TSL Tool Stand

TSL Tool Stand 

Installation and Operation Manual 

Document #: 9610-20-1058 

October 2015 

Engineered Products for Robotic Productivity 

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com

Quick-Change Installation and Operation Manual 

Document #9610-20-1058-27 

Foreword 

Please contact ATI Industrial Automation with any questions concerning your particular model. 

CAUTION: This manual describes the function, application, and safety considerations of this 

product. This manual must be read and understood before any attempt is made to install or 

operate the product, otherwise damage to the product or unsafe conditions may occur. 

Information contained in this document is the property of ATI Industrial Automation, Inc. (ATI) and shall not be 

reproduced in whole or in part without prior written approval of ATI. The information herein is subject to change without 

notice. This manual is periodically revised to reflect and incorporate changes made to the product. 

The information contained herein is confidential and reserved exclusively for the customers and authorized agents of ATI 

Industrial Automation and may not be divulged to any third party without prior written consent from ATI. No warranty 

including implied warranties is made with regard to accuracy of this document or fitness of this device for a particular 

application. ATI Industrial Automation shall not be liable for any errors contained in this document or for any incidental 

or consequential damages caused thereby. ATI Industrial Automation also reserves the right to make changes to this 

manual at any time without prior notice. 

ATI assumes no responsibility for any errors or omissions in this document. Users’ critical evaluation of this document is 

welcomed. 

©Copyright by ATI Industrial Automation. All rights reserved. 

How to Reach Us 

Sale, Service and Information about ATI products: 

ATI Industrial Automation 

1031 Goodworth Drive 

Apex, NC 27539 USA 

WWW.ati-ia.com 

Tel: 919.772.0115 

Fax: 919.772.8259 

E-mail: info@ati-ia.com 

Technical support and questions: 

Application Engineering 

Tel: 919.772.0115, Option 2, Option 2 

Fax: 919.772.8259 

E-mail: mech_support@ati-ia.com 

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com 

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Table of Contents 


Document #9610-20-1058-27 

1. Safety......................................................................................................................................................... 8 

1.1 Explanation of Notifications........................................................................................................................... 8 

1.2 General Safety Guidelines.............................................................................................................................. 8 

1.3 Safety Precautions.......................................................................................................................................... 9 

2. Product Overview................................................................................................................................... 10 

2.1 TSL System with Pin and Bushing Style Mounting................................................................................... 10 

2.1.1 Post Module with Pin and Bushing Style Mounting........................................................................... 10 

2.1.2 Pin and Bushing Mounting Modules..................................................................................................11 

2.1.3 Tooling Interface Plates......................................................................................................................11 

2.1.4 Sensor Modules................................................................................................................................ 12 

2.1.5 Tool Stand Interlock Switches, Trip Dogs, and Sipha Sensors......................................................... 12 

2.2 TSL System with Hook and Hanger Style Mounting.................................................................................. 13 

2.2.1 Post Module with Hook and Hanger Style Mounting......................................................................... 13 

2.2.2 Hook Mounting Modules................................................................................................................... 14 

2.2.3 Vertical Tooling Hook Plate Assembly............................................................................................... 14 

2.2.4 Tool Hook Modules........................................................................................................................... 14 

2.2.5 Proximity Sensors............................................................................................................................. 15 

2.2.6 Tool Stand Interlock Switches, Trip Dogs, and Sipha Sensors......................................................... 15 

2.3 Optional TSL System Common Components............................................................................................. 16 

2.3.1 Horizontal Extension Modules.......................................................................................................... 16 

2.3.2 Debris Shield Actuator...................................................................................................................... 16 

2.3.3 Debris Shield and Shield Arm........................................................................................................... 17 

2.3.4 Post-Mounted Tool Support.............................................................................................................. 17 

2.4 Determining The Tool Stand Configuration................................................................................................ 18 

2.4.1 Configuring a TSL System with Pin and Bushing Mounting Style..................................................... 19 

2.4.2 Configuring a TSL System with Hook and Hanger Mounting Style................................................... 20 

3. Installation............................................................................................................................................... 21 

3.1 Installing the Post Module............................................................................................................................ 21 

3.2 Installing a Sensor Module to a Pin and Bushing Module........................................................................ 22 

3.2.1 Installing a Dual Sensor Module....................................................................................................... 22 

3.2.2 Installing a Single Sensor Module..................................................................................................... 23 

3.3 Installing a Proximity Sensor to a Hook Module........................................................................................ 24 

3.4 Installing a Tool Stand Interlock (TSI) Switch............................................................................................. 24 

3.4.1 Pin and Bushing Module with Tooling Interface Plate....................................................................... 24 

3.4.2 Pin and Bushing Module with Vertical Tooling Interface Plate.......................................................... 25 

3.4.3 Hook Module with Vertical Tooling Hook Plate or Tool Hook Modules.............................................. 26 

3.5 Installing a Debris Shield.............................................................................................................................. 27 

3.6 Installing a Post-mounted Tool Support and Post Support Roller........................................................... 29 


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4. Operation................................................................................................................................................. 30 

4.1 Tool Change Programming Procedure Tips............................................................................................... 30 

4.2 TSL System with Pin and Bushing Style Mounting Operation................................................................. 30 

4.3 TSL System with Hook Style Mounting Operation..................................................................................... 31 

5. Maintenance............................................................................................................................................ 32 

5.1 Preventative Maintenance............................................................................................................................ 32 

5.1.1 All TSL Systems................................................................................................................................ 32 

5.1.2 TSL Systems with Pin and Bushing Style Mounting Modules........................................................... 32 

5.1.3 TSL Systems with Hook and Hanger Style Mounting Modules......................................................... 33 

5.1.4 Preventative Maintenance Procedures............................................................................................. 33 

5.1.4.1 Clean, Lubricate, and Replace Alignment Pins and Bushings......................................... 33 

5.1.4.2 Replace Compression Spring and Lubricate the Compliant Mounting Module............... 34 

5.1.4.3 Inspect, Tighten, and Replace Shoulder Bolts and Hook Attachments........................... 37 

6. Troubleshooting...................................................................................................................................... 38 

7. Recommended Spare Parts................................................................................................................... 39 

7.1 Part Number Cross Reference..................................................................................................................... 39 

7.1.1 TSL Systems with Pin and Bushing Style Mounting......................................................................... 39 

7.1.2 TSL Systems with Hook and Hanger Style Mounting....................................................................... 39 

8. Specifications......................................................................................................................................... 40 

8.1 Components for TSL Systems with Pin and Bushing Style Mounting..................................................... 40 

8.2 Components for TSL Systems with Hook and Hanger Style Mounting................................................... 40 

8.3 Common Optional Components for TSL Systems..................................................................................... 40 

8.3.1 Debris Shield Actuators Specifications............................................................................................. 40 

9. Drawings.................................................................................................................................................. 41 

9.1 TSL Systems with Pin and Bushing Style Mounting Modules.................................................................. 41 

9.1.1 Rigid Mounting, Single Sensor, TSI Switches, Vertical Debris Shields............................................. 41 

9.1.2 Rigid Mounting, TSI Switches, Vertical Debris Shields..................................................................... 42 

9.1.3 Rigid Mounting, TSI Switches, Horizontal Debris Shields................................................................. 45 

9.2 Post Modules with Pin and Bushing Style Mountings............................................................................... 49 

9.2.1 Post Module, (2) Rigid Pin and Bushing Modules, 48” Tall............................................................... 49 

9.2.2 Post Module, (2) Compliant Pin & Bushing Modules, 500 lbs, 48” Tall............................................. 50 

9.3 Pin and Bushing Mounting Modules........................................................................................................... 51 

9.3.1 Pin and Bushing Module, Rigid......................................................................................................... 51 

9.3.2 Pin and Bushing Module, Compliant (500 lbs Shown)...................................................................... 52 

9.4 Tooling Plates................................................................................................................................................ 53 

9.4.1 Tooling Interface Plate Blank............................................................................................................ 53 

9.4.2 Tooling Interface Plate for QC-150 Blank.......................................................................................... 54 

9.4.3 Vertical Tooling Interface Plate Blank................................................................................................ 55 

9.5 TSL Systems with Hook and Hanger Style Mounting Modules................................................................ 56 

9.5.1 Rigid Mounting, Tool Hook Modules TSI, Horizontal Debris Shields................................................ 56 

9.5.2 Compliant Mounting, Proximity Sensor, Vertical Tooling Hook Plate................................................ 57 


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Document #9610-20-1058-27 

9.6 Post Modules with Hook and Hanger Style Mountings............................................................................. 58 

9.6.1 Post Module, (2) Rigid Hook Modules, 48” Tall................................................................................. 58 

9.6.2 Post Module, (2) Compliant Hook Modules, 500 lbs, 48” Tall........................................................... 59 

9.7 Hook Mounting Modules............................................................................................................................... 60 

9.7.1 Hook Module, Rigid........................................................................................................................... 60 

9.7.2 Hook Module, Compliant (500 lbs Shown)........................................................................................ 61 

9.8 Vertical Tooling Hook Plate.......................................................................................................................... 62 

9.9 Horizontal Extension Modules..................................................................................................................... 63 

9.9.1 Horizontal Extension, 16”, Straight................................................................................................... 63 

9.9.2 Horizontal Extension, 12”, 90°.......................................................................................................... 64 

9.10 TSI Switches and Trip Dogs......................................................................................................................... 65 

9.10.1 TSI Switch for Tooling Interface Plate............................................................................................... 65 

9.10.2 TSI Trip Dog for Pin and Bushing Module......................................................................................... 66 

9.10.3 TSI Switch Assembly for Vertical Tooling Interface Plate (Left Side)................................................ 67 

9.10.4 TSI Switch Assembly for Vertical Tooling Interface Plate (Right Side).............................................. 68 

9.10.5 TSI Switch Master Side..................................................................................................................... 69 

9.10.6 TSI Switch Assembly for Tool Hook Modules (Left Side).................................................................. 70 

9.10.7 TSI Switch for Vertical Tooling Hook Plate........................................................................................ 71 

9.10.8 TSI Trip Dog for Vertical Tooling Hook Plate..................................................................................... 72 

9.10.9 TSI Switch Common Wiring Diagram............................................................................................... 73 

9.10.10 Sipha Sensor supporting TSI In/Out 1m Cable Length..................................................................... 74 

9.10.11 Sipha Sensor, 3m Cable Length....................................................................................................... 75 

9.10.12 Sipha Sensor Non-contact switch Actuator....................................................................................... 76 

9.11 Debris Shield Actuators................................................................................................................................ 77 

9.11.1 Debris Shield Actuator - Horizontal 135 Degree Rotation................................................................. 77 

9.11.2 Debris Shield Actuator - Vertical 90 Degree Rotation....................................................................... 78 

9.11.3 Debris Shield Actuator Dual Post - Vertical 135 Degree Rotation..................................................... 79 

9.12 Debris Shields............................................................................................................................................... 80 

9.12.1 Debris Shield 20" with Weld Curtain................................................................................................. 80 

9.12.2 Debris Shield 20” with Fire Retardant Foam Insert.......................................................................... 81 

9.12.3 Debris Shield 17” with Weld Curtain................................................................................................. 82 

9.12.4 Debris Shield 14” with Weld Curtain................................................................................................. 83 

9.12.5 Debris Shield 14” with Fire Retardant Foam Insert.......................................................................... 84 

9.13 Post Supports................................................................................................................................................ 85 

9.13.1 TSL Adjustable Post Support With Arm............................................................................................ 85 

9.13.2 TSL Adjustable Post Support With Strut Channel............................................................................. 86 

9.13.3 Post Support - Roller......................................................................................................................... 87 

10. Terms and Conditions of Sale............................................................................................................... 88 


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Document #9610-20-1058-27 

Term 

Definition 

Glossary of Terms 

Alignment Pins 

The Alignment Pin attach to the Interface Plate Assembly and Mounting Module to 

support and locate the tooling in the Tool Stand. 

Compliant Mounting Modules A feature on the TSL that couples to the tooling interface plate and allows for some 

placement variation in the vertical plane when tool is dropped off or picked up from the 

TSL system. 

Debris Shield 

Debris Shield Actuator 

End-Effector 

Hook and Hanger Mounting 

Cover that provides protect against dirt and debris for the tool changer tool plate, 

modules, and customer tooling. 

Pneumatically actuated device that moves the debris shield over the Tool Changer for 

protection and removes the shield for tool pickup. 

A tool or other device attached to the robot arm in order to perform a task. 

Tool Stand that uses Mounting Modules with hangers to support and accurately locate 

the Tool Changer Tool Plate and Customer Tooling, 

Horizontal Extension Modules Fixture that provides more tool clearance for the customer tooling than the standard TSL 

Post Module 

IP 

Master Plate 

Modules 

Mounting Module 

Pin and Bushing Mounting 

Post Module 

Post-mounted Tool Support 

Proximity Sensor 

Rigid Mounting Modules 

Sensor Modules 

Sipha Sensor 

Tool Hook Modules 

Tooling Interface Plate 

An Interface Plate is used to adapt the Master Plate to the robot. 

The half of the Tool Changer which is mounted to an Interface Plate, robot or End- 

Effector adjacent to the robot. 

Optional components that can be added to the Master and Tool Plates to enhance the 

capabilities of the Tool Changer, e.g. Fluid/Air, Electrical, DeviceNet, Servo, High- 

Current. 

The Mounting Module provides a mounting on the Tool Stand for the Tooling Interface 

Plate or can mount the Tool Changer Tool Plate directly for some specific models. 

Tool Stand that uses Mounting Modules with pins and bushing to support and accurately 

locate the Tool Changer Tool Plate and Customer Tooling, 

The Post Module is a welded steel vertical post, providing one or more Mounting 

Modules. 

A fixture that attaches to the Post Module to support unbalanced tooling. 

The proximity sensor provides a signal indicating the tool is located in the Tool Stand 

A feature on the TSL that couples to the tooling interface plate and provides a fixed 

position when tool is dropped off or picked up from the TSL system. 

The Sensor Modules provides a mounting on the Tool Stand for the Proximity Sensor. 

A proximity sensor type switch used in the Tool Stand Interlock system. 

Tooling fixture that utilizes harden steel hooks to support the Tool Changer Tool Plate 

and customer tooling on the Tool Stand. 

A machined plate that adapts the Quick-Change Tool Body to an End-Effector, and 

provides mounting features for a Tool Stand.. 


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Document #9610-20-1058-27 

Tool Plate 

Trip Dog 

TSI Switch 

TSL system 

The half of the Tool Changer that is mounted to an Tooling Interface Plate or customersupplied 

tooling. 

Mechanical trip for a TSI switch that is mounted to the Tool Stand. 

Tool Stand Interlock Switch provides protection against unintended tool release by 

integrated the switch into the electrical circuit for the Lock and Unlock Air Valve 

through the Control and Signal modules 

Tool Stand Large, a weldment provided by ATI for holding of the Tool Plate when not in 

use. 

Vertical Tooling Interface Plate A machined plate with a vertical surface that adapts the customer tooling and provides 

mounting features for a Tool Stand. 


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Document #9610-20-1058-27 

1. Safety 

The safety section describes general safety guidelines to be followed with this product, explanation of the 

notification found in this manual, and safety precaution that apply to the product. More specific notification are 

imbedded within the sections of the manual were they apply. 

1.1 Explanation of Notifications 

The notifications included here are specific to the product(s) covered by this manual. It is expected that the 

user heed all notifications from the robot manufacturer and/or the manufacturers of other components used 

in the installation. 

DANGER: Notification of information or instructions that if not followed will result in 

death or serious injury. The notification provides information about the nature of the 

hazardous situation, the consequences of not avoiding the hazard, and the method for 

avoiding the situation. 

WARNING: Notification of information or instructions that if not followed could result 

in death or serious injury. The notification provides information about the nature of the 

hazardous situation, the consequences of not avoiding the hazard, and the method for 

avoiding the situation. 

CAUTION: Notification of information or instructions that if not followed could result 

in moderate injury or will cause damage to equipment. The notification provides 

information about the nature of the hazardous situation, the consequences of not 

avoiding the hazard, and the method for avoiding the situation. 

NOTICE: Notification of specific information or instructions about maintaining, operating, 

installation, or setup of the product that if not followed could result in damage to equipment. The 

notification can emphasize but is not limited to specific grease types, good operating practices, 

or maintenance tips. 

1.2 General Safety Guidelines 

The TSL system is intended to for use in industrial applications for tool changing and storage and therefore 

requires the use of a Tool Changer. 

Prior to purchase and installation, the customer should verify that the Tool Changer selected is rated for the 

maximum loads and moments expected during operation. Refer to Tool Changer operation and installation 

manual or contact ATI for assistance. 

WARNING: The customer is responsible for ensuring that the area between the tool 

and the Tool Stand is clear of foreign objects during tool drop-off. Failure to do so may 

result in serious injury to personnel. 

WARNING: The gap between the Master and Tool sides is a pinch point. All personnel 

should be prevented from placing any part of their body or clothing in the gap, 

especially during actuation of the locking mechanism. 


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Document #9610-20-1058-27 

1.3 Safety Precautions 

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

stand components unless the tool is safely supported or docked in the Tool Stand and 

all energized circuits (e.g. electrical, air, water, etc.) have been turned off. Injury or 

equipment damage can occur with tool not docked and energized circuits on. Dock 

the tool safely in the Tool Stand and turn off all energized circuits before performing 

maintenance or repair on Tool Changer, modules, or tool stand components. 

