Table of Contents D. Fluid/Air Modules...2 F34, FA2...2 1. Product Overview...2 2. Installation...3 2.1 Installation...3 2.2 Removal...3 3. Operation...3 4. Maintenance...4 4.1 F34-T and FA2-M-V1...4 4.2 F34-M and FA2-T-V1...4 5. Troubleshooting...5 6. Recommended Spare Parts...6 7. Specifications...6 8. Drawings...7 8.1 Master Fluid/Air Module (9120-F34-M)...7 8.2 Tool Fluid/Air Module (9120-F34-T)...8 8.3 Master Fluid/Air Module (9120-FA2-M-V1)...9 8.4 Tool Fluid/Air Module (9120-FA2-T-V1)...10 8.5 Configuration Fluid/Air Module FA2...11 8.6 F34 Fluid/Air Module Customer Drawing...12 D - 1
D. Fluid/Air Modules F34, FA2 1. Product Overview Modules providing air, fluid and vacuum service are attached to the Master and Tool plates. Refer to the table and figures below for a description of the specific modules being presented in this section. F34 FA2 (2) ¾ NPT self-sealing ports (Master and Tool side) Table 1.1 Fluid/Air Modules NOTE: Self-sealing ports are not to be used for vacuum service. Figure 1.1 F34 Fluid/Air Module FA2 Master Module Figure 1.2 FA2 Fluid/Air Module FA2 Tool Module D - 2
2. Installation The fluid/air modules are typically installed by ATI prior to shipment. The steps below outline the field installation or removal as required. DANGER: Power and air should always be removed prior to maintenance or repair. 2.1 Installation 1. It may be necessary to clean the mounting surface on the tool changer prior to installing the module in order to remove any debris that may be present. 2. Align the module to the holes in the plattern or tool changer mounting surface using the dowels that are pressed into the module housing. Push the module up flush with the mounting surface. Apply Loctite-242 (or similar) thread locker to the socket head cap screws and tighten using a hex key. 3. Connect customer plumbing to the module. 2.2 Removal 1. All customer plumbing connections to the module need to be purged and disconnected. Once the supply lines have been turned off, the self-sealing valves on the module can be manually actuated to purge the line pressure. Cover the valves with a rag prior to purging in order to keep the fluid/air from impinging upon any person. 2. Remove the socket head cap screws and pull the module off the plattern or tool changer. 3. Operation The fluid/air modules are designed to pass fluid/air utilities from the Master to the Tool for use by the customer s tooling. Self-sealing valves are provided so that the fluid/air circuits do not discharge during tool change and also so that the circuits upstream of the tool changer do not have to be closed down prior to tool change. The compressibility of gasses makes it unnecessary to isolate and discharge lines during a tool change. However, liquids are incompressible and therefore coupling lines while pressurized is to be avoided. Liquid displaced by mating coupler components creates extremely high pressure spikes and fluid velocities potentially causing seal damage. These problems become more pronounced as the operating pressure is increased. In all liquid coupling applications, the customer is advised to take the following steps: Plumb the couplers using flexible hoses, which are able to absorb pressure spikes and pulses. Highly reinforced hoses and hard pipe must not be used. Turn off the supply pump to the circuit and discharge pressure in the lines prior to a tool change. Hydraulic pressure accumulators should be installed on both the Master and Tool side plumbing. This is particularly important on the Tool side, even with the pump turned off and Master side pressure discharged. During routine maintenance of the tool changer, the couplers should be inspected and re-lubricated. Water and most solvents will wash away lubricants necessary to prolong seal life.! CAUTION: Failure to follow these steps will result in premature seal failure, jetting of fluid from the couplers during tool changes, and significant pressure pulses in customer tooling.! CAUTION: To maximize the life and performance of fluid/air components, read and follow the steps in the Operations section of this manual. D - 3
