air pressure can damage
the cover plate, O-ring or may cause injury to personnel from flying debris. Always install an
appropriate RIP or SIP and have the Tool Changer mounted securely to the robot before
applying air pressure. Refer to Section3.1Robot Interface Plates (RIP) and Section3.2
Master Plate Installation for more information.
CAUTION: Do not use fasteners that exceed the thread depth in the Tool Changer. Refer to
Section8Drawings for details on mounting hole thread depth. Secure the Tool Changer with
the proper length fasteners. This is true for both robot and tool interfaces.
CAUTION: Failure to follow the Robot Interface Plate or tool interface plate design
consideration in Section3.1Robot Interface Plates (RIP) and Section3.4Tool Interface
Plate may result in cover plate O-ring damage or loosening of the interface during operation.
Follow the guidelines provided when designing a RIP, TIP for the Tool Changer.
13
Document #9610-20-2255-02
Table 3.1Fastener Size, Class, and Torque Specifications
Mounting Conditions
Fastener Size and

Property Class
QC-40, QC-41, and QC-43 Master Plate to Robot

Interface Plate or Sensor Interface plate, Supplied
Fasteners
M5 x 0.8 Class 12.9
QC-60 and QC-71 Master Plate to Robot Interface Plate

or Sensor Interface plate, Supplied Fasteners
M6 x 1.0 Class 12.9
Socket head cap
Recommended
Torque
45 in-lbs (5.08 Nm)
Socket head cap
90 in-lbs (10.2 Nm)
Socket flat head cap
60 in-lbs (6.78 Nm)
QC-100 Master Plate to Robot Interface Plate or Sensor

Interface plate, Supplied Fasteners
M8 x 1.25 Class 12.9
Tool Interface Plate to QC-40, QC-41, QC-43, QC-60 and

QC-71 Tool Plate Minimum thread engagement of 12 mm
[1.5X fastener ]. Do not exceed maximum available
thread depth of 14 mm as shown in Section8Drawings
M8 x 1.25 Class 12.9
Tool Interface Plate to QC-100 Tool Plate Minimum thread

engagement of 15 mm [1.5X fastener ]. Do not exceed
maximum available thread depth as shown in Section8
Drawings
M10 x 1.5 Class 12.9
Optional Module or Adapter Plate to Master or Tool Plate,

Supplied Fasteners
M3 x 0.5 Class 12.9
Socket head cap
140 in-lbs (15.82 Nm)
Socket head cap
140 in-lbs (15.82 Nm)
85 in-lbs (9.6 Nm)
Socket head cap
Thread
Locker
Pre-applied
Adhesive or
Loctite 222
Pre-applied
Adhesive or
Loctite 242
55 ft-lbs (75 Nm)
Socket head cap
10 in-lbs (1.13 Nm)
8 in-lbs (0.9 Nm)
M4 x 0.7 Class 12.9

Socket head cap
15 in-lbs (1.69 Nm)
10 in-lbs (1.13 Nm)
Pre-applied
Adhesive or
Loctite 222
3.1 Robot Interface Plates (RIP)

The Robot Interface Plate (RIP) is used to adapt the Master Plate to a specific robot arm. The RIP is
designed with mounting features such as a boss and/or bolt and dowel holes. These features are used to
accurately position and secure the Master Plate to the robot arm. Custom RIPs are available from ATI upon
request.
If the customer chooses to design and build a robot interface plate, the following should be considered:

The interface plate should be designed to include bolt holes for mounting, dowel pins, and a boss
for accurate positioning on the robot and Master Plate. (Refer to robot manual) (The dowel and boss
features are important to prevent anti-rotation)
A piston cover plate is provided with each Quick-Change Master Plate. If the robot interface plate
provides sealing for the piston cylinder, then the cover plate can be removed. Refer to Figure3.1
The robot interface plate must be properly designed to provide rigid mounting on the boss surfaces.
The interface plate should not contact the Master body outside of the boss. The recommended
dimensions for the interface plate bore, with and without the cover plate, are provided in Section8
Drawings. The mating diameters must provide sufficient clearance so that mating corner radii do not
interfere.
The thickness of the interface plate must be great enough to provide the necessary thread engagement
for the mounting bolts.
Mounting bolts should not be too long, such that a gap is formed at the interface.
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Figure3.1RIP and SIP with Master Plate Configurations
Sensor Plate
O-ring
Sensor Plate (Cover Plate Removed)
Mounting Fasteners
(Supplied by Customer)
Detection shaft
O-ring
Dowel Pin
Sensor Interface plate (SIP)
Master Plate Boss
Master Plate Body
Cover Plate Left In Place

Mounting Fasteners
(Supplied by Customer)
RIP Boss
Robot Interface Plate
(RIP)
Master Plate Boss
O-ring
Cover Plate Left in Place
Maintain a Gap
Cover Plate Removed
RIP Boss
Mounting Fasteners
Dowel Pin (Supplied by Customer)
(RIP)
Master Plate Boss
Maintain a Gap
Master Plate Body
Dowel Pin
O-ring
Master Plate Body
3.2 Master Plate Installation

The Tool Changer Master Plate is mounted to the robot flange using an SIP or RIP. A cover plate is attached
to the Master Plate to protect the internal locking mechanism during shipment. The cover plate will have
to be removed if an SIP is being used and may have to be removed if an RIP is being used. The RIP can be
designed to accommodate the cover plate.
1. Make sure mounting surface of the Master Plate, RIP, or SIP and robot arm are clean and free of debris.
2. Align the Dowel Pin in the RIP or SIP to the corresponding holes in the robot arm and secure with
supplied or customer supplied fasteners, refer to Figure3.1. Refer to Table 3.1 for proper fasteners and
torque.
3. What type of interface plate being installed?
If an RIP that replaces the cover plate being installed, go to step 4.
If an SIP or an RIP that incorporates the cover plate, go to step 6.
4. Remove the two M3 socket Flat head screws and discard.
5. Remove the cover plate.
CAUTION: Make sure the O-ring is properly seated in the groove in the Master Plate. If
the O-ring is not properly seated in the groove it can be cut or damaged, resulting in a
leaking seal. Properly seat O-ring into groove in Master body.
6. Align the Dowel Pin in the RIP or SIP to the corresponding holes in the Master Plate and secure with
supplied fasteners, refer to Figure3.2. Refer to Table 3.1 for proper fasteners and torque.
7. Connect all Lock / Unlock and pass-through air connection to the connections on the Master Plate. For
Lock and Unlock air refer to Section3.8Lock/Unlock Pneumatic Connections and Valving.
8. If equipped connected the Lock and Unlock sensor cables.
9. If equipped connect other utilities to the optional modules on the Master Plate.
10. If installation is complete, the Master plate may be put into normal operations.
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3.3 Master Plate Removal

the Tool is safely supported or docked in the Tool Stand and all energized circuits (e.g.,
with Tool not docked and energized circuits on. Dock the Tool safely in the Tool Stand
Changer or modules.
NOTICE: Depending on maintenance or repair being performed, utilities to modules and Master
Plate may need to be disconnected.
1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the
Master plate.
2. Turn off all energized circuits (e.g. electrical, air, water, etc.).
3. If equipped disconnect all utilities (e.g. electrical, air, water, etc.).
4. If equipped disconnect the Lock and Unlock sensor cables.
5. Remove the fasteners securing the Master Plate to the RIP or SIP. Refer to Figure3.2.
6. Remove the Master Plate. Note: RIP or SIP should not need to be removed.
Figure3.2Typical Master Plate Installation
Robot Arm
Dowel Pins
(Customer Supplied)
Robot Arm
Dowel Pins
(Customer Supplied)
Sensor Interface Plate

(Customer Supplied)
Socket Head Cap Screws
(Customer Supplied)
(2) M3 Socket Flat Head
Screws to temporaraly
hold cover plate in place
Socket Head Cap Screws

(Customer Supplied)
Sensor Plate
(Replaces Cover Plate)
The Cover Plate can remain

in place if RIP is designed
to accomodate the plate
(QC-41 with FN2 module Shown)
(6) M6 Socket Head Cap Screws

(QC-60 with K19 and FR4 modules Shown)
(6) Socket Flat Head
Cap Screws
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3.4 Tool Interface Plate

