Atlas Copco Power Focus 4000 Compact User manual

User guide
Power Focus
Atlas Copco Industrial Technique AB
9836 3123 01
Software release W10.9 SR3
Edition 18.2
2013-03

Copyright Atlas Copco Tools and Assembly Systems
Note! This manual can be altered without further notice.
For further information log in to Atlas Copco www.atlascopco.com

Contents
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Contents
Contents.........................................................................................................................3
1General safety instructions................................................................................11
1.1 Work area .............................................................................................................. 11
1.2 Electrical safety......................................................................................................11
1.3 Personal safety ...................................................................................................... 12
1.4 Service...................................................................................................................13
2Introduction.........................................................................................................15
2.1 Revision history...................................................................................................... 15
2.2 Abbreviations ......................................................................................................... 15
3Introduction to Power Focus..............................................................................17
3.1 PF 4000 ................................................................................................................. 18
3.2 PF 3000/3100/3102................................................................................................ 19
3.3 RBU.......................................................................................................................20
3.4 ToolsTalk PF..........................................................................................................20
3.5 Communication...................................................................................................... 20
3.6 Tensor tools...........................................................................................................22
3.6.1 Tool accessories......................................................................................................23
3.7 Hardware accessories............................................................................................25
3.8 Software accessories............................................................................................. 27
3.8.1 ATS..........................................................................................................................27
3.8.2 ACTA 4000..............................................................................................................28
4Connecting devices ............................................................................................29
4.1 PF connections ......................................................................................................29
4.2 RBU.......................................................................................................................30
4.2.1 MAC-address...........................................................................................................30
4.2.2 PF start-up instructions............................................................................................30
4.3 Tool connection and start-up.................................................................................. 31
4.3.1 Tools with cable connection ....................................................................................31
4.3.2 Tensor STB..............................................................................................................32
4.3.3 Start-up instruction for open-end tools ....................................................................32
4.3.4 Wireless tools ..........................................................................................................33
4.3.5 ST GPIO connection................................................................................................33
4.3.6 ST-selector connection............................................................................................34
4.4 Printer....................................................................................................................35
4.5 Serial connection....................................................................................................35
4.5.1 Serial RS232 #1 ......................................................................................................35
4.5.2 Serial RS232 #2 ......................................................................................................36
4.6 Ethernet TCP/IP..................................................................................................... 36

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4.7 Digital inputs...........................................................................................................36
4.8 Digital outputs (relays)............................................................................................37
4.9 24 VDC output........................................................................................................38
4.10 I/O Bus ...................................................................................................................38
4.11 Remote start connector ..........................................................................................39
4.12 Main power connector ............................................................................................40
5PF user interface.................................................................................................41
5.1 PF Graph................................................................................................................41
5.1.1 Front panel.............................................................................................................. 41
5.1.2 Display.................................................................................................................... 43
5.1.3 Programming PF Graph.......................................................................................... 44
5.2 PF Compact............................................................................................................49
5.2.1 Front panel.............................................................................................................. 49
5.2.2 Display.................................................................................................................... 50
5.2.3 Indicator lights......................................................................................................... 51
5.2.4 Keypad.................................................................................................................... 52
6Getting started with ToolsTalk PF .....................................................................55
6.1 Installing ToolsTalk PF ...........................................................................................55
6.2 ToolsTalk overview.................................................................................................56
6.2.1 Menu list.................................................................................................................. 56
6.2.2 Selection panel ....................................................................................................... 59
6.2.3 Toolbar.................................................................................................................... 60
6.2.4 PF Map ................................................................................................................... 62
6.3 Configuring ToolsTalk settings................................................................................63
6.3.1 Communication....................................................................................................... 63
6.3.2 Application .............................................................................................................. 65
6.3.3 Printout.................................................................................................................... 66
6.3.4 PF List..................................................................................................................... 67
6.4 Connecting a PF.....................................................................................................68
6.4.1 Ethernet connection................................................................................................ 68
6.4.2 Serial connection .................................................................................................... 68
6.4.3 USB connection...................................................................................................... 69
6.4.4 To connect.............................................................................................................. 70
6.4.5 To disconnect ......................................................................................................... 70
6.4.6 Cordless tools......................................................................................................... 70
6.5 Storing programming on file....................................................................................70
6.5.1 Store PF to file........................................................................................................ 71
6.5.2 Read PF from file.................................................................................................... 72
6.6 Offline.....................................................................................................................73
6.6.1 Configuring a tool offline......................................................................................... 74
7Pset.......................................................................................................................75
7.1 Create new Pset/Open Pset ...................................................................................76
7.2 Autoset...................................................................................................................77