4. Maintenance Once installed the operation of the fluid/air modules is generally trouble free. 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 with a clean rag. During inspection, ensure that the fasteners attaching the modules to the tool changer are secure. The modules may be field serviced as needed. The following list describes how to perform various operations. DANGER: Power and air should always be removed prior to maintenance or repair. 4.1 F34-T and FA2-M-V1 1. Use a spanner wrench to remove the stem from the module housing. 2. Once the stem is removed, then all the internal components and seals are accessible. Remove and discard worn components and replace as necessary. 3. Lubricate the seals and re-assemble the module assembly in reverse order (refer to the assembly drawing in Section 8 of this manual for a layout of components). Use Loctite 242 (or similar) on the threads of the stem and torque to 110 in-lbs. 4.2 F34-M and FA2-T-V1 1. Use a flat head screwdriver and pliers to work the retaining ring out of the groove of the module housing. 2. Once the retaining ring is removed, then all the internal components and seals are accessible. Remove and discard worn components and replace as necessary. 3. Lubricate the seals and re-assemble the module assembly in reverse order (refer to the assembly drawing in Section 8 of this manual for a layout of components). Using a flat head screwdriver and pliers, work the retaining ring back into the groove of the module housing. D - 4
5. Troubleshooting Problem Cause Remedy Fluid/Air Leakage Fluid spray during uncoupling Damaged/Worn seals Debris blocking valve seal Bent stem Corrosion Surge/Water Hammer Replace seals. Clean in and around valve components. Ensure fluid stream is free of large particulates, filter as necessary. Replace stem. Check module attachment to tool changer. Check robot program and ensure parallel approach trajectory during tool changer coupling. Consult ATI for assistance. Decrease pressure differential between supply and return lines or install pressure compensation system (e.g., accumulator or surge suppressor as close as possible to spraying port). Consult ATI for assistance. Poor Flow Flow path blockage Inspect valve components and supply/return lines for blockage, clean/repair as necessary. Modules Won't Couple Debris blocking valve seal Bent stem, dowel pin Clean in and around valve components. Ensure fluid stream is free of large particulates, filter as necessary. Replace stem, dowels as necessary. Check module attachment to tool changer. Check robot program and ensure parallel approach trajectory during tool changer coupling. D - 5
6. Recommended Spare Parts Assembly Part Number Description Fluid/Air Master 9120-F34-M, 9120-FA2-T-V Master Fluid/Air Module 3410-0001097-01 4 Lobed, Low Friction Seal, Buna 3410-0001098-01 4 Lobed, Low Friction Seal, Buna 3610-2015100-20 Spring, 1.1 dia,.586 long 3690-210001-20 Smalley Retaining Ring, 1-7/8 3700-20-1550 Valiant F/A Tool Stem 3700-20-1551-02 Valiant F/A Tool Piston Fluid/Air Tool 9120-F34-T, 9120-FA2-M-V Tool Fluid/Air Module 3410-0001072-01 O-Ring, AS-568-123, Buna-N 3410-0001096-01 4 Lobed, Low Friction Seal, Buna-N 3410-0001099-01 4 Lobed, Low Friction Seal, Buna-N 3610-2015001-20 Spring, 1.1 dia, 1.5 long 3700-20-6808 Valiant F/A Master Stem 3700-20-6807 Valiant F/A Master Piston F34-M and FA2-T Kit 9120-F34-M-KIT Master Kit 3410-0001097-01 Quad Ring, 1-1/16 ID 3410-0001098-01 Quad Ring, 1-3/8 ID 3610-2015100-20 Master Spring 3690-2100001-20 Retaining Ring F34-T and FA2-M Kit 9120-F34-T-KIT Tool Kit 3410-0001341-01 O-Ring, AS568A-123 3410-0001096-01 Quad Ring, 13/16 ID 3410-0001099-01 Quad Ring, 1-5/16 ID 3610-2015001-20 Master Spring 7. Specifications Fluid/Air Modules Weight F34-M, F34-T FA2-M, FA2-T 6.8lbs. (3.1 kg) 5.4lbs. (2.44 kg) F34-M / FA2-M F34-T / FA2-T Materials of Construction Various Stainless Steel valve components and housing, Buna-N and Nitrile Rubber seals Fluid Ports, (qty) Size (C v, Min) (2) ¾ NPT (8.0 est.) Maximum pressure of 100psi (6.9bar), Nitrile seals, Self-sealing on Master and Tool (cannot operate under a vacuum). D - 6
8. Drawings 8.1 Master Fluid/Air Module (9120-F34-M) D - 7
8.2 Tool Fluid/Air Module (9120-F34-T) D - 8
8.3 Master Fluid/Air Module (9120-FA2-M-V1) D - 9
8.4 Tool Fluid/Air Module (9120-FA2-T-V1) D - 10
8.5 Configuration Fluid/Air Module FA2 D - 11
8.6 F34 Fluid/Air Module Customer Drawing D - 12