Table of Contents. B. Base Utility Coupler...B-4 G2x/G5x Series Utility Couplers with Integrated Compliance...B-4 1. Product Overview...

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1 Table of Contents B. Base Utility Coupler...B-4 G2x/G5x Series Utility Couplers with Integrated Compliance...B-4 1. Product Overview...B G2x/G5x Compliant Utility Coupler Master... B G2x/G5x Utility Coupler Tool... B G2B Utility Coupler... B G2B-CUCM Compliant Utility Coupler Master...B G2B-UCT Utility Coupler Tool...B G2x Utility Coupler... B G2 and 9121-G2A Compliant Utility Coupler Master...B G2-UCT Utility Coupler Tool...B G2E Compliant Utility Coupler... B G2E-CUCM Compliant Utility Coupler Master...B G2E-UCT Utility Coupler Tool...B G5A Compliant Utility Coupler...B G5A Compliant Utility Coupler Master...B G5-UCT Utility Coupler Tool...B G2-GC Drive Cylinders... B Installation...B Utility Coupler Master Installation... B Utility Coupler Master Removal... B Utility Coupler Tool Assembly Installation... B Utility Coupler Tool Assembly Removal... B Electrical Connections... B Pneumatic Connections... B Air Check Ports...B Guided Cylinder Sensor Adjustment Procedure... B Adjust the Sensor Height...B Adjust the Sensor Position...B Operation...B Conditions for Coupling... B Guided Cylinder Dependency... B Conditions for Uncoupling... B-21 B-1

2 4. Maintenance...B Preventive Maintenance... B Clean, Inspect, and Lubricate Thrust Bearings for Utility Couplers... B Pin Block Inspection and Cleaning... B Clear Dust and Debris from Compliance Springs Area... B Troubleshooting and Service Procedures...B Troubleshooting Procedures... B Service Procedures... B Clean, Inspect, Lubricate, Replace Components for G2B Master side Check Port...B Clean, Inspect, Lubricate, Replace Components for G2B Tool side Check Port...B Clean, Inspect, Lubricate, Replace Components for G2, G2A, G2E, and G5A Master Side Check Port...B Replacement of the G2, G2A, G2E, and G5A Tool Side Check Port...B Seal Replacement...B Tool Presence Sensor Replacement for G5A Units...B Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler... B Compliance Spring Replacement for Utility Coupler (Preferred Method)...B Compliance Spring Replacement for Utility Coupler (Alternative Method)...B Center Swivel Replacement for Utility Coupler...B Alignment Pin Replacement...B Serviceable Parts...B Models 9121-G2B-CUCM... B Models 9121-G2-CUCM, 9121-G2A-CUCM, and 9121-G5A-CUCM... B Models 9121-G2E-CUCM... B Models 9121-G2B-UCT... B Models 9121-G2-UCT and 9121-G5-UCT... B Models 9121-G2E-UCT... B Models 9121-G2-GC-B80S100 Guided Cylinder... B Models 9121-G2-GC-B150S150 Guided Cylinder... B Specifications...B-50 B-2

3 8. Drawings...B G2 Compliant Utility Coupler Drawings... B G2 Application Utility Coupler General Dimensions (Shown with Optional DA2 DeviceNet Module)... B G2A Compliant Utility Coupler Drawings... B G2A Application Utility Coupler General Dimensions (Shown with Optional DA2 DeviceNet Module)... B G2B Compliant Utility Coupler Drawings... B G2B Application Utility Coupler with 10 Port Option (Shown with Optional DA2 DeviceNet Module)... B G2E Compliant Utility Coupler Drawings... B G2E Application Utility Coupler General Dimensions (Shown with Optional DR2 DeviceNet Module)... B G5A Utility Coupler Drawings... B G5A Application Utility Coupler General Dimensions (Shown with Optional DA2 DeviceNet Module)... B Guided Cylinder Proximity Sensor Information...B G2-GC-B80S100-SG Guided Cylinder Proximity Sensor... B G2-GC-B80S100-SR Guided Cylinder Proximity Sensor... B G2-GC-B150S150-SG Guided Cylinder Proximity Sensor ( )... B-74 B-3

4 B. Base Utility Coupler G2x/G5x Series Utility Couplers with Integrated Compliance 1. Product Overview The G2x/G5x Utility Coupler is designed for heavy-duty industrial applications. The Utility Coupler provides pass through utilities such as air, fluids, and electrical signals from both integrated ports within the body and standard ATI add-on ledge mounted modules. Consult ATI for further details. Refer to Table 1.1 for Utility Couplers, the Master and Tool assemblies are grouped into compatible modules. The Utility Couplers are comprised of a compliant Master side and Tool side, refer to Figure 1.1. The Master side is equipped with an unique compliance mechanism that allows for large tooling misalignments. The Utility Coupler depends on brute force from the guided cylinder assembly to maintain constant coupling pressure. The recommended operating pressure for the guided cylinder is 80 psi. The unit will work in operating pressures between psi. Part Number 9121-G2-CUCM G2A-CUCM G2-UCT G2B-CUCM G2B-UCT G2E-CUCM SG 9121-G2E-CUCM SG G2E-UCT G5A-CUCM SG 9121-G5-UCT Table 1.1 G2x/G5x Utility Couplers Description Compliant Utility Coupler Master ± 4mm X-Y, 3 Degrees Angular, (2) 3/4" NPT Checked Ports Compliant Utility Coupler Master with (2) 3/4" NPT Checked Ports - SHORT PINS Utility Coupler Tool with (2) 3/4" NPT Ports Compliant Utility Coupler Master, ± 4mm X-Y, 3 Degrees Angular, with (10) ¼ʺ NPT ports Utility Coupler Tool, with (10) 1/4ʺ NPT Ports Compliant Utility Coupler Master with (4) 3/4" NPT Checked Ports, (2) PNP Sensors to Detect Tool Presence Compliant Utility Coupler Master with (4) 3/4 NPT Checked Ports, (2) PNP M12 Quick Disconnect Tool Presence Sensors Utility Coupler Tool with (4) 3/4" NPT Checked Ports Compliant Utility Coupler Master with (2) 1/2" BSPP Checked Ports- SHORT PINS, (2) PNP Sensors Utility Coupler Tool with (2) 1/2" BSPP Ports and Tool Presence Sensor Targets B-4

5 Figure 1.1 G2x/G5x Compliant Utility Coupler with Guided Cylinder Assembly Utility Coupler Master Side (9121-G2-CUCM Shown) Utility Coupler Tool Side (9121-G2-UCT Shown) Guided Cylinder Assembly with Position Sensors (9121-G2-GC-B80S100-SG Shown) 1.1 G2x/G5x Compliant Utility Coupler Master The Master plate assembly includes an anodized aluminum body and hardened stainless-steel alignment pins. The Utility Coupler Master has a center swivel that allows for ± 4 mm compliance in any direction of the coupling plane. Also it allows for ± 3 degrees angular compliance. There are three sets of pre-loaded springs internal to the plate that force the main body to self-center on custom chamfered thrust bearings. This system allows for a relatively large misalignment of the Master and Tool plates prior to coupling. (3) hardened-steel overload pins provide for the compliance limits. The Master plate has built-in features to pass utilities on to the Tool side, in addition the Master and Tool plates are equipped with up to (4) module ledge mount flats that provide support for additional Utility Coupler utility modules. Consult ATI for further details. Figure 1.2 G2x/G5x Compliant Utility Coupler Master Assembly (9121-G2B Shown) Ledge Mounting Feature for Standard ATI Add-on Utility Modules Hardened Stainless Steel Alignment Pins Built in Pass Through Utilities (3) Sets of Preloaded Springs Provide Centering Reliability Anodized Aluminum Body Center Swivel Compliant Interface Mounting Plate (3) Compliance Overload Pins with Custom Self-Centering Thrust Bearings B-5

6 1.2 G2x/G5x Utility Coupler Tool The Tool plate assembly includes an anodized aluminum body and hardened-steel alignment bushings. The Tool plate also includes a 100 mm BC mounting pattern for direct customer tool mounting. The Tool plate has built in features to receive utilities from the Master side. The Tool plates are equipped with up to (4) module ledge mount flats that provide support for additional Utility Coupler utility modules. Consult ATI for further details. Figure 1.3 G2x/G5x Utility Coupler Tool assembly (9121-G2B Shown) Hardened Stainless Steel Alignment Bushings Built in Pass Through Utilities Anodized Aluminum Body Ledge Mounting Feature for Standard ATI Add-on Utility Modules Ports for Pass Through Utilities Circular Mounting Hole Pattern B-6

7 G2B Utility Coupler The Master and Tool bodies are equipped with (2) ledge mount flats that enable the coupler to accept up to (2) additional utility modules. Contact ATI for further details G2B-CUCM Compliant Utility Coupler Master The G2B model provides (10) 1/4ʺ NPT integrated checked ports or (10) 1/4ʺ BSPP integrated checked ports. Refer to Table 1.1 for specific model numbers and compatible Tool models. The Utility Coupler is equipped with standard hardened stainless-steel alignment pins. Figure G2B Compliant Utility Coupler Master 9121-G2B-CUCM Compliant Utility Coupler (2) Standard Alignment Pins Ledge Mounting Feature Flat B (10) 1/4" NPT Ports Ledge Mounting Feature Flat A (10) Integrated Air Checked Ports G2B-UCT Utility Coupler Tool The G2B model provides (10) 1/4ʺ NPT integrated ports. Refer to Table 1.1 for specific model numbers and compatible Master models. Figure G2B Utility Coupler Tool 9121-G2B-UCT Utility Coupler Tool Ledge Mounting Feature Flat A (2) Alignment Bushings (10) 1/4" NPT Ports Ledge Mounting Feature Flat B 100 mm Bolt Circle Mounting Pattern (10) Integrated Air Checked Ports B-7

8 G2x Utility Coupler The Master and Tool bodies are equipped with (4) ledge mount flats that enable the coupler to accept up to (4) additional utility modules. Contact ATI for further details G2 and 9121-G2A Compliant Utility Coupler Master The G2 model provides (2) 3/4ʺ NPT integrated checked ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Tool models. The G2 Utility Coupler is equipped with standard hardened stainless-steel alignment pins and the G2A is equipped with short hardened stainless-steel alignment pins. Figure G2 and 9121-G2A Compliant Utility Coupler Master Ledge Mounting Ledge Mounting Feature Flat D Feature Flat A (2) 3/4" NPT Ports (2) Integrated Air Checked Ports 9121-G2-CUCM Compliant Utility Coupler Ledge Mounting Feature Flat B Ledge Mounting Feature Flat C (2) 3/4" NPT Plugs (2) Standard Alignment Pins Ledge Mounting Feature Flat A Ledge Mounting Feature Flat D (2) 3/4" NPT Ports (2) Integrated Air Checked Ports 9121-G2A-CUCM Compliant Utility Coupler Ledge Mounting Feature Flat B (2) Short Alignment Pins Ledge Mounting Feature Flat C (2) 3/4" NPT Plugs B-8

9 G2-UCT Utility Coupler Tool The G2-UCT model provides (2) 3/4ʺ NPT integrated ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Master models. Figure G2-UCT Utility Coupler Tool 9121-G2-UCT Utility Coupler Tool Ledge Mounting Feature Flat D (2) Alignment Bushing Ledge Mounting Feature Flat C (2) 3/4" NPT Port (2) Integrated Air Checked Port 100 mm Bolt Circle Mounting Pattern Ledge Mounting Feature Flat A Ledge Mounting Feature Flat B (2) 3/4" NPT Plug (Not Shown) B-9