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7.3 Quick programming................................................................................................78
7.4 Programming help.................................................................................................. 79
7.5 Programming ......................................................................................................... 80
7.6 Control strategies...................................................................................................84
7.6.1 Tq con......................................................................................................................84
7.6.2 Tq con/ang mon.......................................................................................................85
7.6.3 Ang con/tq mon .......................................................................................................85
7.6.4 Tq con/ang con (AND) / (OR)..................................................................................86
7.6.5 Reverse ang ............................................................................................................87
7.6.6 Rotate spindle forward/reverse................................................................................88
7.6.7 Click wrench ............................................................................................................88
7.6.8Home position forward and reverse ........................................................................89
7.6.9 Yield control (Yield) .................................................................................................90
7.6.10 Yield/Tq con (OR)....................................................................................................90
7.6.11 DS con.....................................................................................................................91
7.6.12 DS con/tq mon.........................................................................................................92
7.6.13 Snug gradient ..........................................................................................................93
7.6.14 PVT comp with snug................................................................................................94
7.7 Tightening strategies.............................................................................................. 95
7.7.1 One stage................................................................................................................96
7.7.2 Two stage................................................................................................................96
7.7.3 Quick step................................................................................................................97
7.7.4 Ergo ramp................................................................................................................98
7.7.5 Additional control options ........................................................................................98
7.7.6 Rehit detection.........................................................................................................99
7.8 Programming + ...................................................................................................... 99
7.8.1 Current monitoring.................................................................................................100
7.8.2 PVT selftap............................................................................................................101
7.8.3 PVT monitoring......................................................................................................102
7.8.4 PVT compensate...................................................................................................104
7.8.5 Options ..................................................................................................................105
7.8.6 Gradient monitoring...............................................................................................106
7.8.7 Yield control...........................................................................................................107
7.8.8 Post view torque....................................................................................................109
7.9 Pset setup............................................................................................................ 110
7.10 Statistic programming........................................................................................... 112
7.11 Running a Pset..................................................................................................... 112
8Multistage ..........................................................................................................113
8.1 Create new Multistage/Open Multistage............................................................... 114
9Job......................................................................................................................117
9.1 Job concepts........................................................................................................ 117
9.2 Job configuration.................................................................................................. 119
9.2.1 Creating a Job group.............................................................................................119

Contents
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9.2.2 Creating a new Job............................................................................................... 120
9.2.3 Select Job............................................................................................................. 122
9.3 Functions in the Job monitor.................................................................................124
9.4 Unlock the tool......................................................................................................125
10 Controller...........................................................................................................126
10.1 Information ...........................................................................................................126
10.2 Configuration........................................................................................................128
10.3 Network................................................................................................................130
10.3.1 Cell and Net configuration .................................................................................... 132
10.4 COM ports............................................................................................................136
10.5 Display..................................................................................................................137
10.6 Memory ................................................................................................................138
10.7 Accessibility..........................................................................................................141
11 Tool.....................................................................................................................143
11.1 Tool information....................................................................................................143
11.2 Tool configuration.................................................................................................145
11.2.1 Tool start and Accessory bus ............................................................................... 145
11.2.2 Sound and buzzer................................................................................................. 147
11.2.3 Tool function buttons ............................................................................................ 149
11.2.4 Blue LED............................................................................................................... 151
11.2.5 Tool illuminator and lights..................................................................................... 152
11.2.6 Radio and Connection .......................................................................................... 153
11.3 Tool diagnostic .....................................................................................................154
11.3.1 Sensor tracking..................................................................................................... 155
11.3.1 Transducer calibration.......................................................................................... 155
11.4 Tool maintenance.................................................................................................157
11.4.1 Calibration and Service......................................................................................... 158
11.4.2 Open-end tuning................................................................................................... 158
11.4.3 Wear indicator....................................................................................................... 160
11.4.4 ACTA .................................................................................................................... 160
11.4.5 Motor tuning.......................................................................................................... 161
11.4.6 Disconnect tool ..................................................................................................... 162
11.4.7 Hot swap............................................................................................................... 164
11.5 Tool lock functionality ...........................................................................................164
11.5.1 Locking of tools from an external source in time critical applications................... 164
11.5.2 Intentional locking of tools .................................................................................... 165
11.5.3 Definition of a locked tool...................................................................................... 165
11.5.4 Tool locking event codes ...................................................................................... 165
12 Accessories.......................................................................................................167
12.1 Digital I/O..............................................................................................................167
12.2 I/O bus..................................................................................................................170
12.3 Tool bus................................................................................................................175