WARNING: During operation, the area between the Master and Tool must be kept 

clear. Failure to keep area clear will result in damage to Tool Changer, modules, or endof-arm 

tooling and could cause injury to personnel. 

CAUTION: Do not store TSL system outside or in wet humid environment. Exposed 

steel or black oxide coated surfaces will rust. Store the TSL system inside in a 

controlled environment. 

CAUTION: The TSL system is only to be used for intended applications and 

applications approved by the manufacturer. 


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Document #9610-20-1058-27 

2. Product Overview 

The ATI TSL (Tool Stand Large) system is compatible with ATI Tool Changer sizes QC-150 and larger. The 

stand is designed for durability, longevity, and maximum adaptability to fit most customers’ applications. The 

configurable system allows you to specify tool height, offset, shielding, and sensing. To save space, the TSL can 

even store up to two tools on the same post. The TSL systems can be equipped with actuated debris shields, rigid 

or compliant mounting modules, tool stand interlock switches, horizontal extensions, and different types of tool 

sensing. Two mounting styles are available: a pin and bushing style and a hook and hanger style. 

2.1 TSL System with Pin and Bushing Style Mounting 

The Pin and Bushing Modules are available in a rigid and a compliant mountings. Horizontal and vertical 

Tooling Interface Plates provide a mount for customer tooling. Refer to Figure 2.1 for an example of a Tool 

Stand with Pin and Bushing style mounting. 

Figure 2.1—TSL System with Pin and Bushing Style Mounting 

Pin and Bushing Module 

(Rigid Module shown) 

Debris Shield 

Actuator 

Shield Arm 

Debris Shield with 

Leather Side Guards 

Sensor Module 

Tool Changer 


Vertical Tooling 

Interface Plate 

Horizontal 

Extension 

Post Support 

Post Module 



Tooling Interface 

Plate 

Tool Stand Interlock (TSI) 

Switch Assembly 

Trip Dog Assembly 

2.1.1 Post Module with Pin and Bushing Style Mounting 

The ATI TSL Post Module includes a steel vertical post with welded gussets, base plate, and one 

or two tool mountings. The module is power coated to provide durable finish. The Post Module 

includes either rigid or compliant Pin and Bushing Modules depending on specific model. The 

standard Post module is 48 inches tall, other standard heights are available, contact ATI for other 

heights. 


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Document #9610-20-1058-27 

Post Modules with Pin and Bushing Mountings 

Item Part number Refer to Drawing in: 

Post Module, (1) Rigid Pin and 9120-TSL-PM-148B-R000 

Bushing Module, 48” Tall 

Post Module, (2) Rigid Pin and 9120-TSL-PM-248B-R000 

Section 9.2.1 -9630-20-TSL-PM-248B-R000 

Bushing Modules, 48” Tall 

Post Module, (1) Compliant Pin and 9120-TSL-PM-148B-C500 

Bushing Module, 500 lbs, 48” Tall 

Post Module, (2) Compliant Pin and 9120-TSL-PM-248B-C500 

Section 9.2.2-9630-20-TSL-PM-248B-C500 

Bushing Modules, 500 lbs, 48” Tall 

Notes: 

1. Post Modules are available in various heights, contact ATI for specification. 

2. Used with Tooling Interface Plates: 9120-TSL-HBB-4115, 9210-TSL-HBQ-8389, 9120-TSL-VBB-3328. 

3. Used with Sensor Modules: 9120-TSL-SMA-XXXX. 

2.1.2 Pin and Bushing Mounting Modules 

Pin and Bushing Modules includes two vertical alignment pins and one vertical pin receiver. The 

module includes mounting hardware, and is designed to mount directly to the Post Module. The Pin 

and Bushing Modules can be supplied as a stand alone unit and can be integrated with customer 

specific fixtures. Rigid and compliant models are available. Compliance is factory set for each of 

the compliant models. The module provides mounting features for the debris shield actuator and 

sensor modules. 


Pin and Bushing Module, Rigid 9120-TSL-RMB-R000 Section 9.3.1-9630-20-TSL-RMB-R000 

Pin and Bushing Module, Compliant to 500 

lbs 

9120-TSL-CMB-C500 

Pin and Bushing Module, Compliant to 900 9120-TSL-CMB-C900 

lbs 

Section 9.3.2-9630-20-TSL-CMB-C500 

Pin and Bushing Module, Compliant to 1200 9120-TSL-CMB-C1200 

lbs 

Notes: 

1. Used with Tooling Interface Plates: 9120-TSL-HBB-4115, 9210-TSL-HBQ-8389, 9120-TSL-VBB-3328. 

2. Used with Sensor Modules: 9120-TSL-SMA-XXXX. 

2.1.3 Tooling Interface Plates 

There are two types of Interface Plates, Tooling Interface Plates and Vertical Tooling Interface 

Plates. The Tooling Interface Plate attaches horizontally to the Tool Changer and the customer 

tooling. The Vertical Tooling Plate attaches to the customer tooling and the Tool Changer is 

attached to the customer tooling either directly or using an interface plate. Both types of Interface 

Plates have two bushings and one alignment pin to position the Tooling Interface Plate to the Pin 

and Bushing Mounting Module. 

Tooling Interface Plates 


Tooling Interface Plate - Blank 4 9120-TSL-HBB-4115 Section 9.4.1-9630-20-TSL-HBB-4115 

Tooling Interface Plate for QC-150 - Blank 4 9120-TSL-HBQ-8389 Section 9.4.2-9630-20-TSL-HBQ-8389 

Vertical Tooling Interface Plate 

Vertical Tooling Interface Plate - Blank 5 9120-TSL-VBB-3328 Section 9.4.3-9630-20-TSL-VBB-3328 

Notes: 

1. Used with Post Modules: 9120-TSL-PM-148B-XXXX and 9120-TSL-PM-248B-XXXX. 

2. Used with Mounting Modules: 9120-TSL-RMB-R000 and 9120-TSL-CMB-CXXX. 

3. Used with Sensor Modules: 9120-TSL-SMA-XXXX 

4. Used with TSI Switch and Trip Dog: 9120-TSL-SS-6044 switch, and 9120-TSL-SS-7511 Trip Dog. 

5. Used with TSI Switch and Trip Dog: 9120-TSL-SS-3500 Switch and Trip Dog Left-side mounted 

9120-TSL-SS-7122 Switch and Trip Dog Right-side mounted 


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Document #9610-20-1058-27 

2.1.4 Sensor Modules 

The TSL Sensor Module is an option that provides tool presence detection. The standard model 

mounts directly to the Pin and Bushing Mounting Module and incorporates a proximity sensor 

that senses a face on the Tooling Interface Plate. Other sensor options are available upon customer 

request. 

Dual Sensor Modules 


Dual Sensor Module, SS, Single PNP 18mm Sensor, 9120-TSL-SMA-8090 

N/A 

Shielded 

Dual Sensor Module, SS, No Sensors 9120-TSL-SMA-8089 N/A 

Single Sensor Modules 

Sensor Module, PNP, 18mm Barrel, Shielded, PTFE 9120-TSL-SMA-7979 

Coated, Turck 

Sensor Module, PNP 18mm Barrel, Shielded 9120-TSL-SMA-5077 

Sensor Module, PNP 18mm Barrel, Shielded 9120-TSL-SMA-7511 

Sensor Module, without Sensor 

9120-TSL-SMA-5079 

Sensor Module, PNP 18mm Barrel, Shielded, Turck 9120-TSL-SMA-5078 

Section 9.1.2-9230-20-7704 

2.1.5 Tool Stand Interlock Switches, Trip Dogs, and Sipha Sensors 

TSL system Interlock (TSI) switches can be integrated into the electrical circuit for the Unlock 

Air Valve through the Control and Signal modules to prevent an unintended tool release. Tool side 

and Master side TSI switches are available, contact ATI for information about Control and signal 

Modules with TSI functionality. The TSI switch is activated using a Trip Dog that is attached to the 

Pin and Bushing Module. The tool side TSI switch is attached to the Tooling Interface Plate and 

connects to the Control and Signal module on the Tool side of the Tool Changer. The Master side 

TSI switch is mounted to the Master side of the Tool Changer and connected to the Control and 

Signal Module. Some Control and Signal Modules support sipha sensor TSI, contact ATI for more 

information. 

Tool Stand Interlock Switches used with Pin and Bushing Mounting 


Tool Stand Interlock Switch Assembly no Trip 

Dog 

9120-TSL-SS-6044 Section 9.10.1-9630-20-TSL-SS-6044 

Section 9.1.2-9230-20-7704 

Tool Stand Interlock Trip Dog Assembly 9120-TSL-SS-7511 Section 9.10.2-9230-20 TSL-SS-7511 

Section 9.1.2-9230-20-7704 

Tool Stand Interlock Switches used with Vertical Tooling Interface Plate 

Tool Stand Interlock for Interface Plate (Left 9120-TSL-SS-3500 Section 9.10.3-9630-20-TSL-SS-3500 

side mounted) 

TSI Switch Trip Dog Assembly-Rigid Mount 

(Right side mounted) 

9120-TSL-SS-7122 Section 9.10.4-9630-20-TSL-SS-7122 

Master Side Tool Stand Interlock Switch 

Switch Kit for Master Side TSI 9120-TSL-SS-6077 Section 9.10.5-9630-20-TSL-SS-6077 

Sipha Sensor Tool Stand Interlock Switches 

Direct Mount Sipha Sensor Supporting TSI In/ 9120-TSL-SS-7510 Section 9.10.10-9630-20-TSL-SS-7510 

Out and TSIV, 1m Cable Length 2, 3 

Direct Mount Sipha Sensor, 3m Cable Length 9120-TSL-SS-7508 Section 9.10.11-9630-20-TSL-SS-7508 

Sipha Sensor Tool Stand Interlock Switches Actuator 

Direct Mount Sipha Non-contact Switch 

Actuator 2, 3 9120-TSL-SS-7509 Section 9.10.12-9630-20-TSL-SS-7509 

Note: 

1. Other TSI Switch configuration are available contact ATI for information. 

2. Sipha Sensor 9120-TSL-SS-7510 and 9120-TSL-SS-7508 are used with Sensor actuator 

9120-TSL-SS-7509. 

3. The sensing range for the Sipha Sensor is (Make .35” (9mm) and Break .47” (12mm). 


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Document #9610-20-1058-27 

2.2 TSL System with Hook and Hanger Style Mounting 

Both a rigid and a compliant Hook Modules are available for the hook and hanger mounting style. Vertical 

Tooling Interface Plates provide a mount for customer tooling. Customer Tooling can also be supported 

using NAx Modules that mount to the Tool Changer Tool Plate and Tooling Interface Plate. Refer to 

Figure 2.2 for an example of a Tool Stand with Hook and Hanger style mounting. 

Figure 2.2—TSL System with Hook and Hanger Style Mounting 


Debris Shield with 

Leather Side Guards 


Shield Arm 

Tool Changer Tool Plate 

With NAx Hook Modules 

and Tooling Interface Plate 

Tool Stand Interlock (TSI) 

Switch Assembly 



Horizontal Extension 


Hook Module 


Post Support Roller 

Post Module 

Post Support 

(Adjustable Support Shown) 

2.2.1 Post Module with Hook and Hanger Style Mounting 

The ATI TSL Post Module includes a steel vertical post with welded gussets, base plate, and one 

or two tool mountings. The module is power coated to provide durable finish. The Post Module 

includes either rigid or compliant Hook Modules depending on specific model. The standard Post 

module is 48 inches tall, other standard heights are available, contact ATI for other heights. 

Post Modules with Hook and Hanger Mountings 


Post Module, (1) Rigid Hook 9120-TSL-PM-148H-R000 

Module, 48” Tall 

Post Module, (2) Rigid Hook 9120-TSL-PM-248H-R000 

Section 9.6.1-9630-20-TSL-PM-248H-R000 

Modules, 48” Tall 

Post Module, (1) Compliant Hook 9120-TSL-PM-148H-C500 

Module, 500 lbs, 48” Tall 


Modules, 500 lbs, 48” Tall 

Section 9.6.2-9630-20-TSL-PM-248H-C500 


Module, 800 lbs, 48” Tall 

Notes: 

1. Post Modules are available in various heights, contact ATI for specification. 

2. Used with Tooling Interface Plates: 9121-NA2-T, 9121-NA3-T, 9121-NB2-T, 9121-NB3-T, 

9121-TSL-TH-5641. 

3. Used with Proximity Sensors: 8590-9909999-XXX. 


13


Document #9610-20-1058-27 

2.2.2 Hook Mounting Modules 

Hook Modules includes two horizontal alignment pins that are designed to work with the hook type 

tooling interfaces. The module includes mounting hardware, and is designed to mount directly to 

the Post Module. The Hook Modules can be supplied as a stand alone unit and can be integrated 

with customer specific fixtures. Rigid and compliant models are available. Compliance is factory 

set for each of the compliant models. The module provides mounting for the debris shield actuator 

and 18mm barrel proximity sensor. 


Hook Module, Rigid 9120-TSL-RMH-R000 Section 9.7.1-9630-20-TSL-RMH-R000 

Hook Module, Compliant to 500 lbs 9120-TSL-CMH-C500 

Hook Module, Compliant to 800 lbs 9120-TSL-CMH-C800 

Section 9.7.2-9630-20-TSL-CMH-C500 

Notes: 

1. Used with Tooling Interface Plates: 9121-NA2-T, 9121-NA3-T, 9121-NB2-T, 9121-NB3-T, 

9211-TSL-TH-5641. 


2.2.3 Vertical Tooling Hook Plate Assembly 

The Vertical Tooling Hook Plate Assembly attaches to the customer tooling, the Tool Changer is 

attached to the customer tooling either directly or using an interface plate. The Vertical Tooling 

Hook Plate Assembly has two hardened steel hooks that hang the tooling on the Hook Module. The 

assembly is only used with the Hook Mounting Modules and provides mounting for a Tool Stand 

Interlock Switch Assembly. 


Vertical Tooling Hook Plate Assembly, Blank 9121-TSL-TH-5641 Section 9.8-9630-20-TSL-TH-5641 

Notes: 

1. Used with Post Modules: 9120-TSL-PM-148H-XXXX and 9120-TSL-PM-248H-XXXX. 

2. Used with Mounting Modules: 9120-TSL-RMH-R000 and 9120-TSL-CMH-CXXX. 


4. Used with TSI Switch and Trip Dog: 9120-TSL-SS-8074 switch, and 9120-TSL-SS-8076 Trip Dog. 

2.2.4 Tool Hook Modules 

Tool Hook Modules must be attached to a Tooling Interface Plate and to the Tool Changer Tool 

Plate. The customer tooling attaches to the Tooling Interface plate. The Tool Hook Modules have 

two hardened steel hooks that hang the customer tooling on the Hook Module. The Tool Hook 

Modules are only used with the Hook Mounting Modules and provide mounting for a Tool Stand 

Interlock Switch Assembly. 


Tool Hook Module, QC-210 Right 9121-NA2-T http://www.ati-ia.com/products/toolchanger/QCModule. 

Tool Hook Module, QC-210 Left 9121-NA3-T 

aspx?ID=NAx 

Tool Hook Module, QC-310 Right 9121-NB2-T N/A 

Tool Hook Module, QC-310 Left 9121-NB3-T N/A 

Notes: 

1. Used with Post Modules: 9120-TSL-PM-148H-XXXX and 9120-TSL-PM-248H-XXXX. 

2. Used with Mounting Modules: 9120-TSL-RMH-R000 and 9120-TSL-CMH-CXXX. 


4. Used with TSI Switch and Trip Dog: 9120-TSL-SS-5635 switch and Trip dog Left Side, and 

9120-TSL-SS-8024 Trip Dog only right side mounted. 


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Document #9610-20-1058-27 

2.2.5 Proximity Sensors 

Optional Proximity Sensor provide tool presence detection. The standard model mounts directly 

to the Hook Module and incorporates a proximity switch that senses a face on the Vertical Tooling 

Hook Interface Plate or the Tool Hook Module. The Sensor Module comes equipped with a 

collision guard that protects integrity of the sensor during normal operation. Other sensor options 

are available upon customer request. 

18mm Barrel Proximity Sensors 


PNP Prox Sensor 5mm sensing Range, 18mm 8590-9909999-92 Section 9.5.2-9230-20-7548 

Barrel, Shielded 

Proximity Sensor 18mm Barrel, PNP 3 wire DC 8590-9909999-103 Section 9.5.2-9230-20-7548 

5mm range 

Proximity Sensor, PNP, 18mm Barrel, 8mm 8590-9909999-141 Section 9.5.2-9230-20-7548 

Range, Shielded 

Proximity sensor, 18mm Barrel Prox, PNP 3 wire 

DC, Embeddable, PTFE Coated 

8590-9909999-145 Section 9.5.2-9230-20-7548 

2.2.6 Tool Stand Interlock Switches, Trip Dogs, and Sipha Sensors 

TSL system Interlock (TSI) switches can be integrated into the electrical circuit for the Lock and 

Unlock Air Valve through the Control and Signal modules to prevent an unintended tool release. 

Tool side and Master side TSI switches are available, contact ATI for Control and signal Modules 

with TSI functionality. The TSI switch is activated using a Trip Dog that is attached to the Hook 

Module. The tool side TSI switch is attached to the Tool Hook Module and connects to the Control 

and Signal module on the Tool side of the Tool Changer. The Master side TSI switch is mounted 

to the Master side of the Tool Changer and connected to the Control and Signal Module. Some 

Control and Signal Modules support sipha sensor TSI, contact ATI for more information. 