10 G2E Compliant Utility Coupler The Master and Tool bodies are equipped with (4) ledge mount flats that enable the coupler to accept up to (4) additional utility modules. Contact ATI for further details G2E-CUCM Compliant Utility Coupler Master The G2E model provides (4) 3/4ʺ NPT integrated checked ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Tool models. The Utility Coupler is equipped with standard hardened stainless-steel alignment pins. The 9121-G2E-CUCM SG model has integrated PNP sensors to detect Tool presence. Figure G2E-CUCM Compliant Utility Coupler Master 9121-G2E-CUCM Compliant Utility Coupler Ledge Mounting Feature Flat D Ledge Mounting Feature Flat A (4) 3/4" NPT Ports PNP Tool Presence Sensor Ledge Mounting Feature Flat C PNP Tool Presence Sensor Ledge Mounting Feature Flat B (2) Standard Alignment Pins (4) Integrated Air Checked Ports G2E-UCT Utility Coupler Tool The G2E-UCT model provides (4) 3/4ʺ NPT integrated ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Master models. The Tool has integrated present sensor targets. Figure G2E-UCT Utility Coupler Tool 9121-G2E-UCT Utility Coupler Tool Ledge Mounting Feature Flat B (4) Integrated Air Checked Port (2) Alignment Bushing (2) 3/4" NPT Ports Ledge Mounting Feature Flat A (2) Present Sensor Target Ledge Mounting Feature Flat D 100 mm Bolt Circle Mounting Pattern Ledge Mounting Feature Flat C B-10

11 G5A Compliant Utility Coupler The Master and Tool bodies are equipped with (2) ledge mount flats that enable the coupler to accept up to (2) additional utility modules. Contact ATI for further details G5A Compliant Utility Coupler Master The G5A model provides (2) G 1/2ʺ BSPP integrated checked ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Tool models. The Utility Coupler is equipped with short hardened stainless-steel alignment pins and integrated PNP sensors to detect Tool presence. Figure G5A Compliant Utility Coupler Master 9121-G5A Compliant Utility Coupler Ledge Mounting Feature Flat B PNP Tool Presence Sensor (2) G 1/2" BSPP Ports Ledge Mounting Feature Flat C Cable Channel (2) G 1/2" BSPP Plugs (Not Visible) Ledge Mounting Feature Flat D (2) Short Alignment Pins Ledge Mounting Feature Flat A (2) Integrated Air Checked Ports PNP Tool Presence Sensor G5-UCT Utility Coupler Tool The G5-UCT model provides (2) G 1/2ʺ BSPP integrated ports and (4) ledge mounting flats. Refer to Table 1.1 for specific model numbers and compatible Master models. The Tool has integrated present sensor targets. Figure G5-UCT Utility Coupler Tool 9121-G5-UCT Utility Coupler Tool Ledge Mounting Feature Flat B (2) Integrated Air Checked Port (2) Alignment Bushing (2) G 1/2" BSPP Ports Ledge Mounting Feature Flat A (2) Present Sensor Target (2) G 1/2" BSPP Plug (Not Shown) Ledge Mounting Feature Flat D Ledge Mounting Feature Flat C 100 mm Bolt Circle Mounting Pattern B-11

12 G2-GC Drive Cylinders Certain drive cylinders may not be compatible with all Utility Couplers refer to Table 1.2 for available drive cylinders and compatible Utility Couplers. The use of additional utility modules, utility supply line flexibility, and other factors will affect the selection of the drive cylinder. Consult ATI for proper drive cylinder selection. Part Number 9121-G2-GC-B150S150-SG 9121-G2-GC-B80S100-S0, SG, & SR Table G2-GC Drive Cylinder Models and Compatibility Description Guided Cylinder Assembly 150 mm Bore 150 mm Stroke PNP Prox Sensor to Detect Retract Position Guided Cylinder Assembly 80 mm Bore 100 mm Stroke PNP Prox Sensors Compatible with Utility Coupler Models G2E G2, G2A, G2B, G5A B-12

13 2. Installation The G2x/G5x Utility Coupler and add-on modules are typically installed by ATI prior to shipment. The steps below outline the field installation or removal of the Master and drive cylinder. WARNING: Do not perform maintenance or repairs on Utility Coupler or modules unless all energized circuits (e.g. electrical, air, water, etc.) are turned off, pressurized connections purged, and power discharged from circuits in accordance with the customer s safety practices and policies. Injury or equipment damage can occur with energized circuits on. Turn off and discharge all energized circuits, purge all pressurized connections, and verify all energized circuits are de-energized before performing maintenance or repair on Utility Coupler or modules. CAUTION: Do not use fasteners that exceed the thread depth in the Utility Coupler. Refer to Section 8 Drawings for details on mounting hole thread depth. Secure the Utility Coupler with the proper length fasteners. This is true for both robot and tool interfaces. CAUTION: Do not use fasteners with pre-applied adhesive more than once. Fasteners might become loose and cause equipment damage. Always apply new thread locker when reusing fasteners. 2.1 Utility Coupler Master Installation The compliant Utility Coupler Master assembly is normally attached to the guided drive cylinder. The Master plate is designed with a rectangular mounting pattern to accommodate (4) M8 socket head cap screws. Tools Required: 6 mm Allen wrench, Torque wrench Supplies Required: Clean rag, Loctite 242 (if fasteners do not have pre-applied adhesive) 1. Attach the Utility Coupler Master assembly to the drive cylinder. Align the Master assembly using the dowels in the drive cylinder mounting plate. 2. Secure the Master assembly using the (4) M8 x 35 mm socket head cap screws using a 6 mm Allen wrench. Tighten to 280 in-lbs (31.64 Nm). Note: If fasteners do not have pre-applied thread locker, apply Loctite If add-on modules have not been installed, refer to the module manual for installation instructions. 4. Attach the hoses to the Master body and drive cylinder as required. 5. Power, signal, and sensor cables can be connected to the module and drive cylinder after attaching the module to the Utility Coupler. Ensure that the connectors are cleaned prior to being secured as appropriate. 6. After installation is complete, Master assembly may be put into normal operation. B-13

14 Figure 2.1 Utility Coupler Master Installation Electrical Connections Add-on Module (9121-DA2-M Shown) Utility Coupler Master Side (9121-G2-CUCM Shown) Sensor Connections (4) M8 x 35 mm Socket Head Cap Screws (with Pre-applied Thread Locker) Pnuematic Connections Guided Cylinder Assembly with Position Sensors (9121-G2-GC-B80S100-SG Shown) 2.2 Utility Coupler Master Removal The compliant Utility Coupler Master assembly is normally attached to the guided drive cylinder. The Master plate is designed with a rectangular mounting pattern to accommodate (4) M8 socket head cap screws. Tools Required: 6 mm Allen wrench 1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates. 2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Depending upon the service or repair being done, the customer connections may or may not need to be disconnected. Remove customer connection as required. 4. Remove the (4) M8 x 35 mm socket head cap screws securing the Master assembly to the drive cylinder using a 6 mm Allen wrench and remove the Master assembly. B-14

15 2.3 Utility Coupler Tool Assembly Installation The Tool plate is attached to a customer-supplied fixture. The Tool plate is designed with a 100 mm mounting pattern for (6) M10 socket head cap screws and (2) dowel holes. These features are used to accurately position and secure the Utility Coupler Tooling. Tools Required: 8 mm Allen wrench, Torque wrench Supplies Required: Clean rag, Loctite 242 (if fasteners do not have pre-applied adhesive) 1. Attach the Utility Coupler Tool assembly to the customer supplied fixture using customer supplied fasteners. Note: Fasteners must be grade 12.9 with pre-applied adhesive, if not using pre-applied adhesive, apply Loctite 242 to fasteners. Tighten fasteners to 400 in-lbs (45.19 Nm). 2. If add-on modules have not been installed, refer to the module manual for installation instructions. 3. Attach the hoses to the Tool plate as required. 4. Power and signal cables can be connected to the modules after attaching the module to the Utility Coupler Tool. Ensure that the connectors are cleaned prior to being secured as appropriate. 5. After installation is complete, Tool assembly may be put into normal operation. Figure 2.2 Utility Coupler Tool Installation Electrical Connections Add-on Module (9121-DA2-T Shown) Customer Supplied Interface Plate Utility Coupler Tool Assembly (9121-GL2-UCT Shown) User Supplied M10 Fasteners Pneumatic Connections 2.4 Utility Coupler Tool Assembly Removal Tools Required: 8 mm Allen wrench 1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates. 2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Depending upon the service or repair being done, the customer connections may or may not need to be disconnected. Remove customer connection as required. 4. Remove the (6) M10 socket head cap screws securing the Tool assembly to the customer supplied fixture using a 8 mm Allen wrench and remove Tool assembly. B-15

16 2.5 Electrical Connections The Utility Coupler Master utilizes proximity sensors to detect the position of the piston inside the Master body. The type of sensor is specified by the customer at the time of order. Sensors should be selected to work with the controls used on the customer s equipment. Available sensors include DC PNP sourcing and NPN sinking. The DC sensors operate at a nominal 24 volts (check the labels attached to the installed sensors prior to connecting to any control circuit). Regardless of sensor type specified, ALL sensors must be installed in series with a resistive load to limit current flow. The figures below show the connections for the DC sensors. Figure 2.3 PNP and NPN Sensors B-16

17 2.6 Pneumatic Connections The air supply used for coupling and uncoupling the device should be clean, dry, and non-lubricated. A supply pressure in the range of psi is acceptable for operation of the guided cylinder and the Utility Coupler, with a setting of 80 psi suggested. The air should be filtered 50 micron or better Air Check Ports Prior to pressurization, verify that the checked port pistons on the Master side are seated flush as in Figure 2.5. By design they are self-centering, and as a result have the ability to swivel inside their housings. If a piston is swiveled like in Figure 2.4, then pressure is supplied to the port and the port will leak until the unit is actually coupled. Once the unit is coupled the first time, the swivel is corrected and no leakage occurs. Figure 2.4 Check Port Pistons Swiveled Figure 2.5 Check Port Pistons Flush B-17

18 2.7 Guided Cylinder Sensor Adjustment Procedure The sensors for the guided cylinder assembly are supplied pre-adjusted to detect the fully retracted and fully extended states. The sensor is adjusted to be 0.2ʺ to 0.25ʺ away from the top of the fastener. For wiring information refer to Section 9 Guided Cylinder Proximity Sensor Information. To adjust the sensors height or position: Adjust the Sensor Height Tools Required: 2 mm Allen wrench, torque wrench Supplies Required: Loctite 222 To adjust the sensor distance from the target on the Guided Cylinder assembly, complete the following steps: 1. Loosen the M4 set screws using a 2 mm Allen wrench. 2. Adjust the sensor distance by rotating it. The optimal distance from the sensor to the target is 0.2 to 0.25ʺ (5 to 6.35 mm). 3. Apply Loctite 222 to the M4 set screws and tighten to 10 in-lbs (1.13 Nm) using a 2mm Allen wrench. Figure 2.6 Guided Cylinder Sensor Adjustment M5 Set Screw Sensor M4 Set Screw Rail Sensor Mount " ( mm) Target Adjust the Sensor Position Tools Required: 2.5 mm Allen wrench, torque wrench Supplies Required: Loctite 222 You can adjust the sensors using a rail on the Guided Cylinder assembly. To adjust the sensor position, complete the following steps: 1. Loosen the (2) M5 set screws on the sensor mounts using a 2.5 mm Allen wrench. 2. Adjust the sensor position by sliding the sensor holder along the rail. 3. Apply Loctite 222 to the M5 set screws and tighten to 20 in-lbs (2.26 Nm) using a 2.5 mm Allen wrench. B-18

