Atlas Copco TPS Control User manual

TPS Control
Printed Matter No. 9836 5819 01 Control and drive unit
Publication Date 2018-02-23
Valid for Version No. 1.2 User Guide
WARNING
Read all safety warnings and instructions
Failure to follow the safety warnings and instructions may result in
electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference

2© Atlas Copco Industrial Technique AB - 9836 5819 01
Table of Contents
User guide ...............................................................................................................3
Introduction .......................................................................................................3
Safety and operating instructions ..........................................................3
System overview ...................................................................................3
TPS controller........................................................................................4
ToolsTalk TPS .......................................................................................8
Setup ................................................................................................................9
Starting TPS ..........................................................................................9
Setting up TPS ......................................................................................9
Connecting TPS to tool control systems..............................................12
Installing an I/O extension board .........................................................24
Operation ........................................................................................................27
Quick guide..........................................................................................27
Job handling ........................................................................................27
Maintenance ...................................................................................................30
Firmware updates................................................................................30
Reference .......................................................................................................31
I/O configuration ..................................................................................31
Parameters ..........................................................................................32
Licence handling..................................................................................43
Pneumatic function ..............................................................................43
Barcode function..................................................................................47
Reporting function ...............................................................................49
Printout ................................................................................................49

TPS Control EN User guide
© Atlas Copco Industrial Technique AB - 9836 5819 01 3
User guide
Introduction
Safety and operating instructions
WARNING Read all warnings and all instructions.
The safety and operating instructions as described in the Atlas Copco Product instructions that is included
in the delivery of the system must be read and complied. Ensure that you read and understand all instruc-
tions. Failure to follow all the instructions may result in electric shock, fire and/or serious personal injury.
All locally legislated safety regulations with regard to installation, operation and maintenance must be ad-
hered to at all times. Refer installation and servicing to qualified personnel only.
Save all instructions for future reference.
Contact your Atlas Copco representative if questions regarding the safety and operating instructions arise.
System overview
This user guide describes how to install, configure and use the Tool Positioning System (TPS) Control.
TPS Control is used for controlling and monitoring the tightening sequences and positioning operations for
a variety of pneumatic and electronic tools. The TPS Control system is designed for the modern assembly
industry with high demands on quality and production efficiency, and offers full modularity through the
combination of different hardware and software.
A typical setup of the TPS contains the controller itself connected to a screwdriver and torque arm, with
external operating and display elements and a digital I/O cable to a tool controller.

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The TPS can either be used with a single tool or be connected to a torque arm that holds the tool. If the
controller is used with a torque arm, the arm is equipped with an analogue and an SSI encoder that can
detect the position of the screw being handled.
The TPS primarily monitors the sequence of screws and the tightening program, with and without position
control.
The TPS can easily be connected to different tool controllers using digital 24 VDC signals. These digital
input and output signals are used to enable and control workstations. The OK/NOK classification of the in-
dividual tightening operations is handled by the tool controllers which transmit these results through the
digital input signals to the TPS Control. The TPS has 10 digital inputs and 6 digital outputs.
In TPS, the complete sequence definition for a work piece is called a job. The TPS can store up to 50 jobs
with a total of 500 sequence element memories for positions used for these jobs. These sequence ele-
ments can be freely allocated to the 50 supported jobs. Each position within a job can be assigned to a
specific Pset, or several positions can be assigned to the same Pset. Psets are configured in the Tool-
sTalk software, which contains the complete set of parameters that control the tightening process.
TPS Control can also handle additional functions, such as input queries defined for specific positions and
external starting signals and output signals used in clamping procedures.
TPS Control can either be powered with an external power supply unit or through an external power signal
from the tool controller. The external power supply unit and cord are ordered separately. Note that an ex-
ternal power supply unit is required for air tools, MicroTorque and EBL RE-Drive.
TPS controller
The main part of the TPS Control system is the TPS controller. It is contained in a metal casing with a
front panel and connection interface on the short side of the unit. The front panel can be rotated 180 de-
grees to house the connections on the top or the bottom of the unit, depending on how the controller will
be installed.
User Interface
You operate the controller using the front panel, which has a graphical display and a keyboard with special
keys and navigation keys. The display has a resolution of 128 x 64 pixels and supports different fonts and
text sizes as well as graphics. The display backlight has four colour options: red, green, blue, or white
colour.