The end-effector is typically attached to the Tool Plate with a tool interface plate. The tool interface Plate
is designed with mounting features such as a recess and/or bolt and dowel holes. These features are used to
accurately position and secure the customers tooling. Most often a tool interface plate is utilized to adapt
the Tool Plate to customers tooling that is not compatible with the Tool Plate mounting features. Custom
tool interface plates can be supplied by ATI to meet customers requirements (see Figure3.3) (Refer to
Section8Drawings for specific mounting features for your model).
If the customer chooses to design and build a tool interface plate, the following should be considered:

The tool interface plate should be designed to include bolt holes for mounting, dowel pins, and a boss
that mates with Tool Plate recess for accurate positioning. (The dowel and boss features are important
to prevent anti-rotation).
The locating boss height should not exceed the customer interface depth specified on the drawing.
The thickness of the interface plate must be great enough to provide the necessary thread engagement
for the mounting bolts. Fasteners should be chosen to 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 should take into account clearances required for Tool Changer module attachments
and accessories.
The tool interface plate should be designed with a hole in its center to allow for manually returning
the locking mechanism to the unlocked position under adverse conditions (i.e. unintended loss of
power and/or air pressure). The center access hole should be kept small [minimum recommended hole
diameter: 1 (25.4 mm)] to prevent debris from contaminating the locking mechanism while operating
in dirty environments.
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3.5 Tool Plate Installation

The end-effector is typically attached to the Tool Plate with an interface plate designed refer to Section3.4
Tool Interface Plate for specific requirements for your application.
1. Make sure mounting surface of the Tool Plate and tool interface plate is clean and free of debris.
2. Align the Dowel Pins in the tool interface plate or customer tooling to the corresponding holes in the
Tool Plate and secure with customer supplied mounting fasteners. Apply Loctite 242 to threads or use
fasteners with pre-applied adhesive, refer to Table 3.1 for proper thread engagement and torque. (Note:
Mounting fasteners are supplied with ATI custom tool interface plates).
3. Connect utilities to the appropriate module and Tool Plate connections.
4. If installation is complete, the Tool plate may be put into normal operations.
Figure3.3Typical Tool Plate Installation
Tool Plate Assembly
(QC-60 with FR4 and K19
Modules Shown)
Tool Plate Assembly

(QC-41 with FN2 Module Shown)
Dowel Pin
(Customer Supplied)
Dowel Pin
(Customer Supplied)
Interface Plate
(Customer Supplied)
Interface Plate
(Customer Supplied)
(Customer Supplied)
Note: Mounting Fasteners

and Dowel Pins included
with ATI Interface Plates

(Customer Supplied)
3.6 Tool Plate Removal

the Tool is safely supported or docked in the Tool Stand and all energized circuits (e.g.,
with Tool not docked and energized circuits on. Dock the Tool safely in the Tool Stand
Changer or modules.
NOTICE: Depending on maintenance or repair being performed, utilities to modules and Tool
Plate may need to be disconnected.
1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Tool
plate.
2. If equipped disconnect all utilities (e.g. electrical, air, water, etc.).
3. Remove the fasteners securing the Tool Plate to the tool interface Plate or customer tooling. Refer to
Figure3.3.
4. Remove the Tool Plate.
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3.7 Optional Module Installation

The optional modules are typically installed on tool changers by ATI prior to shipment. The steps below
outline field 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.
3.7.1 QC-60 Flat A Optional K Series Module Installation

1. If the Tool Changer is in service, dock the Tool safely in the tool stand and uncouple the Tool
Changer to allow clear access to the Master and Tool plates. Leave the locking mechanism in
the unlocked.
2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).
3. Align optional module on flat A of Master or Tool Plate Assembly.
4. If not using fasteners with pre-applied adhesive, apply Loctite 222 to M3 mounting
fasteners.
5. Secure module with two M3 mounting fasteners. Refer to Table 3.1 for proper torque for your
specific mounting fasteners.
6. Remove all protective caps, plugs, tape, etc from the module prior to operation.
7. If installation is complete, return circuits to normal operation.
Figure3.4QC-60 Flat A Optional K Series Module Installation
(2) M3 Socket Head

Cap Screws
Electrical Module
(9120-K19-M Shown)
(QC-60 Shown)
Tool Plate Assembly
(QC-60 Shown)
Electrical Module
(9120-K19-T Shown)
(2) M3 Socket Head
Cap Screws
3.7.2 QC-60 Flat A Optional K Series Module Removal

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to
the Master or Tool plate.
3. Disconnect any cables, air line, etc. if required.
4. Supporting the module, remove the two M3 socket head cap screws. Note: For the module
on the master, the Master Plate may have to be removed refer to Section3.3Master Plate
Removal.
5. Remove the module from the Master or Tool Plate.
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3.7.3 QC-60 Flat B Optional Module Installation

the unlocked.
3. Align Adapter Plate to Flat B of the QC-60 Master or Tool Plate as shown in Figure3.5.
4. If not using fasteners with pre-applied adhesive, apply Loctite 222 to M4 socket flat head
cap screws.
5. Secure Adapter Plate to the Tool Changer with two M4 socket head cap screws. Tighten to 10
in-lbs.
6. Align optional module on the Adapter Plate.
7. If not using fasteners with pre-applied adhesive, apply Loctite 222 to four M4 mounting
fasteners.
8. Secure module with four M4 mounting fasteners. Refer to Table 3.1 for proper torque for your
Figure3.5QC-60 Flat B Optional Module Installation
Adapter Plate (9005-20-1388 Shown)

(4) M4 Socket Head
Cap Screws
(QC-60 Shown)
Fluid/Air Module
(9120-FR2-M Shown)
(4) M4 Socket Head
Cap Screws
Tool Plate Assembly

(QC-60 Shown)
Adapter Plate
(9005-20-1389 Shown)
Fluid/Air Module
(9120-FR2-T Shown)
3.7.4 QC-60 Flat B Optional Module Removal

4. Supporting the module, remove the four M4 socket head cap screws.
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5. Remove the module from the Adapter Plate.
6. Remove the two M4 socket head cap screws securing the adapter plate to the Master or Tool
Plate.
7. Remove the adapter plate.
3.7.5 QC-40. QC-41, QC-43, QC-71, and QC-100 Optional Module Installation
the unlocked.
3. Align optional module on the Master or Tool Plate as shown in Figure3.6.
4. If not using fasteners with pre-applied adhesive, apply Loctite 222 to four M4 socket head
cap screws.
5. Secure module with four M4 mounting fasteners. Refer to Table 3.1 for proper torque for your
Figure3.6Optional Module Installation
(4) M4 Socket Head

Cap Screws

(QC-41 Shown)
(4) M4 Socket Head

Cap Screws
Tool Plate Assembly

(QC-41 Shown)
Fluid/Air Module
(9120-FR2-T Shown)
3.7.6 QC-40, QC-41, QC-43, QC-71, and QC-100 Optional Module Removal
4. Supporting the module, remove the four M4 socket head cap screws.
5. Remove the module from the Master or Tool Plate.
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3.8 Lock/Unlock Pneumatic Connections and Valving

WARNING: The Quick-Change 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 within the Tool Changer.
Air must be supplied to the Lock air port on the Master Plate (robot-side) to move the internal piston,
which moves the cam, and forces the locking balls outward. The locking balls move outward until they
contact the bearing race on the mating Tool Plate. This will rigidly engage the Master Plate and Tool Plate
providing high load capacity and positional accuracy. The patented cam profile prevents the Tool Plate from
becoming disengaged in the event that there is a loss of air in the locked state.
To unlock the Tool Plate from the Master Plate, lock air must be vented and air supplied to the Unlock air
port on the Master Plate.
3.8.1 Air Requirements

For proper operation of the Quick-Change system, the Master Plate must be supplied with clean,
dry, non-lubricated air supplied between 65 and 100 psi (4.56.9 Bar) and filtered at 20 microns or
better. Flow requirements are negligible, typically no more than 1/3 CFM at 70 PSI when cycled
continuously.
CAUTION: Do not use the Tool Changer in the fail-safe condition for extended
periods of time. Do not transport the Tool Changer in the fail-safe condition.
Possible damage to the locking mechanism could occur.
3.8.2 Valve Requirements and Connections