19 3. Operation The Master coupling plate is pneumatically-driven to couple and uncouple with the Tool side plate. The Master plate is driven by a guided cylinder assembly. WARNING: During operation, the area between the Master and Tool must be kept clear. Failure to keep area clear will result in damage to Utility Coupler, add-on modules, or end-ofarm tooling and could cause injury to personnel. WARNING: During operation, the area between the driver cylinder mounting plate and body must be kept clear. Failure to keep area clear will result in damage to drive cylinder or could cause injury to personnel. 3.1 Conditions for Coupling Position the Tool to within the extendable reach of the Master and move the Master into coupling position. The mating surfaces of the Master and Tool should be parallel and not touching. Make sure that the tapered alignment pins from the Master side enter the alignment bushings on the Tool side. The alignment pins should be relatively concentric with the alignment holes such that they do not rub against the edge. For some applications, cylinder stroke proximity sensing is included, providing the ability to sense cylinder retracted and extended states. The target for the cylinder and proximity sensors face on the Master housing must be positioned within approximately 5 mm of each other for the sensor to detect target. A signal is not required to couple the Master and Tool but is recommended as further confirmation of coupling. CAUTION: The guided cylinder must be in the retracted position when attempting to couple the device. Failure to adhere to this condition may result in damage to the unit and/or the machine. CAUTION: Never couple or uncouple the unit without first disconnecting and discharging the power that passes through the contacts. This is especially true if high voltage circuits are involved. Arcing and contact damage will occur if this is not observed. Always disconnect and discharge electrical power from both upstream and downstream modules. CAUTION: Since the system may not have a secondary locking mechanism, it is critical to the operation of the coupler that cylinder pressure is maintained at all times during operation. 3.2 Guided Cylinder Dependency If the Utility coupler is not equipped with a locking mechanism and the air supply is lost to the Guided Cylinder, the Utility Coupler will uncouple. A separation between the Master and Tool plates occurs just after air loss and the utilities will disconnect because the integrated air ports have check valve features that react against the force of the guided cylinder in a manner that will pry the Master and Tool apart. CAUTION: Drive cylinders can exert thousands of pounds of coupling force. Care is needed to accommodate these coupling forces in the design of the mating customer fixture. B-19

20 Figure 3.1 shows the resistance force on the 3/4ʺ checked valve ports corresponding to line pressure. For example, for the 2-port Utility Coupler, such as G2 and G2A, the resistance force of the ports, if they are pressurized to 60 psi, is 400 lbs. For the G2E 4-port coupler, the resistance force at 60 psi is 800 lbs. It is recommended that drive unit be sized with ample factor of safety to handle these resistance forces from the ports. Also, remember to consider what additional utilities are being passed on optional modules, and consider at what pressure the drive cylinder will be operated. Figure 3.1 Resistance Force on the ¾ʺ Checked Valve Ports Corresponding to Line Pressure Figure 3.2 shows the maximum recommended line pressure for the (2) checked air lines when plotted against the cylinder line pressure. This is for applications that use the G2-port coupler with the 9121-G2- GC-B80 drive cylinder. For example, if the cylinder is pressurized to 80 psi, the max line pressure is approximately 115 psi. Figure 3.2 Maximum Line Pressure for Two Checked Air Line Against Cylinder Line Pressure B-20

21 Figure 3.3 shows the maximum recommended line pressure for the (4) checked air lines when plotted against the cylinder line pressure. This is for applications that use the G2E 4-port coupler with the 9121-G2- GC-B150 drive cylinder. For example, if the cylinder is pressurized to 80 psi, the max line pressure is approximately 200 psi. Since the checked port max line pressure is rated for 100 psi, this gives a factor of safety of 2. Figure 3.3 Maximum Line Pressure for Four Checked Air Line Against Cylinder Line Pressure If your application requires a redundant fail-safe feature, please consult ATI and ask about our standard line of Quick Change Tool Changers. ATI s patented Quick Change 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 reestablished to the Lock port. 3.3 Conditions for Uncoupling The Utility Coupler should be positioned in the same location as that when coupling took place. After the Utility coupler is in the proper location air must be supplied to the unlock side of the drive cylinder to uncouple the Master and Tool sides. B-21

22 4. Maintenance The G2x/G5x Compliant Utility Coupler is designed to provide a long life with little maintenance required. A visual inspection and maintenance schedule is provided in Section 4.1 Preventive Maintenance. Assembly details are provided in Section 8 Drawings of this manual. WARNING: Do not perform maintenance or repairs on Utility Coupler or modules unless all energized circuits (e.g. electrical, air, water, etc.) are turned off, pressurized connections purged, and power discharged from circuits in accordance with the customer s safety practices and policies. Injury or equipment damage can occur with energized circuits on. Turn off and discharge all energized circuits, purge all pressurized connections, and verify all energized circuits are de-energized before performing maintenance or repair on Utility Coupler or modules. 4.1 Preventive Maintenance The preventive maintenance schedule is based on a general use application with a tool change frequency of less than one per minute. More frequent tool changes or dirty environments will require an increased frequency of the inspection schedule. Table 4.1 Maintenance Schedule Weekly Monthly 6 Months Checklist Thrust Bearings, Compression Springs, Alignment Pins and Bushings, refer to: Section 4.2 Clean, Inspect, and Lubricate Thrust Bearings for Utility Couplers. гг Clean and lubricate bronze thrust bearing in Master body. гг Inspect /Test compliance springs in Master body. гг Inspect alignment pins for wear or damage and proper lubrication in Master body. гг Inspect alignment bushing in Tool body. Pin Blocks, Electrical Contacts, and V-ring seals, refer to Section 4.3 Pin Block Inspection and Cleaning. гг Clean, and inspect pin block and electrical contacts for wear or damage in Master and Tool bodies. гг Inspect V-ring seals on the Master add-on modules, if worn or damaged replace, refer to Section Seal Replacement. Mounting Fasteners and Interface Connections in the Master and Tool Modules гг Inspect mounting fasteners to verify they are tight and if loose, then tighten to the proper torque. гг гг Cable connections should be inspected during maintenance periods to ensure they are secure. Loose connections should be cleaned and tightened as appropriate. Inspect cable sheathing for damage, repair or replace damaged cabling. Loose connections or damaged cabling are not expected and may indicate improper routing and/or strain relieving. Clean Compliance Springs in the Master гг Clean compliance spring area, refer to Section 4.4 Clear Dust and Debris from Compliance Springs Area. Check Ports and Pass Through ports гг Clean, Inspect and Lubricate Check Port seals and components in the Master and Tool bodies. Refer to Section Clean, Inspect, Lubricate, Replace Components for G2B Master side Check Port, Section Clean, Inspect, Lubricate, Replace Components for G2B Tool side Check Port, Section Clean, Inspect, Lubricate, Replace Components for G2, G2A, G2E, and G5A Master Side Check Port, and Section Replacement of the G2, G2A, G2E, and G5A Tool Side Check Port. B-22

23 4.2 Clean, Inspect, and Lubricate Thrust Bearings for Utility Couplers Supplies Required: Cotton swabs, clean rag, MobilGrease XHP222 Special Grease 1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates. 2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Press on Utility Coupler Master to compress the springs and expose the bronze thrust bearing. Note: This also tests the compliance springs, if springs do not return the Master to the neutral position replace springs. Refer to Section Compliance Spring Replacement for Utility Coupler (Preferred Method). Figure 4.1 Press on Utility Coupler Master Press on Utility Couper Master Cotton Swab Thrust Bearing 4. With the thrust bearing exposed from pressing on the Master plate, remove all the grease from the (3) thrust bearings with a cotton swab or clean rag. 5. Inspect the thrust bearings. If thrust bearing is not worn, apply MobilGrease XHP222 Special grease to thrust bearings chamfered edge. If thrust bearing or other components are worn, replace worn components. Refer to Section Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler. 6. Inspect the (2) alignment pins in the Master body for wear or damage. If pins are not worn, apply MobilGrease XHP222 Special grease to alignment pins. If pins are worn or damaged, replace. Refer to Section Alignment Pin Replacement. 7. If repairs are complete, return circuits to normal operation. B-23

24 4.3 Pin Block Inspection and Cleaning Tools required: Nylon Brush (ATI Part Number ) 1. Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 4. Inspect the Master and Tool pin blocks for any debris or darkened pins. Figure 4.2 Inspect Master and Tool Pin Blocks Note: Pin blocks shown are for illustration purposes only. Blackened Pins Weld Debris Tool Module Pin Block Master Module Pin Block 5. If debris or darkened pins exist, remove debris using a vacuum and clean using a nylon brush (ATI Part Number ). NOTICE: Do not use an abrasive media, cleaners, or solvents to clean the contact pins. Using abrasive media, cleaners, or solvents will cause damage to the contact surface or cause pins to stick. Clean contact surfaces with a vacuum or non-abrasive media such as a nylon brush (ATI Part Number ) Figure 4.3 Clean Pin Blocks with a Nylon Brush 6. Inspect the Master and Tool pin blocks for stuck pins or pin block damage. Figure 4.4 Stuck Pin and Pin Block Damage Note: Pin blocks shown are for illustration purposes only. Stuck Pins Pin Block Damage 7. If stuck pins or pin block damage exists, contact ATI for possible pin replacement procedures or module replacement. 8. After the procedure is complete, resume normal operation. B-24

25 4.4 Clear Dust and Debris from Compliance Springs Area Supplies Required: Compressed air, Clean rag 1. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 2. Clear dust and debris out of spring compliance area by blowing with compressed air in the gap between the interface plate and the Utility Coupler body or the compliance assembly, as shown in Figure Wipe off unit with a clean rag. 4. If repairs are complete, return circuits to normal operation. Figure 4.5 Clear Dust and Debris from Compliance Springs Interface Plate Blow Compressed Air in Gap Between Interface Plate and Utility Coupler Body Utility Coupler Body B-25

26 5. Troubleshooting and Service Procedures The following section provides troubleshooting and service information to help diagnose conditions and repair the Utility Coupler or control/signal module. WARNING: Do not perform maintenance or repairs on Utility Coupler or modules unless all energized circuits (e.g. electrical, air, water, etc.) are turned off, pressurized connections purged, and power discharged from circuits in accordance with the customer s safety practices and policies. Injury or equipment damage can occur with energized circuits on. Turn off and discharge all energized circuits, purge all pressurized connections, and verify all energized circuits are de-energized before performing maintenance or repair on Utility Coupler or modules. CAUTION: Do not use fasteners with pre-applied adhesive more than once. Fasteners might become loose and cause equipment damage. Always apply new thread locker when reusing fasteners. 5.1 Troubleshooting Procedures The troubleshooting table is provided to assist in diagnosing issues that may cause the Utility Coupler not to function properly. Table 5.1 Troubleshooting Symptom Cause Resolution Unit will not Couple Reduced air flow to Tool function Unit is unlocked but Unlock signal does not read on Object trapped between Master, Tool, add-on modules, or drive cylinder body and mounting plate Drive cylinder has improper air supply Drive cylinder not functioning properly Utility Coupler is misaligned beyond the intended specification Object trapped between Master and Tool or between modules Master or Tool side Check port O-ring seals worn or damaged Hose or connector leaking or damage Unlock sensor/cable is damaged. Clear object from between Master, Tool, add-on modules, or drive cylinder Body and mounting plate. Verify the air is supplied at a minimum of 60 psi (4.1 Bar). Refer to Section 2.6 Pneumatic Connections. Ensure that the drive cylinder pneumatic connections are properly secured and not leaking, if leaking repair connection. Verify that cylinder guide rods are moving freely. Clean and lubricate as needed to restore smooth operation. Verify the drive cylinder is not leaking air from rod seals, if leaking repair or replace drive cylinder. Check fixture alignment and make adjustments as necessary. Clear object from between Master and Tool or modules. Inspect O-rings seals, if worn or damaged replace. Refer to Section Clean, Inspect, Lubricate, Replace Components for G2B Master side Check Port, Section Clean, Inspect, Lubricate, Replace Components for G2B Tool side Check Port, Section Clean, Inspect, Lubricate, Replace Components for G2, G2A, G2E, and G5A Master Side Check Port, and Section Replacement of the G2, G2A, G2E, and G5A Tool Side Check Port. Inspect hoses and connectors, if damaged or leaking, repair or replace. Inspect hoses and connectors, if damaged or leaking, repair or replace. B-26