Tool Stand Interlock Switches used with Hook and Hanger Mounting 


TSI Switch Assembly with Trip Dog (Left side 9120-TSL-SS-5635 

mounted) 

TSI Trip Dog only for NA2/3 Hooks, (Right 9120-TSL-SS-8024 

Section 9.10.6-9630-20-TSL-SS-5635 

side mounted) 

Tool Stand Interlock Switches used with Vertical Tooling Hook Plate 

TSI Switch Assembly - Vertical Hooks, No 9120-TSL-SS-8074 Section 9.10.7-9630-20-TSL-SS-8074 

Trip Dog 

TSI Trip Dog - Vertical Hooks 9120-TSL-SS-8076 Section 9.10.8-9630-20-TSL-SS-8076 

Master Side Tool Stand Interlock Switch 

Switch Kit for Master Side TSI 9120-TSL-SS-6077 Section 9.10.5-9630-20-TSL-SS-6077 

Sipha Sensor Tool Stand Interlock Switches 

Direct Mount Sipha Sensor Supporting TSI In/ 9120-TSL-SS-7510 Section 9.10.10-9630-20-TSL-SS-7510 

Out and TSIV, 1m Cable Length 2, 3 

Direct Mount Sipha Sensor, 3m Cable Length 9120-TSL-SS-7508 Section 9.10.11-9630-20-TSL-SS-7508 

Sipha Sensor Tool Stand Interlock Switches Actuator 

Direct Mount Sipha Non-contact Switch 9120-TSL-SS-7509 Section 9.10.12-9630-20-TSL-SS-7509 

Actuator 2, 3 

Note: 

1. Other TSI Switch configuration are available contact ATI for information. 

2. Sipha Sensor 9120-TSL-SS-7510 and 9120-TSL-SS-7508 are used with Sensor actuator 

9120-TSL-SS-7509. 

3. The sensing range for the Sipha Sensor is (Make .35” (9mm) and Break .47” (12mm). 


15


Document #9610-20-1058-27 

2.3 Optional TSL System Common Components 

There are components that can be used on either the Pin and Bushing style mounting or Hook style 

mounting Tool Stands. These components provide flexibility to fit most customers’ applications. 

2.3.1 Horizontal Extension Modules 

The TSL Horizontal Extension Module is an option that provides more tool clearance than the 

standard TSL Post Module. It is a steel weldment that mounts directly to the Post Module. The 

Pin and Bushing Module or Hook Module mounts directly to the Horizontal extension. ATI offers 

a standard extension length of 16” straight and a 12” 90°. Other lengths and configurations are 

available upon customer request. 


Horizontal Extension, 16”, Straight 9120-TSL-HE16S-8004 Section 9.9.1-9630-20-TSL-HE16S-8004 

Horizontal Extension, 12”, 90° 9120-TSL-HE12A-7572 Section 9.9.2-9630-20-TSL-HE12A-7572 

Note: 

The Horizontal extension Modules are available in other lengths and configurations, contact ATI for 

specifications. 

2.3.2 Debris Shield Actuator 

The Debris Shield Actuator positions the Debris Shield in the open or closed position. On single 

Tool Stands, the DSA module can be oriented so that the shield swings in the vertical or horizontal 

plane. The shield will swing up to 135 degrees for most arrangements. The Shield Actuator mounts 

directly to the Pin and Bushing Module or the Hook Module, and comes equipped with a pneumatic 

powerclamp to provide actuation of the Shield. The powerclamp comes equipped with integrated 

position sensing that uses PNP proximity sensing to detect Shield Open position. The Debris Shield 

mounts to the Shield Arm which is clamped to the Debris shield Actuator and can be positioned in 

virtually any orientation to accommodate the specific tooling arrangement. 

Debris Shield Actuator - Horizontal 


Debris Shield Actuator - Horizontal 

- 135° 

9120-TSL-DSA-135-7475 Section 9.11.1-9630-20-TSL-DSA-135-7475 

Debris Shield Actuator - Vertical - 

90° 

Debris Shield Actuator - Dual Post - 

Vertical - 135° 

Debris Shield Actuator - Vertical 




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Document #9610-20-1058-27 

2.3.3 Debris Shield and Shield Arm 

The Debris Shield mounts to an aluminum tubular Shield Arm that in turn is mounted to the Debris 

Shield Actuator. The Debris Shield is designed to cover the Tool Changer Tool Side unit when 

the Tool is in storage. The Debris Shield provides protection from dust, weld spatter and other 

debris through the use of weld curtain guards or fire retardant foam. These Side Guards are easily 

removable and can be ordered as spare parts for scheduled maintenance. 

Debris Shields 


Debris Shield 20” with Weld 9120-TSL-DS-20-W7787 Section 9.12.1-9630-20-TSL-DS-20-W7787 

Curtain Shields 

Debris Shield 20” with Fire 

9120-TSL-DS-20-F7788 Section 9.12.2-9630-20-TSL-DS-20-F7788 

Retardant Foam Insert 





Debris Shield 14” with Fire 

9120-TSL-DS-14-F4592 Section 9.12.5-9630-20-TSL-DS-14-F4592 

Retardant Foam 

Shield Arms 

Debris Shield Arm - 90° 16” x 6” 3700-20-7503 N/A 





Debris Shield Arm - 45° 14.2” x 4.7” 3700-20-3527 N/A 


2.3.4 Post-Mounted Tool Support 

The Post-mounted Tool Support mounts to the Post Module and provides support for customer 

tooling. The Post-mounted Tool Supports can be mounted on the 4" or 6" direction on the Post 

Module. Both Supports include a fixed bumper, a Support Roller is available that can be used in 

place of the fixed bumper. 

Post-mounted Tool Support Components 


Adjustable Post Support with Arm 9120-TSL-PS-7980 Section 9.13.1-9630-20-TSL-PS-7980 

Adjustable Post Support for Strut Channel 9120-TSL-PS-7979 Section 9.13.2-9630-20-TSL-PS-7979 

Support - Roller 9120-TSL-PS-8229 Section 9.13.3-9630-20-TSL-PS-8229 


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Document #9610-20-1058-27 

2.4 Determining The Tool Stand Configuration 

A TSL system provides for various Post Module heights and Horizontal Extensions to accommodate a 

variety of customer tooling sizes. Tool presence detection, vertical and horizontal actuated Debris Shields, 

TSI Switches, and Post-mounted Tool Support options to provide the most flexible system for Tool Changer 

models QC-150 and larger. Horizontal or vertical tooling interface plates can be used to secure the Tool 

Changer and customer tooling to the stand. Refer to Section 9.1—TSL Systems with Pin and Bushing 

Style Mounting Modules or Section 9.5—TSL Systems with Hook and Hanger Style Mounting Modules 

for example configurations. Refer to Section 2.1—TSL System with Pin and Bushing Style Mounting or 

Section 2.2—TSL System with Hook and Hanger Style Mounting for TSL system components available. 

To determine the components needed for a Tool Stand, will require knowledge of the system being 

designed. When selecting the Tool Stand components you will need to consider the following information: 

• What model Tool Changer will be used and if add on modules will be required for the customer tooling. 

• If the Tool Stand will support one or two tools and what height Tool Stand will be needed to 

accommodate the dimensions and weight of the tooling. Contact ATI for Tool Stand weight limitations. 

• What size, shape, and Center of Gravity of end-effector and tooling 

• What mounting style Tool Stand will be used, pin and bushing or hook and hanger. 

• Will customer tooling mount directly to a Vertical Tooling Plate with an interface plate attaching the 

Tool changer or will the customer tooling and Tool Changer attach directly to a Tooling Interface plate. 

• Size, reach and capabilities of the robot being used. 

• Area available to accommodate the Tool Stand. 

• What options will be required: Horizontal Extension, Tool Presence Sensing, Tool Stand Interlock 

Switch, Post-mounted Tool Support, and Debris Shields. 

Figure 2.3—Configuring a Tool Stand 

Horizontal Extension 

Tool Change Model 

Electrical Connectors 

and Cables Pneumatic 

Fittings and Hoses 

Optional Utility Modules 


Customer 

Tooling 

Height of Tooling, Adapter Plate, 

Utility Fittings, Hoses, and Cabling 

Will Be Needed to Determine 

the Post Module Height 

Customer 


Post Module 

Post Support 

Depth of the Tooling is limited 

by the Tooling Interface Plate, 

a Horizontal Extension provides 

for additional tool depth. Custom 

Tooling Inerface Plates are available 

contact ATI for information. 


18


Document #9610-20-1058-27 

2.4.1 Configuring a TSL System with Pin and Bushing Mounting Style 

TSL Systems with Pin and Bushing Modules are available in rigid and compliant mountings. 

Tooling Interface Plates provide mounting for the Tool Changer Tool Plate and the customer 

tooling. Customer tooling can be mounted directly to the Vertical Tooling Interface Plate. This 

configuration requires the Tool Changer Tool Plate to be mounted separately to the tooling either 

directly or using an interface plate. The Pin and Bushing Module provides mounting for Sensor 

Modules, TSI Trip Dogs, and Debris Shields. Refer to Section 9.1—TSL Systems with Pin and 

Bushing Style Mounting Modules for example configurations. Refer to Section 2.1—TSL System 

with Pin and Bushing Style Mounting for TSL system components available. 

Figure 2.4—TSL System with Pin and Bushing Mounting Style 


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Document #9610-20-1058-27 

2.4.2 Configuring a TSL System with Hook and Hanger Mounting Style 

TSL Systems with Hook and Hanger style mounting are available in rigid and compliant 

mountings. Tool Hook Modules with Tooling Interface Plates provide mounting for the Tool 

Changer Tool Plate and the customer tooling. Customer tooling can be mounted directly to the 

Vertical Tooling Interface Plate. This configuration requires the Tool Changer Tool Plate to be 

mounted separately to the tooling either directly or using an interface plate. The Hook Module 

provides an integrated mounting for proximity sensors and mounting for TSI Trip Dogs, and Debris 

Shields. Refer to Section 9.5—TSL Systems with Hook and Hanger Style Mounting Modules for 

example configurations. Refer to Section 2.2—TSL System with Hook and Hanger Style Mounting 

for TSL system components available. 

Figure 2.5—TSL System with Hook and Hanger Mounting Style 


20


Document #9610-20-1058-27 

3. Installation 

The Tool Stand is shipped unassembled. The customer must perform the final assembly and determine the proper 

location for the Tool Stand. 

All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the application without 

failing. The routing of electrical and pneumatic lines must minimize the possibility of stress pullout, kinking, 

rupture, etc. Failure of some critical electrical and/or pneumatic lines to function properly may result in injury to 

personnel and equipment. 

3.1 Installing the Post Module 

1. Determine the proper location and orientation for the Tool Stand. 

2. Anchor the Post Module to a smooth flat level floor surface using the eight 20mm through holes that 

are on the Base Plate. (Mounting fasteners are to be provided by the customer). There are eight M12 

threaded holes in the Base Plate that can be used for leveling. Level and mount the Post Module. 

3. Does the application require a Horizontal Extension? 

If yes go to step 4. 

If no go to step 6. 

4. Apply Loctite 242 ® to the four M12 socket head cap screws supplied with the Horizontal Extension. 

5. Attach the Horizontal extension to the Post Module using the four M12 socket head cap screws and 

tighten to 65 ft-lbs. 

6. Are the Pin and Bushing Module(s) or Hook Module(s) installed? 



7. Apply Loctite 242 ® to the four M12 socket head cap screws supplied with the Pin and Bushing or Hook 

Module. 

8. Attach the Pin and Bushing or Hook Module to the Post Module or Horizontal Extension using the four 

M12 socket head cap screws. Tighten to 65 ft-lbs. 

Figure 3.1—Installing a Horizontal Extension and Pin and Bushing or Hook Module 

(4) M12 Socket Head Cap Screws 

Horizontal 

Extension 

(4) M12 Socket 

Head Cap Screws 





Post Module 

9. Determine what type of tooling interface is being used. 

If Tooling Interface Plate, Vertical Tolling Interface Plate, or Vertical Tooling Hook Plate go to step 10. 

If NAx or NBx Tool Hook Modules go to step 12. 


21


Document #9610-20-1058-27 

10. If Tooling Interface Plate or Vertical Tooling Hook Plate is blank, the mounting pattern for the customer 

tooling will have to be machined into the plate. Refer to Section 9.4.1—Tooling Interface Plate Blank or 

Section 9.4.3—Vertical Tooling Interface Plate Blank for detailed information. 

11. Assemble the Tool Changer Tool Plate, Customer Tooling, and Tooling Interface Plate, or Vertical 

Tooling Hook Plate. Refer to the Installation and Operation manual for the specific Tool Changer model 

being installed (http://www.ati-ia.com/products/toolchanger/tool_changer_models.aspx). 

Then go to step 13. 

12. Install the NAx or NBx Tool Hook Modules as instructed in the Installation and Operation manual for 

the NAx Tool Hook Module (http://www.ati-ia.com/products/toolchanger/QCModule.aspx?ID=NAx). 

WARNING: If NAx or NBx Tool Hook Modules are being used to mount the Tool 

Changer and Customer Tooling, the Tool Changer and the Tool Hook Modules must be 

attached to the Interface plate. Failure to attach the Tool Changer and the Tool Hook 

Modules to the Interface plate could cause damage to equipment or injury to personnel. 

For proper installation, refer to the Installation and Operation manual for the NAx Tool 

Hook Module (http://www.ati-ia.com/products/toolchanger/QCModule.aspx?ID=NAx). 

13. Position the tool assembly (Tooling Interface Plate, Tool Change Tool Plate, and Customer Tooling) on 

the Pin and Bushing Module or the Hook Module on the TSL system. Note: Verify that the tool rests 

even and parallel in the Tool Stand. 

14. To continue installation refer to the following sections: 

Section 3.2—Installing a Sensor Module to a Pin and Bushing Module 

Section 3.3—Installing a Proximity Sensor to a Hook Module 

Section 3.4—Installing a Tool Stand Interlock (TSI) Switch 

Section 3.5—Installing a Debris Shield 

Section 3.6—Installing a Post-mounted Tool Support and Post Support Roller 

3.2 Installing a Sensor Module to a Pin and Bushing Module 

There are two types of sensor modules: Dual Sensor Module and Single Sensor Module. 

Section 3.2.1—Installing a Dual Sensor Module 

Section 3.2.2—Installing a Single Sensor Module 

3.2.1 Installing a Dual Sensor Module 

1. Install the bracket as shown in Figure 3.2. 

2. Secure the bracket using the two M8 socket head cap screws. Tighten to 25 in-lbs. 

3. Slide the Proximity sensor on the bracket and initially position so the face of the sensor is .09˝ from the 

side of the Tooling Interface Plate. 

4. Snug the jam nuts finger tight, and connect the sensor cable. 

5. Cycle the tool pick-up and drop off and adjust the sensor position to achieve the desired result. Tighten 

the jam nuts. 

Bracket 

(2) M8 Socket 


Figure 3.2—Installing a Dual Sensor Module 



Tool Changer Tool Plate 

Customer Tooling 

Adjust the sensor 

to an initial position 

.09" from the face 

of the sensor to the 

side of the Tooling 



22

3.2.2 Installing a Single Sensor Module 

1. Remove the tooling from the Tool Stand. 


Document #9610-20-1058-27 

2. Install the Sensor adapter Block supplied with the Pin and Bushing module, as shown in Figure 3.3. 

3. Secure with the two M8 socket head cap screw supplied. Tighten to 250 in-lbs. 

Figure 3.3—Installing the Sensor Adapter Block 


Sensor Adapter 

Bracket 

4. Replace the tooling on the Tool Stand. 

5. Install the Bracket to the sensor Adapter Block as shown in Figure 3.4. 

6. Secure with the two M10 socket head cap screws supplied. Tighten to 25 in-lbs. 

7. Thread the Proximity Sensor into the bracket and initially position so the face of the sensor is 0.2˝ from 

the side of the Tooling Interface Plate. 

8. Apply Loctite 222 ® to the M4 set screw supplied. 

9. Thread the set screw into the bracket to secure the Proximity Sensor. Tighten finger tight. 

10. Connect the sensor cable. 


the set screw to 48 in-oz. 

Figure 3.4—Installing the Single Sensor Module 

Bracket 

Proximity 

Sensor 

M4 Set Screw Nylon Tip 




0.2" from the face 


side of the Tooling 



23


Document #9610-20-1058-27 

3.3 Installing a Proximity Sensor to a Hook Module 

1. Thread the Proximity Sensor into the Hook Module and initially position so the face of the sensor is 

0.19” from the side of the Hook. 

2. Snug the jam nuts finger tight, and connect the sensor cable. 


the jam nuts. 

Figure 3.5—Installing a Proximity Sensor to a Hook Module 

Jam Nuts 




0.19" from the face 


side of the Tool Hook 

3.4 Installing a Tool Stand Interlock (TSI) Switch 

There are several many possible configuration, the following are samples of common Tool Stand Interlock 

switches: 

Section 3.4.1—Pin and Bushing Module with Tooling Interface Plate 

Section 3.4.2—Pin and Bushing Module with Vertical Tooling Interface Plate 

Section 3.4.3—Hook Module with Vertical Tooling Hook Plate or Tool Hook Modules 

3.4.1 Pin and Bushing Module with Tooling Interface Plate 

1. Install the Mounting Plate to Tooling Interface Plate as shown in Figure 3.6. 

2. Secure with two M6 socket head cap screws supplied. Tighten to 50 in-lbs. 

3. Install the Safety Switch to the Mounting Plate. 

4. Apply Loctite 242 ® to the four M5 socket head cap screws supplied with the Safety Switch. 

5. Install the Safety Switch to the Mounting Plate using the four M5 socket head cap screws. Tighten to 

50 in-lbs. Note: The safety switch actuator arm can be reposition to the desired location refer to the 

manufacturer instruction for repositioning the actuator. 