As with all pneumatic piston arrangements, smooth operation requires proper porting of the
supplied and vented air. It is recommended that a single 4-way valve be used to actuate the locking
mechanism in the Master Plate. The valve may be of either 4-port or 5-port configuration. 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 (i.e., 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 will
negate the locking force of the Quick-Change mechanism.
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 within the Tool Changer. Connect the Lock and Unlock supply
air to a single 2-position 4-way or 5-way valve with either 4-port or 5-port
configuration. This could result in damage to the product, attached tooling, or
personnel.
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Figure3.7QC-40, QC-43 and QC-71 Lock and Unlock Pneumatic Connections
4 or 5 -way Valve
Lock Port
Unlock Port
Supply Clean, Dry,

Non -lubricated Air
65 100 psi (4.5 6.9 Bar)
Exhaust
Open to Atmosphere
Figure3.8QC-41 Lock and Unlock Pneumatic Connections

4 or 5 -way Valve
Lock Port
Unlock Port
Supply Clean, Dry,

Non -lubricated Air
65 100 psi (4.5 6.9 Bar)
Exhaust
Open to Atmosphere

4 or 5 -way Valve
Unlock Port
Lock Port
Supply Clean, Dry,

Non -lubricated Air
65 100 psi (4.5 6.9 Bar)
Exhaust
Open to Atmosphere

4 or 5 -way Valve
Lock Port
Unlock Port
Supply Clean, Dry,

Non -lubricated Air
65 100 psi (4.5 6.9 Bar)
Exhaust
Open to Atmosphere
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Document #9610-20-2255-02
3.9 Electrical Connections

The Optional Lock and Unlock sensors are available in PNP and NPN type.
3.9.1 PNP Type Lock and Unlock Sensors

The PNP Lock and Unlock sensors are 8mm cylindrical inductive proximity sensor.
Table 3.2PNP (Current Sourcing)
Description
Value
Voltage Supply Range
10-30 VDC
Output Current
< 100 mA
Nominal Sensing Distance Sn
0.8 mm
Output Circuit
PNP make function (NO)
Figure3.11PNP Type Lock and Unlock Sensors
PNP (Current Sourcing)

Brown (1)
PNP
Connector
(4) Black
+Vs
Black (4)
Output
Z
Blue (3)
(3) Blue
Brown (1)
0V
3.9.2 NPN Type Lock and Unlock Sensors

The NPN Lock and Unlock sensors are 8mm cylindrical inductive proximity sensor.
Table 3.3NPN (Current Sourcing)
Description
Value
Voltage Supply Range
10-30 VDC
Output Current
< 100 mA
Nominal Sensing Distance Sn
0.8 mm
Output Circuit
NPN make function (NO)
Figure3.12NPN Type Lock and Unlock Sensors
NPN (Current Sinking)

Brown (1)
NPN
Black (4)
Blue (3)
Connector
(4) Black
+Vs
Z
Output
Brown (1)
0V
(3) Blue
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4. Operation
The Master locking mechanism is pneumatically driven to couple and uncouple with the bearing race on the Tool
Plate. The Master Plate utilizes air ports to provide lock and unlock pressure to the locking mechanism.
CAUTION: Safe, reliable operation of the tool changer is dependent on a continuous supply
of compressed air at a pressure of 65 to 100 psi. Robot motion should be halted if the air
supply pressure drops below 60 psi for any reason.
NOTICE: All Tool Changers are initially lubricated using MobilGrease XHP222 Special grease. The
end user must apply additional lubricant to the locking mechanism components and alignment pins
prior to start of service (See Section5.2Cleaning and Lubrication of the Locking Mechanism and
Alignment Pins). Tubes of lubricant for this purpose are shipped with every tool changer. Note:
MobilGrease XHP222 Special is a NLGI #2 lithium complex grease with molybdenum disulfide.
The robot should be programmed to minimize misalignment during coupling and uncoupling. Additionally, the Tool
Stand should be durable and not allow deflection, under uncoupled Tool weight that will take alignment of the Tool
Changer plates outside of accepted offsets. See Figure4.1 and Table 4.1 for recommended maximum allowable
offsets prior to coupling. In some cases, greater offsets than shown in Table 4.1 can be accommodated by the
Master and Tool Plates, but will increase wear.
Lock-up should occur with the Master Plate in the No-Touch Locking zone (see Table 4.1) but not touching the
Tool Plate. As locking occurs, the Master Plate should draw the Tool Plate into the locked position.
Figure4.1 Offset Definitions
Master Plate
Tool Plate
Z
Cocking Offset
(About X and Y)
Y
Twisting Offset
(About Z)
X
X, Y, and Z Offset
Table 4.1Maximum Recommended Offsets Prior to Coupling

Model
No-Touch Zone Z
Offset (Max)*
(mm)
X and Y Offset (Max)

(mm)
Cocking Offset
(Max)
(degrees)
Twisting Offset
(Max)
(degrees)
QC-40
QC-41
QC-43
+3
1.0
QC-60
QC-71
+3
0.6
QC-100
+3
0.7
Notes: *Maximum values shown. Decreasing actual values will minimize wear during coupling/uncoupling.
Actual allowable values may be higher in some cases but higher offsets will increase wear during coupling.
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4.1 Coupling Sequence

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. Prior to coupling and with air supplied to the Unlock Port (if equipped the Unlock sensor will indicate
the Tool Change is Unlocked), position the Master Plate above the Tool Plate.
2. Move the Master Plate toward the Tool Plate so that the two Master Plate alignment pins enter the
alignment holes on the Tool Plate. Take care to program the robot so that the Master Plate and Tool
Plate are aligned axially and are parallel to each other as closely as possible, refer to Table 4.1. 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 just prior to coupling. Contact may result in
damage to the unit and/or the robot.
3. When the two faces are within the specified No-Touch distance (refer to Table 4.1), release the
pressure from the Unlock Port and supply air to the Lock Port. The Tool Plate will be 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 will indicate the Tool Change is in the Locked position).
4. A sufficient delay must be programmed between locking valve actuation and robot motion so that the
locking process is complete before moving the robot.
5. ATIs patented fail-safe design prevents the Tool Plate from being released in the event of air-pressure
loss to the Lock port, thereby increasing safety and reliability. Positional accuracy may not be
maintained during air loss, but will be regained once air pressure is re-established to the Lock port.
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 initially 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. ATIs 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 will not be maintained during this Fail Safe condition. The Tool Changer
is not to be operated in the fail-safe condition. Once source air is lost to the unit, movement should be
stopped until air is restored. Once air pressure is reestablished to the Master Plate, the locking mechanism
will energize securely locking the master and Tool Plates together. If equipped, make sure the lock sensor
indicate the Tool changer is in the locked position before resuming normal operations.
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. Once air pressure is reestablished to the Master Plate, the locking mechanism
will energize securely locking the master and Tool Plates together. Make sure the
lock sensor indicate the Tool changer is in the locked position, it may be necessary to
consult your Control and Signal Module Manual for specific error recovery information
before resuming normal operations.
4.3 Uncoupling Sequence

1. Position the Tool Plate in the Tool Stand such that there is little or no contact force between the Tool
Plate and Tool Stand.
2. Release air on the Lock port and apply air to the Unlock Port (if equipped the Unlock sensor will
indicate the Tool Change is in the Unlocked position). The air will cause the locking mechanism to be
released and the weight of the Tool Plate and attached tooling will assist in its removal. (Note: Tool
weight assists in uncoupling if the Tool is released in the vertical position only). Move the Master Plate
axially away from the Tool Plate.
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3. A sufficient delay must be programmed between unlocking valve actuation and robot motion so that the
unlocking process is complete and the Tool Plate is fully released before moving the robot.
4. In automated Tool change applications, it is recommended that a Tool presence sensor(s) be used in
the Tool Stand to verify that the Tool is present and to verify that the Tool remains in place as the robot
moves away after the unlocking process.
4.4 Tool Identification
When using multiple Tools, it is good practice to implement a Tool-ID system that identifies each Tool
with a unique code. This can be used to verify that the robot has picked up the proper Tool. This may be
accomplished by using an optional electrical module (for power and signal pass-through) and uniquely
jumpering pins on the Tool-side of the module. See electrical module documentation for more information.
DeviceNet Tool-ID modules are also available.
4.5 Tool Storage Considerations