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Number Part Description
1 Display The front panel has a configurable display. A power-save function de-
activates the backlight on the display if it is not used for a user-defined
period of time (in minutes).
The display is divided into three segments:
■Upper part shows the last selected job/current job.
■Middle part shows status information about ongoing operations.
■Lower part shows the menu alternatives that can be accessed us-
ing the function keys.
2 Function keys Soft keys which function according to what is displayed on the display
screen.
3 ESC Use this key to cancel any ongoing jobs or parameter settings. When
cancelling parameter settings, no changes are stored in memory.
4 Left/Right arrow key Use these keys to display parameter options or to create/remove posi-
tions when programming new jobs.
5 INFO Press this key to get information about the TPS Control device ID,
firmware version and activated licensed functions.
6 START Use this key to start selected job.
7 Up/Down Arrow keys When in parameter list, use these keys to go up or down in the list to
select a desired parameter.
For selected parameter, use the up/down arrow keys to change the op-
tions of the parameter.
8 NOK Use this key to release the tool after a position has resulted in NOK
state and the tool is disabled. This is only used if parameter NOK ac-
knowledge has been set to ON.
9 RESET Use this key to stop the ongoing job during any time of the procedure
10 VAL Use this key to validate and store all changed parameters in memory
11 OK Use this key to open the list with possible options for a selected param-
eter or confirm the selected option for the parameter.
12 MENU Use this key to enter the setup menu parameters

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Connections
Number Part Description
1 Ground For flash plug for ground connection.
2 Analogue encoder inter-
face
For 5-pin flange socket (Binder, Series 680) connected to the analogue
encoder on the torque arm
3 SSI encoder interface For 7-pin flange socket (binder, Series 680) connected to the angle en-
coder on the torque arm
4 Power supply For connection to the 24 VDC power supply unit, 5.5 mm socket with
2.1 mm center pin
5 RS-232C serial interface For 9-pin Sub-D socket connected to the external equipment, for exam-
ple Barcode scanner or PC
6 Digital I/O connection I/O
Port 1
For 25-pin Sub-D socket connected to the tool controller.
7 I/O Port 2 Not used.
Ground connection
A 6.3 mm flash plug used for ground connection. This connection must be linked to the protective ground
for safe operation of the TPS Control.
Analogue encoder connection
Interface with a 5-pole connection for an analogue encoder. Use a 5-pole pin plug from the Binder 680 Se-
ries. This encoder can either be of a lineary or angle type using analogue 0-10 V.
PIN Signal
1 24 V Supply
2 24 V GND
3 Analogue input
4 Analogue GND
5 Not connected
SSI encoder connection
SSI interface with a 7-pole connection for the SSI encoder. Use a 7-pole pin plug from the Binder 680 Se-
ries.

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PIN Signal
1 24 V Supply
2 Clock +
3 Clock -
4 Data -
5 Data +
6 Not connected
7 24 V GND
Power supply
The TPS Control is powered by an external 24-volt power supply unit. The external power supply unit can
be ordered as an accessory from Atlas Copco.
As an alternative, the unit can be supplied with 24 VDC from an external power signal through the I/O
plug.
Power consumption
The table below shows the power consumption of the TPS Control.
Status Power consumption
Inrush 400 mA
Operating 200 mA
RS-232C serial interface
Serial interface with a 9-pole connection for external devices, such as PC or barcode scanners. COM port
settings: 9600 Baud to 115 KBaud.
Note that for a PC a straight cable must be used. It is not possible to use the type of cross cable generally
used for connection to Power Focus or Tensor.
PIN Signal Description
1 Not connected
2 TxD Transmit 1
3 RxD Receive 1
4 Not connected
5 GND Potential-free GND of
RS-232 interface
6 Not connected
7 HSHI Handshake input or Re-
ceive 2
8 HSHO Handshake output (con-
stantly -12 V) or Transmit
2
9 Not connected
Digital I/O connection
Digital I/O interface with a 25-pole connection for synchronization with tool controllers.