27 Table 5.1 Troubleshooting Symptom Cause Resolution Communications to Tool intermittent or non existent Object trapped between Master and Tool or between modules Debris between contacts, worn or damaged contact pins Cables or connector loose or damage Clear object from between Master and Tool or modules. Inspect V-ring seal for damage, replace damaged seal. Refer to Section Seal Replacement. Inspect pin blocks, refer to Section 4.3 Pin Block Inspection and Cleaning Inspect cables and connectors, if connectors are loose, tighten. If cables are damaged, repair or replace. 5.2 Service Procedures The following service procedures provide instructions for component replacement. Refer to Section 6 Serviceable Parts for seal kit Part Numbers for the specific Utility Coupler model being serviced. Periodically, the condition of the self-sealing valves should be checked. Replace any damaged or degraded components as necessary. Any contamination in or around the mating surfaces of the modules should be removed using a stiff nylon brush. B-27

28 5.2.1 Clean, Inspect, Lubricate, Replace Components for G2B Master side Check Port Parts Required: Refer to Section 6 Serviceable Parts Tools Required: 2.5 mm Allen Wrench, torque wrench Supplies Required: Clean rag, Magnalube G lubricant 1. Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). NOTICE: Debris can be expelled at high velocity during the purge, take all required safety precautions. 4. Purge and disconnect all customer plumbing connections to the module. a. Turn the supply lines off. b. Cover the valves with a rag for safety. c. Manually actuate the module s self-sealing valves to purge the line pressure. Note: Debris can be expelled at high velocity during the purge, take all required safety precautions. 5. Depending on the type of service or repair, connections to the module might also need to be disconnected. 6. Remove the valve stem using a 2.5 mm Allen wrench. Do not strip the hex on the valve stem during removal. 7. Remove the check valve piston and spring. Clean any lubrication from the check valve piston, valve stem, spring, and bore in the module housing using a clean rag. 8. Inspect the valve stem for straightness, and replace, if bent. 9. Inspect the o-rings and u-cup seal on the valve stem and check valve piston for wear and damage. Replace components that are damaged or worn. 10. Inspect the spring in the assembly and replace if damaged or worn. Figure 5.1 Master Self-Sealing Valve Valve Stem 2.5mm Allen Wrench Valve Stem (Inspect) Check Valve Spring (Inspect) O-Ring (Inspect) O-Ring (Inspect) U-Cup Seal (Inspect) O-Ring O-Ring (Face Seal) Check Valve U-Cup Seal Bore in Module Housing (Clean) B-28

29 Valve Stem 11. Lubricate the bore in the module housing with Magnalube G (Teflon/Petroleum based grease). NOTICE: Do not lubricate the O-ring face seal until after installation. Lubricating the O-ring before installation can cause the O-ring to blow out during coupling and uncoupling. 12. If replacing seals, lubricate the valve stem O-ring and the check valve piston U-cup seal with Magnalube G (Teflon/Petroleum based grease). 13. Install the O-ring on the valve stem. 14. Install the U-cup seal on the check valve. Do not get lubrication in the face seal groove in the check valve. 15. Install the non-lubricated O-ring (face seal) into the check valve. 16. Install the spring into the bore in the module housing, seat the check valve on the spring. 17. If the threaded end of the valve stem does not have pre-applied adhesive, apply Loctite 7649 primer and then Loctite 222 or similar thread locker to the threaded end of the valve stem. If the module housing is stainless steel, also add Loctite 7649 primer to the housing threads. Figure 5.2 Master Self-Sealing Valve Installation O-Ring (Lubricate) Check Valve Spring O-Ring (Face Seal) (Lubrication after Installation) U-Cup Seal (Lubricate) Bore in Module Housing (Lubricate) Install U-Cup Seal as Shown 18. Install the valve stem. The check valve piston must be pushed down flush with the mating surface of the Master housing in order to install the threaded end of the valve stem. Do not damage the U-cup seal around the check valve piston. A small, flat-head screwdriver can be used to ensure that the U-cup seal is fully located in the recess and not folded over itself prior to screwing in the valve stem. Tighten the stem to 10 in-lbs (1.1 Nm). 19. Lubricate the installed O-ring (face seal) with Magnalube G (Teflon/Petroleum based grease). 20. After the procedure is complete, resume normal operation. B-29

30 5.2.2 Clean, Inspect, Lubricate, Replace Components for G2B Tool side Check Port Parts Required: Refer to Section 6 Serviceable Parts Tools required: 10 mm Allen wrench, Torque wrench Supplies required: Clean rag, Magnalube G lubricant 1. Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). NOTICE: Debris can be expelled at high velocity during the purge, take all required safety precautions. 4. All customer plumbing connections to the module must be purged. a. Verify that the supply lines are turned off. b. Cover the valves with a rag for safety. c. Manually actuate the self-sealing valves to purge the line pressure. 5. If required disconnect connections to the module. NOTICE: You might need to remove the Tool side module to access the plug. 6. Remove the plug assembly from the bottom of the air module using a 10 mm Allen wrench. 7. Remove the spring and valve assembly from the housing. Figure 5.3 Tool Self-Sealing Valve (Disassembly) 10 mm Allen Wrench Plug Assembly Spring (Inspect) Valve Assembly O-Ring (Inspect) Dowel Pin (Inspect) O-Ring (Inspect) Plug Assembly O-Ring (Lubricate) Valve Assembly O-Ring (Lubricate) Bore in Module Housing (Clean and Lubricate) 8. Clean all lubrication from the plug assembly, valve assembly, spring, and bore in the housing using a clean rag. 9. Inspect the dowel pin that is contained in the plug assembly for straightness. Replace the plug assembly if the dowel pin is bent. 10. Inspect the O-rings on the plug and valve assemblies, replace if worn or damaged. 11. Inspect the spring in the assembly and replace if worn or damaged. B-30

31 12. If replacing the O-rings, lubricate both new O-rings with Magnalube G (Teflon/Petroleum based grease). 13. Install the O-rings on the plug assembly and the valve assembly. Figure 5.4 Tool Self-Sealing Valve (Assembly) Plug Assembly Spring Valve Assembly Torque Wrench O-Ring 10 mm Allen Wrench O-Ring 14. Install the check valve piston, make sure it is seated properly in the housing. 15. Install the spring into the housing, make sure it is installed over the step on the check valve. CAUTION: Do not use excess force when installing the plug assembly into the housing. Using excessive force can damage the O-ring and strip the threads on the plug assembly. Thread the plug assembly into the Tool housing by hand, until several threads are engaged into the housing. Then use a 10 mm Allen wrench to complete the installation. Torque the plug to 30 in-lbs (3.39 Nm). 16. Carefully install the plug assembly aligning the dowel pin into the check valve piston. Thread the plug assembly into the housing by hand until several threads are engaged in the housing. 17. Tighten the plug assembly using a 10 mm Allen wrench to 30 in-lbs. (3.39 Nm). 18. Verify the check valve piston is seated properly in the housing. 19. After the procedure is complete, resume normal operation. B-31

32 5.2.3 Clean, Inspect, Lubricate, Replace Components for G2, G2A, G2E, and G5A Master Side Check Port Parts Required: Refer to Section 6 Serviceable Parts Tools required: Snap ring pliers Supplies required: Clean rag, Magnalube 1. Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). NOTICE: Debris can be expelled at high velocity during the purge, take all required safety precautions. 4. Purge and disconnect all customer plumbing connections to the module. a. Turn the supply lines off. b. Cover the valves with a rag for safety. c. Manually actuate the module s self-sealing valves to purge the line pressure. 5. Remove the retaining ring using snap ring pliers. 6. Remove the valve stem, valve piston and spring, inspect for wear or damage. Replace any worn or damaged components. 7. Remove the O-rings form the valve piston and the valve bore in the housing. 8. Clean the valve bore and internal components with a clean dry rag. Figure 5.5 Master Self-Sealing Valve Retaining Ring Valve Stem O-ring Valve Piston O-ring Spring B-32

33 Figure 5.6 Master Self-Sealing Valve Cross Sectional View O-ring Valve Piston Retaining Ring Valve Stem O-ring Spring 9. Lubricate the replacement O-rings and valve piston with Magnalube. 10. Place the larger O-ring on the seat of the valve bore. 11. Place the smaller O-ring in the groove of the valve piston. 12. Place the spring to the bottom boss of the valve piston, and insert into the valve bore. 13. Place the valve stem in the bore of the housing so that the stem s flange rests on the seat of the housing. The valve piston should be flush with the top rim of the valve stem. 14. Using snap ring pliers, secure the self-sealing valve assembly by installing the retaining ring in the groove of the housing. 15. After the procedure is complete, resume normal operation. B-33

34 5.2.4 Replacement of the G2, G2A, G2E, and G5A Tool Side Check Port Parts Required: Refer to Section 6 Serviceable Parts Tools Required: Spanner wrench (legacy product) or 5 mm Allen wrench (latest product revision) Supplies Required: Clean rag, Magnalube G lubricant, Loctite Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3. Turn off and de-energize all energized circuits, for example, electrical, air, and water. NOTICE: Debris can be expelled at high velocity during the purge; take all required safety precautions. 4. Purge and disconnect all customer plumbing connections to the module. a. Turn the supply lines off. b. Cover the valves with a rag for safety. c. Manually actuate the module s self-sealing valves to purge the line pressure. 5. Use a spanner wrench or 5 mm Allen wrench to remove the valve stem assembly, the valve piston assembly, and spring from the housing. Figure 5.7 Remove Valve Stem Assembly, Valve Piston Assembly, and Spring Valve Stem Valve Stem Assembly Assembly (Legacy Product) (Latest Product Revision) Valve Piston Assembly Spring Valve Piston Assembly Spring 6. Inspect the valve stem, valve piston, and the spring for wear or damage; replace all worn or damaged components. 7. Remove all O-ring and Quad-ring seals from the valve stem and piston assemblies. Figure 5.8 Replace the O-rings and Quad-rings Valve Stem Valve Stem Quad-Ring O-ring O-ring (Face Seal) O-ring (Face Seal) (Lubricate after installation) (Lubricate after installation) Valve Piston Quad-Ring Valve Piston Quad-Ring NOTICE: Do not lubricate the O-ring face seal for the valve piston prior to installation. 8. Lubricate the replacement valve Piston Quad-ring and the valve stem Quad-ring or O-ring. 9. Install the O-ring face seal into the top groove in the valve piston. Then lubricate the O-ring. 10. Clean the check port with a clean dry rag. Assemble the components in the order shown. 11. Apply Loctite 242 on the valve stem s threads. Push down, compressing the spring, and thread the valve stem into the housing. Tighten to 110 in-lbs (12.4 Nm) using a spanner wrench or 5 mm Allen wrench. 12. After the procedure is complete, resume normal operation. B-34