CAUTION: Tool Stand design is critical to proper operation of the Tool Changer.
Improperly designed Tool Stands can cause misalignments that will cause jamming
and/or excessive wear of Tool Changer components.
The tools may be stored in a Tool Stand when not being used by the robot. ATI provides compatible Tool
Stands designed for durability, longevity, and maximum adaptability to fit most customers applications. The
ATI TSM (Tool Stand Medium) system is compatible with ATI Tool Changer sizes QC-20 to QC-110. The
TSM systems can be equipped with horizontal modules, clamp modules, and different types of tool sensing.
Visit the ATI Web Site http://www.ati-ia.com/products/toolchanger/toolstand/medium/MediumStand.aspx for
products available for your specific application or contact ATI for recommendations and assistance.
If the customer is supplying the tool stand, it should be designed to provide a fixed, repeatable, level, and
stable positions for tool pick-up and drop-off. The tool stand must support the weight of the Tool Changer
Tool Plate, Tool Interface Plate, optional modules, cables, hoses, and customer tooling without allowing
deflection in excess of the offsets specified in Section4Operation.
Ideally, the Tool should be hanging vertically in the Tool Stand so that gravity assists to uncouple the Tool
Plate from the Master Plate during unlocking. It is possible to design Tool Stands that hold tools in the
horizontal position, but care must be taken that the necessary compliance is provided during coupling and
uncoupling. In general, horizontal-position Tool Stands cause more wear on the locking mechanism and
locating features of the Tool and Tool Stand.
A variety of methods may be used to position the Tool in the Tool Stand. A common method is to use
tapered alignment pins and bushings. Robot programming and positional repeatability are vital in tool pickup and drop-off, refer to Section4Operation.
It is highly recommended that the customer provide a sensor that detects the presence of a properly seated
Tool in the Tool Stand. The sensor may be used prior to coupling to ensure there is a Tool properly seated in
the stand. Sensors may also be used as the robot starts to move away after uncoupling. This provides a safety
measure in the event that a Tool should become jammed in the stand or if the Tool should fail to release
properly from the robot.
Proximity sensors should be positioned so that the sensing face is vertical to prevent metal shavings, weld
spatter, or other debris from falling on the sensor and creating false readings.
Tool Stands may also need to incorporate means for covering Tools and modules to protect them in dirty
environments, such as grinding or welding. Alternatively, positioning Tool Stands in areas shielded from
weld spatter, fluids, adhesives, or other debris would eliminate the need for tool covers.
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5. Maintenance
WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the
Tool is safely supported or docked in the Tool Stand and all energized circuits (e.g., electrical,
air, water, etc.) have been turned off. Injury or equipment damage can occur with Tool not
docked and energized circuits on. Dock the Tool safely in the Tool Stand and turn off all
energized circuits before performing maintenance or repair on Tool Changer or modules.
NOTICE: The cleanliness of the work environment strongly influences the trouble free operation of
the Tool Changer. The dirtier the environment, the greater the need for protection against debris.
Protection of the entire EOAT, the Master, the Tool and all of the modules may be necessary. Protective
measures include the following: 1) Placement of Tools Stands away from debris generators. 2) Covers
incorporated into the Tool Stands. 3) Guards, deflectors, air curtains, and similar devices built into the
EAOT and the Tool Stand.
5.1 Preventive Maintenance

The Tool Changer and optional modules are designed to provide a long life with regular maintenance. A
visual inspection and preventive maintenance schedule is provided in the table below depending upon the
application. Detailed assembly drawings are provided in Section8Drawings of this manual.
Table 5.1Preventive Maintenance Check List
Application(s)
Tool Change Frequency
Inspection Schedule
General Usage Material Handling Docking Station
> 1 per minute
Weekly
< 1 per minute
Monthly
All
Weekly
Welding/Servo/Deburring, Foundry Operations (Dirty Environments)

Checklist
Mounting Fasteners
Inspect fasteners for proper torque, interference or wear. Tighten and correct as required. Refer to Section3
Installation.
Balls/Alignment Pins/Holes/Bearing Race
Inspect for lubrication and wear. MobilGrease XHP222 Special a NLGI #2 lithium complex grease with
molybdenum disulfide additive is suggested for locking mechanism and alignment pin lubrication. Over time,
lubricants can become contaminated with process debris. Therefore, it is recommended to thoroughly clean
the existing grease and replace with new as needed. See Section5.2Cleaning and Lubrication of the
Locking Mechanism and Alignment Pins.
Inspect for excessive alignment pin/bushing wear may be an indication of poor robot position during pickup/
drop-off. Adjust robot position as needed. Check tool stand for wear and alignment problems. The QC-100
model has replaceable alignment pins, refer to Section6.2.4QC-100 Alignment Pin Replacement
Inspect for wear on the balls/bearing race could be an indication of excessive loading.
Sensors and Cables

Inspect sensor cable connectors for tightness, if loose tighten connections.
Inspect sensor cables for any damage, cuts, and abrasion. Replace as necessary.
Hoses
Inspect hose connection for tightness and leaks. If leaking or loose secure hose connection.
Inspect hoses for interferences, abrasions, cuts, and leaks. Replace as required.
Seals Pass Through Air and Optional Modules

Inspect for wear, abrasion, and cuts. Replace damaged seals, or rubber bushings as needed. Refer to
Section6.2.11/8 and 1/4 Rubber Bushing Inspection & Replacement, Section6.2.23/8 Rubber Bushing
Replacement, or Section6.2.3Optional Electrical Module Seal Inspection and Replacement
Electrical Contacts/Pin Block (Modules)
Inspect for damage, debris, and stuck/burnt pins. Clean pin blocks as required, refer to Section5.3Optional
Electrical Module Pin Block Inspection and Cleaning.
28
Document #9610-20-2255-02
5.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins
Master and Tool plates. Leave the locking mechanism in the unlocked.
2. The locking mechanism must be in the unlock state before cleaning.
3. Use a clean rag to thoroughly remove the existing lubricant and debris from the ball bearings, the male
coupling, the cam and the alignment pins.
Figure5.1 Cleaning Ball Bearings and Outer Surfaces of Male Coupling
4. Use a clean rag to thoroughly remove the existing lubricant and debris from the inner surface of the
male coupling and the cam.
Figure5.2 Cleaning Ball Bearings, Cam and Inner Surfaces of Male Coupling
29
Document #9610-20-2255-02
5. Check each ball bearing to make sure it moves freely in the male coupling. Additional cleaning may be
necessary to free up any ball bearings that are sticking in place.
Figure5.3 Check Ball Bearing Movement
6. Apply a liberal coating of MobilGrease XHP222 Special grease to the ball bearings, the male
coupling (inside and out), and the alignment pins.
Figure5.4 Apply Lubricant to Locking Mechanism
Apply Lubricant on Alignment

Pins and Outer Surface
of Male Coupling
Apply Lubricant on Inner

Surface of Male Coupling
7. Use a clean rag to thoroughly remove the any lubricant and debris from the bearing race and the
bushings from the Tool Plate.
Figure5.5 Clean Tool Plate Surfaces of Locking Mechanism
Clean Bushing Surfaces
Clean Bearing
Race Surfaces
8. No application of lubrication is necessary on the Tool Plate components.