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PIN Signal I/O Port 1 Signal I/O Port 2 Description
1 GND 24 V GND 24 V
2 OUT 1 OUT 7 Output, positive switching
24V, max 0.7 A, short-cir-
cuit proof
3 OUT 2 OUT 8 Output, positive switching
24V, max 0.7 A, short-cir-
cuit proof
4 OUT 3 OUT 9 Output, positive switching
24V, max 0.7 A, short-cir-
cuit proof
5 IN 2 IN 12 Digital input 16-32 volt
6 IN 4 IN 14 Digital input 16-32 volt
7 GND 24 V GND 24 V
8 IN 6 IN 16 Digital input 16-32 volt
9 IN 9 IN 19 Digital input 16-32 volt
10 OUT 4 OUT 10 Output, positive switching
24V, max 0.7 A, short-cir-
cuit proof
11 OUT 5 OUT 11 Output, positive switching
24V, max 0.7 A, short-cir-
cuit proof
12 OUT 6 OUT 12 Output, positive switching
24V, max 0.7 A, short-cir-
cuit proof
13 GND 24 V GND 24 V
14 +24 V +24 V
15 GND 24 V GND 24 V
16 GND 24 V GND 24 V
17 IN 1 IN 11 Digital input 16-32 volt
18 IN 3 IN 13 Digital input 16-32 volt
19 IN 5 IN 15 Digital input 16-32 volt
20 IN 7 IN 17 Digital input 16-32 volt
21 IN 8 IN 18 Digital input 16-32 volt
22 IN 10 IN 20 Digital input 16-32 volt
23 GND 24 V GND 24 V
24 GND 24 V GND 24 V
25 Not connected Not connected
ToolsTalk TPS
ToolsTalk TPS is a Microsoft Windows application that simplifies setup of the system. Only the main func-
tions needed for setting up the system are available in ToolsTalk TPS. The complete set of functions and
parameters is available in the TPS controller.

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In ToolsTalk TPS you can do the following:
■Handle TPS Control configuration files (select/read/write)
■Configure connection between PC and TPS Control
■Change language (ToolsTalk TPS)
■Handle report function (configure/create)
■Import licenses for optional functions
■Update firmware in TPS Control
Setup
Starting TPS
1. Connect cables and ground connection according to section TPS Controller.
2. Switch on the power. The controller starts up immediately.
Setting up TPS
Setting up system parameters
This section describes how to set up general system parameters in TPS.
1. Press MENU.
2. Press SETUP.
3. The default language is English. If you want to change the language, go to Service and press OK to
enter the menu.
4. Select the appropriate language in User language. Confirm your selection with OK. Possible lan-
guages are English, German or French.
5. Press VAL to change to the selected language.
6. Go to System parameter and press OK to enter the menu.
7. Set Special functions to ON to view advanced programming functions. Press OK.
8. Enter values for additional parameters. The parameters and options are described in detail in section
System Parameters [Page000].
9. Press VAL to confirm changes or ESC to quit without making any changes.