6. Apply Loctite 242 ® to the two M8 socket head cap screws supplied with the Trip Dog. 

7. Install the Trip Dog to the Pin and Bushing Module secure with the two M8 socket head cap screws. 

Initially position the Trip Dog so that it will actuate the Safety Switch about 45° with the tooling secure 

in the Tool Stand. Note: Do not actuate the switch more than 75°. Snug the screws to hold it position. 

8. Connect the cable from the Safety Switch to the tool side control and signal module. 

9. Cycle the tool pick-up and drop off and adjust the Trip Dog position to achieve the desired result. 

Tighten the two M8 socket head cap screws to 100 in-lbs. 


24


Document #9610-20-1058-27 

Figure 3.6—Installing a TSI Switch to a Pin and Bushing Module with a Tooling Interface Plate 

(2) M8 Socket Head 

Cap Screws 

TSI Trip Dog 

Set initial 

trip position 

to 45 deg. 

Mounting Plate 


Safety Switch 

(4) M5 Socket 


Customer to set Switch 

Actuator Arm Orientation 

3.4.2 Pin and Bushing Module with Vertical Tooling Interface Plate 


2. Install the Safety Switch to the Vertical Tooling Interface Plate, as shown in Figure 3.7. 

3. Secure the switch using the four M5 socket head cap screws. Tighten to 50 in-lbs. Note: The safety 

switch actuator arm can be reposition to the desired location refer to the manufacture instruction for 

repositioning the actuator. 

4. Apply Loctite 242 ® to the two M8 socket head cap screws supplied with the Trip Dog. 

5. Install the Trip Dog to the Pin and Bushing Module and secure with the two M8 socket head cap screws. 


in the Tool Stand. Note: Do not actuate the switch more than 75°. Snug the Screws to hold it position. 




Figure 3.7—Installing a TSI Switch to a Pin and Bushing Module with a Vertical Tooling Interface Plate 

(4) M5 Socket 


Set initial 

trip position 

to 45 deg. 

TSI Trip Dog 


Cap Screws 



Safety Switch 





25


Document #9610-20-1058-27 

(4) M5 Socket 


3.4.3 Hook Module with Vertical Tooling Hook Plate or Tool Hook Modules 

1. Install the Switch Mounting Plate to the Tooling Interface Plate as shown in Figure 3.8. 

2. Apply Loctite 242 ® to the three M5 socket flat head cap screws supplied. 

3. Secure the Mounting Plate using the three M5 socket flat head cap screws supplied. Tighten to 50 in-lbs. 

4. Install the Safety Switch to the Mounting Plate. 


6. Install the Safety Switch to the Mounting Plate using the four M5 socket head cap screws. Tighten to 

50 in-lbs. Note: The safety switch actuator arm can be reposition to the desired location refer to the 

manufacture instruction for repositioning the actuator. 

7. Install the Adapter Plate or the Adjustment Bar to the Hook Module. Note: Place Flat Washer between 

the Hook Module and the Adjustment Bar. Secure using the M8 socket head cap screws supplied. 

Tighten to 100 in-lbs. 

8. If the Trip Dog mounting fasteners do not have pre-applied adhesive, apply Loctite 242 ® to the two M8 

socket head cap screws supplied 

M5 Socket Flat 


Trip Dog 

Figure 3.8—Installing a TSI Switch to a Hook Module 

Adjustment Bar 

Flat Washers 

Adapter Plate 

Safety Switch 

(3) M5 Socket Flat 




Cap Screws 

NAx Tool Hook Modules 


(3) M5 Socket Flat 


Safety Switch 


Hook Plate 

Trip Dog 


Cap Screws 



(4) M5 Socket 


9. Install the Trip Dog to the Adapter Plate or Adjustment Bar, secure with the M8 socket head cap screws. 


in the Tool Stand. Note: Do not actuate the switch more than 75°. Snug the Screws to hold it position. 




Figure 3.9—Installing a TSI Switch to a Hook Module 

Set initial trip position to 45 deg. 


26

3.5 Installing a Debris Shield 


Document #9610-20-1058-27 

1. Does the Debris Shield requires a Shield Offset Plate? 



2. Attach the Shield Offset Plate to the Mounting Module using the four M8 socket head cap screws 

supplied. Tighten to 250 in-lbs. 

3. Install the Clamp Mounting Bracket to the Mounting Module or Shield Offset Plate using the three M8 

socket head cap screws supplied. Adjust the Clamp Mounting Bracket so that when the Debris Shield is 

installed there will be plenty of clearance between the Tool Changer Tool Plate and the Debris Shield. 

Snug tight, they will be tighten after shield is set to the proper height. 

4. Attach the Debris shield Actuator to the Clamp Mounting Bracket using the four M8 socket head cap 

screw supplied as shown in Figure 3.10. Tighten to 250 in-lbs. 

5. Make sure the two M6 set screws in the clamp on the actuator are far enough out that they allow the 

Shield arm to slide into the clamp. Remove the four M6 socket head cap screws and apply Loctite 222 ® 

and replace screws. 

6. Insert the Shield Arm into the clamp on the Debris Shield Actuator. Snug the four socket head cap screws 

so that you can still slide the Shield Arm in and out. 

7. Remove the four M6 socket head cap screws holding the Debris Shield Clamps to the debris Shield, 

apply Loctite 222 ® and replace the screws. Leave clamps loose. 

8. Slide the Debris Shield on the Shield Arm. 

Figure 3.10—Installing a Debris Shield 

Debris Shield Clamps 


Debris Shield 

Shield Arm 

Mounting Module (Hook Module Shown) 

Shield Offset Plate 


(2) M6 Set Screws 


Clamp 



Clamp Mounting Bracket 


9. Adjust the Debris Shield and Shield Arm so that the shield is centered above the Tool Changer Tool Plate 

as shown in Figure 3.11. 

10. Tighten the four M6 socket head cap screws on the clamp holding the Shield Arm to the Actuator clamp. 

11. Tighten the four M6 socket head cap screws on the two clamps holding the Debris Shield to the Shield 

Arm. 


27


Document #9610-20-1058-27 

12. Remove the two M6 set screws from the clamp on the actuator and apply Loctite 222 ® and replace. 

Tighten to 25 in-lbs. 

13. Loosen the three M8 socket head cap screws holding the Clamp Mounting and Actuator to the Mounting 

Module or Shield Offset. 

14. Adjust the Debris Shield height so that it clears the Tool Changer Tool Plate and utility lines. 

15. Tighten the three M8 socket head cap screws holding the Clamp Mounting and Actuator to the Mounting 

Module or Shield Offset to 250 in-lbs. 

16. Connect the open and close pneumatic lines to the actuator. Refer to Figure 3.11. Any additional valve 

required for operating the actuator is supplied by the customer. Refer to Section 8.3.1—Debris Shield 

Actuators Specifications. 

17. Connect the cable to the actuator sensors. Cabling and line termination is supplied by the customer. 

Refer to Section 8.3.1—Debris Shield Actuators Specifications. 

18. Cycle the Debris Shield and adjust as necessary. Note: Verify that the TSL Debris Shield actuates open 

and closed freely and without interference from robot dressing or other objects. 

19. Adjust the Flow Controls, start with flow control valve closed, then open 1/4 turn. Cycle the actuator and 

adjust the flow control valves as desired. 

20. Verify that the tool path will not interfere with the Debris Shield when the Shield is in its OPEN position. 

Figure 3.11—Adjust Debris Shield 

Center Debris 

Shield over the 

Tool Changer 


(4) M6 Socket 


(4) M6 Socket 


(2) Set Screws 

8mm Quick Connect 

Sensor Connection 

Flow Control Valve 



Reducer Pneumatic 

Connection Open 

Flow Control Valve 


Reducer Pneumatic 

Connection Close 

Clamp Mounting 

Adjust the height of 

the Debris Shield so 

that it clears the Tool 

Changer Tool Plate 

and all utility lines 

(3) M8 Socket 



28


Document #9610-20-1058-27 

3.6 Installing a Post-mounted Tool Support and Post Support Roller 

1. Assemble the Rear Post Support Plate, Front Post Support Plate, four 3/8" Threaded Rods as shown in 

Figure 3.12. 

2. Apply Loctite 242 ® to eight 3/8 flange hex locknuts and thread on the ends of the threaded rods. Tighten 

to 400 in-lbs. 

NOTICE: Do not tighten nut on one rod at a time. Alternate tightening each rod a little at a time 

until all are tighten to the proper torque. 

3. Apply Loctite 242 ® to the M16 socket head cap screw. 

4. Attach the Post Support Arm to the Front Post Support Plate, secure with the M16 socket head cap 

screw. Position the Arm as desired. Tighten the M16 socket head cap screw to 150 ft-lbs. 

Figure 3.12—Installing a Post-Mounted Tool Support 

(8) 3/8" Flange 

Hex Locknut 

Post Support Arm 

3/8" Threaded Rod 

Front Post 

Support Plate 

M16 Socket 

Head Cap Screw 

Rear Post 

Support Plate 

5. Apply Loctite 242 ® to three 3/8" flange hex lock nuts. Attach the Bump Stop or optional Post Support 

Roller to the end of the threaded rod and secure with a 3/8" flange hex locknut. Tighten to 400 in-lbs. 

6. Thread a 3/8” flange hex locknut on the threaded rod and insert the threaded rod through the Post 

Support Arm as shown in Figure 3.13. 

7. With the tooling supported in the Tool Stand, set the bump stop or optional Post Support Roller against 

the tooling. Thread a 3/8” flange hex locknut on the threaded rod and tighten to 400 in-lbs. 

Figure 3.13—Installing a Post-Mounted Tool Support and Post Support Roller 

(2) 3/8" Flange 

Hex Locknut 

Customer 


Post Support Roller (Optional) 

Post Support Arm 

3/8" Threaded Rod 


29


Document #9610-20-1058-27 

4. Operation 

The TSL system is intended for use with No-touch locking Tool Changers only, such as ATI changers QC-150 and 

larger. 

4.1 Tool Change Programming Procedure Tips 

• Jog robot so that TSL Tooling Interface Plate is directly above the Mounting Module on the Post 

Module. 

• Carefully lower the TSL Tooling Interface Plate toward the Mounting Module so that the post locating 

pins are centered in the Plate Bushings. 

• When the pins and bushings are nearly touching, adjust the robot position making sure that the Tool 

with Interface Plate are nearly parallel to the Post Module. Be careful not to bind the locating pins 

during this procedure. 

• Carefully jog the robot down vertically, until all 3 pins and bushings are fully engaged and distance 

between the Mounting Module and the Tooling Interface Plate is less than the maximum tool drop off of 

3mm (0.118"). 

• Record this position as drop off point. Note: This can be used as an initial pick up point as well, but 

may have to be adjusted depending on the deflection caused by the weight of the tooling. 

• If equipped, make sure TSI switch is tripped and Proximity sensor indicates tool is in stand. 

• If dropping off the Tool, adjust the robot payload to remove the weight of the tooling. 

• Move the robot up vertically making sure the Tool with Interface Plate are nearly parallel to the Post 

Module until the tool is completely clear of the TSL Debris Shield envelope, and record this position as 

Clear of Tool Stand. 

4.2 TSL System with Pin and Bushing Style Mounting Operation 

CAUTION: Damage will occur if contact is made between the TSL Pin and Bushing 

Tooling Plate and the mounting module prior to tool drop-off 

For proper tool drop-off, ATI recommends 3mm (0.118") maximum clearance between TSL Pin and Bushing 

Mounting Module contact surfaces and the TSL Tooling Interface Plate contact surface. See Figure 4.1 for 

reference. 

Figure 4.1—Maximum Clearance for Proper Tool Drop-off for Pin and Bushing Style Mounting 

3mm (.118") Gap max. 

Prior to Tool Drop Off 





30

4.3 TSL System with Hook Style Mounting Operation 


Document #9610-20-1058-27 

CAUTION: Damage will occur if contact is made between the TSL Tooling Hook Plate 

and the mounting module prior to tool drop-off 

For proper tool drop-off, ATI recommends 3mm (0.118”) maximum clearance between the Hook Mounting 

Module contact surfaces and the Tooling Hook Plate contact surface. The reference dimension is shown 

for ease measurement, 7.9mm (0.311”) maximum from the top of the Hook to the top of the Hanger. See 

Figure 4.2 for reference. 

Figure 4.2 —Maximum Clearance for Proper Tool Drop-off for Hook Style Mounting 

7.9mm (.311") Reference from the top 

of the Hook to the top of the Hanger 

3mm (.118") Gap max. 

Prior to Tool Drop Off 

Hook 

Hanger 

Tooling Hook 

Plate Assembly 

Hook Module 



31


Document #9610-20-1058-27 

5. Maintenance 

WARNING: Do not perform maintenance or repair on Tool Changer, modules, or tool stand 

components unless the tool is safely supported or docked in the Tool Stand and all energized 

circuits (e.g. electrical, air, water, etc.) have been turned off. Injury or equipment damage can 

occur with tool not docked and energized circuits on. Dock the tool safely in the Tool Stand 

and turn off all energized circuits before performing maintenance or repair on Tool Changer, 

modules, or tool stand components. 

5.1 Preventative Maintenance 

It is recommended that the following areas should be checked at least once every 5,000 cycles. Earlier intervention 

may be necessary if a problem is identified prior to the scheduled maintenance checks. 

5.1.1 All TSL Systems 

• Inspect Post Module Base Plate Anchor Bolts to verify secure connection to floor. 

• Inspect all hoses and utility lines for wear. Repair or replace as needed. 

• Check to Verify Horizontal Extensions, Pin and Bushing Modules, and Hook Modules have 

not loosened. If required, apply Loctite 242 ® and tighten mounting fasteners as specified in 

Section 3.1—Installing the Post Module. 

• Inspect all steel components for rust, even steel components with black oxide finish such as 

trip dogs and mounting hooks may develope rust. If needed clean and lubricate with a brush 

and M1 oil. For wet or humid environments more frequent inspection is recommended. 

• If equipped check that all sensor module mounting fasteners are not loose. If required 

apply Loctite ® and tighten fasteners. Check that proximity sensor is not loose and correctly 

positioned, adjust and tighten if required. Refer to Section 3.2—Installing a Sensor Module to 

a Pin and Bushing Module for details. 

• If equipped inspect and wipe clean all proximity sensor faces to ensure proper functioning. 

• If equipped check that all TSI Switch and Trip Dog mounting fasteners are not loose. If 

required apply Loctite ® and tighten fasteners. Check TSI Switch adjusted properly, adjust and 

tighten if required. Refer to Section 3.4—Installing a Tool Stand Interlock (TSI) Switch. 

• If equipped check that all Debris Shield, Shield Arm, and Debris Shield Actuator mounting 

fasteners are not loose. If required apply Loctite ® and tighten fasteners. Check Debris Shield 

operation and adjust if necessary. Refer to Section 3.5—Installing a Debris Shield. 

• If equipped check that all Post Support and Post Support Roller mounting fasteners are not 

loose. If required apply Loctite ® and tighten fasteners. Refer to Section 3.6—Installing a Postmounted 

Tool Support and Post Support Roller 

5.1.2 TSL Systems with Pin and Bushing Style Mounting Modules 

• Clean and Lubricate Pin and Bushing Module. Check the three Alignment Pins for looseness, 

wear, and damage. If loose apply Loctite ® and tighten, if worn or damaged replace. Check 

the three Alignment Bushing for wear and damage. If worn or damaged replace. Refer to 

Section 5.1.4.1—Clean, Lubricate, and Replace Alignment Pins and Bushings for details. 

• Clean and Lubricate the Compliant Spring Housing to ensure that the Compliant Interface 

slides freely. Refer to Section 5.1.4.2—Replace Compression Spring and Lubricate the 

Compliant Mounting Module 

• Inspect the Compliant Interface Compression spring for damage. Replace if needed. Refer to 

Section 5.1.4.2—Replace Compression Spring and Lubricate the Compliant Mounting Module 


32


Document #9610-20-1058-27 

5.1.3 TSL Systems with Hook and Hanger Style Mounting Modules 

• Check the two shoulder bolts for looseness, wear, and damage. If loose apply Loctite ® and 

tighten, if worn or damaged replace. Check the two hooks for looseness, wear and damage. 

If loose tighten the three M10 socket head cap screws, if worn or damaged replace. Refer to 

Section 5.1.4.3—Inspect, Tighten, and Replace Shoulder Bolts and Hook Attachments. 

• Lubricate the Compliant Spring Housing to ensure that the Compliant Interface slides freely. 

Refer to Section 5.1.4.2—Replace Compression Spring and Lubricate the Compliant Mounting 

Module 

• Inspect the Compliant Interface Compression spring for damage. Replace if needed. Refer to 

Section 5.1.4.2—Replace Compression Spring and Lubricate the Compliant Mounting Module 

5.1.4 Preventative Maintenance Procedures 

The following procedures provide preventative maintenance instruction to provide 

5.1.4.1 Clean, Lubricate, and Replace Alignment Pins and Bushings 

1. Remove the tool from the Tool Stand. 

2. Using a lint free rag remove the debris from the Alignment Pins, Alignment 

Bushing, and top surface of the Mounting Module. Also remove the debris form 

the two Bushings and Alignment Pin in the Tooling Interface Plate shown in 

Figure 5.1. 

