Table of Contents. D. Air Modules...D-2 PV Series...D-2 1. Product Overview...D-2 2. Installation...D-5

Transcription

1 Table of Contents D. Air Modules...D-2 PV Series...D-2 1. Product Overview...D-2 2. Installation...D Master Module Installation... D Installing the PV1, PV2, and PV3 Master Modules... D Removing the PV1, PV2, and PV3 Master Modules... D Installing the PV4, PV5, and PV6 Master Modules... D Removing the PV4, PV5, and PV6 Master Modules... D Tool Module Installation... D Installing the PV Series Tool Modules... D Removing the PV Series Tool Modules... D-9 3. Operation...D-9 4. Maintenance...D Troubleshooting and Service Procedures...D Troubleshooting Procedures...D Service Procedures... D Master Side Self-Sealing Valve... D Rubber Bushing and Collar Replacement... D V-Ring Seal Replacement... D Serviceable Parts...D PV1, PV2, and PV3 Master Module Mounting Hardware... D PV4, PV5, and PV6 Master Module Mounting Hardware... D PV1, PV2, PV3, and PV6 Tool Module Mounting Hardware... D PV4 and PV5 Tool Module Mounting Hardware... D Specifications...D Drawings...D PV1 (PV3 is similar but has NPT ports)... D PV2... D PV4... D PV5... D PV6... D-24 D-1

2 D. Air Modules PV Series 1. Product Overview Air modules provide air and vacuum services when attached to the Master and Tool plates. When the Tool Changer is coupled, the Master module passes the air supply to the Tool module for use by the customer tooling. Significant forces are encountered when using these modules. Assistance from the robot may be required to overcome these forces when coupling the Tool Changer. NOTICE: The PV1, PV2, and PV3 Master modules contain self-sealing valves. Do not use self-sealing valves for vacuum utility. Depending on the model, the Master module contains self-sealing valves, which prevent air circuits from discharging and eliminate the need to close those circuits upstream. The Tool modules contain pass-through ports. Unlike self-sealing valves, pass-through ports release the air when the Tool Changer is uncoupled. Before uncoupling the Tool Changer, turn off the air pressure or supply for the pass-through ports. Refer to Figure 1.1, Figure 1.2, Figure 1.3, Figure 1.4, and the following table for services that are provided by different modules. Module Table 1.1 PV Series Vacuum and Air Modules Description Master Tool (2) G 3/8 (BSPP) self-sealing ports (S1, S2) 2) G 3/8 (BSPP) self-sealing ports (S1, S2) PV1 PV2 PV3 (2) G 3/8 (BSPP) pass-through air/vacuum ports (P1, P2) (2) G 3/4 (BSPP) vacuum ports (V1, V2) (2) G 3/8 (BSPP) self-sealing air ports (S1, S2) (6) G 3/8 (BSPP) pass-through air/vacuum ports (P1 - P6) (2) 3/8 NPT self-sealing air ports (S1, S2) (2) 3/8 NPT pass-through air/vacuum ports (P1, P2) (2) G 3/8 (BSPP) pass-through air/vacuum ports (P1, P2) (2) G 3/4 (BSPP) vacuum ports (V1, V2) (8) G 3/8 (BSPP) pass-through air/vacuum ports (S1, S2, P1 - P6) (2) 3/8 NPT self-sealing air ports (S1, S2) (2) 3/8 NPT pass-through air/vacuum ports (P1, P2) (2) 3/4 NPT vacuum ports (V1, V2) (2) 3/4 NPT vacuum ports (V1, V2) PV4 (8) 3/8 NPT pass-through air/vacuum ports (P1 - P8) PV5 (8) G 3/8 (BSPP) pass-through air/vacuum ports (P1 - P8) PV6 (12) G 1/4 (BSPP) pass-through air/vacuum ports (P1 - P12) axial connections. D-2