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Setting up input and output parameters
This section describes how to set up the input signals and output signals in TPS for communication with
the tool controller. Note that the input signals in the tool controller correspond to the output signals for TPS
control, and the relays in the tool controller correspond to the input signals in TPS Control. For a complete
parameter list, see section Parameters, Input Configuration and Output Configuration.
1. Go to Input configuration.
2. Set the required inputs corresponding to the relays set in ToolsTalk. See section Connect TPS to tool
control systems for an example configuration.
3. Press VAL to confirm changes or ESC to quit without making any changes.
4. Go to Output Configuration.
5. Set the required outputs corresponding to the input signals set in ToolsTalk. See Connect TPS to tool
control systems for an example configuration.
6. Press VAL to confirm changes or ESC to quit without making any changes.
Setting up encoder parameters
This section describes how to set the position parameters related to the analogue and SSI encoders on
the torque arm that must be calibrated before any tightening operations can be created. For a complete
list of position parameters, see section Position.
The parameters to set are as follows:
■SSI Interface parameters
■SSI coding
■SSI factor
■SSI resolution
■Length
■Length 1 (L1)
■Length 2 (L2)
The calculations of L1 and L2 differ, depending on what type of torque arm will be used.
The following arm types can be used together with TPS:
■Angle/Linear
■Linear/Linear
■Angle/Angle A (for arm types with an horizontal arm mounted to the left, 180 degrees analogue en-
coder mounted on the top of the arm)
■Angle/Angle B (for arm types with 360 degrees analogue encoder)
■Angle/Angle C (for arm types with an horizontal arm mounted to the right, 180 degrees analogue en-
coder mounted on the bottom of the arm)
Note! The Rotation stop kit must be kept intact on the torque arm to ensure that the analogue and SSI en-
coder will work properly. For more information on different arm types, see the applicable PI.
Setting up SSI Interface
See section Position to set up the parameters for SSI interface.
Setting up SML T arms

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1. In TPS Control, go to Position.
2. Set Arm type to Angle/Linear.
3. Measure Length 1 (L1) on the torque arm from the centre of the axis to the centre of the tool when
fully retracted to start position. Check that the encoder value is set to zero in this position in Ser-
vice>Test functions>Test Inputs.
4. Measure Length 2 (L2) on the torque arm from the centre of the axis to the centre of the tool when
fully protracted to maximum length.
If the fully protracted arm has an analogue encoder value less than 1023, the following formula should
be used to calculate L2:
L2Input = L1 + 1023 * (L2 - L1)/(D2 - D1), where D stands for encoder value.
5. Enter the values for L1 and L2 in Length 1 and Length 2.
6. Press VAL to confirm changes or ESC to quit without making any changes.
Setting up SMS T arms
The figure above shows an SMS T arm from above with horizontal arm mounted to the left (angle/angle
A).
1. In TPS Control, go to Position.
2. Set Arm type to one of the following angle/angle values:
■Angle/Angle A (SMS T, position from above: horizontal arm mounted to the left, 180-degree ana-
logue encoder mounted on top of the torque arm)
■Angle/Angle B (Positioning arm with 360-degree analogue encoder)
■Angle/Angle C (SMS T, position from above: horizontal arm mounted to the right, 180-degree ana-
logue encoder mounted on bottom of the torque arm)
For more information on how to mount the positioning encoder on either the top or the bottom of the
torque arm, see the applicable torque arm instructions.
3. Measure Length 1 (L1) from the centre of the axis to the centre of the elbow when fully retracted to
start position.
4. Measure Length 2 (L2) from the centre of the elbow to the centre of the tool when fully protracted to
maximum length.
5. Enter the values for L1 and L2 in Length 1 and Length 2.
6. Press VAL to confirm changes or ESC to quit without making any changes.
7. Go to Service>Test functions>Test inputs to check that the fully retracted arm has an analogue en-
coder value of 100.
For information on how to set the encoder value to 100, see the applicable torque arm instructions.