Figure 5.1—Clean and Lubricate the Alignment Pins and Alignment Bushings 

(2) Alignment Pins 

(2) Alignment 

Top Surface of the 

Bushings 


Alignment Pin 

Alignment Bushing 

Apply MobilGrease® XHP222 Special 

grease to the contact surfaces of the 

Alignment Pins and Alignment Bushing 

3. Inspect the three Alignment Pins for looseness, wear, or damage. 

a. If worn or damaged remove, discard, and replace with new Alignment 

Pin. Apply Loctite 242 ® to the threads of the new pin and thread into the 

Mounting Module. Tighten to 250 in-lbs. 

b. If loose, remove and apply Loctite 242 ® to the threads. Thread into the 



33


Document #9610-20-1058-27 

4. Inspect the three Alignment Bushings for wear or damage. If worn or damaged 

remove, discard, and replace with new Alignment Bushing. Press out old bushing 

using an arbor press, then press in new bushing. 

5. Apply liberal amounts of MobilGrease ® XHP222 Special grease to the Alignment 

Pins and the Alignment bushing on the Mounting Module as shown in Figure 5.1. 

6. Replace the tool in the Tool Stand. 

5.1.4.2 Replace Compression Spring and Lubricate the Compliant 



2. Remove the four M12 socket head cap screws securing the Compliant Mounting 

Module to the Post Module, and remove the Compliant Mounting Module. 

3. Remove the M5 set screw from the Compliance Spring Housing. 

Figure 5.2—Remove the Mounting Module form the Post Module 

Compliant Mounting module 

(Pin and Bushing Module shown) 


M5 Set Screw 

4. Using a 10mm allen wrench, from the bottom of the Mounting Module loosen 

the Preload Bolt until the top of the spring is flush with the top of the Compliance 

Spring Housing. 

5. Remove the two M10 socket head cap screws in the top of the Compliance Mount 

Interface Plate. 


34


Document #9610-20-1058-27 

Figure 5.3—Remove the Mounting Module form the Post Module 


Compliant Mount Interface Plate 

Loosen the Preload Bolt until the 

Top of the spring is flush with the 

top of the Compliance Spring 

Housing 

Compliance Spring Housing 

10mm Allen Wrench 

6. Lift out the Compliance Spring Housing from the Compliance Mount Interface 

Plate. 

7. Clean dirt and debris from the Compliance Spring Housing and Compliance Mount 

Interface Plate. 

8. Remove the Compression Spring from the Compliance Spring Housing. 

Figure 5.4—Lubricate the Compliance Spring Housing 

Compression Spring 

Apply MobilGrease® XHP222 

Special grease to the contact 

surfaces on the Compliance 

Spring Housing 


Preload Bolt 


9. Inspect for damage or wear. If spring is damaged or worn discard old spring and 

replace with a new spring. 

10. Apply MobilGrease ® XHP222 Special grease to the Compliance Spring Housing 

as shown in Figure 5.4. 


35


Document #9610-20-1058-27 

11. Apply Loctite 242 ® to the exposed threads on the Preload Bolt. 

12. Assemble the Compliance Spring Housing to the Compliance Mount Interface 

Plate. 

13. Apply Loctite 242 ® to the Tighten the two M10 socket head cap screws. Insert into 

the Compliance Mount Interface Plate and tighten to 250 in-lbs. 

14. Tighten the preload bolt until the top of the compression spring just touches the 

Compliant Mount Interface Plate. To set the proper compliance preload, refer to 

Table 5.1 for the number of additional turns required for a specific preload force 

desired. 

Figure 5.5—Lubricate the Pin and Bushings 

Tighten the Preload Bolt until the Commpression Spring 

just touches the Compliant Mount Interface Plate 

Compression Spring 



10mm Allen Wrench 

Table 5.1—Compliance Preload Settings 

Mounting Module Part number Preload Setting Number of additional Turns 

9120-TSL-CMB-C500 - Pin and Bushing Module 

9120-TSL-CMH-C500 - Hook Mounting Module 

500 lbs. 3.6 

9120-TSL-CMH-C800 - Hook Mounting Module 800 lbs. 5.7 

9120-TSL-CMB-C900 - Pin and Bushing Module 900 lbs. 6.4 

9120-TSL-CMB-C1200* - Pin and Bushing Module 1200 lbs. 4.4 

Note*: Mounting Modules with compliance preload 1000 lbs and higher require a heavy duty spring. 

15. Apply Loctite 222 ® to the M5 set screw and install into the Compliance Spring 

Housing. Tighten to 30 in-lbs. 

16. Apply Loctite 242 ® to the four M12 Socket head cap screws. 

17. Assemble the Mounting module to the post module and secure using the four M12 

socket head cap screws. Tighten to 65 ft-lbs. 



36


Document #9610-20-1058-27 

5.1.4.3 Inspect, Tighten, and Replace Shoulder Bolts and Hook 

Attachments 


2. Using a lint free rag remove the debris from the shoulder bolts, Hook Attachments 

and the face of the Proximity Sensor. 

3. Inspect the two Shoulder Bolts in the Mounting module for looseness, wear or 

damage. 

a. If worn or damaged remove, discard, and replace with new shoulder bolt. 

Apply Loctite 242 ® to the threads of the new Shoulder Bolt and thread into 

the Mounting Module. Tighten to 50 in-lbs. 

b. If loose, remove and apply Loctite 242 ® to the threads. Thread into the 


4. Inspect the two Hook Attachments in the Tooling Interface Plate for looseness, 

wear or damage. 

a. If worn or damaged remove the three M10 socket head cap screws 

and remove the Hook attachment. Discard and replace with new Hook 

Attachment. Assemble the Hook Attachment to the Tooling Plate, secure with 

the three M10 socket head cap screws. Tighten to 38 ft-lbs. 

b. If loose, tighten the three M10 socket head cap screws to 50 in-lbs. 


Figure 5.6—Inspect, Tighten, and Replace the Shoulder Bolts and Hook Attachments 

Remove Debris form the Face 

Shoulder Bolt 

of the Proximity Sensor 

(3) M10 Socket 

Head Cap screws 

Hook Attachment 

Remove Debris 

form the Shoulder 

Bolts and Hook 

Attachments 


37


Document #9610-20-1058-27 

6. Troubleshooting 

Refer to the table below for trouble shooting information. 

Symptom Possible Cause Correction 

Tool dropoff 

location 

no longer 

repeatable 

Tool position 

while in storage 

is no longer 

straight and 

parallel 

Proximity 

Sensor Fails 

Debris Shield 

malfunctioning 

Tool Stand 

Interlock Switch 

not functioning 

properly 

Compliant Mounting 

Module may need 

lubrication. 

Compression Springs 

for compliant mounting 

module may be damaged. 

Tool Alignment Pin may 

be loose, worn, damaged, 

or missing. 

Alignment Bushing may 

be worn 

Shoulder bolt may be 

loose, worn or missing. 

Hook attachment may be 

loose or worn. 

Debris build up on 

Proximity Sensor. 

Proximity sensor loose or 

not positioned properly. 

Sensor cable broken or 

damaged. 


damaged or not 

functioning. 

Debris Shield mounting 

loose or out of adjustment. 


sensor malfunctioning or 

cables damaged. 

TSI Switch or Trip Dog 

out of adjustment or loose 

mounting fasteners 

TSI Switch or cable 

damaged. 

Inspect compliant movement and lubricate if necessary. 

Refer to Section 5.1.4.2—Replace Compression Spring 

and Lubricate the Compliant Mounting Module 

Inspect compression spring for damage, replace if needed. 

Refer to Section 5.1.4.2—Replace Compression Spring 

and Lubricate the Compliant Mounting Module 

Tighten or replace Alignment Pins if necessary. Refer to 

Section 5.1.4.1—Clean, Lubricate, and Replace Alignment 

Pins and Bushings 

Inspect the Alignment bushings for wear. Replace if 

necessary. Refer to Section 5.1.4.1—Clean, Lubricate, and 

Replace Alignment Pins and Bushings 

Inspect shoulder bolt, tighten or replace if necessary. 

Refer to Section 5.1.4.3—Inspect, Tighten, and Replace 

Shoulder Bolts and Hook Attachments 

Inspect Hook attachment, tighten or replace if necessary. 

Refer to Section 5.1.4.3—Inspect, Tighten, and Replace 

Shoulder Bolts and Hook Attachments 

Check for debris build up and clean if necessary. 

Verify that the correct distance between sensing face and 

target is set. Adjust if necessary. For Pin and Bushing 

Mounting Modules refer to Section 3.2—Installing a Sensor 

Module to a Pin and Bushing Module. For Hook and 

Hanger Mounting Modules refer to Section 3.3—Installing a 

Proximity Sensor to a Hook Module. 

Inspect sensor cable for damage, test continuity, replace if 

damaged. 

Inspect Proximity Sensor for damage, test sensor 

Inspect mounting for looseness, tighten fasteners. Inspect 

for proper adjustment, adjust if necessary. Refer to 

Section 3.5—Installing a Debris Shield. 

Inspect sensor cable for damage, test continuity, replace if 

damaged. Inspect Sensor for damage, test sensor, replace 

if necessary. 

Inspect TSI Switch and Trip Dog for loose mounting 

fasteners and adjustment, Tighten fasteners or adjust 

Switch and Trip Dog. Refer to Section 3.4—Installing a Tool 

Stand Interlock (TSI) Switch. 

Inspect switch cable for damage and test for continuity 

if damaged replace. Test Switch for functionality if not 

functioning replace. 


38


Document #9610-20-1058-27 

Symptom Possible Cause Correction 

Tool/End- 

Effector 

malfunctioning 

Utility lines and cables 

damaged. 

Tool Changer or utility 

modules not functioning 

properly. 

7. Recommended Spare Parts 

The following items are commonly used as spare parts for the TSL system. 

Other components are available upon request. 

Inspect utility lines and cables for damage or wear. Inspect 

all connections for damage. Test cable continuity. Replace 

any damaged utility lines and cables. 

Verify Tool Changer and utility modules for proper function. 

Refer to the Tool Changer and module Installation and 

Operation manual for troubleshooting. 

Model Part Number Name 

Common Tool Stand 

Components 

Tool Stand with the 

Pin and Bushing 

Style Mounting 

Tool Stand with the 

Hook and Hanger 

Style Mounting 

8590-9909999-92 PNP Prox Sensor 5mm sensing Range, 18mm Barrel, Shielded 

8590-9909999-103 Proximity Sensor 18mm Barrel, PNP 3 wire DC 5mm range 

8590-9909999-141 Proximity Sensor, PNP, 18mm Barrel, 8mm Range, Shielded 

8590-9909999-145 Proximity sensor, 18mm Barrel Prox, PNP 3 wire DC, Embeddable, 

PTFE Coated 

3610-3207601-10 Compression Spring for Compliance under 1000 lbs. 

3610-3507601-10 Heavy Duty Compression Spring for Compliance over 1000 lbs. 

3700-20-3323 Tool Stand Alignment Pin 

3710-20-1028 Large Tool Stand Bronze Bushing 

3500-2035175-11 Shoulder Bolt 

3700-20-5697 TSL Hook Attachment 

7.1 Part Number Cross Reference 

7.1.1 TSL Systems with Pin and Bushing Style Mounting 

Section 2.1.2—Pin and Bushing Mounting Modules 

Original Part Number New Part Number Description 

9120-TSL-CMB-R000 9120-TSL-RMB-R000 Pin and Bushing Module, Rigid 

Section 2.1.3—Tooling Interface Plates 

9120-TSL-HBB-4115 9120-TSL-TP-4104 Tooling Interface Plate - Blank 

9120-TSL-HBQ-8389 9120-TSL-TP-8389 Tooling Interface Plate for QC-150 - Blank 

9120-TSL-VBB-3328 9120-TSL-TP-3328 Vertical Tooling Interface Plate - Blank 

7.1.2 TSL Systems with Hook and Hanger Style Mounting 

Section 2.2.2—Hook Mounting Modules 

Original Part Number New Part Number Description 

9120-TSL-CMH-R000 9120-TSL-RMH-R000 Hook Module, Rigid 


39


Document #9610-20-1058-27 

8. Specifications 

Weights shown below are prior to custom machining and additional tooling requirements. 

8.1 Components for TSL Systems with Pin and Bushing Style Mounting 

Part Description Material Approx. Weight-Mass 

Post Module with one Mounting Module, Steel weldment with Anodized T-6 

186 lbs. 

48” Tall 

Aluminum Mounting Modules 

Post Module with two Mounting Modules, Steel weldment with Anodized T-6 

203 lbs. 

48” Tall 


Pin and Bushing Module, Rigid Anodized T-6 Aluminum 16.8 lbs. 

Pin and Bushing Module, Compliant Anodized T-6 Aluminum 16.4 lbs. 

Tooling Interface Plate - Blank Anodized T-6 Aluminum 15.9 lbs. 

Tooling Interface Plate for QC-150 - Blank Anodized T-6 Aluminum 12.5 lb. 

Vertical Tooling Interface Plate - Blank Anodized T-6 Aluminum 11.0 lbs 

8.2 Components for TSL Systems with Hook and Hanger Style Mounting 

Part Description Material Approx. Weight-Mass 

Post Module with one Mounting Module, Steel weldment with Anodized T-6 

184 lbs. 

48” Tall 


Post Module with two Mounting Modules, Steel weldment with Anodized T-6 

199 lbs. 

48” Tall 


Hook Module, Rigid Anodized T-6 Aluminum 15.3 lbs. 

Hook Module, Compliant Anodized T-6 Aluminum 14.8 lbs. 

Vertical Tooling Interface Plate - Blank Anodized T-6 Aluminum 10.6 lbs 

8.3 Common Optional Components for TSL Systems 

Part Description Material Weight-Mass 

Debris Shield Actuator - Horizontal - 135° Steel weldment 42.0 lbs 

Horizontal Extension, 12”, 90° Steel weldment 40.4 lbs. 

8.3.1 Debris Shield Actuators Specifications 

Part Number 9120-TSL-DSA-135-7475 9120-TSL-DSA-90-7477 9120-TSL-DSA-135-7476 

Max. Operating pressure 

116 psi 

Min. Operating pressure 

44 psi 

Min Operating time 

1.0 second to open, 1.0 second to close 

Actuation Horizontal - 135° Vertical - 90° Vertical - 135° 

Pneumatic Ports 

Pneumatic Ports 6mm quick connect 

Sensing Positions 

Open and closed 

Sensor Output 

N.O., PNP 

Sensor Supply Voltage 

10 to 30 VDC 

Sensor Current Load 

≤150 mA 

Figure 8.1—Debris Shield Sensor Wiring Diagram (SMC Clamp) 


40


Document #9610-20-1058-27 

9. Drawings 

9.1 TSL Systems with Pin and Bushing Style Mounting Modules 

9.1.1 Rigid Mounting, Single Sensor, TSI Switches, Vertical Debris Shields 

8X 20 

Thru 

8X M16X2.0 

Thru 

406 

51 

60 

419 

19 

210 

457.2 

Square 

184 

368 44.5 

Post is steel weldment 

6" x 4" cross section 

13 

Plate 

28 

Pins 

1245 

1248 

Rev. Description Initiator Date 

Part Numbers: 

(A) Tool Post: 9120-TSL-ASY-7615 

(B) Tool Plate: 9120-TSL-TP-4104 

(C) Safety Switch: 9120-TSL-SS-8026 

(D) Actuator: 9120-TSL-DSA-120-7511 

(E) Arm: 3700-20-3376 

(F) Debris Shield: 9120-TSL-DS-14-F4592 

(F) 

(E) 

(D) 

(B) 

20.3 

(C) 

(A) 

NOTES: UNLESS OTHERWISE 

SPECIFIED. 

DO NOT SCALE DRAWING. 

ALL DIMENSIONS ARE IN 

MILLIMETERS. 

1031 Goodworth Drive, Apex, NC 27539, USA 

Tel: +1.919.772.0115 Email: info@ati-ia.com 

Fax: +1.919.772.8259 www.ati-ia.com 

ISO 9001 Registered Company 

PROPERTY OF ATI INDUSTRIAL AUTOMATION, INC. NOT TO BE REPRODUCED IN ANY 

MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI. 

DRAWN BY: 

CHECKED BY: 

D. Swanson 8/1/13 

D. Wagner 8/2/13 

TITLE 

TSL Assembly: ASY-7615, TP-4104, SS-8026, DSA-120- 

7511, 3700-20-3376 and DS-14-F4592 

3rd ANGLE PROJECTION 

SCALE SIZE DRAWING NUMBER 

REVISION 

- 1 1 1:13 B 01 

PROJECT # SHEET OF 9230-20-4223 


41


Document #9610-20-1058-27 

9.1.2 Rigid Mounting, TSI Switches, Vertical Debris Shields 

48 

1215 


01 Initial Drawing DSS 01/16/2014 

22 

559 

Note 2 

Note 2 

56 

1415 

Sheet Description 

1 General View of Tool Stand 

2 Final Assembly and Dimensional Detail 

3 9120-TSL-TP-4104 Details 

Assembly Notes: 

1. 

2. 

Customer to supply I/O block for sensors. 

TSL Tooling Interface Brackets and Interlock Switches ordered and shipped separately. 