9. After repair is complete, return all circuits to normal operation (e.g. electrical, air, water, etc.).
30
Document #9610-20-2255-02
5.3 Optional Electrical Module Pin Block Inspection and Cleaning

Master and Tool plates. Leave the locking mechanism in the unlocked.
3. Inspect the Master and Tool pin blocks for any debris or darkened pins.
Figure5.6Inspect Master and Tool Pin Blocks
Blackened Pins
Note: Pin blocks shown are for

illustration purposes only.
Weld Debris
Master Module Pin Block
Tool Module Pin Block
4. If debris or darkened pins exist, remove debris using a vacuum, and clean using a nylon brush (ATI part
number 3690-0000064-60).
NOTICE: Do not use an abrasive media, cleaners, or solvents to clean the contact pins. Using
abrasive media, cleaners, or solvents will cause erosion to the contact surface or pins to stick.
Clean contact surfaces with a vacuum and non-abrasive media such as a nylon brush (ATI part
number 3690-0000064-60)
Figure5.7Clean Pin Blocks with a Nylon Brush
5. Inspect the Master and Tool pin blocks for stuck pins or severe pin block damage.
Figure5.8Stuck Pin and Pin Block Damage
Note: Pin blocks shown are for
illustration purposes only.
Severe Pin Block Damage
Stuck Pins
6. If stuck pins or severe pin block damage exists, contact ATI for possible pin replacement procedures or
module replacement.
7. After maintenance is complete, return all circuits to normal operation (e.g. electrical, air, water, etc.).
31
Document #9610-20-2255-02
6. Troubleshooting and Service Procedures

The following section provides troubleshooting information to help diagnose conditions with the Tool Changer and
service procedures to help resolve these conditions.
WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the
Tool is safely supported or docked in the tool stand and all energized circuits (e.g., electrical,
air, water, etc.) have been turned off. Injury or equipment damage can occur with Tool not
docked and energized circuits on. Dock the Tool safely in the tool stand and turn off all
energized circuits before performing maintenance or repair on Tool Changer or modules.
6.1 Troubleshooting
The troubleshooting table is provided to assist in diagnosing issues that may cause the Tool Changer not to
function properly.
Table 6.1Troubleshooting
Symptom
Cause
Resolution
Debris caught between the

Master and Tool plates.
Clean debris from between Master and Tool Plates. Verify

mounting hardware is secure and does not protrude
above the mating surfaces.
Insufficient or no air pressure Verify proper air pressure and pneumatic valve is
supplied. Refer to Section3.8Lock/Unlock Pneumatic
supply to the lock or unlock
ports.
Connections and Valving.
Tool Changer
will not lock and/
or unlock (or
Lock sensor
does not indicate
Tool Changer is
Locked)
Air pressure trapped in deenergized Lock or Unlock

ports.
Air pressure must be vented to the atmosphere

properly, refer to Section3.8Lock/Unlock Pneumatic
Connections and Valving.
Pneumatic connections
loose or damaged.
Inspect hose connection for tightness and leaks. If

leaking or loose secure hose connection.
Inspect hoses for interferences, abrasions, cuts, and
leaks. Replace as required.
The ball bearings and/or cam Clean and lubricate as needed to restore smooth
are not moving freely in the
operation (see Section5.2Cleaning and Lubrication of
male coupling.
the Locking Mechanism and Alignment Pins).
Unit is locked but

Lock signal does
not read on
(true).
Unit is unlocked
but Unlock signal
does not read
on (true).
The Master plate and Tool

plate are not within the
specified No-Touch zone
when attempting to lock.
Check that the Tool is properly seated in the tool stand.

Refer to Section4.5Tool Storage Considerations.
Re-teach the robot to bring the Master plate and Tool
plate closer together prior to attempting to lock.
Lock sensor/cable is out of

adjustment or damaged.
Adjust or replace the lock sensor assembly as necessary.

Refer to Section6.2.5Proximity Sensor Adjustment,
Test, or Replacement.
Adjust or replace the unlock sensor assembly as

Unlock sensor/cable is out of necessary. Refer to Section6.2.5Proximity Sensor
adjustment or damaged.
Adjustment, Test, or Replacement.
Units Equipped with Electrical/Servo/Control/Signal Modules
Loss of
Communication
Debris in and around contact Inspect V-ring seal for damage, replace damaged seal.
pins. Contact Pin worn or
Refer to Section6.2.3Optional Electrical Module Seal
damaged.
Inspection and Replacement
Cable connections loose or
cables damaged
Check that cable connection are secure and cables are

not damaged.
32
Document #9610-20-2255-02
6.2 Service Procedures

The following service procedures provide instructions for inspection, adjustment, test or replacement of
components.
the Tool is safely supported or docked in the tool stand and all energized circuits (e.g.,
with Tool not docked and energized circuits on. Dock the Tool safely in the tool stand
Changer or modules.
6.2.1 1/8 and 1/4 Rubber Bushing Inspection & Replacement

The rubber bushings seal the air passage from the Master plate to the Tool plate. If the bushing
become cut or damaged they need to be replaced.
the Master and Tool plates. Leave the locking mechanism in the unlocked.
3. Remove damaged rubber bushing by grasping with fingers and pulling the bushing out of the
body.
4. Dip new bushing in water to aid in installation.
5. Insert the beveled (chamfered) end of the rubber bushing into the bore, leaving ribbed end of
the bushing facing outward.
6. Press the bushing in by hand until it is seated completely in the bore. If necessary, use a
plastic or rubber soft-faced mallet to tap the bushings into place.
7. After maintenance is complete, return all circuits to normal operation (e.g. electrical, air,
water, etc.).
Figure6.1 1/8 and 1/4 Rubber Bushing Replacement (QC-41 Shown)
Rubber Bushing
6.2.2 3/8 Rubber Bushing Replacement

3. Using needle nose pliers grasp the rubber bushing and pull it out of the Master body. Refer to
Figure6.2.
33
Document #9610-20-2255-02
4. If the collar remains in the Master body, remove it.
5. Lightly lubricate the new rubber bushing and push into the Master body (refer to Figure6.2).
6. Insert the new collar into the rubber bushing, make sure the bushing is pressed all the way in.
water, etc.).
Figure6.2 3/8 Rubber Bushing Replacement (QC-41 Shown)
Collar
Rubber Bushing
6.2.3 Optional Electrical Module Seal Inspection and Replacement

The seal protect the electrical connection between the Master and Tool module. If the seal becomes
worn or damaged it needs to be replaced.
3. To remove the existing seal, pinch edge of seal with fingers and gently pull the seal away from
the pin block on the Master.
4. Pull the seal off the pin block.
5. To install a new seal, stretch the new seal over the shoulder of the pin block.
6. Push the seals hub down against the pin block using finger tip.
water, etc.).
Figure6.3V-Ring Seal Replacement
Stretch seal over shoulder of pin
block and push seal hub down
against the pin block with finger tip
V-ring Seal
V-ring Seal
Pinch edge of seal with

fingers and gently pull
away from pin block
34
Document #9610-20-2255-02
6.2.4 QC-100 Alignment Pin Replacement

Excessive alignment pin/bushing wear may be an indication of poor robot position during pickup/
drop-off. Adjust robot position as needed. Check tool stand for wear and alignment problems. If
necessary replace the alignment pins.
the Master plate.
3. Using a 2.5mm allen wrench remove the alignment pin and discard
4. Apply loctite 242 to the treads of the new alignment pin and thread into the Master Plate
assembly. Tighten to 18 in-lbs.
5. Apply a liberal coating of MobilGrease XHP222 Special grease to the alignment pins.
water, etc.).
Figure6.4QC-100 Alignment Pin Replacement
2.5mm Allen Wrench

Alignment Pin
6.2.5 Proximity Sensor Adjustment, Test, or Replacement

The proximity sensors are very reliable and normally do not need to be replaced. Exhaust all other
possible solutions, check continuity, air supply, lubrication, and pneumatic components prior to
testing or replacing the sensor
the Master plate.
3. If you are testing or replacing the Lock sensor make sure the QC is in the locked position,
if you are replacing the Unlock sensor make sure the QC is in the unlocked position before
continuing.
6. Remove the mounting fasteners securing the Master Plate Assembly to the sensor interface
plate. Refer to Figure6.5
35
Document #9610-20-2255-02
7. Disconnect the sensor cable.
8. Loosen the hex nut and unscrew the proximity sensor from the Master Plate Assembly. Retain
the washer from the sensor.
9. To test the suspect sensor, connect the sensor cable and place a ferrous target in front of the
Proximity Sensor to confirm that the sensor is functional. The sensor lock or unlock signal
should read on(true) and the sensor LED should illuminate.
10. If the proximity sensor is not functioning properly replace. Disconnect the sensor cable and
discard.
11. Back the sensor hex nut to the connector end of the new sensor.
12. Thread the proximity sensor into the Master Plate Assembly until it touches the Detection
Shaft, then back the sensor off 1/2 turn.
CAUTION: Do not operate locking mechanism with sensor touching the
detection shaft. Operating the locking mechanism with the sensor touching the
detection shaft will damage the sensor. Back off the sensor turn and secure
with the set screw before operating the locking mechanism.
13. Connect the sensor cable. The Proximity Sensor LED should be illuminated.
14. Holding the sensor in position apply Loctite 222 to the proximity sensor threads between the
hex nut and the Master Plate Assembly. Tighten the hex nut and torque to 20 in-lbs.
15. Attach the Master Plate to the sensor interface plate using the mounting fasteners. Refer to
Table 3.1 for torque and thread locker specifications.
16. If required, connect other utilities to the optional modules on the Master Plate.
17. Confirm the operation of the replaced sensor by issuing the Lock command to lock a Tool to
the Master and then checking to see that the LED in the replaced Sensor body is on.
Figure6.5Replace Proximity Sensor
Sensor Interface Plate (SIP)
Detection Shaft
Master Plate
(QC-41 Shown)
Washer
Lock Sensor
Sensor LED
Sensor Cable
Unlock Sensor
Mounting Fasteners
36
Document #9610-20-2255-02
7. Serviceable Parts
The following items are commonly used as spare parts for the QC-40 through QC-100 Tool Changers.
7.1 Models QC-40
QC-40 Master Plate