3 Figure 1.1 PV1 and PV3 Vacuum/Air Modules (The PV1 modules shown. The PV3 modules are similar but have NPT ports) P1 and P2, G 3/8 pass-through port connection for air/vacuum service S1 and S2, G 3/8 checked port connection for air service PV1 Master Module (2) Self-Sealing Port (2) Pass-Through Port with a Rubber Bushing and Collar V1 and V2 G 3/4 (BSPP) pass-through port connections for vacuum service (2) Vacuum Port and V-ring Seal (4) Pass-Through Port Common Mounting Feature S1 and S2, G 3/8 pass-through port connection for air service P1 and P2, G 3/8 pass-through port connection for air/vacuum service (2) Pass-Through Vacuum Port PV1 Tool Module V1 and V2 G 3/4 (BSPP) pass-through port connections for vacuum service Figure 1.2 PV2 Vacuum/Air Modules S1 and S2: G 3/8 (BSPP) checked connections for air service (2) Self-Sealing Ports P1 to P6: G 3/8 (BSPP) pass-through port connectors for air/vacuum service PV2 Master Module (8) Pass-Through Port (6) Pass-Through Port with a Rubber Bushing and Collar S1 and S2: G 3/8 (BSPP) pass-through port connections for air service Common Mounting Feature P1 to P6: G 3/8 (BSPP) pass-through port connectors for air/vacuum service PV2 Tool Module D-3

4 Figure 1.3 PV4 and PV5 Vacuum/Air Modules (The PV5 modules shown. The PV4 modules are similar but have NPT ports) P1 through P8: G 3/8 (BSPP) pass-through for air/vacuum service PV5 Master Module (8) Pass-Through Port with a Rubber Bushing and collar. (8) Pass-Through Port Common Mounting Feature P1 through P8: G 3/8 (BSPP) pass-through for air/vacuum service PV5 Tool Module Figure 1.4 PV6 Vacuum/Air Modules (12) Pass-Through Port with a Rubber Bushing P1 through P12: G 1/4 ( (BSPP) pass-through port connection for air/vacuum service (Not Shown) Common Ledge Mounting Feature PV6 Master Module (12) Pass-Through Port PV6 Tool Module P1 through P12: G 1/4 ( (BSPP) pass-through port connection for air/vacuum service (Not Shown) D-4

5 2. Installation Air modules are typically installed by ATI prior to shipment. Use the following steps to install or remove air modules. WARNING: Do not perform maintenance or repair(s) on the Tool Changer or modules unless the Tool is safely supported or placed in the tool stand, all energized circuits (e.g. electrical, air, water, etc.) are turned off, pressurized connections are purged and power is discharged from circuits in accordance with the customer s safety practices and policies. Injury or equipment damage can occur with the Tool not placed and energized circuits on. Place the Tool in the tool stand, turn off and discharge all energized circuits, purge all pressurized connections, and verify all circuits are de-energized before performing maintenance or repair(s) on the Tool Changer or modules. WARNING: All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the application without failing. The routing of electrical and pneumatic lines must minimize the possibility of over stressing, pullout, or kinking the lines. Failure to do so can cause critical electrical and/or pneumatic lines to malfunction and might result in injury to personnel or damage to equipment. CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners might become loose and cause equipment damage. Always apply new thread locker when reusing fasteners. 2.1 Master Module Installation Installing the PV1, PV2, and PV3 Master Modules Refer to Figure 2.1. Tools required: 3 mm and 4 mm Allen wrench (hex key), torque wrench Supplies required: Clean rag, Loctite 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. Clean the mounting surfaces. 5. Place the module into the appropriate location on the Tool Changer or Utility Coupler body. Align the module with the Tool Changer using the dowel pins. 6. Apply Loctite 222 to the (3) M5 socket head cap screws. Using a 4 mm Allen wrench, install the (3) M5 socket head cap screws securing the module to the Tool Changer or Utility Coupler and tighten to 45 in-lbs (5.08 Nm). 7. Apply Loctite 222 to the (1) M4 socket head cap screws. Using a 3 mm Allen wrench, install the M4 socket head cap screws securing the module to the Tool Changer or Utility Coupler and tighten to 20 in-lbs (2.26 Nm). 8. Connect air plumbing to the module. Ensure that the connectors are clean. 9. After the procedure is complete, resume normal operation. D-5