35 5.2.5 Seal Replacement The seal protects the electrical connection between the Master and Tool module. If the seal becomes worn or damaged, it must be replaced. 1. Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 4. To remove the existing seal, pinch the edge of the seal with your fingers and pull the seal away from the pin block on the Master. 5. To install a new seal, stretch the new seal over the shoulder of the pin block. 6. Push the seal hub down against the pin block using your finger tip. 7. After the procedure is complete, resume normal operation. Figure 5.9 V-ring Seal Replacement V-ring Seal Stretch seal over shoulder of pin block and push seal hub down against the pin block with finger tip V-ring Seal Pinch edge of seal with fingers and gently pull away from pin block B-35

36 5.2.6 Tool Presence Sensor Replacement for G5A Units Parts Required: Refer to Section 6 Serviceable Parts Tools Required: 1/2 socket wrench, Torque wrench Supplies Required: Loctite 222 (if fasteners do not have pre-applied adhesive) 1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates. 2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Disconnect the sensor cable, loosening the lock nut using a 1/2 socket wrench, and unscrewing the sensor from the body. 4. Check to be sure the female threads on the housing are free and clear of debris, then thread a new sensor into the tool presence mounting holes until the face of the sensor is flush or 0.010ʺ below flush with the coupling face of the Master assembly. 5. Apply Loctite 222 to the exposed threaded area of the sensor where the lock nut will seat (only this area). 6. Screw the lock nut onto the sensor until it is snug to the Master body using a 1/2 socket wrench. Tighten to 20 in-lbs (2.26 Nm). 7. Connect the sensor cable. 8. If repairs are complete, return circuits to normal operation. Figure 5.10 Tool Presence Sensor Replacement (G5A Shown) B-36

37 5.2.7 Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler Parts Required: Refer to Section 6 Serviceable Parts Tools Required: 6 mm Allen wrench, Torque wrench Supplies Required: Loctite 7649 and 242 (if fasteners do not have pre-applied adhesive), Magnalube G lubricant, Clean rag Remove 1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates. 2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Press on Utility Coupler Master to compress the springs and release the pressure on the thrust bearing, chamfered washer and shoulder bolt. 4. Remove the M12 shoulder bolt using a 6 mm Allen wrench. 5. Remove the chamfered washer and thrust bearing. Note: To remove the thrust bearing may require the use of a flat head screw driver (or similar) to push bearing out from the back side. 6. Clean the housing with a rag to remove grease and debris. Install 7. Apply Loctite Primer 7649 to the threads in the Master body and the threads of the shoulder bolt. 8. Insert the new thrust bearing with the chamfered side facing outward. 9. Apply MobilGrease XHP222 Special grease the chamfered edges of the thrust bearing and the new chamfered washer. 10. Insert the new chamfered washer with the chamfer facing inward. 11. Apply Loctite 242 to the threads of the new shoulder bolt. 12. Press on Utility Coupler Master to compress the springs so that the shoulder bolt will bottom out in the housing and leave the thrust bearing and chamfered washer loose. Figure 5.11 Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement 13. Insert the new shoulder bolt and tighten the new shoulder bolt using 6 mm Allen wrench to 250 in-lbs (28.25 Nm). 14. If repairs are complete, return circuits to normal operation. B-37

38 5.2.8 Compliance Spring Replacement for Utility Coupler (Preferred Method) Note: If environment is dirty or gritty an alternative method may be preferable, refer to Section Compliance Spring Replacement for Utility Coupler (Alternative Method). Parts Required: Refer to Section 6 Serviceable Parts Tools Required: 5/16 Allen wrench Supplies Required: Loctite 222 (if fasteners do not have pre-applied adhesive), Compressed air, Clean rag 1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates. 2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Remove Utility Coupler Master from drive cylinder refer to Section 2.2 Utility Coupler Master Removal. 4. Clear dust and debris out of spring compliance area by blowing with compressed air in the gap between the interface plate and the Utility Coupler body. Figure 5.12 Compliance Springs Replacement 5. Using a 5/16ʺ Allen wrench, remove the compliant preload pusher from the interface plate. 6. Remove the (2) compression springs. 7. Insert (2) new compression springs. 8. Apply Loctite 222 to the threads of the new compliant preload pusher. 9. Using a 5/16ʺ Allen wrench, tighten the compliant preload pusher until it is 0.4ʺ to 0.5ʺ below the face of the interface plate. 10. Install the Utility Coupler Master to the drive cylinder refer to Section 2.1 Utility Coupler Master Installation. 11. If repairs are complete, return circuits to normal operation. B-38

39 5.2.9 Compliance Spring Replacement for Utility Coupler (Alternative Method) Parts Required: Refer to Section 6 Serviceable Parts Tools Required: 6 mm Allen wrench, Torque wrench Supplies Required: Loctite 7649 and 242 (if fasteners do not have pre-applied adhesive), Magnalube G lubricant, Compressed air, Clean rag 1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates. 2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Remove Utility Coupler Master from drive cylinder refer to Section 2.2 Utility Coupler Master Removal. 4. Clear dust and debris out of spring compliance area by blowing with compressed air in the gap between the interface plate and the Utility Coupler body. 5. Remove the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler (Remove). 6. Lift off the Master body to expose the compression springs. Figure 5.13 Compliance Springs Replacement (G2A Shown) (3) Thrust Bearings (3) Chamfered Washers Master Body (3) Shoulder Bolts (6) Compression Springs 7. Replace compression springs as necessary. Note: If an individual compression spring is worn out or broken it is recommended that all compression spring be replaced. 8. Place the Master body on the compliance interface plate, making sure the compression springs are in the proper recesses in the back of the Master body. 9. Replace the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler (Install). 10. Install the Utility Coupler Master to the drive cylinder refer to Section 2.1 Utility Coupler Master Installation. 11. If repairs are complete, return circuits to normal operation. B-39

40 Center Swivel Replacement for Utility Coupler Parts Required: Refer to Section 6 Serviceable Parts Tools Required: 6 mm Allen wrench, 8 mm Allen wrench, Torque wrench Supplies Required: Loctite 7649, 242, and 271 (if fasteners do not have pre-applied adhesive), Magnalube G lubricant, Compressed air, Clean rag 1. Uncouple the Utility Coupler to allow clear access to the Master and Tool plates. 2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). 3. Remove Utility Coupler Master from drive cylinder refer to Section 2.2 Utility Coupler Master Removal. 4. Clear dust and debris out of spring compliance area by blowing with compressed air in the gap between the interface plate and the Utility Coupler body, refer to Section 4.4 Clear Dust and Debris from Compliance Springs Area. 5. Remove the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler (Remove). 6. Lift off the Master body to expose the center pivot. 7. Using a 8 mm Allen wrench, remove the set screw and ball tip set screw. Figure 5.14 Position the Center Swivel (Installed set screw should be below flush) Set Screw Apply Loctite Primer 7649 and then Loctite 271) (Torque to 150 in-lbs) Ball Tip Set Screw (Apply Loctite Primer 7649 and then Loctite 271) Utility Coupler Master (Side Toward the Compliance Plate) Ball Protrusion Seated Position 8. Apply Loctite Primer 7649 and then Loctite 271 to the threads of the new ball tip set screw. 9. Using a 8 mm Allen wrench, install the new ball tip set screw. Position the ball tip set screw so that the ball tip protrudes between.110 and.120 from the surface of the Utility Coupler body. 10. Allow 5 minutes for the Loctite to dry before proceeding to the next step. 11. Apply Loctite Primer 7649 and then Loctite 271 to the threads of the set screw. 12. Using a 8 mm Allen wrench, install the set screw. Tighten to 150 in-lbs (16.95 Nm). 13. Place the Master body on the compliance interface plate, making sure the compression springs are in the proper recesses in the back of the Master body. 14. Replace the (3) shoulder bolts, thrust washers, and chamfered washers, refer to Section Thrust Bearing, Chamfered Washer, and Shoulder Bolt Replacement for Utility Coupler (Install). 15. Install the Utility Coupler Master to the drive cylinder refer to Section 2.1 Utility Coupler Master Installation. 16. If repairs are complete, return circuits to normal operation. B-40

41 Alignment Pin Replacement Parts Required: Refer to Section 6 Serviceable Parts Tools required: 5 mm Allen wrench, Torque wrench Supplies required: Magnalube G lubricant 1. Uncouple the Utility Coupler and space to allow clear access to the Master and Tool. 2. Turn off all energized circuits (e.g., electrical, air, water, etc.) 3. Remove the M6 socket head cap screw using a 5 mm Allen wrench. 4. Remove the alignment pin from the housing. NOTICE: If the alignment pin is difficult to remove, it can be knocked out using a 0.1 diameter pin from the back side of the housing. 5. Insert the new alignment pin into the housing, align the tapped hole in the pin with the M6 screw hole in the housing. Figure 5.15 Alignment Pin Replacement Alignment Pin M6 Socket Head Cap Screw M6 Threaded Hole 6. Secure the alignment pin with the M6 socket head cap screw using a 5 mm Allen wrench, and tighten to 140 in-lbs (15.82 Nm). 7. Apply MobilGrease XHP222 Special grease to the alignment pin. 8. If repairs are complete, return circuits to normal operation. B-41

42 6. Serviceable Parts 6.1 Models 9121-G2B-CUCM Figure 6.1 Master plate Item No. Qty Part Number Description G2B-CUCM-0-0 G2B Compliant Utility Coupler Master with (10) 1/4" NPT ports Steel Compression Spring 2-1/2ʺ L, 5/8ʺ OD Custom SAE 841 Bronze Thrust Bearing Custom Chamfered Washer SHCS Shoulder M12 x 35 Shoulder M10 Thread Rolling Ball Tip Set Screw, Black Oxide Steel M x 9 mm Set Screw, Hollow Hex LONG ½ʺ Dia. Alignment Pin 4 mm Taper Diamond LONG ½ʺ Dia. Alignment Pin 4 mm Taper Round O-Ring 6 mm X 2 mm Buna D Valve Stem, High Strength O-Ring 14 mm X 2 mm Buna Master Check Valve Piston, FA Mini U-Cup Seal 18 mm ID x 22 mm Buna SW-150A Master Fluid / Air Spring SS A M6x16 SHCS, Class 12.9, Blue dyed Magni-565, ND Microspheres Epoxy Steel Spring.845ʺ OD, 2.5ʺ Long 43.4 Rate Compliant IP Preload Pusher A M8x35 SHCS, Class 12.9, Blue dyed Magni-565, ND Microspheres Epoxy Utility Coupler Compliance Kit (Includes item #6,7)(Not Shown) B-42