ITEM NO.
QTY
PART NUMBER
DESCRIPTION
9120-040M-000-000
QC-40 Master, no options
3500-1064035-12
SHCS, M5x35, ZN
QC-40 Tool Plate

3
9120-040T-000-000
4010-0000013-01
QC-40 Tool, no options

1/8 NPT Rubber Bushing, Nitrile
QC-40 SIP Assemblies

PNP Sensors - 9120-040M-SIP-B-XXXX
5
8590-9909999-04
PNP Prox Switch Hardwired
8590-9909999-08
PNP Prox Switch
6*
8590-9909999-07
High-flex cable w/ straight snap-on connector, 5M long flying leads (Type-BU)
8590-9909999-02
PNP Sensors - 9120-040M-SIP-D-XXXX and 9120-040M-SIP-G-XXXX
NPN Sensors - 9120-040-SIP-A-XXXX

NPN Prox Switch Hardwired
NPN Sensors - 9120-040M-SIP-E-XXXX and 9120-040M-SIP-F-XXXX

5
8590-9909999-14
NPN Proximity Sensor w/ LED
6*
8590-9909999-07
Note: *Sensor cables for 9120-040M-SIP-D-XXXX and 9120-040M-SIP-F-XXXX models.

37
Document #9610-20-2255-02
7.2 Models QC-41
7
8
1
5
2
3
QC-41 Master Plate

ITEM NO.
QTY
PART NUMBER
DESCRIPTION
9120-041M-000-000
QC-41 Master Assembly, No Options
4010-0000010-01
3/8 Rubber Bushing. Nitrile
3700-20-2000
Collar for 3/8 Bushing
4010-0000013-01
3500-1064035-12
M5 x 35mm SHCS Zinc
QC-41 Tool Plate

6
9120-041T-000-000
QC-41 Tool Assembly, No Options

7
8*
8590-9909999-08
PNP Prox Switch
8590-9909999-12
Straight Picofast Cordset, 2 Meter

7
8590-9909999-14
8*
8590-9909999-12
Straight Picofast Cordset, 2 Meter
38
Document #9610-20-2255-02
7.3 Models QC-43
QC-43 Master Plate

ITEM NO.
QTY
PART NUMBER
DESCRIPTION
9120-043M-000-000
3500-1064035-15
M5 x 35mm SHCS, Blue Dyed Magni
9120-043T-000-000
4010-0000013-01
QC-43 Tool Plate
QC-43 SIP Assemblies (uses the QC-40 SIP Assemblies)

5
8590-9909999-04

5
8590-9909999-08
PNP Prox Switch
6*
8590-9909999-07

5
8590-9909999-02
8590-9909999-14
6*
8590-9909999-07

39
Document #9610-20-2255-02
7.4 Models QC-60
QC-60 Master Plate

ITEM NO.
QTY
PART NUMBER
DESCRIPTION
9120-060M-000-000
3500-1266040-15
M6 x 40mm SFHCS, Blue Dyed Magni-565
9120-060T-000-000
4010-0000013-01
QC-60 Tool Plate

5
8590-9909999-08
PNP Prox Switch
6*
8590-9909999-07
8590-9909999-02


5
8590-9909999-14
6*
8590-9909999-07
40
Document #9610-20-2255-02
7.5 Models QC-71
2
1
3
4
QC-71 Master Plate

ITEM NO.
QTY
PART NUMBER
DESCRIPTION
9120-071M-000-000
QC-71 Master Assembly, No Options
4010-0000021-01
3500-1066040-12
M6 x 40mm SHCS Zinc
9120-071T-000-000
QC-71 Tool Plate

QC-71 Tool Assembly, No Options

5
8590-9909999-08
PNP Prox Switch
6*
8590-9909999-07
NPN Sensors - 9120-071M-SIP-E-XXXX

5
8590-9909999-14
8590-9909999-09
NPN Prox Switch
6*
8590-9909999-07
NPN Sensors - 9120-071M-SIP-F-XXXX

41
Document #9610-20-2255-02
7.6 Models QC-100
7
8
3
6
5
QC-100 Master Plate

ITEM NO.
QTY
PART NUMBER
DESCRIPTION
9120-100M-000-000
3700-20-1373
Monolithic Alignment Pin, QC-100, A2
3500-1068055-15
M8 x 55mm SHCS, Blue Dyed Magni-565
QC-100 Tool Plate

4
9120-100T-000-000
4010-0000010-01
3/8 Rubber Bushing. Nitrile
3700-20-2000
Collar for 3/8 Bushing

7
8590-9909999-04

7
8590-9909999-08
PNP Prox Switch
8*
8590-9909999-07
PNP Sensors - 9120-100M-SIP-L-XXXX

7
8590-9909999-23
PNP Hall Effect Sensor Switch for QC-100

7
8590-9909999-14
8*
8590-9909999-07
Note: *Sensor cable for 9120-100M-SIP-D-XXXX and 9120-100M-SIP-F-XXXX models.

42
43
80
5
7
54.1
J16
Modules
Tool Side
(projection only)
49
(Typ.)
30
(Typ.)
20
(Typ.)
Notes:
1. Master mounting hardware provided.
2. Cover plate is not necessary if robot interface plate provides
sealing. The recommended interface plate bore depth without
a cover plate is 2.5mm, with a cover plate is 5.6mm.
3. Orientation marks are provided to assist in robot teaching.
4. Shown with optional J16 Electrical Modules. For other modules
see the Modules and Options section of the catalog.
Flat A
50 H7, 6 Dp.
Customer Interface
B.C.
Pneumatic
Port I.D.
(6) Tapped M8 x 1.25, 8 Dp.

Equally Spaced
Customer Interface
115
(2) 8 H7, 8 Dp.

Customer Interface
15
(Typ.)
33
J16-T
(B)
Amphenol Connector
PT02A-14-19S
60
J16
Modules
Flat B
(8) 1/8 NPT

Pneumatic
Thru Ports
27
Tool
Plate
54.2
Coupled
(A)
10.1
15.1
QC-40 Tool Changer
115
80 h7, Boss
Customer
Interface
1/8 NPT
Unlock Port
Flat B
Warning:
Do not apply lock/unlock air pressure without master cover plate
properly attached. If cover plate is not used, master should be
properly attached to interface. Failure to do so could result in
damage to cover plate and o-ring.
42.5
J16-M
(8) 1/8 NPT

Pneumatic
Thru Ports
(Even #s10.1 From
Mating Surface)
(6) Thru Hole for M5 x 35

SHCS Provided
(Odd #s 15.1
Equally Spaced
From Mating
Customer Interface
Surface)
10.3 M5 SHCS
Provided
3.2 Cover Plate

3 Boss
15.5
27
Master
Plate
Part Numbers Shown:

(A) Master: 9120-040M-000-J16
(B) Tool: 9120-040T-000-J16
Amphenol Connector
PT02A-14-19P
15.1
18.1
Male
Coupling
1031 Goodworth Drive, Apex, NC 27539, USA

Tel: +1.919.772.0115
Email: info@ati-ia.com
Fax: +1.919.772.8259
www.ati-ia.com
ISO 9001 Registered Company
12.5
Master Side
(projection only)
12.5
10
B.C.
Flat A
79
Cover
Plate
65
1/8 NPT
Lock Port
(2) 6 H7, 6 Dp.