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12.4 Printer.................................................................................................................. 178
13 Sync ...................................................................................................................181
13.1 Sync prerequisites and limitations........................................................................ 182
13.2 Hardware configuration........................................................................................ 183
13.3 Sync configuration................................................................................................ 184
13.3.1 Sync members configuration.................................................................................184
13.3.2 Sync reference configuration.................................................................................185
13.4 Troubleshooting ................................................................................................... 187
14 Identifier.............................................................................................................189
14.1 Identifier concepts................................................................................................ 189
14.2 Identifier prerequisites and details........................................................................ 190
14.3 Configuration of identifier functions ...................................................................... 192
14.3.1 Configuring identifiers............................................................................................193
14.3.2 Configuring a work order .......................................................................................195
14.3.3 Configuring result parts .........................................................................................196
14.3.4 Additional identifier functions.................................................................................197
15 Fieldbus .............................................................................................................199
15.1 General setup ...................................................................................................... 200
15.1.1 Parameters in General setup.................................................................................201
15.1.2 View fieldbus information.......................................................................................203
15.2 From PF setup and to PF setup ........................................................................... 204
15.2.1 Fieldbus modes .....................................................................................................205
15.3 Storing fieldbus configuration............................................................................... 206
15.4 Disable fieldbus carried signals............................................................................ 206
15.5 Fieldbus data format ............................................................................................ 207
15.5.1 Bitmap select (Endian mode) ................................................................................207
15.5.2 Fieldbus data types ...............................................................................................207
15.6 Fieldbus selector configuration............................................................................. 212
15.7 Select Pset from fieldbus and set batch size........................................................ 213
15.8 Fieldbus information............................................................................................. 214
15.8.1 ProfiBus-DP...........................................................................................................214
15.8.2 DeviceNet..............................................................................................................218
15.8.3 InterBus/InterBus2MB ...........................................................................................223
15.8.4 ModBusPlus...........................................................................................................227
15.8.5 Ethernet/IP.............................................................................................................231
15.8.6 Modbus/TCP..........................................................................................................233
15.8.7 ControlNet..............................................................................................................234
15.8.8 Profinet ..................................................................................................................236
15.8.9 FL-Net....................................................................................................................238
15.8.10 CC-Link..................................................................................................................239
16 Logic Configurator............................................................................................245
16.1 Process description (an example) ........................................................................ 246

Contents
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16.2 Logic operators and function blocks......................................................................247
16.2.1 Logic gates............................................................................................................ 247
16.2.2 Function blocks..................................................................................................... 248
16.3 Logic Configurator setup.......................................................................................251
16.3.1 Simulation............................................................................................................. 256
17 Monitors.............................................................................................................259
17.1 Result Monitor ......................................................................................................260
17.2 Job Monitor...........................................................................................................262
17.3 Operator Monitor ..................................................................................................263
17.3.1 Picture Monitor...................................................................................................... 266
17.4 Identifier Monitor...................................................................................................267
17.5 Get all results........................................................................................................268
18 Trace...................................................................................................................271
18.1 The trace window .................................................................................................271
19 Statistics............................................................................................................275
19.1 Statistic alarm.......................................................................................................276
19.2 Trend deviation alarm...........................................................................................277
19.3 Calculation of UCL and LCL .................................................................................277
19.4 Calculation of mean values...................................................................................277
19.5 Calculation formulas.............................................................................................278
19.6 Constants for calculation of SPC variables ...........................................................280
20 Quick reference guide.......................................................................................281
20.1 Tq con ..................................................................................................................282
20.1.1 One stage ............................................................................................................. 282
20.1.2 Two stage ............................................................................................................. 283
20.1.3 Quick step............................................................................................................. 284
20.1.4 Ergo ramp............................................................................................................. 285
20.2 Tq con/ang mon....................................................................................................286
20.2.1 One stage ............................................................................................................. 286
20.2.2 Two stage ............................................................................................................. 287
20.2.3 Quick step............................................................................................................. 288
20.2.4 Ergo ramp............................................................................................................. 289
20.3 Tq con/ang con (AND) and Tq con/ang con (OR).................................................290
20.3.1 One stage ............................................................................................................. 290
20.3.2 Two stage ............................................................................................................. 291
20.3.3 Quick step............................................................................................................. 292
20.3.4 Ergo ramp............................................................................................................. 293
20.4 Ang con/tq mon ....................................................................................................294
20.4.1 One stage ............................................................................................................. 294
20.4.2 Two stage ............................................................................................................. 295
20.4.3 Quick step............................................................................................................. 296
20.4.4 Ergo ramp............................................................................................................. 297