43 6.2 Models 9121-G2-CUCM, 9121-G2A-CUCM, and 9121-G5A-CUCM Figure 6.2 Master plate Item No. Qty Part Number Description G2-CUCM Compliant Utility Coupler Master with (2) 3/4" NPT Checked Ports G2A-CUCM Compliant Utility Coupler Master with (2) 3/4" NPT Checked Ports - SHORT PINS 1 Compliant Utility Coupler Master with (2) G 1/2 BSPP Checked Ports - SHORT G5A-CUCM SG PINS, and (2) PNP Tool Presence Sensors G5A-CUCM SL Compliant Utility Coupler Master with (2) G 1/2" BSPP Checked Ports - SHORT PINS, and (2) PNP Tool Presence Sensors with LED Cables ¾ʺ NPT Hex Socket Plug, SS (for G2 and G2A models) G 1/2 BSPP Plug, Nickel Plated Brass (for G5A models) Custom SAE 841 Bronze Thrust Bearing Custom Chamfered Washer SHCS Shoulder M12 x 35 Shoulder M10 Thread Rolling Ball Tip Set Screw, Black Oxide Steel M x 9 mm Set Screw, Hollow Hex LONG ½ʺ Dia. Alignment Pin 4 mm Taper Diamond (G2) LONG ½ʺ Dia. Alignment Pin 4 mm Taper Round (G2) Retaining Ring, Internal Inverted (Also See #13) /4ʺ Valve Master Stem /4ʺ Valve Piston GL2CM-SEAL Seal Kit for Master Assembly Check Valve (2 sets of Seals #13 & Rings #10) Steel Compression Spring 2-1/2ʺ L, 5/8ʺ OD Spring, 1.1 inch dia,.586 long, 13 lb/in SS A M6x16 SHCS, Class 12.9, Blue dyed Magni-565, ND Microspheres Epoxy Steel Spring.845ʺ OD, 2.5ʺ Long 43.4 Rate Compliant IP Preload Pusher A M8x35 SHCS, Class 12.9, Blue dyed Magni-565, ND Microspheres Epoxy Utility Coupler Compliance Kit (Includes item #6,7) SHORT ½ʺ Dia. Alignment Pin 4 mm Taper Diamond (G2A, G5A) SHORT ½ʺ Dia. Alignment Pin 4 mm Taper Round (G2A, G5A) B-43

44 6.3 Models 9121-G2E-CUCM Figure 6.3 Master plate Item No. Qty Part Number Description G2E-CUCM Compliant Utility Coupler Master with (4) 3/4 NPT Checked Ports Compliant Utility Coupler Master with (4) 3/4 NPT Checked Ports, (2) G2E-CUCM SG 1 PNP Sensors to Detect Tool Presence G2E-CUCM SG1 Compliant Utility Coupler Master with (4) 3/4 NPT Checked Ports, (2) PNP M12 Quick Disconnect Tool Presence Sensors Utility Coupler Compliance Kit (Includes item #6,7)(Not Shown) Custom SAE 841 Bronze Thrust Bearing Custom Chamfered Washer SHCS Shoulder M12 x 35 Shoulder M10 Thread Rolling Ball Tip Set Screw, Black Oxide Steel M x 9 mm Set Screw, Hollow Hex LONG ½ʺ Dia. Alignment Pin 4 mm Taper Diamond LONG ½ʺ Dia. Alignment Pin 4 mm Taper Round Retaining Ring, Internal Inverted (Also See #13) /4ʺ Valve Master Stem /4ʺ Valve Piston GL2CM-SEAL Seal Kit for Master Assembly Check Valve (2 sets of seals #13 & Retaining rings #10) True 2 PNP Proximity Sensor (SG model) 14 Prox Sensor M8 Barrel M12 Connection, N.O. 3 Wire DC PNP, 4mm Sensing Range (SG1 model) Spring, 1.1 inch dia,.586 long, 13 lb/in SS A M6x16 SHCS, Class 12.9, Blue dyed Magni-565, ND Microspheres Epoxy Steel Compression Spring 2-1/2ʺ L, 5/8ʺ OD Compliant IP Preload Pusher A M8x35 SHCS, Class 12.9, Blue dyed Magni-565, ND Microspheres Epoxy Steel Spring.845ʺ OD, 2.5ʺ Long 43.4 Rate B-44

45 6.4 Models 9121-G2B-UCT Figure 6.4 Tool plate Item No. Qty Part Number Description G2B-UCT-0-0 G2B Utility Coupler Tool with (10) 1/4 NPT Ports O-ring,.669OD x.047 wall, 70D, Buna-N QC-151 Tool Check Valve Piston SW-150A tool Fluid/Air Spring O-ring,.669OD x.047 wall, 70D, Buna-N Plug, F/A Tool (Includes Dowel Pin 1/16 x 3/ Stainless Steel) B-45

46 6.5 Models 9121-G2-UCT and 9121-G5-UCT Figure 6.5 Tool plate Item No. Qty Part Number Description G2-UCT G2 Utility Coupler Tool with (2) 3/4 NPT Ports 1 G5 Utility Coupler Tool with (2) G 1/2 BSPP Checked Ports, Tool Presence G5-UCT Targets /4 NPT Socket Hex Plug, SS (G2 Model) G 1/2 BSPP Plug, Nickel Plated Brass (G5 Model) Spring (Legacy) 3/4ʺ Valve Piston, Tool (Legacy) 3/4ʺ Valve Stem, Tool GL2T-SEAL (Legacy) Seal Kit for Tool Assembly Check Valve (2 sets of seals) /4ʺ Valve Piston, Tool, Conical Seal /4ʺ Valve Stem, Tool, Conical Seal /4 Valve Seal Kit, Tool, Hex Stem B-46

47 6.6 Models 9121-G2E-UCT Figure 6.6 Tool plate Item No. Qty Part Number Description G2E-UCT G2E Utility Coupler Tool with (2) 3/4 NPT Ports Spring (Legacy) 3/4ʺ Valve Piston, Tool (Legacy) 3/4ʺ Valve Stem, Tool GL2T-SEAL (Legacy) Seal Kit for Tool Assembly Check Valve (2 sets of seals) /4ʺ Valve Piston, Tool, Conical Seal /4ʺ Valve Stem, Tool, Conical Seal /4 Valve Seal Kit, Tool, Hex Stem, Blind Thread Housing B-47

48 6.7 Models 9121-G2-GC-B80S100 Guided Cylinder Figure 6.7 Guided Cylinder Item No. Qty Part Number Description G2-GC-B80S100-S0 Guided Cylinder Assembly, 80 mm Bore, 100 mm Stroke, Sensor Holder for 18 mm Barrel Proximity Sensor G2-GC-B80S100-SG G2 Guided Cylinder Assembly with 80 mm Bore, 100 mm Stroke, and PNP Prox Sensors G2-GC-B80S100-SR G2 Guided Cylinder Assembly, 80 mm Bore, 100 mm Stroke, PNP Turck Prox Sensors Modified Guided Cylinder 80 mm Bore (Cylinder Only) /8 NPT Flow Control Prox Sensor 12 mm Sensing Range, 18 mm Barrel 3-wire DC PNP; 2-wire DC PNP/NPN (SG Models) mm Barrel, PNP 3 wire DC Prox (SR Models) C-4EM-4EF-020 Prox Cable, 2 Meter Long, 4 pin Euro (Not Shown) B-48

49 6.8 Models 9121-G2-GC-B150S150 Guided Cylinder Figure 6.8 Guided Cylinder Item No. Qty Part Number Description G2-GC-B150S150-SG Guided Cylinder Assembly, 150 mm Bore, 150 mm Stroke, PNP Proximity Sensor to Detect Retracted Position Triple Rod Cylinder 6ʺ Bore (Cylinder Only) Prox Sensor for Guided Cylinder, PNP, NO, Strokemaster M12 B-49

50 7. Specifications Recommended Max Payload Max. Recommended distance between Master and Tool plate Operating Pressure Weight 1 Table 6.1 Master and Standard Tool plates Total end-effector weight should be supported Not applicable independently of the Utility Coupler TBD psi ( bar) G2 Coupler G2A Coupler G2B Coupler G2E Coupler G5A Coupler **Recommended distance between Master and Tool plate is at least 4 mm less than cylinder stroke length. Locking mechanism supply pressure operating range. Supply to be clean, dry, and filtered to 50 micron or better. Master TBD lbs, (TBD kg) Tool TBD lbs, (TBD kg) Master TBD lbs, (TBD kg) Tool TBD lbs, (TBD kg) Master TBD lbs, (TBD kg) Tool TBD lbs, (TBD kg) Master TBD lbs, (TBD kg) Tool TBD lbs, (TBD kg) Master TBD lbs, (TBD kg) Tool TBD lbs, (TBD kg) *Note: Weights do not include add-on modules or Compliance assembly weight, refer to Compliance Assemblies in this section or specific module manual for weights of add-on modules. Pass through Port, (Qty) Size Mounting Patterns Note: G2 Coupler G2A Coupler G2B Coupler G2E Coupler G5A Coupler See Section 8 Drawings (2) 3/4ʺ NPT Ports (2) 3/4ʺ NPT Ports (10) 1/4ʺ NPT Ports (4) 3/4ʺ NPT Ports (2) G ½ʺ BSPP Ports 1. Weights do not include add-on modules or Compliance assembly weight, refer to Compliance Assemblies in this section or specific module manual for weights of add-on modules. Coupling 80 psi Coupling 80 psi Table 6.2 G2 drive cylinders 620 lbs (2314 N) Axial holding force G2-GC-B lbs (9741 N) Axial holding force G2-GC-B150 B-50

51 8. Drawings 8.1 G2 Compliant Utility Coupler Drawings B.C Flat B Flat C X 10mm Dowel Slip Fit 12mm Tool Side View Flat A 3/4" NPT Air Pass Thru Tool 98.2 Coupled 52.6 Master 3/4" NPT Air Pass Thru Rev. Description Initiator Date ECO 15367; Replaced with , replaced with , replaced with SZJ 3/7/ , added Note 2, and added Magnalube call outs Flat A 4X M8 x 1.25 SHCS 23 Flat D 4X M8 x 1.25 SHCS Flat B Flat D X 10.7 THRU ALL From Other SIde Equally Spaced For M10 SHCS /4" NPT Air Pass Thru 3/4" NPT Air Pass Thru 6mm Slip Fit 6mm Flat C Master Side View Part Numbers: (A) Master: 9121-G2-CUCM (B) Tool: 9121-G2-UCT Notes: 1) Continuous Coupling Force must be maintained in order to keep Master and Tool engaged. NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. DRAWN BY: CHECKED BY: D.Brewer, 2/11/11 DAN, 2/10/11 TITLE PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. G2 Compliant Utility Coupler 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company 3rd ANGLE PROJECTION SCALE SIZE DRAWING NUMBER REVISION :5 B 06 PROJECT # SHEET OF G2 B-51

52 G2 Compliant Utility Coupler Master Assembly Magnalube Magnalube NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION Rev. Description Initiator Date - See Sheet Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company DRAWN BY: D.Brewer, 2/11/11 CHECKED BY: DAN, 2/10/11 PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. TITLE G2 Compliant Utility Coupler SCALE SIZE DRAWING NUMBER REVISION :2 B 06 PROJECT # SHEET OF G2 B-52

53 G2 Compliant Utility Coupler Tool Assembly 6 1 Magnalube Bores Notes: 2. See Manual for replacement parts, including older valve designs which require a spanner wrench for Stem installation. New Stems install with a hex wrench. Magnalube Note 2. 3 Magnalube 5 Magnalube 7 Magnalube Note 2. 8 Note 2. 2 NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION Rev. Description Initiator Date - See Sheet Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company DRAWN BY: D.Brewer, 2/11/11 CHECKED BY: DAN, 2/10/11 PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. TITLE G2 Compliant Utility Coupler SCALE SIZE DRAWING NUMBER REVISION :2 B 06 PROJECT # SHEET OF G2 B-53