6 Figure 2.1 Module Installation Use the dowel pins on the module to properly align the module on the mounting surface. (1) M4 Socket Head Cap Screw Tool Changer Master Module (3) M5 Socket Head Cap Screw Customer Air Connection(s) Removing the PV1, PV2, and PV3 Master Modules Tools required: 3 mm and 4 mm Allen wrench Supplies required: Clean rag 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. Use a marker pen to indicate where the module is to be re-installed. 6. Disconnect air plumbing to the module. 7. Remove the (1) M4 socket head cap screw using a 3 mm Allen wrench. 8. Remove the (3) M5 socket head cap screw using a 4 mm Allen wrench. 9. Remove the module from the Tool Changer or Utility Coupler. D-6

7 2.1.3 Installing the PV4, PV5, and PV6 Master Modules Tools required: 3 mm Allen wrench (hex key), torque wrench Supplies required: Clean rag, Loctite 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. Clean the mounting surfaces. 5. Place the module into the appropriate location on the Tool Changer or Utility Coupler body. Align the module with the Tool Changer using the dowel pins. 6. Apply Loctite 222 to the (4) M4 socket head cap screws. Using a 3 mm Allen wrench, install the (4) M4 socket head cap screws securing the module to the Tool Changer or Utility Coupler and tighten to 25 in-lbs (2.82 Nm). 7. Connect air plumbing to the module. Ensure that the connectors are clean. 8. After the procedure is complete, resume normal operation. Figure 2.2 Module Installation Use the dowel pins on the module to properly align the module on the mounting surface. Customer Air Connection(s) Tool Changer Master Module (4) M4 Socket Head Cap Screw D-7

8 2.1.4 Removing the PV4, PV5, and PV6 Master Modules Tools required: 3 mm Allen wrench Supplies required: Clean rag 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. Use a marker pen to indicate where the module is to be re-installed. 6. Disconnect air plumbing to the module. 7. Remove the (4) M4 socket head cap screw using a 3 mm Allen wrench. 8. Remove the module from the Tool Changer or Utility Coupler. 2.2 Tool Module Installation Installing the PV Series Tool Modules See Figure 2.1. Tools required: 3 mm or 4 mm Allen wrench (hex key) (refer to step 6), torque wrench Supplies required: Clean rag, Loctite 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. Clean the mounting surfaces. 5. Place the module into the appropriate location on the Tool Changer or Utility Coupler body. Align the module with the Tool Changer using the dowels in the bottom of the ledge feature. 6. Install the mounting fasteners. For PV4 and PV5 Tool modules, apply Loctite 222 to the (3) M4 socket head cap screws. Using a 3 mm Allen wrench, install the (3) M4 socket head cap screws securing the module to the Tool Changer or Utility Coupler and tighten to 25 in-lbs (2.82 Nm). For all other PV Tool modules, apply Loctite 242 to the (3) M5 socket head cap screws. Using a 4 mm Allen wrench, install the (3) M5 socket head cap screws securing the module to the Tool Changer or Utility Coupler and tighten to 45 in-lbs (5.08 Nm). 7. Connect air plumbing to the module. Ensure that the connectors are clean. 8. After the procedure is complete, resume normal operation. D-8

9 Figure 2.3 Module Installation Use the dowel pins on the module to properly align the module on the mounting surface. (3) M5 Socket Head Head Cap Screw (PV4 and PV5 have (3) M4 Socket Head Cap Screw.) Tool Changer Tool Module Customer Air Connection(s) 3. Operation Removing the PV Series Tool Modules Tools required: 3 mm or 4 mm Allen wrench (hex key) (Refer to step 6) 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. Use a marker pen to indicate where the module is to be re-installed. 5. Disconnect air plumbing to the module. 6. Remove mounting fasteners. For the PV4 and PV5 Tool modules, remove the (3) M4 socket head cap screws using a 3 mm Allen wrench. For all other PV Tool modules, remove the (3) M5 socket head cap screws using a 4 mm Allen wrench. 7. Remove the module. Air modules pass air utilities from the Master to the Tool for use by the customer s tooling. Unlike pass-through ports, self-sealing valves prevent the air circuits from discharging, which eliminates the need to close upstream circuits. Self-sealing valves and pass-through ports operate at a maximum pressure of 100 psi (6.9 bar). NOTICE: If the air pressure is not released from the Tool side of the pass-through port, debris can be expelled at high velocity when the Tool Changer uncouples. Take all required safety precautions. D-9