32 

811 

ITEM NO. QTY. PART NUMBER DESCRIPTION 

1 1 9120-TSL-ASY-7677 TSL Dual Stand - Dual R000, SMA, SS - 30" High 

2 2 3700-20-3376 Tool Stand Shield Arm 

3 2 9120-TSL-DS-14-F4592 Debris Shield 14" with Fire Retardant Foam Insert 

4 2 9120-TSL-DSA-120-7511 Shield Actuator, 120° Swing 


SPECIFIED. 



MILLIMETERS. 


DRAWN BY: 

CHECKED BY: 

D. Swanson 1/16/14 

J. Winterroth 1/16/14 

TITLE 








9120-TSL-ASY-7677 w/ Debris Shield - Customer Drawing 

1 3 1:10 B PROJECT # SHEET OF 9230-20-7704 01 

REVISION 


42


Document #9610-20-1058-27 

Base Mounting Dimensions 

457 

419 

210 

184 

19 

8X 20 Thru 

8X M16X2.0 Thru 

28 

Pins 

Post is steel 

weldment 

6" x 4" 

cross section 

787 

724 

52 

30 

762 

Post Height 

T.O.P. 

64 

Assembly Notes: 

13 

Plate Thickness 

3. Interface Bracket, Interlock Switch, Debris Shield Actuator, Debris Shield and Shield Arm 

are shipped loose. To be installed by customer. 

4. Dry fasteners installed hand tight on Tool Stand for shipment. Customer to set final placement and 

secure with suggested Loctite or similar threadlocker and torque to recommended torque value. 


- See Sheet1 - - 

4X M6 SHCS 

222 / 80 in-lbs 

Note 4 

2X M6 Set Screw 

222 / 25 in-lbs 

Note 4 

4X M6 SHCS 

222 / 89 in-lbs 

Note 4 

3700-20-3376 

Shield Arm 

Note 3 

9120-TSL-DSA-120-7511 


120 Swing, Position Sensing 

M12X1, 4 pin 

Note 3 

G1/4" (BSPP) Connections on 

Open/Close Flow Controls 

9120-TSL-DS-14-F4592 

Debris Shield, 14" Wide 

Fire Retardant Foam 

Note 3 

2X M5 SHCS 

Pre / 50 in-lbs 

4X M8 SHCS 


3X M8 SHCS 


9120-TSL-SS-8026 

Interlock Switch Assembly 

M12X1, 4 pin 

Note 3 

Customer to orient 

switch arm as needed 

2X M6 SHCS 


9120-TSL-TP-4104 

Note 3 

9120-TSL-ASY-7677 

(REF: 9230-20-7686) 

9120-TSL-SMA-7979 

Sensor Module 

PNP, 18mm Shielded, 

PTFE Coated 

M12X1, 4 pin 


SPECIFIED. 



MILLIMETERS. 







DRAWN BY: D. Swanson 1/16/14 

CHECKED BY: J. Winterroth 1/16/14 

TITLE 




REVISION 



43


Document #9610-20-1058-27 

222.3 

359.4 

381 

48.9 

264.2 

240.3 

287.7 

Customer Notes: 

5. Interface Bracket are shipped loose, to be installed by customer. 

6. Blank Interface Bracket - Customer to machine. 

7. Plate Material: 6061-T6 Softcoat Black Anodized. 

20.3 

Customer to add 

Mounting Patterns 

160 

190.5 


SPECIFIED. 



MILLIMETERS. 








DRAWN BY: D. Swanson 1/16/14 

CHECKED BY: J. Winterroth 1/16/14 



TITLE 



REVISION 



44


Document #9610-20-1058-27 

9.1.3 Rigid Mounting, TSI Switches, Horizontal Debris Shields 

48.05 

1220.4 

Clamp shown in 

closed position. 

52.68 

1338.2 

Note 1 


Shown with customer tool. 

58.59 

1488.2 

Sheet Description 

1 General View of Tool Stand 

2 Final Assembly and Dimensional Detail 

3 9120-TSL-TP-7571 & Mounting Detail 

4 912TSL-TP-7572 & Mounting Detail 

Notes: 

1. TSL Tooling Interface Bracket and TSL Interlock Switch shown for illustration purposes only. 

2. Customer to supply one independent valve per tool stand for actuator control. 

Customer to supply interbus I/O module for actuators, sensors & valve control. 

01 Initial Drawing JMW 12/31/2012 

Note 1 


Shown with customer tool. 

9120-TSL-ASY-7571 


1 1 9120-TSL-PM-248B-R000 

TSL Dual Post Weldment, 2 tools, 48" with Noncompliant 

Interface Modules both sides 

2 4 9120-TSL-SS-7511 TSL Tool Stand Interlock Trip Dog Assembly 

3 1 9120-TSL-DSA-135-7475 TSL Debris Shield Actuator - Dual Post - Horizontal - 135° 

4 1 3700-20-7972 TSL DSA Arm Mount Adapter 



6 1 9120-TSL-DS-17-B3528 Debris Shield 17" Wide with Leather Guards 



SPECIFIED. 






MILLIMETERS. 



DRAWN BY: 

CHECKED BY: 

J. Winterroth, 12/17/12 

D. Swanson, 12/31/12 

TITLE 

TSL Application Drawing for 9120-TSL-ASY-7571 



121210-1 1 4 1:20 B 01 


REVISION 


45


Document #9610-20-1058-27 

19.1 

Shield shown open 

135° 

8X 20 Thru 

8X M16X2 Thru 

Adjust height settings 

of shield actuator here 

(As required). 



419 

210 184 


Adjust height settings 

of trip dog here 

(As required). 

DETAIL A 

SCALE 1 : 4 

Note 4 

4X M5 SHCS 

242 / 75 in-lbs 

Note 4 

2X M6 SHCS 


Note 4 


Interface Bracket 

Note 5 


222 / 25 in-lbs 

Note 5 

4X M6 SHCS 

222 / 89 in-lbs 

3700-20-3527 

Shield Arm 

9120-TSL-DS-17-B3528 

Debris Shield, 17" Wide 

Leather Guards 

Note 5 

4X M6 SHCS 

222 / 80 in-lbs 

1264 

845 48 

1219 

Post Height 

(T.O.P.) 

A 

Note 4 


Interface Bracket 

Note 4 


Interlock Switch Assembly 

Customer to orient switch 

arm as needed. 

Note 6 

11X M8 SHCS 


Note 5 

2X M8 SHCS 

242 / 100 in-lbs 

1/4" NPT x 1/4" Tube 

Open/Close Flow Controls 

Note 6 

9120-TSL-DSA-135-7475 


135° Swing, Position Sensing 

M12x1, 4 pin 

52 

Post is Steel Weldment 

6" x 4" Cross Section 



64 

9120-TSL-PM-248B-R000 

Post Module 48" Tall 

Dual Non-Compliant Interface 

13 


Notes: 


Bracket and Switch are shipped loose, to be installed by customer. 

5. Dry fasteners installed hand tight on Tool Stand for shipment, customer to set final placement and 

loctite with suggested or similar threadlocker and torque to recommended torque value. 

6. Debris Shield Actuator shipped loose, to be installed by customer. 


SPECIFIED. 



MILLIMETERS. 


DRAWN BY: 

CHECKED BY: 


D. Swanson, 12/31/12 

TITLE 









121210-1 2 4 1:12 B 01 


REVISION 


46


Document #9610-20-1058-27 

257.8 

100 Thru 

6X M10 Clearance 

Thru 

Equally Spaced 

B.C. 

4.921 

125 

30° 

2X M10 Dowel PF 14 


QC-210 Mounting Pattern 

Customer Mounting Pattern 


20.3 

30° 

TYP 

218 

381 

48.9 

Notes: 

222.3 

23.8 

212.4 



8. Customer to supply mounting screws and dowels. 

27.9 



Note 7 


9120-TSL-TP-7571 & Mounting Detail 


SPECIFIED. 



MILLIMETERS. 







DRAWN BY: J. Winterroth, 12/17/12 

CHECKED BY: D. Swanson, 12/31/12 

TITLE 




REVISION 

121210-1 3 4 1:4 B 01 



47


Document #9610-20-1058-27 

182.9 

30° 

B.C. 

4.921 

125 

6X M10 Clearance 

Thru 




100 

QC-210 Mounting Pattern 

Customer Mounting Pattern 

30° 

Typ 


20.3 

191.1 

284.5 

48.9 

222.3 

23.8 

212.4 

27.9 

Notes: 



10. Customer to supply mounting screws and dowels. 



Note 9 


9120-TSL-TP-7572 & Mounting Detail 


SPECIFIED. 



MILLIMETERS. 

DRAWN BY: 

CHECKED BY: 


D. Swanson, 12/31/12 

TITLE 










121210-1 4 4 1:4 B 01 


REVISION 


48

9.2 Post Modules with Pin and Bushing Style Mountings 


Document #9610-20-1058-27 

9.2.1 Post Module, (2) Rigid Pin and Bushing Modules, 48” Tall 

01 Initial Drawing ERDO 10/29/2013 


8X 20 Thru 

Note 2 

184 

419 

457 

19.1 

210 

4X M8 SHCS 


Note 2 


28 

Pins 

8X M12 SHCS 

242 / 65 ft-lbs 

Note 1 

825.5 

Post is Steel weldment 


1245 

52 

48.50 

1232 

Post Height 

(T.O.P.) 



1 1 9120-TSL-PM-248B-R000 TSL Post Module, (2) Rigid Pin & Bushing Modules, 48" Tall 

64 



SPECIFIED. 






MILLIMETERS. 



13 

E. Donkor 10/29/2013 

TITLE 

DRAWN BY: Notes: 


CHECKED BY: J. Winterroth, 1/06/14 

TSL Post Module, (2) Rigid Pin & Bushing Modules, 48" Tall 

1. Customer to use Loctite or similar thread locker and torque fasteners to listed torque value. 

2. Bracket and pre-applied fasteners shipped loose. Customer to torque fasteners to listed torque value. 


- 1 1 1:10 B 01 

PROJECT # SHEET OF 9630-20-TSL-PM-248B-R000 

3rd ANGLE PROJECTION REVISION 


49


Document #9610-20-1058-27 

9.2.2 Post Module, (2) Compliant Pin & Bushing Modules, 500 lbs, 48” Tall 


8X 20 Thru 

210 

419 

457 

184 

19 

28 

Pins 



1244.6 

826 

52 

48.00 

1219 

Post Height 

(T.O.P.) 

64 

Notes: 

13 


1. Customer to use Loctite or similar thread locker and torque fasteners to listed torque value. 

Bracket and pre-applied fasteners shipped loose. Customer to torque fasteners to listed torque value. 

01 Eco 11644; Release ERDO 10/29/2013 

Note 2 

4X M8 SHCS 


Note 1 

8X M12 SHCS 

242 / 65 ft-lbs 

Note 2 



1 1 NOTES: UNLESS OTHERWISE 


SPECIFIED. 






MILLIMETERS. 



E. Donkor 10/29/2013 

TITLE 

DRAWN BY: CHECKED BY: J. Winterroth, 1/08/14 

TSL Post Module, (2) Compliant Pin & Bushing Modules, 

500 lbs, 48" Tall 

TSL Post Module, (2) Compliant Pin & Bushing Modules, 500 lbs, 

48" Tall 



- 1 1 1:10 B 01 

PROJECT # SHEET OF 9630-20-TSL-PM-248B-C500 

REVISION 


50


Document #9610-20-1058-27 

9.3 Pin and Bushing Mounting Modules 

9.3.1 Pin and Bushing Module, Rigid 

03 

Eco 13560; Removed Sensor adapter plate and associated 

hardware. 

LJH 8/18/15 

254 

41 

81 

Serviceable Items 


3 1 3710-20-1028 Large Tool Stand Bronze Bushing 

6 2 3700-20-3323 QC Tool Stand Alignment Pin 

7649 - 242 / 250 in-lbs 

1 

6 

Sensor Bracket Shown 


3 

4X M12 SHCS 

20 

5X M8X1.25 16 

242 / 65 ft-lbs 7 

13 

Both Sides 

10X M8X1.25 16 

13 

Both Sides 

28 

25 

4 

89 

2 

38.1 

Typ 

38.1 

5 4X M8 SHCS 

Typ 

242 / 250 in-lbs 

254 

76.2 

2. 

25 

50.8 102 


1 1 9120-TSL-RMB-R000 TSL Pin & Bushing Module, Rigid 


SPECIFIED. 



MILLIMETERS. 







Notes: 

1. Assembly Weight: 17 lbs. 

Serviceable component materials: Hardened Stainless Steel alignment pins and Bronze bushing. 

DRAWN BY: 

CHECKED BY: 

E. Donkor 12/19/2013 


TITLE 

TSL Pin & Bushing Module, Rigid 



REVISION 

- 1 1 1:4 B 03 

PROJECT # SHEET OF 9630-20-TSL-RMB-R000 


51


Document #9610-20-1058-27 

9.3.2 Pin and Bushing Module, Compliant (500 lbs Shown) 

03 

Eco 13560; Removed sensor adapter plate and associated 

hardware. 

LJH 8/18/15 

254 

41 

81 



4 1 3610-3207601-10 Spring McMaster#9595K15 



7649 - 242 / 250 in-lbs 

2X M10 SHCS 

242 / 250 in-lbs 

1 

12 

7 


10X M8X1.25 16 

4 

13 

20 

Both Sides 

13 

4X M8X1.25 16 

Both Sides 

28 

25 

3 

9 

89 

2 

38.1 

Typ 254 

38.1 

76.2 

Typ 

8 

11 

16.9 

50.8 102 

6 

5 

4X M12 SHCS 

242 / 65 ft-lbs 

M5 Set Screw 

222 / 30 in-lbs 

10 

4X M8 SHCS 

242 / 250 in-lbs 


SPECIFIED. 



MILLIMETERS. 

Notes: 

1. Assembly Weight: 17 lbs. 

Serviceable component materials: Hardened Stainless Steel alignment pins, Steel die spring and 


1 1 9120-TSL-CMB-C500 TSL Pin & Bushing Module, Compliant to 500 lbs 

DRAWN BY: E. Donker, 12/19/2013 








TITLE 

TSL Pin & Bushing Module, Compliant to 500 lbs 



REVISION 

- 1 1 1:4 B 03 

PROJECT # SHEET OF 9630-20-TSL-CMB-C500 


52


Document #9610-20-1058-27 

9.4 Tooling Plates 

9.4.1 Tooling Interface Plate Blank 

22 

93 

381 

264 

241 

288 

23 

Notes: 

1. Plate material: 6061-T6 Aluminum, soft coat black anodize. 



02 ECO 12417: Added 'Serviceable Items' Table DBoh 7/24/2014 





5X M12 SHCS 

Pre / 65 ft-lbs 

Note 1 

Customer to add mounting patterns 

222 

191 

85 

114 

1 

212 

38.1 

38.1 

2 


97.8 

160 


1 1 9120-TSL-HBB-4115 TSL Tooling Interface Plate - Blank 


SPECIFIED. 



MILLIMETERS. 







DRAWN BY: E. Donkor 12/19/2013 


TITLE 

TSL Tooling Interface Plate - Blank 



REVISION 

- 1 1 1:4 B 02 

PROJECT # SHEET OF 9630-20-TSL-HBB-4115 


53


Document #9610-20-1058-27 

9.4.2 Tooling Interface Plate for QC-150 Blank 

21.6 222.3 

30° 

Typ 

B.C. 125 

225 

203 

6X 10.7 Thru 

17.3 10.4 

(10mm SHCS) 


165.5 

23.8 

15.1 

M10 SHCS 

111 

Bottom View 

240.3 

160 

190.5 





Notes: 

1. 

2. 

Fasteners & dowels shipped loose. To be installed by customer 

Plate material: 6061-T6 Aluminum, soft coat black anodize. 

15 

M10 Dowel 




QC-150 Tool Body 

M10 Dowel 

Customer to press 

into Tool Changer Body 

Note 1 

198.1 

Customer can machine tool 

pattern as needed. 

324.8 

6X M10 SHCS 


Note 1 

1 

304.2 

2 

Tool Changer Shown for Clarity 

Tool Changer Shown for Clarity 


1 1 9120-TSL-HBQ-8389 TSL Tooling Interface Plate for QC-150 - Blank 


SPECIFIED. 



MILLIMETERS. 

DRAWN BY: 

CHECKED BY: 

E. Donkor 01/03/2014 


TITLE 







TSL Tooling Interface Plate for QC-150 - Blank 



REVISION 

- 1 1 1:5 B 02 

PROJECT # SHEET OF 9630-20-TSL-HBQ-8389 


54

9.4.3 Vertical Tooling Interface Plate Blank 


Document #9610-20-1058-27 

58.4 

221 

269 

241.3 

Notes: 

1. Plate material: 6061-T6 Aluminum, soft coat clear anodize. 








Customer to add mounting pattern 

77.5 

29 

2 

This area must be kept clear of obstructions 

1 


1 1 9120-TSL-VBB-3328 TSL Vertical Tooling Interface Plate - Blank 


SPECIFIED. 



MILLIMETERS. 









TITLE 

TSL Vertical Tooling Interface Plate - Blank 



REVISION 

- 1 1 1:3 B 02 

PROJECT # SHEET OF 9630-20-TSL-VBB-3328 


55


Document #9610-20-1058-27 

9.5 TSL Systems with Hook and Hanger Style Mounting Modules 

9.5.1 Rigid Mounting, Tool Hook Modules TSI, Horizontal Debris Shields 

QC-210 Tool 

(With NA2/NA3 Hooks) 

QC-210 Master 

Reference Tool Changer standard drawing 

for servo or servo/MH combo. 