54 8.2 G2 Application Utility Coupler General Dimensions (Shown with Optional DA2 DeviceNet Module) DA2 Tool Devicenet Module See DA Recommended Distance to Close TOP VIEW RETRACTED 3/4" NPT 3/4" NPT B.C /4" NPT 141 (2) 10mm Dowel Slip Fit 12mm 6X 10.7 Thru From Other Side Equally Spaced For M10 SHCS 3/4" NPT Note Note 5 TOOL SIDE VIEW 9121-G2-UCT-DA Utility Coupler Tool With (2) Integrated 3/4" NPT Checked Ports 9121-G2-CUCM-DA Compliant Utility Coupler Master With (2) Integrated 3/4" NPT Checked Ports Master Side is Compliant to +/- 4mm Plus 3 Angular Compliance 63.9 Note Note TOP VIEW EXTENDED NOTES: 1. Linear Actuator Unit is Driven by SMC Guided Cylinder Series MGPM 2. For Proper Operation, Cylinder Pressure MUST BE MAINTAINED in order to resist the spring forces in the integrated 3/4" checked Ports. 3. Utility coupler coupling force is approximately 625lbs at 80 psi. Care is needed in designing mating customer fixture. 4. Master side coupler body compresses 2mm - 4mm when coupled. 5. Max Cylinder stroke is 100mm. Recommended Master to Tool spacing is 75mm. 6. Position of cylinder proxes are adjustable once installed DA2 Master Devicenet Module See DA2 Rev. Description Initiator Date 08 ECO 14986; Updated due to new BOM structure SZJ 11/7/ X 10.7 Thru From Other Side For M20 SHCS Plate Thickness X 10mm Dowel Slip Fit, Thru Plate PNP 18mm Prox Note 6 MASTER SIDE VIEW CYLINDER MOUNTING PLATE VIEW 9121-G2-GC-B80S100-SG Linear Actuator Unit See Notes Section 3/8" NPT ROSS Brand Flow Control Y NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. DRAWN BY: CHECKED BY: Dan Norton 1/9/05 D. Swanson, 6/16/05 TITLE ISO VIEW 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. Openrobogate Compliant Utility Coupler X Z 3rd ANGLE PROJECTION SCALE SIZE DRAWING NUMBER REVISION :4 B 08 PROJECT # SHEET OF B-54

55 8.3 G2A Compliant Utility Coupler Drawings Flat A 3/4 NPT Air Pass Thru 45.6 Tool 98.3 Coupled 18.9 Pin 52.6 Master /4 NPT Air Pass Thru Rev. Description Initiator Date 06 ECO 15367; Replaced with , replaced with , replaced with , added Note 2, and added Magalube callouts Flat A SZJ 3/7/2017 4X M8 x 1.25 SHCS 23 B.C. 100 Flat D 4X M8 x 1.25 SHCS Flat B Flat D Flat B 55.7 Flat C 2X 10mm Dowel Slip Fit 12mm 6X 10.7 Thru From Other Side Equally Spaced For M10 SHCS 3/4 NPT Air Pass Thru 3/4 NPT Air Pass Thru 2X 6 Slip Fit 6 Flat C Tool Side View Master Side View Part Numbers: (A) Master: 9121-G2A-CUCM (B) Tool: 9121-G2-UCT Notes: 1. Continuous Coupling Force must be maintained in order to keep Master and Tool engaged. NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. DRAWN BY: CHECKED BY: D Brewer, 2/7/11 DAN, 2/10/11 TITLE 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. G2A Compliant Utility Coupler 3rd ANGLE PROJECTION SCALE SIZE DRAWING NUMBER REVISION :2 B 06 PROJECT # SHEET OF G2A B-55

56 G2A Compliant Utility Coupler Master Assembly Magnalube Magnalube 6 2 NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION Rev. Description Initiator Date - See Sheet Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. TITLE DRAWN BY: D Brewer, 2/7/11 CHECKED BY: DAN, 2/10/11 G2A Compliant Utility Coupler SCALE SIZE DRAWING NUMBER REVISION :5 B 06 PROJECT # SHEET OF G2A B-56

57 1 6 Magnalube Bores Notes: 2. See Manual for replacement parts, including older valve designs which require a spanner wrench for Stem installation. New Stems install with a hex wrench. Magnalube Note 2. 3 Magnalube 5 Magnalube 7 Magnalube Note 2. 8 Note 2. 2 NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION Rev. Description Initiator Date - See Sheet Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. TITLE DRAWN BY: D Brewer, 2/7/11 CHECKED BY: DAN, 2/10/11 G2A Compliant Utility Coupler SCALE SIZE DRAWING NUMBER REVISION :2 B 06 PROJECT # SHEET OF G2A B-57

58 8.4 G2A Application Utility Coupler General Dimensions (Shown with Optional DA2 DeviceNet Module) DA2 Tool Devicenet Module See DA MIN Distance to Close MASTER AND TOOL UNCOUPLED Rev. Description Initiator Date 05 Eco 10908; Update to show ledge mount feature with integrated valve. DA2 Master Devicenet Module See DA2 LJH 4/11/13 06 ECO 11483; Drawing Update ERDO 10/21/ Pin Length 3/4" NPT 3/4" NPT A (2) "Y" Direction Compliance mm Slip Fit 6.4 B.C. 100 DETAIL A SCALE 1 : (2) 10mm Dowel Slip Fit 12mm TOOL SIDE VIEW (6) 10.7 THRU ALL From Other Side Equally Spaced For M10 SHCS 3/4" NPT G2-UCT-D Utility Coupler Tool With (2) Integrated 3/4 NPT Checked Ports NOTES: 1. Utility Coupler required coupling force is approximately 625lbs at 80psi air line pressure. Care is needed in accomodating this force in mating customer fixture. 2. Current Design does not have integrated sensing. 3. Master Side Compliance is accomplished via use of Preloaded Die Springs, and Custom Thrust Bearings. 4. Master and Tool Bodies have (2) Integrated Checked 3/4" NPT Ports to Pass Air Utilities, PLUS (4) Additional Utility Module Mounting Flats. 5. UNIT MUST BOTTOM OUT IN "Z" DIRECTION IN ORDER TO COUPLE 3 Angular Compliance 52.6 MASTER AND TOOL COUPLED 3/4" NPT 2mm-4mm "Z" Direction Compliance (4) 8.7 Thru From Other Side For M8 SHCS Master Side Mounting Pattern 3rd ANGLE PROJECTION 4 "X" Direction Compliance MASTER SIDE VIEW 9121-G2A-CUCM-DA Compliant Utility Coupler Master With (2) Integrated 3/4" NPT Checked Ports Master Side is Compliant to +/- 4mm Plus 3" Angular Compliance NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. DRAWN BY: CHECKED BY: Dan Norton 3/31/06 D. Swanson, 3/31/06 TITLE SCALE SIZE DRAWING NUMBER Y ISO VIEW 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. Compliant Utility Coupler (Lifter Application) :4 B 06 PROJECT # SHEET OF Z X REVISION B-58

59 8.5 G2B Compliant Utility Coupler Drawings B.C Flat B 2X 10 Dowel Slip Fit 8.7 Scale 1: Tool Side View 94.2 Coupled 41.6 Tool 45.2 Pin Flat A X 10.7 Thru From Other Side Equally Spaced For M10 SHCS Part Numbers: (A) Master: 9121-G2B-CUCM-0-0 (B) Tool: 9121-G2B-UCT-0-0 Notes: 1) Continuous Coupling Force must be maintained in order to keep Master and Tool engaged. Rev.Description InitiatorDate 05 ECO 13911; Replaced with , with , and with (Master Center Swivel Bearing Components) SZJ 10/29/ Master X M8 x 1.25 SHCS X M8 x 1.25 SHCS 24 Flat B 130 Flat A X mm Slip Fit 6mm Master Side View NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. DRAWN BY: CHECKED BY: D. Brewer, 2/14/11 D. Norton, 2/14/11 TITLE 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. G2B Compliant Utility Coupler 3rd ANGLE PROJECTION SCALE SIZE DRAWING NUMBER REVISION :2 B 05 PROJECT # SHEET OF G2B B-59

60 G2B Compliant Utility Coupler Master Assembly NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION Rev. Description Initiator Date - See Sheet Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. TITLE DRAWN BY: D. Brewer, 2/14/11 CHECKED BY: D. Norton, 2/14/11 G2B Compliant Utility Coupler SCALE SIZE DRAWING NUMBER REVISION PROJECT # SHEET OF G2B :2 B 05 B-60

61 8 8 G2B Compliant Utility Coupler Tool Assembly NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION Rev. Description Initiator Date - See Sheet Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. TITLE DRAWN BY: D. Brewer, 2/14/11 CHECKED BY: D. Norton, 2/14/11 G2B Compliant Utility Coupler SCALE SIZE DRAWING NUMBER REVISION :2 B 05 PROJECT # SHEET OF G2B B-61

62 8.6 G2B Application Utility Coupler with 10 Port Option (Shown with Optional DA2 DeviceNet Module) TOOL SIDE VIEW TOP VIEW RETRACTED Rev. Description Initiator Date 05 ECO 14986; Updated due to new BOM structure SZJ 11/7/ DA2 Tool Devicenet Module See DA2 75mm Recommended Distance to Close X 10.7 Thru From Other Side For M10 SHCS (2) 10mm Slip Fit 12 (6) 10.7 THRU ALL From Other Side Equally Spaced For M10 SHCS Note Note X 10.7 Thru For M10 SHCS PNP 18mm Prox Note X 10mm Dowel Slip Fit Thru Plate (5) 1/4" NPT Connections (5) 1/4" NPT Connections G2B-UCT-DA2-0 Utility Coupler Tool With DA2, and (10) 1/4" NPT Integrated Checked Air Ports 9121-G2-GC-B80S100-SG Linear Actuator Unit See Notes Section 9121-G2B-CUCM-DA2-0 G2B Compliant Utility Coupler Master DA2, (10) Integrated Checked 1/4" NPT Air Ports, Master Side is Compliant to +/- 4mm Plus 3 Angular Compliance 3/8" NPT ROSS Brand Flow Control (5) 1/4" NPT Connections X DA2 Master Devicenet Module See DA Note 4 NOTES: 1. Drive Cylinder Assembly features SMC Guided Cylinder Series MGPM 2. For Proper Operation, Cylinder Pressure MUST BE MAINTAINED in order to resist the spring forces in the integrated checked Ports. 3. Utility Coupler coupling force is approximately 625lbs at 80 psi. Care is needed in accomodating this force in the mating customer fixture. 4. Master side coupler body compresses 2mm - 4mm when coupled. 5. Max cylinder stroke is 100mm. Recommended Master to Tool spacing is 75mm. 6. Position of cylinder proxes are adjustable once installed Note 5 TOP VIEW EXTENDED NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION DRAWN BY: CHECKED BY: Dan Norton 3/20/07 D. Swanson, 3/20/07 TITLE (5) 1/4" NPT Connections SCALE SIZE DRAWING NUMBER ISO VIEW 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. G2B Compliant Utility Coupler With 10 Port Option :4 B 05 PROJECT # SHEET OF Y Z REVISION B-62