10 4. Maintenance Perform maintenance to maximize the operational life of the module. WARNING: Do not perform maintenance or repair(s) on the Tool Changer or modules unless the Tool is safely supported or placed in the tool stand, all energized circuits (e.g. electrical, air, water, etc.) are turned off, pressurized connections are purged and power is discharged from circuits in accordance with the customer s safety practices and policies. Injury or equipment damage can occur with the Tool not placed and energized circuits on. Place the Tool in the tool stand, turn off and discharge all energized circuits, purge all pressurized connections, and verify all circuits are de-energized before performing maintenance or repair(s) on the Tool Changer or modules. A preventive maintenance schedule and checklist are provided in the following tables: Table 4.1 Preventive Maintenance Schedule Inspection Schedule Action Required Weekly Clean and inspect 6 months or 500,000 cycles Seal replacement Table 4.2 Checklist Weekly Maintenance: гг Clean mating surfaces. гг Inspect modules for air leaks. Replace components as necessary. 6 months or 500,000 cycle Maintenance: гг гг гг гг On modules with self-sealing ports, remove and replace self-sealing valve O-rings and seals. During O-ring and seal replacement inspect components (valve stem, check valve piston, and spring) of the valve assemblies in the Master modules. See Section Master Side Self- Sealing Valve. Remove and replace the rubber bushings and collars. See Section Rubber Bushing and Collar Replacement. Remove and replace the V-ring seals. See Section V-ring Seal Replacement. Check that module mounting bolts are secure. See Section 2.1 Master Module Installation or Section 2.2 Tool Module Installation. D-10

11 5. Troubleshooting and Service Procedures The following section provides troubleshooting information to help diagnose conditions with the Tool Changer or air module and service procedures to help resolve these conditions. WARNING: Do not perform maintenance or repair(s) on the Tool Changer or modules unless the Tool is safely supported or placed in the tool stand, all energized circuits (e.g. electrical, air, water, etc.) are turned off, pressurized connections are purged and power is discharged from circuits in accordance with the customer s safety practices and policies. Injury or equipment damage can occur with the Tool not placed and energized circuits on. Place the Tool in the tool stand, turn off and discharge all energized circuits, purge all pressurized connections, and verify all circuits are de-energized before performing maintenance or repair(s) on the Tool Changer or modules. CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners might become loose and cause equipment damage. Always apply new thread locker when reusing fasteners. 5.1 Troubleshooting Procedures Refer to the following table for troubleshooting information: Table 5.1 Troubleshooting Procedures Symptom Possible Cause Correction Replace damaged or worn seals. See Section Seals are worn or damaged. Master Side Self-Sealing Valve or Section Rubber Bushing and Collar Replacement. Air leakage. Reduced air flow. Reduced vacuum flow. The modules are unable to couple. Debris blocking valve seal (for self-sealing valves). The valve piston is bent (for self-sealing valves). Corrosion. Flow path is blocked. Debris is blocking the valve seal (for self-sealing valves). The vacuum lines or connections are damaged or blocked. The V-ring seal is damaged. The valve piston and/or dowel pin is bent (for selfsealing valves) Clean in and around valve components. Ensure fluid stream is free of large particulates; filter as necessary. Replace the stem. See Section Master Side Self- Sealing Valve. Ensure the module is attached securely to the Tool Changer. See Section 2.1 Master Module Installation. Check the robot program and ensure the approach trajectory is parallel during Tool Changer coupling. Consult ATI Applications Engineering for assistance. Inspect valve components and supply/return lines for blockage. Clean/repair as necessary. Clean in and around valve components. Ensure the air stream is free of large particulates; filter as necessary. Inspect the supply/return hoses and connections for damage or blockage. Clean/repair/replace as necessary. Inspect the V-ring seal. Clean or replace as necessary. Refer to Section V-ring Seal Replacement. Replace the stem. See Section Master Side Self- Sealing Valve. Ensure the module is attached securely to the Tool Changer. See Section 2.1 Master Module Installation and Section 2.2 Tool Module Installation. Check the robot program and ensure the approach trajectory is parallel during Tool Changer coupling. D-11

12 5.2 Service Procedures The following service procedures provide instructions for component replacement and adjustment Master Side Self-Sealing Valve Parts required: See Section 8 Drawings. 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) D-12

13 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 Valve Stem 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. D-13