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20.5 Reverse ang......................................................................................................... 298
20.6 Rotate spindle forward and Rotate spindle reverse .............................................. 299
20.7 Home position forward and reverse...................................................................... 300
20.8 DS con................................................................................................................. 301
20.8.1 One stage..............................................................................................................301
20.8.2 Two stage..............................................................................................................301
20.8.3 Quick step..............................................................................................................302
20.8.4 Ergo ramp..............................................................................................................303
20.9 Snug gradient....................................................................................................... 304
20.9.1 One stage..............................................................................................................304
20.9.2 Two stage..............................................................................................................305
20.9.3 Quick step..............................................................................................................306
21 Digital I/O and fieldbus items...........................................................................307
21.1 Digital output (relay) and fieldbus items from PF.................................................. 307
21.2 Digital input and fieldbus items to PF ................................................................... 328
22 Parameter list ....................................................................................................341
22.1 Pset...................................................................................................................... 341
22.1.1 Programming.........................................................................................................341
22.1.2 Programming +......................................................................................................346
22.1.3 Pset setup..............................................................................................................350
22.1.4 Statistic programming............................................................................................350
22.2 Multistage............................................................................................................. 353
22.2.1 Setup .....................................................................................................................353
22.2.2 Multistage programming........................................................................................354
22.3 Job....................................................................................................................... 356
22.3.1 Setup .....................................................................................................................356
22.3.2 Programming.........................................................................................................357
22.4Controller ............................................................................................................. 360
22.4.1 Information.............................................................................................................360
22.4.2 Configuration .........................................................................................................361
22.4.3 Network..................................................................................................................362
22.4.4 COM ports .............................................................................................................364
22.4.5 Display...................................................................................................................364
22.4.6 Memory..................................................................................................................365
22.4.7 Accessibility...........................................................................................................366
22.5 Tool...................................................................................................................... 366
22.5.1 Information.............................................................................................................366
22.5.2 Configuration .........................................................................................................367
22.5.3 Diagnostic..............................................................................................................371
22.5.4Maintenance..........................................................................................................371
22.5.5 Buzzer configuration..............................................................................................374
22.5.6 Sound configuration...............................................................................................374
22.6 Accessories.......................................................................................................... 375

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22.6.1 Digital I/O.............................................................................................................. 375
22.6.2 I/O bus .................................................................................................................. 376
22.6.3 Tool bus................................................................................................................ 377
22.6.4 Printer ................................................................................................................... 377
22.7 Sync .....................................................................................................................377
22.7.1 Programming ........................................................................................................ 377
22.8 Identifier................................................................................................................378
22.8.1 Identifier setup ...................................................................................................... 378
22.9 Fieldbus................................................................................................................379
23 Event codes.......................................................................................................383
23.1 Event code list......................................................................................................385
23.1.1 E001-E099 Rundown failures............................................................................... 386
23.1.2 E100-E199 Event related errors........................................................................... 387
23.1.3 E200-E299 User input events............................................................................... 398
23.1.4 E300-E399 Statistical events................................................................................ 401
23.1.5 E400-E499 Communication events...................................................................... 405
23.1.6 E500-E599 Hardware events (tools) .................................................................... 409
23.1.7 E600-E699 Hardware events................................................................................ 415
23.1.8 E700-E799 Hardware events................................................................................ 416
23.1.9 E800-E899 Software events................................................................................. 418
23.1.10 E900-E999 Events MMI........................................................................................ 421
24 Index...................................................................................................................422