63 8.7 G2E Compliant Utility Coupler Drawings B.C Flat B Scale 1:3 Flat C X 10mm Dowel Slip Fit 12mm Tool Side View 98.2 Coupled Rev.Description InitiatorDate 06 ECO 14949; Replaced with , replaced with , replaced with , and added Note 2. SZJ 11/3/2016 Flat A 3/4" NPT Air Pass Thru 45.6 Tool Master 3/4" NPT Air Pass Thru Flat A 4X M8 x 1.25 SHCS 4X M8 x 1.25 SHCS Flat D Flat B Flat D THRU ALL From Other Side Equally Spaced For M10 SHCS 3/4" NPT Air Pass Thru 3/4" NPT Air Pass Thru 2X 6mm Slip Fit 6mm Flat C Master Side View Part Numbers: (A) Master: 9121-G2E-CUCM SG (B) Tool: 9121-G2E-UCT Notes: 1. Continuous Coupling Force must be maintained in order to keep Master and Tool engaged. NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. DRAWN BY: CHECKED BY: D.Brewer, 2/11/11 DAN, 2/10/11 TITLE 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. G2E Compliant Utility Coupler 3rd ANGLE PROJECTION SCALE SIZE DRAWING NUMBER REVISION :5 B 06 PROJECT # SHEET OF G2E B-63

64 G2E Compliant Utility Coupler Master Assembly Magnalube 19 2 Magnalube NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION Rev. Description Initiator Date - See Sheet Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company DRAWN BY: D.Brewer, 2/11/11 CHECKED BY: DAN, 2/10/11 PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. TITLE G2E Compliant Utility Coupler SCALE SIZE DRAWING NUMBER REVISION :2 B 06 PROJECT # SHEET OF G2E B-64

65 G2E Compliant Utility Coupler Tool Assembly Magnalube Bores Note: 2. See Manual for replacement parts, including older valve designs which require a spanner wrench for Stem installation. New Stems install with a hex wrench. Magnalube Note 2. 8 Magnalube 2 Magnalube 3 Magnalube 1 Note 2. 9 Note 2. NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION Rev. Description Initiator Date - See Sheet Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company DRAWN BY: D.Brewer, 2/11/11 CHECKED BY: DAN, 2/10/11 PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. TITLE G2E Compliant Utility Coupler SCALE SIZE DRAWING NUMBER REVISION :2 B 06 PROJECT # SHEET OF G2E B-65

66 8.8 G2E Application Utility Coupler General Dimensions (Shown with Optional DR2 DeviceNet Module) 6X C'Bored for M10 SHCS 10.4 from other side Equally Spaced 9121-DR2-T See DR DR2-M See DR2 Rev. Description Initiator Date 04 ECO 14986; Updated due to new BOM structure SZJ 11/8/ X 3/4" NPT mm Dowel Slip Fit, 12 (B) 3/4" NPT (A) (C) /4" NPT BC 100 TOOL SIDE MOUNTING VIEW /4" NPT Note 4 125mm 52.6 Max Distance To Close 94.5 TOP VIEW RETRACTED X 20.6 THRU Z Y X ISO VIEW 3/4" NPT Port 2 Ports on Each Side, 4 Ports Total Ports are Checked on Master and Tool Halves Part Numbers: (A) Master: 9121-G2E-CUCM-DR SG (B) Tool: 9121-G2E-UCT-DR (C) Actuator: 9121-G2-GC-B150S150-SG BOTTOM VIEW RETRACTED Prox Sensor Detects Fully Retracted PNP 3 Wire DC NOTES: 1. Linear Actuator Unit is Triple Rod Cylinder 6" Max Stroke, and features a Prox Sensor to detect fully retracted position. Prox is PNP 3 Wire DC. 2. Drive Cylinder exterts approximately 2,200lbs of coupling force at 80 psi. Care is needed to accomodate these coupling forces in the design of the mating customer fixture. 3. For Proper Operation, Cylinder Pressure Must be Maintained in order to resist the spring forces in the integrated 3/4" Checked Ports. 4. Master side coupler body compresses 2mm-4mm when coupled. 5. Max cylinder stroke is 150mm. Recommended MAX Master to Tool Spacing is 125mm. NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION DRAWN BY: CHECKED BY: Dan Norton 3/3/10 KRZ 5/24/10 TITLE PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. G2E Arrangement SCALE SIZE DRAWING NUMBER 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company :4 B 04 PROJECT # SHEET OF REVISION B-66

67 Prox Sensor Detects Cylinder Full Retract See Notes Section Sheet 1 SIDE VIEW WITH CYLINDER EXTENDED Rev. Description Initiator Date - See Sheet /2"NPT Air Supply Extend 1/2"NPT Air Supply Retract Prox Sensor Detects Tool Side Presence ISO VIEW CYLINDER RETRACTED Prox Sensor Detects Tool Side Presence NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. DRAWN BY: CHECKED BY: Dan Norton 3/3/10 KRZ 5/24/10 TITLE PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. G2E Arrangement 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company 3rd ANGLE PROJECTION SCALE SIZE DRAWING NUMBER REVISION :4 B 04 PROJECT # SHEET OF B-67

68 8.9 G5A Utility Coupler Drawings B.C Flat B Scale 1:3 Flat C Flat A (2) 10mm Dowel Slip Fit 12mm Tool Side View 3/4" NPT Air Pass Thru 45.6 Tool Coupled 18.9 Pin 52.6 Master 15.1 Rev. Description Initiator Date ECO 14949; Replaced with , 04 replaced with , replaced SZJ 11/3/ with , and added Note Flat A (4) M8 x 1.25 SHCS 3/4" NPT Air Pass Thru Flat D (4) M8 x 1.25 SHCS Flat D Flat B X 10.7 THRU ALL From Other Side Equally Spaced For M10 SHCS 3/4" NPT Air Pass Thru 3/4" NPT Air Pass Thru (2) 6mm Slip Fit 6mm Flat C Master Side View Part Numbers: (A) Master: 9121-G5A-CUCM SG (B) Tool: 9121-G5-UCT Notes: 1) Continuous Coupling Force must be maintained in order to keep Master and Tool engaged. NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. DRAWN BY: CHECKED BY: D.Brewer, 2/10/11 DAN, 2/10/11 TITLE 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. Compliant G5A Utility Coupler 3rd ANGLE PROJECTION SCALE SIZE DRAWING NUMBER REVISION :5 B 04 PROJECT # SHEET OF G5A B-68

69 G5A Compliant Utility Coupler Master Assembly Magnalube Magnalube NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION Rev. Description Initiator Date - See Sheet Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. TITLE DRAWN BY: D.Brewer, 2/10/11 CHECKED BY: DAN, 2/10/11 Compliant G5A Utility Coupler SCALE SIZE DRAWING NUMBER REVISION :2 B 04 PROJECT # SHEET OF G5A B-69

70 G5A Compliant Utility Coupler Tool Assembly Magnalube Bores 6 3 Magnalube Note 2. 5 Magnalube 4 Magnalube 8 Note 2. Magnalube 7 Note NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. Notes: 2. See Manual for replacement parts, including older valve designs which require a spanner wrench for Stem installation. New Stems install with a hex wrench. 3rd ANGLE PROJECTION Rev. Description Initiator Date - See Sheet Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. TITLE DRAWN BY: D.Brewer, 2/10/11 CHECKED BY: DAN, 2/10/11 Compliant G5A Utility Coupler SCALE SIZE DRAWING NUMBER REVISION :2 B 04 PROJECT # SHEET OF G5A B-70

71 8.10 G5A Application Utility Coupler General Dimensions (Shown with Optional DA2 DeviceNet Module) DA2 Tool Devicenet Module See DA Recommended Distance to Close TOP VIEW RETRACTED 1/2" BSPP DA2 Master Devicenet Module See DA2 Rev. Description Initiator Date 07 ECO 14986; Updated due to new BOM structure SZJ 11/7/ X 10.7 Thru From Other Side For M10 SHCS 1/2" BSPP B.C /2" BSPP 141 (2) 10mm Dowel Slip Fit 12mm TOOL SIDE VIEW 6X 10.7 Thru From Other Side Equally Spaced For M10 SHCS 1/2" BSPP Note Note PNP 18mm Prox Note Plate Thickness MASTER SIDE VIEW X 10mm Dowel Slip Fit, Thru Plate 88.9 Location of Tool Presence Sensor 9121-G5-UCT-DA Utility Coupler Tool With (2) Integrated 1/2" BSPP Checked Ports 9121-G5A-CUCM-DA SG Compliant Utility Coupler Master With (2) Integrated 1/2" BSPP Checked Ports Master Side is Compliant to +/- 4mm Plus 3 Angular Compliance (2) PNP Tool Presence Sensors 64.5 Note Note TOP VIEW EXTENDED NOTES: 1. Linear Actuator Unit is Driven by SMC Guided Cylinder Series MGPM 2. For Proper Operation, Cylinder Pressure MUST BE MAINTAINED in order to resist the spring forces in the integrated checked Ports. 3. Utility Coupler coupling force is approximately 625lbs at 80 psi. Care is needed to accomodate these forces in the design of the mating customer fixture. 4. Master side coupler body compresses 2mm-4mm when coupled. 5. Max cylinder stroke is 100mm. Recommended master to tool spacing is 75mm. 6. Position of cylinder proxes are adjustable once installed. 7. Tool Presence Sensors are Turck PNP 8mm G2-GC-B80S100-SG Linear Actuator Unit See Notes Section (2) 3/8" NPT ROSS Brand Flow Control (2) 3/8" NPT to 3/8" BSPP Adapter NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION DRAWN BY: CHECKED BY: Dan Norton, 6/16/09 D. Swanson, 6/16/09 TITLE ISO VIEW SCALE SIZE DRAWING NUMBER Y Location of Tool Presence Sensor 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. G5 Compliant Utility Coupler, (2) 1/2" BSPP Checked Ports, (2) PNP Tool Presence Sensors :4 B 07 PROJECT # SHEET OF X Z REVISION B-71

72 9. Guided Cylinder Proximity Sensor Information G2-GC-B80S100-SG Guided Cylinder Proximity Sensor IGS209 IGKC012-ASKG/M/US Inductive sensor Metal thread M18 x 1 Connector Operation as 3-wire or 2-wire possible Increased sensing range Optical setting aid (2 LED) gold-plated contacts Sensing range 12 mm [nf] non-flush mountable Electrical design Output 3-wire DC PNP; 2-wire DC PNP/NPN normally open Made in Germany Operating voltage [V] DC Current rating [ma] 100 Minimum load current [ma] 2 *) Short-circuit protection pulsed Reverse polarity protection yes Overload protection yes Overload protection yes Voltage drop [V] < 2.8 Leakage current [ma] < 0.5 *) Current consumption [ma] < 12 (24 V) Real sensing range [mm] 12 ± 10 % Operating distance [mm] Switch-point drift [% of Sr] Hysteresis [% of Sr] Switching frequency [Hz] 300 Correction factors mild steel = 1 / stainless steel approx. 0.7 / brass approx. 0.5 / Al approx. 0.4 / Cu approx. 0.3 Ambient temperature [ C] Protection IP 67, II EMC EN ESD: 4 kv CD / 8 kv AD EN HF radiated: 10 V/m ( MHz) EN Burst: 2 kv EN HF conducted: 10 V ( MHz) EN 55011: class B Housing materials brass white bronze coated; active face: PBT (Pocan) Function display Switching status LED yellow (4 x 90 ) Setting aid LED red Connection M12 connector; gold-plated contacts Weight [kg] Remarks suitable for PLC type 1 according to IEC *) only in 2-wire operation Accessories (included) 2 lock nuts Wiring B-72

73 G2-GC-B80S100-SR Guided Cylinder Proximity Sensor B-73