TSL post by others 

or ATI 3700-20-5480 

Weld guns by others 

Notes: 

1. 

2. 

Customer to supply two independant valves per actuator for actuator control. 

Customer to supply interbus I/O module for actuators, sensor & valve control. 



5 

8 

4 

1 

ATI part 9121-TSL-TP-6754 

or bolt pattern can be added 

to customer tooling. 

2 

Norgren Powerclamp 

#EC50G-N-1-0-0-XMG53M-2-0-0-L-135-2 

-Air - 1/4" NPT - QTY 2 

- Sensor - 4 pin M12 

Arm swings 135° 

Compliant Plate Optional 

ATI part 9120-TSL-CMH-C500 

6 

7 

3 

Euchner TSI 

- 4 pin M12 

(to DB IO Module) 

Tool Nest Sensor 

- IMF Effector # IGW200 

- 4 pin M12 


1 2 9121-NA3-T 210 Tool Hook Module, Left 

2 2 9121-NA2-T 210 Tool Hook Module, Right 

3 2 9120-TSL-SS-5635 TSL TSI Switch Assembly for Tool Hooks 

4 1 9120-TSL-DSA-135-3525 Tool Stand Debris Shield Actuator Dual Post 

5 1 9120-TSL-DS-17-B3528 Debris Shield 17" Wide with Leather Guards 

6 2 9120-TSL-CMH-R000 TSL Hanger Module, Rigid 

7 2 8590-9909999-92 Efector Prox #IGW200 18mm Barrel 12mm Range, Shielded 



SPECIFIED. 



MILLIMETERS. 

DRAWN BY: 

CHECKED BY: 

J. Winterroth 7/05/12 

D. Swanson, 8/06/12 

TITLE 







TSL Hook Arrangement for QC-210 



REVISION 

- 1 1 1:8 B 01 



56


Document #9610-20-1058-27 

9.5.2 Compliant Mounting, Proximity Sensor, Vertical Tooling Hook Plate 

1240 

1038 

375 

C 

72 

52 

101 

DETAIL C 

SCALE 2 : 1 

Sensor Gap 

.3mm - .6mm 


SPECIFIED. 



MILLIMETERS. 



01 Initial Drawing MDP 7/17/2012 

5 

2 

1 

4 

3 


1 1 3700-20-5480 Stand Post Weldment 48" High 

2 1 9005-20-2029 TSL Sensor Carrier Assembly 

3 1 9120-TSL-CMH-C500 

4 1 9121-TSL-TH-5641 

TSL Hook Module, Compliant to 500 

lbs 

TSL Tooling Hook Plate Assembly, 

Blank 

5 1 8590-9909999-08 PNP Proximity Sensor 







DRAWN BY: M. Perrault 7/17/12 

CHECKED BY: D. Norton 8/13/12 

TITLE 

TSL Stand Alone Hook Assembly with New Sensor Carrier 


REVISION 

120117-1 1 1 1:20 B 01 



57


Document #9610-20-1058-27 

9.6 Post Modules with Hook and Hanger Style Mountings 

9.6.1 Post Module, (2) Rigid Hook Modules, 48” Tall 


8X 20 Thru 

184 

419 

457 

210 

19 



781 

1232 

1187 

52 

64 

13 


Notes: 

1. 

Customer to use Loctite or similar thread locker and torque fasteners to listed torque value. 

48.00 

1219 

Post Height 

(T.O.P.) 



8X M12 SHCS 

242 / 65 ft-lbs 

Note 1 


1 1 9120-TSL-PM-248H-R000 TSL Post Module, (2) Rigid Hook Modules, 48" Tall 


SPECIFIED. 



MILLIMETERS. 

DRAWN BY: 

CHECKED BY: 

E. Donkor 10/29/2013 


TITLE 







TSL Post Module, (2) Rigid Hook Modules, 48" Tall 



REVISION 

- 1 1 1:10 B 01 

PROJECT # SHEET OF 9630-20-TSL-PM-248H-R000 


58


Document #9610-20-1058-27 

9.6.2 Post Module, (2) Compliant Hook Modules, 500 lbs, 48” Tall 


8X 20 Thru 

184 

419 

457 

19 

210 

Base Mounting Dimnesions 



780 

1232 

1187 

52 

64 

13 


Notes: 

1. 

Customer to use Loctite or similar thread locker and torque fasteners to listed torque value. 

48.00 

1219 

Post Height 

(T.O.P.) 



8X M12 SHCS 

242 / 65 ft-lbs 

Note 1 


1 1 9120-TSL-PM-248H-C500 TSL Post Module, (2) Compliant Hook Modules, 500 lbs, 48" Tall 


SPECIFIED. 



MILLIMETERS. 







DRAWN BY: 

CHECKED BY: 

E. Donkor 10/30/2013 


TITLE 

TSL Post Module, (2) Compliant Hook Modules, 500 lbs, 48" 

Tall 



REVISION 

- 1 1 1:10 B 01 

PROJECT # SHEET OF 9630-20-TSL-PM-248H-C500 


59


Document #9610-20-1058-27 

9.7 Hook Mounting Modules 

9.7.1 Hook Module, Rigid 


254 



7 2 3500-2035175-11 

SHCS, 5/8-11, Shoulder 1-3/4 long x 

3/4 Dia McMaster 91259A841 

3 


4 

1 

57 

98 

2 

7 

2X 5/8" Shoulder SHCS 

7649-242 / 50 ft-lbs 

16.5 

40.6 

20 

25 

60 

8X M8X1.25 16 

Both Sides 

13 

34 

8 

5 

4X M12 SHCS 

242 / 65 ft-lbs 

6 

4X M8 SHCS 


4X M8 SHCS 


38.1 

Typ 

76.2 

38.1 

Typ 


4X M8X1.25 16 

27 

50.8 102 

Both Sides 


1 1 9120-TSL-RMH-R000 TSL Hook Module, Rigid 






Notes: 

1. Assembly Weight: 15lbs. 


2. Serviceable component materials: Alloy Steel shoulder bolts. 

TITLE 

TSL Hook Module, Rigid 


SPECIFIED. 



MILLIMETERS. 





REVISION 

- 1 1 1:4 B 02 

PROJECT # SHEET OF 9630-20-TSL-RMH-R000 


60

9.7.2 Hook Module, Compliant (500 lbs Shown) 


Document #9610-20-1058-27 


254 


6 1 3610-3207601-10 Spring McMaster#9595K15 

10 2 3500-2035175-11 

SHCS, 5/8-11, Shoulder 1-3/4 long x 

3/4 Dia McMaster 91259A841 

57 

98 

16.5 

40.6 

20 

8X M8X1.25 16 

Both Sides 

25 

60 

38.1 

Typ 

76.2 

4X M8X1.25 16 

Both Sides 

27 

50.8 102 


SPECIFIED. 



MILLIMETERS. 

Notes: 

1. Assembly Weight: 15lbs. 

Serviceable component materials: Alloy Steel shoulder bolts and Steel die spring. 




6 

3 

2 

1 

5 

7 


12 M5 Set Screw 

222 / 30 in-lbs 

13 

4 10 2X 5/8" Shoulder SHCS 

7649-242 / 50 ft-lbs 

8 4X M8 SHCS 

34 

242 / 50 in-lbs 

9 4X M8 SHCS 

242 / 50 in-lbs 

11 4X M12 SHCS 

242 / 65 ft-lbs 

38.1 

Typ 


1 1 9120-TSL-CMH-C500 TSL Hook Module, Compliant to 500 lbs 







DRAWN BY: 

CHECKED BY: 

E. Donkor 12/20/2013 


TITLE 

TSL Hook Module, Compliant to 500 lbs 


REVISION 

- 1 1 1:4 B 02 

PROJECT # SHEET OF 9630-20-TSL-CMH-C500 


61


Document #9610-20-1058-27 

9.8 Vertical Tooling Hook Plate 

102.7 

18 

223.5 

160 

77.6 

36.3 

58.5 

236.9 

190.5 

127 

Customer to add 

mounting pattern 

as required. 

12.7 

25.4 

191.7 

218.4 

Notes: 

1. Tool Hook Plate shipped assembled. 

2. If disassembled for machining, customer to torque pre-applied fasteners to listed torque value. 

3. Plate Material: 6061-T6 Aluminum, Soft Coat Black Anodize 

4. For Tools Over 250lbs, Use features provided to Attach Secondary tool Brace Components. 

Custom Brace Components Required 

5. 

Bracket Weight = 16 lbs 


01 Initial Drawing AMC 6/11/2013 

22 

3X M5 9.5 

Both Sides 4X M12 SHCS 

Pre / 65 ft-lbs 

Note 2 


1 1 9121-TSL-TH-5641 TSL Tooling Hook Plate Assembly, Blank 


SPECIFIED. 



MILLIMETERS. 

DRAWN BY: 

CHECKED BY: 

A. Crockett, 7/2/13 

D. Norton, 2/24/14 

TITLE 







TSL Tooling Hook Plate Assembly, Blank 



REVISION 

- 1 1 1:4 B 01 

PROJECT # SHEET OF 9630-20-TSL-TH-5641 


62


Document #9610-20-1058-27 

9.9 Horizontal Extension Modules 

9.9.1 Horizontal Extension, 16”, Straight 

419 

32 

4X 12.7 Thru 


114.3 

228.6 

153.7 

50.8 

356 

101.6 

2X 1/4-20 UNC 

24 

Notes: 

1. Customer to use Loctite or similar threadlocker and torque fasteners to listed torque value. 



50.8 

8X M12X1.75 Thru All 

153.7 

76.2 

38.7 

4X M12 SHCS 

242 / 65 ft-lbs 

Note 1 


1 1 9120-TSL-HE16S-8004 TSL Hoizontal Extension, 16", Straight 


SPECIFIED. 



MILLIMETERS. 









TITLE 

TSL Horizontal Extension, 16", Straight 



REVISION 

- 1 1 1:4 B 01 

PROJECT # SHEET OF 9630-20-TSL-HE16S-8004 


63


Document #9610-20-1058-27 

9.9.2 Horizontal Extension, 12”, 90° 

349 

102 

50.8 

229 153.7 

102 

50.8 

4X 12.7 Thru 

279.4 

356 

Notes: 

1. 

Customer to use Loctite or similar threadlocker and torque fasteners to listed torque value. 

102 

133 

8X M12X1.75 Thru All 

38.7 

76.2 

153.7 


SPECIFIED. 



MILLIMETERS. 




4X M12 SHCS 

242 / 65 ft-lbs 

Note 1 

127 


1 1 9120-TSL-HE12A-7572 TSL Horizontal Extension, 12", 90° 









TITLE 

TSL Horizontal Extension, 12", 90° 


REVISION 

- 1 1 1:4 B 01 

PROJECT # SHEET OF 9630-20-TSL-HE12A-7572 


64


Document #9610-20-1058-27 

9.10 TSI Switches and Trip Dogs 

9.10.1 TSI Switch for Tooling Interface Plate 

41.9 

69.5 

62 

12.9 

113.3 

100 

32 

Notes: 

1. Fasteners and switch shipped loose. To be installed by customer. 

2. Customer to install pre-applied fasteners and torque to listed torque value. 

3. Customer to use Loctite or similar thread locker and torque to listed torque value. 

Customer to orient switch arm as needed. 


2X M6 SHCS 


Note 2 

10.5 

4X M5 SHCS 

242 / 50 in-lbs 

Note 3 

14.6 

44.5 

2X M5 Counterbore 

Safety Switch and Connector 

4-pin M12 Eurofast 

9005-20-1165 

Note 1, 4 

4. 



1 1 9120-TSL-SS-6044 TSL Tool Stand Interlock Switch Assembly no Trip Dog 


SPECIFIED. 



MILLIMETERS. 







DRAWN BY: 

CHECKED BY: 


D. Norton, 2/18/14 

TITLE 

TSL Tool Stand Interlock Switch Assembly no Trip Dog 



REVISION 

- 1 2 1:2 B 01 

PROJECT # SHEET OF 9630-20-TSL-SS-6044 

For Page 2 of this drawing refer to Section 9.10.9—TSI Switch Common Wiring Diagram. 


65


Document #9610-20-1058-27 

9.10.2 TSI Trip Dog for Pin and Bushing Module 

46.1 38.1 31.8 

76.2 

61 

Slot 

Notes: 

1. Fasteners shipped loose. To be installed by customer. 

Customer to use Loctite or similar thread locker and torque to listed torque value. 

11.9 


25X M8 SHCS 

242 / 100 in-lbs 

Note 1, 2 



1 1 9120-TSL-SS-7511 TSL Tool Stand Interlock Trip Dog Assembly 



SPECIFIED. 






MILLIMETERS. 




TITLE 

DRAWN BY: D. Norton, 2/18/14 

TSL Tool Stand Interlock Trip Dog Assembly 

CHECKED BY: 3rd ANGLE PROJECTION 


- 1 1 2:3 B 01 


REVISION 


66


Document #9610-20-1058-27 

9.10.3 TSI Switch Assembly for Vertical Tooling Interface Plate (Left Side) 

60 

57.2 

25.4 

30 

25.4 

18 

Notes: 





38.1 


4X M5 SHCS 

242 / 50 in-lbs 

Note 3 

2X M8 SHCS 


Note 2 



9005-20-1165 

Note 1, 4 

76.2 

Slot 



1 1 9120-TSL-SS-3500 Tool Stand Interlock for TSL Interface Plate 



SPECIFIED. 






MILLIMETERS. 



DRAWN BY: 

CHECKED BY: 


D. Norton, 2/18/14 

TITLE 

Tool Stand Interlock for TSL Interface Plate 



REVISION 

- 1 2 1:3 B 01 




67


Document #9610-20-1058-27 

9.10.4 TSI Switch Assembly for Vertical Tooling Interface Plate (Right Side) 

60 

30 

39.4 

25.4 

177.8 

33 

76.2 

Notes: 






4X M5 SHCS 

242 / 50 in-lbs 

Note 3 

2X M6 SHCS 


Note 2 Safety Switch and Connector 


9005-20-1165 

Note 1, 4 



1 1 9120-TSL-SS-7122 TSLTSI Switch Trip Dog Assembly-Rigid Mount 



SPECIFIED. 






MILLIMETERS. 




TITLE 


TSL TSI Switch Trip Dog Assembly - Rigid Mount 



REVISION 

- 1 2 1:3 B 01 




68


Document #9610-20-1058-27 

9.10.5 TSI Switch Master Side 

60 

40 

8 

30 

13 

99 

60 

131 

Notes: 




32 


SPECIFIED. 



MILLIMETERS. 





9005-20-1165 

Note 1, 3 

4X M5 SHCS 

242 / 50 in-lbs 

Note 2 







1 1 9120-TSL-SS-6077 TSL Switch Kit for Master Side TSI 




CHECKED BY: D. Norton, 2/18/14 

TITLE 

TSL Switch Kit for Master Side TSI 


REVISION 

- 1 2 1:2 B 01 




69


Document #9610-20-1058-27 

9.10.6 TSI Switch Assembly for Tool Hook Modules (Left Side) 

41.9 

69.5 

61 

3X M3 SFHCS 

100 

22 

7.4 

32 

12.7 

25.4 

25.4 

Notes: 






2X M8 SHCS 


Note 2 



9005-20-1165 

Note 1, 4 

2X M8 SHCS 

242 / 100 in-lbs 

Note 3 

3X M5 SFHCS 

242 / 50 in-lbs 

Note 3 

114.3 

139.7 

4X M5 SHCS 

242 / 50 in-lbs 

Note 3 



1 1 9120-TSL-SS-5635 TSL TSI Switch Assembly for Tool Hooks 



SPECIFIED. 






MILLIMETERS. 




TITLE 


TSL TSI Switch Assembly for Tool Hooks 



REVISION 

- 1 2 1:3 B 01 




70

9.10.7 TSI Switch for Vertical Tooling Hook Plate 


Document #9610-20-1058-27 

41.9 

69.5 

61 

3X M3 SFHCS 

100 

22 

32 

7.4 

12.7 

Notes: 








9005-20-1165 

Note 1, 4 

3X M5 SFHCS 

242 / 50 in-lbs 

Note 3 

25.4 

4X M5 SHCS 

242 / 50 in-lbs 

Note 3 


1 1 9120-TSL-SS-8074 TSL TSI Switch Assembly - Vertical Hooks, No Trip Dog 




SPECIFIED. 






MILLIMETERS. 



DRAWN BY: 

CHECKED BY: 


D. Norton, 2/24/14 

TITLE 

TSL TSI Switch Assembly - Vertical Hooks, No Trip Dog 



REVISION 

- 1 2 1:2 B 01 




71


Document #9610-20-1058-27 

9.10.8 TSI Trip Dog for Vertical Tooling Hook Plate 

30.5 

25.4 

43.2 

111.8 

127 

152.4 

71.8 

89.5 

Notes: 

1. Fasteners shipped loose. To be installed by customer. 

Customer to install pre-applied fasteners and torque to listed torque value. 

12.9 


6X M8 SHCS 


Note 2 

3X M8 SHCS 

3X 10.2 

38.1 

76.2 



1 1 9120-TSL-SS-8076 TSL TSI Trip Dog - Vertical Hooks 



SPECIFIED. 






MILLIMETERS. 




TITLE 


TSL TSI Trip Dog - Vertical Hooks 



REVISION 

- 1 1 1:2 B 01 



72

9.10.9 TSI Switch Common Wiring Diagram 


Document #9610-20-1058-27 

4 (Black) 

M12x1.0 

1 (Brown) 

3 (Blue) 

2 (White) 

Face View 

Part #1510-1313006-04 

4-Pin Male Eurofast Receptacle 


SPECIFIED. 