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Setting up SMC POSI L arms
1. In TPS Control, go to Position.
2. Set Arm type to Linear/Linear.
3. Set Length 1 (L1) to 300.
4. Set Length 2 (L2) to 2000.
5. Set SSI coding to binary.
6. Set SSI resolution to 24, SSI factor to 1 and SSI divider to 2.
7. Press VAL to confirm changes or ESC to quit without making any changes.
See section Position for more information on how to set up the parameters for SSI interface.
Setting up SMC POSI LA arms
1. In TPS Control, go to Position.
2. Set Arm type to Angle/Linear 2.
3. Set Length 1 (L1) to 1056.
4. Set Length 2 (L2) to 4332,7.
5. Set SSI coding to binary.
6. Set SSI resolution to 25, SSI factor to 1 and SSI divider to 4.
7. Set a value for SSI code by length 0 by following the instruction below.
8. Press VAL to confirm changes or ESC to quit without making any changes.
How to retrieve the correct value for SSI code by length 0:
1. Go to TPS menu setup->service->Test functions->Test inputs.
2. By changing the arm linear position, the code for SSI sensor changes accordingly.
3. Change the arm linear position to the minimum arm length, to retrieve the correct code value to use in
SSI code by length 0.
See section Position for more information on how to set up the parameters for SSI interface.
Setting up start parameters
This section describes how to set parameters required to start jobs with the TPS controller.
To set up start parameters controlled by external devices, see section Sequence.
1. Go to System Parameter.
2. In Job Selection, select Keyboard.
3. Go to Sequence.
4. Set start signal as follows:
■Set to Edge if you want to start the job each time by pressing Start on the TPS controller.
■Set to Level to start the job the first time by pressing Start on TPS controller. After that the job is
started automatically.
Connecting TPS to tool control systems
Connecting to Power Focus 4000
This section describes how to configure Power Focus 4000 and TPS Control to set up communication be-
tween the controllers. Power Focus has four relay contacts (outputs) and four inputs that can be used for
communication with TPS. All inputs and outputs can be configured using the ToolsTalk software. For a
complete instruction of PF ToolsTalk, see the applicable Power Focus user guide.
Note! This section describes an example of how to configure the tool controller and TPS. Depending on
the type of operation you may need to set the inputs and outputs to other values.
1. Check that the digital I/O cable is connected to the TPS and the Power Focus.

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2. Check that a PC with the ToolsTalk PF software installed is connected to the Power Focus.
In ToolsTalk PF
1. Depending on how Power Focus is connected to the PC, make sure it is visible in either PF Map>Eth-
ernet Connected or PF Map>Serial.
2. In PF Map window, double-click on Controller and then double-click on Configuration. A new win-
dow appears.
3. In Select Source, set Pset to Digin to enable TPS to control which Pset to use. Click Store.
4. In PF Map, select Accessories>Digital I/O and double-click Configuration.
5. Set PF input signals in Digital Input and PF output signals in Relay according to the figure below.

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6. Click Store to store all selected values in memory.
In TPS Control
1. Go to Menu>Setup>Input Configuration and set the signals and inputs matching the relay signals
set up in ToolsTalk PF.
2. Press VAL to confirm the selection.
3. Press ESC to leave the menu.
4. Go to Output Configuration and set the signals matching the input signals in the ToolsTalk PF.
5. Press VAL to confirm the selection.
6. Press ESC to leave the menu.
Connecting to Power Focus 600/Power Focus 6000
This section describes how to configure Power Focus 600/Power Focus 6000 and TPS Control to set up
communication between the controllers. Power Focus has four relay contacts (outputs) and four inputs
that can be used for communication with TPS. The Power Focus 600/Power Focus 6000 controller soft-
ware is configured trough a web interface or the keypad. For a complete instruction of the Power Focus
600/Power Focus 6000 controller software, see the applicable Power Focus user guide.

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Note! This section describes an example of how to configure the tool controller and TPS. Depending on
the type of operation you may need to set the inputs and outputs to other values.
1. Check that the digital I/O cable is connected to the TPS and the Power Focus.
In PF600/PF6000 or through a web interface (or ToolsTalk 2 for PF6000)
1. Go to Accessories >Internal I/O>Outputs and select Output 1.
2. Set Output 1 values as follows: Output signal =Tightening OK, Duration = To next tightening, and
Flash = Off
3. Change to Output 2 and set values as follows: Output signal =Tightening NOK, Duration = To next
tightening, and Flash = Off
4. Go to Accessories >Internal I/O>Inputs.
5. Set values for Input 1 to 4 as follows:
■Input 1 = Lock tightening
■Input 2 = Select input bit 0
■Input 3 = Select input bit 1
■Input 4 = Select input bit 2
6. Click OK to store all selected values in memory.
In TPS Control