14 5.2.2 Rubber Bushing and Collar Replacement Parts required: Refer to Section 8 Drawings. Tools required: Needle-nose pliers Supplies required: P80 lubricant Rubber bushings seal the ports in the Master and Tool plates. If the bushings are damaged, replace them. 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. Remove the bushing and collar. a. Use needle-nose pliers to remove the bushing from the module housing. NOTICE: The PV6 Master module does not have collar(s). b. If the collar remains in the module housing or inside the bushing, remove the collar. 5. Install the replacement bushing and collar. a. Apply a thin coat of P80 lubricant to the outer surface of the replacement bushing. b. Insert the beveled (chamfered) end of the bushing into the port. NOTICE: The PV6 Master module does not have collar(s). c. Insert the collar into the bushing. d. Seat the bushing completely in the bore. 6. After the procedure is complete, resume normal operation. Figure 5.3 Replacing the Bushing and Collar Collar Bushing D-14

15 5.2.3 V-Ring Seal Replacement Parts required: Refer to Section 8 Drawings. 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. Purge and disconnect all customer plumbing connections to the module. Once the supply lines have been turned off, manually actuate the module s self sealing valves to purge the line pressure. Cover the valves with a rag prior to purging in order to keep the air from the impinging upon any person. Depending upon the service or repair being done connections up to the module may or may not need to be disconnected. 5. To remove the existing seal, pinch edge of the seal with fingers and gently pull the seal away from the vacuum valve on the Master. 6. To install a new seal, stretch the new seal over the shoulder of the vacuum valve. 7. Push the seal s hub down against the vacuum valve using finger tip. 8. After the procedure is complete, resume normal operation. Figure 5.4 Master Self Sealing Valve V-ring Seal Pinch edge of seal with fingers and gently pull away from the valve Stretch seal over the shoulder of the valve and push the seal hub down against the valve with finger tip V-ring Seal D-15

16 6. Serviceable Parts The following sections list the Master and Tool modules mounting hardware. Refer to Section 8 Drawings for additional serviceable parts. 6.1 PV1, PV2, and PV3 Master Module Mounting Hardware Table 6.1 PV1, PV2, and PV3 Master Module Mounting Hardware Part Number Qty Description M4 x 55 Socket Head Cap Screw, Class 12.9, Blue dyed Magni M5x50 Socket Head Cap Screw, Class 12.9, Blue dyed Magni PV4, PV5, and PV6 Master Module Mounting Hardware Table 6.2 PV4, PV5, and PV6 Master Module Mounting Hardware Part Number Qty Description A 3 M4X30 Socket Head Cap Screw, 12.9, ISO4762/DIN912, ES-ATI-007, YL M-spheres/IFI PV1, PV2, PV3, and PV6 Tool Module Mounting Hardware Table 6.3 PV4, PV5, and PV6 Master Module Mounting Hardware Part Number Qty Description M5x50 Socket Head Cap Screw, Class 12.9, Blue dyed Magni PV4 and PV5 Tool Module Mounting Hardware Table 6.4 PV4, PV5, and PV6 Master Module Mounting Hardware Part Number Qty Description A 3 M4X30 Socket Head Cap Screw, 12.9, ISO4762/DIN912, ES-ATI-007, YL M-spheres/IFI 525 D-16

17 7. Specifications Table 7.1 PV1 Vacuum/Air Modules Specifications Master: Anodized aluminum housing, stainless steel valve components, Materials of Nitrile seals, and brass collars. Construction: Tool: Anodized aluminum housing. Master: lbs (1.127kg) Weight: Tool: lbs ( kg) Self-Sealing Valves: Quantity 2 (2 pass-through ports on the Tool side) Air Pressure Maximum pressure of 100 psi (6.9 bar) Cv, Min 1.6 Customer Port Connection: G 3/8 (BSPP) Pass-Through Ports: Quantity 2 Air Pressure Supports positive pressure and vacuum flow conditions. Cv, Min 2.45 Customer Port Connection G 3/8 (BSPP) Vacuum Ports: Quantity 2 (2 pass-through ports on the Tool side) Air Pressure Cannot support positive pressure. Cv, Min 8.0 (estimate) Customer Port Connection G 3/4 (BSPP) Table 7.2 PV2 Vacuum/Air Modules Specifications Master: Anodized aluminum housing, stainless steel valve components, Materials of Nitrile seals, and brass collars. Construction: Tool: Anodized aluminum housing. Master: lbs (1.13 kg) Weight: Tool: lbs (0.94 kg) Self-Sealing Valves: Quantity 2 (2 pass-through ports on the Tool side) Air Pressure Maximum pressure of 100 psi (6.9 bar) Cv, Min 1.6 Customer Port Connection: G 3/8 (BSPP) Pass-Through Ports: Quantity 6 Air Pressure Supports positive pressure and vacuum flow conditions. Cv, Min 2.45 Customer Port Connection G 3/8 (BSPP) D-17