Customer Interface
9230-20-1966-03
Document #9610-20-2255-02
8. Drawings
8.1 QC-40 Tool Changer with J16 Module
44
10
55.8
R19
Modules
Tool Side
(projection only)
60.2
R19
Modules
80
25
25
Amphenol Connector
PT02E-14-19S
33.3
R19-T
6.3
(B)
6X 3/8 NPT
Pneumatic
Thru Ports
(14.1 From
Mating Surface)
Pneumatic
Port I.D.
30
30
27.1
Tool Plate
4X 1/8 NPT
Pneumatic
Thru Ports
(15.1 From
Mating Surface)
50 H7 6
Customer Interface
B.C.
Notes:
sealing. The recommended interface plate bore depth with
a cover plate is 2.5mm.
4. Shown with optional R19 Electrical Modules. For other modules
57.6
(Typ.)
8 H7 8
Customer Interface
130
Tapped M8 x 1.25 8
Equally Spaced
Customer Interface
15.1
14.1
(A)
15.1
20.1
10
130
12.5
1/8 NPT
Lock Port
14.8
44.9
R19-M
6X Thru Hole for M5 x 35

SHCS Provided
Equally Spaced
Customer Interface
79
Cover Plate
6 H7 20
Customer Interface
6X 3/8 NPT
Pneumatic
Thru Ports
4X 1/8 NPT
Pneumatic
Thru Ports
10.3 M5 SHCS
Provided
3.2 Cover Plate
30.1
Master
Plate
40.1
R19
Modules
65
6 H7 6
Customer Interface
B.C.
1/8 NPT
Unlock Port
12.5
9230-20-1967-03
Master Side
(projection only)
Warning:
Amphenol Connector
PT02E-14-19P
18
Male
Coupling
QC-41 Tool Changer

Part Numbers Shown:
(A) Master: 9120-041M-R19-000
(B) Tool: 9120-041T-R19-000
57.2
Coupled

Tel: +1.919.772.0115
Fax: +1.919.772.8259
www.ati-ia.com
Document #9610-20-2255-02
8.2 QC-41 Tool Changer with R19 Module
80
45
49
(Typ.)
30
(Typ.)
Tool Side
(projection only)
5
6
7
20
(Typ.)
Notes:
Warning:
Flat A
6
50 H7
Customer Interface
B.C.
Pneumatic
Port I.D.
6X Tapped
8
M8 x 1.25
Equally Spaced
Customer Interface
115
8
2X 8 H7
Customer Interface
15
(Typ.)
Part Numbers Shown:

(A) Master: 9120-043M-000-000
(B) Tool: 9120-043T-000-000
Flat B
(B)
8X 1/8 NPT
Pneumatic
Thru Ports
3X 15.5
Alignment
Pins
15.1
27
Tool
Plate
3rd ANGLE PROJECTION
DO NOT SCALE DRAWING.

ALL DIMENSIONS ARE IN
MILLIMETERS.
NOTES: UNLESS OTHERWISE

SPECIFIED.
10.1
15.1
54.2
Coupled
18.1
Male
Coupling
PROJECT #
CHECKED BY:
DRAWN BY:
DSS 7/9/14
SHEET 1 OF 1
D. Wagner 7/9/14
(A)
Description
115
80 h7, Boss
Customer
Interface
Initial Drawing
Date
1/8 NPT
Lock Port
Flat A
79
Cover
Plate
65
7/9/2014
SIZE
SCALE
1:1.7
9230-20-4583
DRAWING NUMBER
01
REVISION
PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY

MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI.
QC-43 Tool Changer
TITLE
12.5
Master Side
(projection only)
12.5
10
B.C.
6
2X 6 H7
Customer Interface
DAW
Initiator

Tel: +1.919.772.0115 Email: info@ati-ia.com
Fax: +1.919.772.8259 www.ati-ia.com
1/8 NPT
Unlock Port
Flat B
6X Thru Hole
for M5 x 35
SHCS Provided
Equally Spaced
Customer Interface
8X 1/8 NPT
Pneumatic
Thru Ports
(Even #s 10.1 From
Mating Surface)
(Odd #s 15.1
From Mating
Surface)
10.3 M5 SHCS
Provided
3.2 Cover Plate

3 Boss
27
Master
Plate
01
Rev.
Document #9610-20-2255-02
8.3 QC-43 Tool Changer
46
2 0
130
Tool Side
(projection only)
3 9 .8
K1 9
Modules
(8) 1/8 NPT

Pneumatic
Thru Ports
2 3 .1
T ool
Plate
6 .1
(B)
14. 1
Amphenol Connector
PT02E-14-19S
30. 9
K19-T
Pneumatic
Port I.D.
8 H7, 16 Dp.
Customer Interface
53
(Typ.)
80
50 H7, 6 Dp.
Customer Interface
Flat A
B.C.
Notes:
4. Shown with optional K19 Electrical Modules. For other modules
see the M odules and Options section of the catalog.
2 0
20
20
Flat B
(6) Tapped M8 x 1.25, 16 Dp.

Equally Spaced
Customer Interface
12. 1
16
Male
Coupling
(A)
47.2
Coupled
Amphenol Connector
PT02E-14-19P
30. 6
K19-M
8. 5
55
(Typ.)
100 h7, Boss

Customer 1/8 NPT
Interface Lock Port
(8) 1/8 NPT
Pneumatic
Thru Ports
13 0
50
K 19
Modules
Flat A
Flat B
1/8 NPT
Unlock Port
15
86
9 9 .1
Cover
Plate
B.C.
9230-20-1968-02
Master Side
(projection only)
(6) Thru Holes for M6 x 40

SFHCS Provided
Equally Spaced
Customer Interface
(2) 6 H7, 6 Dp.

Customer Interface
13.3 M6 SFHCS
Provided
3.2 Cover Plate
3 Boss
24. 1
Master
Plate
Part Numbers Shown:

(A) Master: 9120-060M-K19-000
(B) Tool: 9120-060T-K19-000
QC-60 Tool Changer
Warning:

Tel: +1.919.772.0115
Fax: +1.919.772.8259
www.ati-ia.com
Document #9610-20-2255-02
8.4 QC-60 Tool Changer with K19 Module
47
Flat B
80
4
2
5 6 .9
G19-T
Tool Side
(projection only)
60
(Typ.)
30
(Typ.)
20
(Typ.)
10
(Typ.)
1 5 .1
(8) 1/4 NPT
Pneumatic
Thru Ports
1 3 .9
(B)
Amphenol Connector
PT02E-14-19S
6 0 .2
G19
Modules
Flat A
(6) Tapped M8 x 1.25, 8 Dp.

Equally Spaced
Customer Interface
Pneumatic
Port I.D.
Notes:
4. Shown with optional G19 Electrical Modules. For other modules
50 H7, 6 Dp.
Customer Interface
B.C.
150
8 H7, 8 Dp.
Customer Interface
32
To o l
Plate
45. 9
G1 9 - T
(A)
19
(2) 6 H7, 6 Dp.