MILLIMETERS. 




Wiring Diagram (switch not actuated) 









TITLE 

TSL Tool Stand Interlock Switch Assembly no Trip Dog 


REVISION 

- 2 2 1:2 B 01 



73


Document #9610-20-1058-27 

9.10.10 Sipha Sensor supporting TSI In/Out 1m Cable Length 

Target Face to Target Face Orientation 

1m 

Key 

2 

82 

68 

73.2 

1 

5 


03 

ECO 13290; Added Actuator, added Target Face to Target Face 

Orientation picture for clarification, and updated Title 

SZJ 8/13/2015 

4 

3 

Face View 

SCALE 2 : 1 

4.2 

2X 19.6 

8 


1 1 9120-TSL-SS-7510 

Direct Mount Sipha Sensor and Actuator Supporting TSI In/Out and 

TSIV, 1m Cable Length 


SPECIFIED. 



MILLIMETERS. 

DRAWN BY: 

CHECKED BY: 

W. Berrocal, 9/19/12 

D. Norton, 2/18/14 

TITLE 







Direct Mount Sipha Sensor and Actuator Supporting TSI 

In/Out and TSIV, 1m Cable Length 



REVISION 

1 1 1:1 B PROJECT # SHEET OF 9630-20-TSL-SS-7510 03 


74

9.10.11 Sipha Sensor, 3m Cable Length 


Document #9610-20-1058-27 

Target Face to Target Face Orientation 

3 m 

2 

Key 

3 

82 

68 

73.2 


1 

02 

ECO 13290; Added Actuator, added Target Face to Target Face Orientation 

picture for clarification, and updated Title 

SZJ 8/13/2015 

5 

4 

Face View 

SCALE 2 : 1 

4.2 

2X 19.6 

8 


1 1 9120-TSL-SS-7508 Direct Mount Sipha Sensor and Actuator 


SPECIFIED. 



MILLIMETERS. 









TITLE 

Direct Mount Sipha Sensor and Actuator 



REVISION 

- 1 1 1:1 B 02 



75


Document #9610-20-1058-27 

9.10.12 Sipha Sensor Non-contact switch Actuator 

5 

72.1 

9.8 

7 

41 4.2 

4.4 

82 

73.2 

7 

19.5 

Notes: 

1. Sensing range - Make .35" (9mm) - Break .47" (12mm) 

8 

8 

2.9 

M4 Fasteners 

M2.5 Fasteners 


SPECIFIED. 



MILLIMETERS. 




19.5 

19.6 









TITLE 

Direct Mount Sipha Non-contact Switch Actuator 


REVISION 

- 1 1 3:2 B 01 



76


Document #9610-20-1058-27 

9.11 Debris Shield Actuators 

9.11.1 Debris Shield Actuator - Horizontal 135 Degree Rotation 

4X M6 SHCS 

222 / 89 in-lbs 


222 / 25 in-lbs 

Note 1 

Note 1 3415-0021036-01 

135° Powerclamp, SMC 

3405-2020004-01 

2X 1/4" BSPP x 8mm Tube 

Flow Control, 180° Swivel 

4X M8 SHCS 


3405-1220030-01 

2X 8mm to 6mm Reducer 

4X M8 SHCS 


3X M8 SHCS 


Sensor Wiring 

9120-TSL-CMP-7080 

TSL Clamp Mounting Kit 

-Ref 9630-20-TSL-CMP-7080 

Clamp Shown Closed 

For mounting dimensions 

1. 

Customer to use Loctite or similar threadlocker and torque fasteners to listed torque. 

376 

332 

12.7 

3X 38.1 

4X 9 

152.4 

Clamp Shown Open 135° 


SPECIFIED. 



MILLIMETERS. 

Notes: 

Fasteners shipped w/o thread locker and tightened to contact only. 




Male Eurofast Connector 

(M12x1, 4 pin) 

Open Fitting 

Close Fitting 

320 

163 

139.7 

120 

19 

Typ 









TITLE 

TSL Debris Shield Actuator - Dual Post - Horizontal - 135° 


REVISION 

- 1 1 1:5 B 01 

PROJECT # SHEET OF 9630-20-TSL-DSA-135-7475 


77


Document #9610-20-1058-27 

9.11.2 Debris Shield Actuator - Vertical 90 Degree Rotation 


222 / 25 in-lbs 

Note 1 

4X M6 SHCS 

222 / 89 in-lbs 

Note 1 

3415-0021041-01 


4X M8 SHCS 


3405-2020004-01 



3405-1220030-01 


3X M8 SHCS 


Clamp Shown Closed 

9120-TSL-CMP-7080 




Notes: 



263 

107 

90° 

410 


(M12x1, 4 pin) 

Open Fitting 

Close Fitting 


Sensor Wiring 


SPECIFIED. 



MILLIMETERS. 

1. 



DRAWN BY: 

CHECKED BY: 


D. Norton, 8/28/13 







TITLE 

TSL Debris Shield Actuator - Vertical - 90° 



REVISION 

- 1 1 1:5 B 01 



78


Document #9610-20-1058-27 

9.11.3 Debris Shield Actuator Dual Post - Vertical 135 Degree Rotation 


222 / 25 in-lbs 

Note 1 

4X M6 SHCS 

222 / 89 in-lbs 

Note 1 

3415-0021036-01 


3405-2020004-01 



4X M8 SHCS 


3405-1220030-01 


3X M8 SHCS 


Clamp Shown Closed 9120-TSL-CMP-7080 




Notes: 

1. 


Sensor Wiring 




SPECIFIED. 



MILLIMETERS. 




263 

107 

135° 

410 


(M12x1, 4 pin) 

Open Fitting 

Close Fitting 









TITLE 

TSL Debris Shield Actuator - Vertical - 135° 


REVISION 

- 1 1 1:5 B 01 



79


Document #9610-20-1058-27 

9.12 Debris Shields 

9.12.1 Debris Shield 20" with Weld Curtain 

111.8 

76.2 

406.4 

254 

Customer to set 

clamp positions. 

111.8 

508 

106.9 

172.9 

Notes: 

1. 

2. 

Debris shield is shipped assembled. Customer to determine final configuration. 

Customer to Loctite or similar thread locker and torque to listed torque value. 



4X M6 SHCS 

222 / 80 in-lbs 

Note 2 

508 

9005-20-2191 

TSL Weld Curtain Shield, 4 snaps, 4" Tall 

(Replaceable part) 


1 1 9120-TSL-DS-20-W7787 TSL Debris Shield, 20" Wide, Weld Curtain 


SPECIFIED. 



MILLIMETERS. 

DRAWN BY: 

CHECKED BY: 


D. Norton, 2/18/14 

TITLE 







TSL Debris Shield, 20" Wide, Weld Curtain 



REVISION 

- 1 1 1:6 B 01 

PROJECT # SHEET OF 9630-20-TSL-DS-20-W7787 


80

9.12.2 Debris Shield 20” with Fire Retardant Foam Insert 


Document #9610-20-1058-27 

111.8 

76.2 

406.4 

254 



111.8 

508 

58.7 

124.8 

Notes: 

1. 

2. 

3. 

Debris shield is shipped partially assembled. Customer to determine final configuration. 


Customer to remove adhesive backing and adhere foam to shield. 



4X M6 SHCS 

222 / 80 in-lbs 

Note 2 

508 

3700-20-7788 

TSL 20" Debris Shield Foam Insert - 2.25" Thick 

Note 3 


1 1 9120-TSL-DS-20-F7788 TSL Debris Shield 20" with Fire Retardant Foam Insert 


SPECIFIED. 



MILLIMETERS. 









TITLE 

TSL Debris Shield 20" with Fire Retardant Foam Insert 



REVISION 

- 1 1 1:6 B 01 

PROJECT # SHEET OF 9630-20-TSL-DS-20-F7788 


81


Document #9610-20-1058-27 

9.12.3 Debris Shield 17” with Weld Curtain 

111.8 

254 

203.2 



111.8 

431.8 

107.8 

173.9 

Notes: 

1. 

2. 



431.8 



4X M6 SHCS 

222 / 80 in-lbs 

Note 2 

9005-20-2190 




1 1 9120-TSL-DS-17-W3528 TSL Debris Shield, 17” Wide, Weld Curtain 


SPECIFIED. 



MILLIMETERS. 

DRAWN BY: 

CHECKED BY: 


D. Norton, 2/18/14 

TITLE 







TSL Debris Shield, 17" with Weld Curtain Shields 



REVISION 

- 1 1 1:6 B 01 



82

9.12.4 Debris Shield 14” with Weld Curtain 


Document #9610-20-1058-27 

254 



111.8 

111.8 

355.6 

355.6 

173 

106.9 

Notes: 

1. 

2. 





4X M6 SHCS 

222 / 80 in-lbs 

Note 2 

9005-20-2190 



9005-20-2189 




1 1 9120-TSL-DS-14-W3337 TSL Debris Shield, 14" Wide, Weld Curtain 


SPECIFIED. 



MILLIMETERS. 









TITLE 

TSL Debris Shield, 14" Wide, Weld Curtain 



REVISION 

- 1 1 1:5 B 01 



83


Document #9610-20-1058-27 

9.12.5 Debris Shield 14” with Fire Retardant Foam Insert 

111.8 

254 

111.8 



355.6 

355.6 

58.7 

124.8 

Notes: 

1. 

2. 

3. 

Debris shield is shipped partially assembled. Customer to determine final configuration. 


Customer to remove adhesive backing and adhere foam to shield. 


SPECIFIED. 



MILLIMETERS. 




4X M6 SHCS 

222 / 80 in-lbs 

Note 2 

3700-20-4592 

TSL Shield Foam Insert - 2.25" Thick 

Note 3 









TITLE 

Debris Shield 14" with Fire Retardant Foam Insert 


REVISION 

- 1 1 1:5 B 01 

PROJECT # SHEET OF 9630-20-TSL-DS-14-F4592 


84


Document #9610-20-1058-27 

9.13 Post Supports 

9.13.1 TSL Adjustable Post Support With Arm 

8.00 

203.2 

Note 1 

127 

Note 2 

102 

203 

91 

Note 1 

31.8 

140 

70 

121 

60 

Notes: 

9120-TSL-PS-7980 - Detail 

1. Threaded rod supplied. Customer to cut to desired final length. 

2. Post Support can be located on the 4" or 6" side of ATI post. 

3. Customer to use Loctite or similar threadlocker and torque fasteners to listed torque. 



2 

M16 SHCS 

242 / 150 ft-lbs 

Note 3 

6 

7 

5 

1 

4 

3 

10X 3/8"-16 Hex Nut 

242 / 400 in-lbs 

Note 3 


1 1 3700-20-7980 TSL Post Support Plate, Front 

2 1 3700-20-7979 TSL Post Support Plate, Rear 

3 10 3505-0859000-12 3/8" Flange Hex Locknut, Zinc Plated 

4 5 3690-1280001-12 3/8" Threaded Rod - 8" OAL - Zinc Plated 

5 1 3700-20-7975 TSL Post Support Arm 

6 1 3500-1075050-15 M16 x 50mm Lg SHCS Zinc 

7 1 3690-0000010-50 Hard Polyurethane Bumper - 3/8"-16 Threaded 


SPECIFIED. 



MILLIMETERS. 









TITLE 

TSL Adjustable Post Support with Arm 



REVISION 

121218-4 1 1 1:5 B 01 

PROJECT # SHEET OF 9630-20-TSL-PS-7980 


85


Document #9610-20-1058-27 

9.13.2 TSL Adjustable Post Support With Strut Channel 

8.00 

203.2 

Note 1 

127 

Note 2 

50.8 

Note 1 

41.3 

203 

140 

111 

168 

273 


Notes: 


1. Items shipped as loose parts. 

2. Post Support can be located on the 4" or 6" side of ATI post. (Ref 9230-20-7594) 

3. Customer to torque pre-applied fasteners to listed torque. 

4. Customer to use Loctite or similar threadlocker and torque fasteners to listed torque. 



8 

4 

2X M8 SHCS 


Note 3 

1 

7 

5 

10X 3/8"-16 Hex Nut 

242 / 400 in-lbs 

Note 4 

2 

9 

3 

6 


1 2 3500-1068016-15A M8 x 16mm SHCS, Blue Dyed Magni-565 w/ ND Microspheres Epoxy 


3 1 3505-5929000-12 Strut Channel Washer, No Spin 

4 3 3510-5067002-12 M8 Flat Washer, Zinc Coated 

5 1 3690-0000010-50 Hard Polyurethane Bumper - 3/8"-16 Threaded 

6 1 3690-0000078-50 Cover for 1 5/8" Single Strut Channel, Plastic, Black 

7 5 3690-1280001-12 3/8" Threaded Rod - 8" OAL - Zinc Plated 

8 2 3700-20-7979 TSL Post Support Plate, Rear 

9 1 3710-20-3417 Strut Channel, Aluminum, 24" 


SPECIFIED. 



MILLIMETERS. 

DRAWN BY: 

CHECKED BY: 


D. Norton, 10/23/13 

TITLE 







TSL Adjustable Post Support for Strut Channel 



REVISION 

121218-4 1 1 1:5 B 01 



86


Document #9610-20-1058-27 

9.13.3 Post Support - Roller 

41.9 

5.1 

25.4 19.1 

Notes: 

1. 

Hex nut shipped loose. 

49.5 5.7 




Threads onto 3/8"-16 rod. 

1 

4 

Note 1 

2 

3 

242 / 90 in-lbs 

Apply XHP-222 Special to this surface. 


1 1 3700-20-8229 TSL Roller Stop Bracket 

2 1 3710-20-3430 UHMW Roller - 1" OD, 5/16" ID, 1" Wide 

3 1 3500-2024150-11 Shoulder SHCS, 1/4"-20 Thread, 5/16" Shoulder, 1.5" Long Alloy Steel 



SPECIFIED. 



MILLIMETERS. 









TITLE 

TSL Post Support - Roller 



REVISION 

121218-4 1 1 1:1 B 01 



87


Document #9610-20-1058-27 

10. Terms and Conditions of Sale 

The following Terms and Conditions are a supplement to and include a portion of ATI’s Standard Terms and 

Conditions, which are on file at ATI and available upon request. 

ATI warrants to Purchaser that robotic Tool Changer products purchased hereunder will be free from defects 

in material and workmanship under normal use for a period of three (3) years from the date of shipment. This 

warranty does not cover components subject to wear and tear under normal usage or those requiring periodic 

replacement. ATI will have no liability under this warranty unless: (a) ATI is given written notice of the claimed 

defect and a description thereof within thirty (30) days after Purchaser discovers the defect and in any event not 

later than the last day of the warranty period; and (b) the defective item is received by ATI not later ten (10) days 

after the last day of the warranty period. ATI’s entire liability and Purchaser’s sole remedy under this warranty is 

limited to repair or replacement, at ATI’s election, of the defective part or item or, at ATI’s election, refund of the 

price paid for the item. The foregoing warranty does not apply to any defect or failure resulting from improper 

installation, operation, maintenance or repair by anyone other than ATI. 

ATI will in no event be liable for incidental, consequential or special damages of any kind, even if ATI has been 

advised of the possibility of such damages. ATI’s aggregate liability will in no event exceed the amount paid by 

purchaser for the item which is the subject of claim or dispute. ATI will have no liability of any kind for failure of 

any equipment or other items not supplied by ATI. 

No action against ATI, regardless of form, arising out of or in any way connected with products or services supplied 

hereunder may be brought more than one (1) year after the cause of action accrued. 

No representation or agreement varying or extending the warranty and limitation of remedy provisions contained 

herein is authorized by ATI, and may not be relied upon as having been authorized by ATI, unless in writing and 

signed by an executive officer of ATI. 

Unless otherwise agreed in writing by ATI, all designs, drawings, data, inventions, software and other technology 

made or developed by ATI in the course of providing products and services hereunder, and all rights therein under 

any patent, copyright or other law protecting intellectual property, shall be and remain ATI’s property. The sale of 

products or services hereunder does not convey any express or implied license under any patent, copyright or other 

intellectual property right owned or controlled by ATI, whether relating to the products sold or any other matter, 

except for the license expressly granted below. 

In the course of supplying products and services hereunder, ATI may provide or disclose to Purchaser confidential 

and proprietary information of ATI relating to the design, operation or other aspects of ATI’s products. As between 

ATI and Purchaser, ownership of such information, including without limitation any computer software provided 

to Purchaser by ATI, shall remain in ATI and such information is licensed to Purchaser only for Purchaser’s use in 

operating the products supplied by ATI hereunder in Purchaser’s internal business operations. 

Without ATI’s prior written permission, Purchaser will not use such information for any other purpose or provide or 

otherwise make such information available to any third party. Purchaser agrees to take all reasonable precautions to 

prevent any unauthorized use or disclosure of such information. 

Purchaser will not be liable hereunder with respect to disclosure or use of information which: (a) is in the public 

domain when received from ATI; (b) is thereafter published or otherwise enters the public domain through no fault 

of Purchaser; (c) is in Purchaser’s possession prior to receipt from ATI; (d) is lawfully obtained by Purchaser from a 

third party entitled to disclose it; or (f) is required to be disclosed by judicial order or other governmental authority, 

provided that, with respect to such required disclosures, Purchaser gives ATI prior notice thereof and uses all legally 

available means to maintain the confidentiality of such information. 


88

TSL Tool Stand

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