18 Table 7.3 PV3 Vacuum/Air Modules Specifications Master: Anodized aluminum housing, stainless steel valve components, Materials of Nitrile seals, and brass collars. Construction: Tool: Anodized aluminum housing. Master: lbs (1.13 kg) Weight: Tool: lbs (0.92 kg) Self-Sealing Valves: Quantity 2 (2 pass-through ports on the Tool side) Air Pressure Maximum pressure of 100 psi (6.9 bar) Cv, Min 1.6 Customer Port Connection: 3/8 NPT Pass-Through Ports: Quantity 2 Air Pressure Supports positive pressure and vacuum flow conditions. Cv, Min 2.45 Customer Port Connection 3/8 NPT Vacuum Ports: Quantity 2 (2 pass-through ports on the Tool side) Air Pressure Cannot support positive pressure. Cv, Min 8.0 (estimate) Customer Port Connection 3/4 NPT D-18

19 Table 7.4 PV4 Vacuum/Air Modules Specifications Materials of Master: Anodized aluminum housing, Nitrile seals, and brass collars. Construction: Tool: Anodized aluminum housing. Master: 2.08 lbs (0.94 kg) Weight: Tool: 1.72 lbs (0.78 kg) Pass-Through Ports: Quantity 8 Air Pressure Supports positive pressure and vacuum flow conditions. Cv, Min 2.45 Customer Port Connection 3/8 NPT Table 7.5 PV5 Vacuum/Air Modules Specifications Materials of Master: Anodized aluminum housing, Nitrile seals, and brass collars. Construction: Tool: Anodized aluminum housing. Master: 2.08 lbs (0.94 kg) Weight: Tool: 1.71 lbs (0.78 kg) Pass-Through Ports: Quantity 8 Air Pressure Supports positive pressure and vacuum flow conditions. Cv, Min 2.45 Customer Port Connection G 3/8 (BSPP) Table 7.6 PV6 Vacuum/Air Modules Specifications Materials of Master: Anodized aluminum housing, Nitrile seals, and brass collars. Construction: Tool: Anodized aluminum housing. Master: 3.34 lbs (1.51 kg) Weight: Tool: 2.93 lbs (1.33 kg) Pass-Through Ports: Quantity 12 Air Pressure Supports positive pressure and vacuum flow conditions. Cv, Min 1.03 Customer Port Connection G 1/4 (BSPP) D-19