Customer Interface
Amphenol Connector
PT02E-14-19P
49
G19-M
(8) 1/4 NPT

Pneumatic
Thru Ports
1/8 NPT
Unlock
Port
57
G19-M
Flat A
(6) Thru Hole for M6 x 40

SHCS Provided
Equally Spaced
Customer Interface
1 2 . 8 M 6 SH C S
Provided
3 Boss
3.2 Cover Plate
16.7
3 0 .2
Master
Plate
Warning:
properly att ached to interface. Failure to do so could result in
20
Male
Coupling
QC-71 Tool Changer

Part Numbers Shown:
(A) Master: 9120-071M-G19-000
(B) Tool: 9120-071T-G19-000
62. 2
Coupled

Tel: +1.919.772.0115
Fax: +1.919.772.8259
www.ati-ia.com
10
Master Side
(projection only)
10
1/8 NPT
Lock
Port
15
Flat B
B.C.
86
9 9 .1
Cover
Plate
15 0
100 h7, Boss

Customer Interface
9230-20-1969-02
Document #9610-20-2255-02
8.5 QC-71 Tool Changer with G19 Module
B.C.
48
Flat A
60.2
Interface Advice:
The tool interface plate should be designed to use M10 screws,
10 dowel pin and 80 recess.
35
41
27
1/8 NPT
Lock Port
Master
Plate
45.5
Notes:
1. Optional electrical module shown; consult catalog for other options.
2. Mounting hardware is provided; cover plate, o-ring and master plate screws.
3. Cover plate is not necessary if robot interface plate provides sealing.
The recommended interface plate bore depth without the cover plate is 2.5mm,
with the cover plate is 5.6mm.
5. Misalignments allowed when coupling; consult specifications.
6. See sheet 2 of 2 for Flat B bolt hole patterns.
7. DXF and DWG images available upon request.
41
54.2
41.5
3.2
12.7
1/8 NPT
Unlock Port
DO NOT SCALE. DRAWN IN SOLID WORKS 98 .

ALL DIMENSIONS ARE IN MM
NOTES: UNLESS OTHERWISE SPECIFIED
Side View
60.2
2/11/03
5/8/02
JHS
JHS
APPROVAL
INITIATOR
75
75
150
100
+0.015
10
H7
-0
10 deep
Customer Interface
(2)
40
B.C.
77 Cylinder Bore
PD
1:2
SCALE
TITLE
B-11X17
SIZE
DRAWING NUMBER
SHEET
9230-20-1201-04
QC-100 With T19 & F02
OF

Interface Advice:
The robot interface plate should be designed to use M8 screws,
10 dowel pin and 115 boss. Reference Note 3.
Top View Master Plate

Without Cover Plate
Flat A
Flat B
60
Added F02 Manifold on Flat B
170
20
20
J.SNAPE 3/19/99
MFG. APPR:
ASSEMBLY REF.
ENG. APPR.
CK'D. BY:
DR. BY:
114
177
DESCRIPTION
Added sheet 2 of 2
(6) thru holes for

M8 x 55 SHCS
provided
Customer Interface
04
03
REVISION
Cover O-ring
AS568-042
Plate
provided provided
+0
115
h7
- 0.035
Customer
Interface
19
(8) 3/8 NPT

pneumatic
thru ports
F02 Master Manifold
T19 Electrical Module

with Bendix MS3102E22-14P
27
79.5 Coupled
T19 Electrical Module

with Bendix MS3102E22-14S
+0.015
H7
-0
20 deep
Customer
Interface
11
10
(6) M10, 20 deep

Customer Interface
30
20
20
+0.030
H7, 10 deep
-0
Customer Interface
Tool
Plate
3
80
Bottom View Tool Plate
Optional Tool I.D.
125
(8) 3/8 NPT

pneumatic
thru ports
Warning:
Do not apply lock air pressure without master interface plate
properly attached; otherwise, damage may occur to cover plate and o-ring.
150
75
75
177.01
Flat B
60
F02 Tool Manifold
Document #9610-20-2255-02
8.6 QC-100 Tool Changer with T19 and F02 Modules
18
13.500.05
13.50.05
18
PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC.

NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON
ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI.
49
(2)
+0.01
0
55
500.05
500.05
(4)
DRAWN BY:
ASSEMBLY REF:
WEIGHT LBS:
CHECKED BY:
16.99
20
J.Snape 3/19/99
10
17
10
+0.10
0
100.10
(8) M4-0.7
(8) M4-0.7,
83.60.05
DO NOT SCALE DRAWING. DRAWN IN SOLIDWORKS.

ALL DIMENSIONS ARE IN MILLIMETERS.
NOTES: UNLESS OTHERWISE SPECIFIED
View Flat B Hole Locations

Typical Both Flats
85.60
50
50
85.60
REVISION
SIZE
DATE:
SHEET
OF
9230-20-1201-04
DRAWING NUMBER
QC-100 With T19 & F02
PRODUCT RELEASE #
1:2
SCALE
TITLE
INITIATOR

DESCRIPTION
DATE
Document #9610-20-2255-02
Document #9610-20-2255-02
9. Terms and Conditions of Sale

The following Terms and Conditions are a supplement to and include a portion of ATIs Standard Terms and
Conditions, which are on file at ATI and available upon request.
ATI warrants to Purchaser that robotic Tool Changer products purchased hereunder will be free from defects
in material and workmanship under normal use for a period of three (3) 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. ATIs entire liability and Purchasers sole remedy under this warranty is
limited to repair or replacement, at ATIs election, of the defective part or item or, at ATIs 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. ATIs 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 accrued.
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 ATIs 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 ATIs 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 Purchasers use in
operating the products supplied by ATI hereunder in Purchasers internal business operations.
Without ATIs 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 Purchasers 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.
50

9610 20 2255

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Quick-Change

High-Precision Robotic Tool Changer

Engineered Products for Robotic Productivity

Sale, Service and Information about ATI products:

General Safety Guidelines............................................................................................................. 6

Master Plate Assembly................................................................................................................ 10

Tool Plate Assembly..................................................................................................................... 11

Master Plate/Tool Plate Locking Mechanism............................................................................. 11

Optional Sensor Interface Plate (SIP)......................................................................................... 12

Robot Interface Plates (RIP)........................................................................................................ 14

Master Plate Installation.............................................................................................................. 15

Master Plate Removal.................................................................................................................. 16

Tool Interface Plate...................................................................................................................... 17

Tool Plate Installation.................................................................................................................. 18

Tool Plate Removal...................................................................................................................... 18

Optional Module Installation....................................................................................................... 19

QC-60 Flat A Optional K Series Module Installation.......................................................... 19

QC-60 Flat A Optional K Series Module Removal............................................................. 19

QC-60 Flat B Optional Module Installation........................................................................ 20

QC-60 Flat B Optional Module Removal........................................................................... 20

QC-40. QC-41, QC-43, QC-71, and QC-100 Optional Module Installation....................... 21

QC-40, QC-41, QC-43, QC-71, and QC-100 Optional Module Removal.......................... 21

Lock/Unlock Pneumatic Connections and Valving................................................................... 22

Valve Requirements and Connections.............................................................................. 22

PNP Type Lock and Unlock Sensors................................................................................. 24

NPN Type Lock and Unlock Sensors................................................................................ 24

Tool Storage Considerations...................................................................................................... 27

Cleaning and Lubrication of the Locking Mechanism and Alignment Pins............................ 29

Optional Electrical Module Pin Block Inspection and Cleaning.............................................. 31

6. Troubleshooting and Service Procedures............................................................................ 32

Optional Electrical Module Seal Inspection and Replacement.......................................... 34

QC-100 Alignment Pin Replacement................................................................................. 35

Proximity Sensor Adjustment, Test, or Replacement........................................................ 35

QC-40 Tool Changer with J16 Module........................................................................................ 43

QC-41 Tool Changer with R19 Module....................................................................................... 44

QC-43 Tool Changer..................................................................................................................... 45

QC-60 Tool Changer with K19 Module....................................................................................... 46

QC-71 Tool Changer with G19 Module....................................................................................... 47

QC-100 Tool Changer with T19 and F02 Modules..................................................................... 48

9. Terms and Conditions of Sale................................................................................................ 50

Tool used by the robot to perform a particular function.

1.1 Explanation of Notifications

1.2 General Safety Guidelines

1.3 Safety Precautions

WARNING: Do not perform maintenance or repair on Tool Changer or modules unless

Table 2.1Standard QC Tool Changer Models and Features

2.1 Master Plate Assembly

Master Plate Assembly

Pass-Through Air Ports

2.2 Tool Plate Assembly

Pass Through Air Ports

Tool Plate Assembly

Optional Module Flat B

Harden Stainless Steel

(8) 1/4" NPT Pass-Through Air Ports

Optional Module Flat A

(8) 1/8" NPT

2.3 Master Plate/Tool Plate Locking Mechanism

2.4 Optional Sensor Interface Plate (SIP)

Sensor Interface Plate (SIP)

2.5 Optional Modules

Table 2.2Tool Changer Models and Features

Head of Mounting Fastener Must Be Flush or