20 8. Drawings PV1 (PV3 is similar but has NPT ports) P1, P2: 3/8G Pass-Thru S1, S2: 3/8G Checked V1, V2: 3/4G Pass-Thru PV1 Master Module (9120-PV1-M) 53.3 Note 4 / 10 in-lb Magnalube Magnalube after installation Magnalube 2 4 Magnalube bores 2 places where Valve Stem is used PV1-M Serviceable Parts ITEM NO. QTY. PART NO. DESCRIPTION O-Ring 14MM X 2MM Buna Mini U-Cup Seal 18mm ID x 22mm Buna O-Ring 6MM X 2MM Buna D SW-150A Master Fluid / Air Spring SS Collar for 3/8" Bushing Master Check Valve Piston, FA VALVE STEM, HIGH STRENGTH /8" Rubber Bushing. Nitrile V-Ring Seal Note: Service Kit 9120-F2-M-Kit consists of (1) each of items 1 thru 4. Note: Service Kit 9120-F4-M-Kit consists of (1) each of items 1, 2, 3, 4, 6, & 7. Rev. Description Initiator Date 04 ECO 14751; Added torque and Magnalube information, added Note 4, added information for 9120-F4-M-Kit, and updated Title Block. SZJ 9/22/2016 PV1 Tool Module (9120-PV1-T) Coupled (Approx.) 48 P1, P2: 3/8G Pass-Thru (Air/Vacuum Service) S1, S2: 3/8G Pass-Thru (Air Service) V1, V2: 3/4G Pass-Thru (Vacuum Service) Notes: Material of Construction: 1. Housings: Anodized Aluminum 2. Valve Components: Stainless Steel & Nitrile 3. Other: Brass 4. Replacement stem contains pre-applied thread locker. Use Loctite 7649 primer and Loctite 222 if reassembling with original stem. Operation: 5. Pneumatic Operation Only. 6. Checked Ports S1 & S2 do not support vacuum conditions. 7. Vacuum Ports V1 & V2 do not support positive pressures. 8. Checked ports can produce significant forces when under high supply pressures. These forces have to be overcome to achieve tool changer coupling. 9. For optimum performance inspect mating surfaces regularly to ensure they are free of debris. PV1-T No Serviceable Parts NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. DRAWN BY: CHECKED BY: P.Sparrow, 7/24/03 R. Heavner, 11/14/03 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. PV1 Master & Tool Module Drawing 3rd ANGLE PROJECTION SCALE SIZE DRAWING NUMBER REVISION :2 B 04 PROJECT # SHEET OF PV1 D-20

21 PV2 Rev. Description Initiator Date P1-P6: 3/8G Pass-Thru S1, S2: 3/8G Checked PV2 Master Module (9120-PV2-M) 05 ECO 14751; Added torque and Magnalube information, added Note 4, added information for 9120-F4-M-Kit, and updated Title Block. SZJ 9/22/ PV2 Tool Module (9120-PV2-T) Coupled (Approx.) P1-P6: 3/8G Pass-Thru (Air/Vacuum Service) S1, S2: 3/8G Pass-Thru (Air Service) Note 4 / 10 in-lb 7 Magnalube Magnalube after installation 1 Magnalube Magnalube bores 2 places where Valve Stem is used Notes: Material of Construction: 1. Housings: Anodized Aluminum 2. Valve Components: Stainless Steel & Nitrile 3. Other: Brass 4. Replacement stem contains pre-applied thread locker. Use Loctite 7649 primer and Loctite 222 if reassembling with original stem. Operation: 5. Pneumatic Operation Only. 6. Checked Ports S1 & S2 do not support vacuum conditions. 7. Checked ports can produce significant forces when under high supply pressures. These forces have to be overcome to achieve tool changer coupling. 8. For optimum performance inspect mating surfaces regularly to ensure they are free of debris. PV2-M Serviceable Parts ITEM NO. QTY PART NUMBER DESCRIPTION O-Ring 14MM X 2MM Buna Mini U-Cup Seal 18mm ID x 22mm Buna O-Ring 6MM X 2MM Buna D SW-150A Master Fluid / Air Spring SS Collar for 3/8" Bushing Master Check Valve Piston, FA VALVE STEM, HIGH STRENGTH /8" Rubber Bushing. Nitrile Note: Service Kit 9120-F2-M-Kit consists of (1) each of items 1 thru 4. Note: Service Kit 9120-F4-M-Kit consists of (1) each of items 1, 2, 3, 4, 6, & 7. NOTES: UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS. 3rd ANGLE PROJECTION DRAWN BY: CHECKED BY: P.Sparrow, 7/24/03 R. Heavner, 11/18/03 TITLE SCALE SIZE DRAWING NUMBER PV2-T No Serviceable Parts 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. PV2 Master & Tool Module Drawing :2 B 05 PROJECT # SHEET OF PV2 REVISION D-21

22 PV4 PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. EXCEPT NOT TO BE REPRODUCED IN ANY MANNER ON OF ATI. ORDER OR WITH PRIOR WRITTEN AUTHORIZATION PV4 Master Module (9120-PV4-M) P1-P8: 3/8NPT Pass-Thru (Air/Vacuum Service) PV4-M Serviceable Parts I TEM NO. Q TY. P ART NUMBE R DESCRIPTIO N Collar for 3/8" Bushin g 3/8" Rubber Bushing Nitrile 92.4 Coupled Approx. Notes: Material of Construction: 1. Housings: Anodized Aluminum 2. Other: Nitrile & Brass Operation: 1. Pneumatic Operation Only. 2. For optimum performance to ensure they are free of inspect debris. mating surfaces NOTES: UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING. DRAWN IN SOLIDWORKS. ALL DIMENSIONS ARE IN MILLIMETERS. DRAWN BY: CHECKED BY: WEIGHT LBS: 3rd ANGLE PROJECTION ASSEMBLY REF: ev. escriptio R n r D Dat Initiato e Updated notes 0. ECO# S 1/4/200 P 5 PV4 Tool Module (9120-PV4-T) 50.8 P1-P8: 3/8NPT Pass-Thru (Air/Vacuum Service) PV4-T No Serviceable Parts regularly 1031 Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company B. Digeso, P.Sparrow, /30/03 1/7/05 TITLE PV4 Module Drawing S CALE SIZ E DRAWING NUMBE R 1:2 B PV RODUCT RELEASE # P D ATE : SHEET O F D-22

23 PV5 PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. EXCEPT NOT TO BE REPRODUCED IN ANY MANNER ON OF ATI. ORDER OR WITH PRIOR WRITTEN AUTHORIZATION P1-P8: 3/8G Pass-Thru PV5 Master Module (9120-PV5-M) PV5-M Serviceable Parts I TEM NO. Q TY. PART NO. DESCRIPTIO N Collar for 3/8" Bushin g /8" Rubber Bushing. Nitril e ev. escriptio R n r D Dat Initiato e CO# 3690 Updated notes 03. E 1/4/200 PS PV5 Tool Module (9120-PV5-T) Coupled (Approx.) P1-P8: 3/8G Pass-Thru (Air/Vacuum Service) 43.1 Notes: Material of Construction: 1. Housings: Anodized Aluminum 2. Other: Nitrile & Brass Operation: 1. Pneumatic Operation Only. 2. For optimum performance to ensure they are free of inspect debris. mating surfaces regularly PV5-T No Serviceable Parts NOTES: UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING. DRAWN IN SOLIDWORKS. ALL DIMENSIONS ARE IN MILLIMETERS Goodworth Drive, Apex, NC 27539, USA Tel: info@ati-ia.com Fax: ISO 9001 Registered Company 3rd ANGLE PROJECTION DRAWN BY: CHECKED BY: WEIGHT ASSEMBLY LBS: REF: B. Digeso, P.Sparrow, /30/03 11/19/03 TITLE PV5 Master & Tool Module S CALE SIZ E DRAWING NUMBE R 1:1 B Drawing PV RODUCT RELEASE # P D ATE : SHEET O F D-23

24 PV6 PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. EXCEPT NOT TO BE REPRODUCED IN ANY MANNER ON OF ATI. ORDER OR WITH PRIOR WRITTEN AUTHORIZATION PV6 Master Module (9120-PV6-M) P1-P12: 1/4G Pass-Thru PV6-M Serviceable Parts I TEM NO. QTY. PART NUMBE R DESCRIPTIO N /4" NPT Rubber Bushing, Nitril e ev. escriptio R n r D Dat Initiato e 3 CO# 3690 Updated notes 0. E S 1/4/200 P 5 PV6 Tool Module (9120-PV6-T) Approx. Coupled Notes: Materials 1. Housing 2. Other of Construction: Anodized Aluminum Nitrile P1-P12: 1/4G Pass-Thru (Air/Vacuum Service) Operation: 1. Pneumatic Operation Only. 2. For optimum performance to ensure they are free of inspect debris. mating surfaces regularly PV6-T No Serviceable Parts NOTES: UNLESS OTHERWISE SPECIFIED 1031 Goodworth Drive, Apex, NC 27539, USA DO NOT SCALE DRAWING. DRAWN IN SOLIDWORKS. Tel: info@ati-ia.com ALL DIMENSIONS ARE IN MILLIMETERS. Fax: ISO 9001 Registered Company 3rd ANGLE PROJECTION DRAWN BY: CHECKED BY: WEIGHT ASSEMBLY LBS: REF: B. Digeso, P.Sparrow, /30/03 1/7/05 TITLE PV6 Module Drawing CALE SIZ S E DRAWING NUMBE R 1:1 B PV RODUCT RELEASE # P D ATE : SHEET O F - - D-24