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1. Go to Menu>Setup>Input Configuration and set the signals and inputs matching the output signals
set up in PF.
2. Press VAL to confirm the selection.
3. Press ESC to leave the menu.
4. Go to Output Configuration and set the signals matching the input signals set up in PF.
5. Press VAL to confirm the selection.
6. Press ESC to leave the menu.
Connecting to Tensor DS Drive D312 or DL Drive D313
This section describes how to configure Tensor DS/DL Drive D312/D313 and TPS Control to set up com-
munication between the controllers. Tensor DS/DL Drive D312/D313 has four relay contacts (outputs) and
four inputs that can be used for communication with TPS. All inputs and outputs can be configured using
the ToolsTalk software. For a complete instruction of ToolsTalk DSDL, see the applicable Tensor DS/DL
Drive D312/D313 user guide.
Note! This section describes an example of how to configure the tool controller and TPS. Depending on
the type of operation you may need to set the inputs and outputs to other values.
1. Check that the digital I/O cable is connected to the TPS and Tensor.
2. Check that a PC with the ToolsTalk software installed is connected to Tensor.
In ToolsTalk DSDL
1. Select Configuration in the menu Window. A new window appears.
2. Select I/O Setup.
3. Set Select Source to Digital Inputs.
4. Set input and output signals as seen in the figure below.

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5. Click Store to store all selected values in memory.
In TPS Control
1. Go to Menu>Setup>Input Configuration and set the signals and inputs matching the relay signals
set up in ToolsTalk DSDL.
2. Press VAL to confirm the selection.
3. Press ESC to leave the menu.
4. Go to Output Configuration and set the signals matching the input signals in the tool controller.
5. Press VAL to confirm the selection.
6. Press ESC to leave the menu.

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Connecting to MicroTorque G4
This section describes how to configure MicroTorque G4 and TPS Control to set up communication be-
tween the controllers. MicroTorque G4 has predefined outputs and inputs that can be used for communi-
cation with TPS. For a complete instruction of MicroTorque G4, see the MicroTorque System user guide.
Note! This section describes an example of how to configure the tool controller and TPS. Depending on
the type of operation you may need to set the inputs and outputs to other values.
To ensure that TPS works properly with MicroTorque G4, the function Screw cycle sequence must be
disabled.
1. Check that the digital I/O cable is connected to TPS and MicroTorque G4.
2. Check that a PC installed with the ToolsTalk MT software version 4.44.00 or later is connected to the
MicroTorque G4 with a firmware version 4.44.00 or later.
In ToolsTalk MT
1. In the folder Controller parameter set TPS mode to On to enable correct IO behavior.
2. Check that the predefined input and output signals are set according to the figure below.
In TPS Control
1. Go to Menu>Setup>Input Configuration and set the signals and inputs matching the relay sig-
nals set up in ToolsTalk MT.

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2. Press VAL to confirm the selection.
3. Press ESC to leave the menu.
4. Go to Output Configuration and set the signals matching the input signals in the tool controller.
5. Press VAL to confirm the selection.
6. Press ESC to leave the menu.
Connecting to MTF 400
This section describes how to configure MTF 400 and TPS Control to set up I/O communication between
the controllers. MTF 400 has several digital relay outputs and inputs that can be used for communication
with TPS. All inputs and outputs can be configured using the ToolsTalk software. For a complete instruc-
tion of ToolsTalk MTF, see the ToolsTalk MTF user guide.
To ensure that the TPS works properly with MTF 400, the I/O connections must be connected in PNP
mode (source type, positive logic), as described in the applicable instruction for separate MTF 400 con-
troller.
Note! This section describes an example of how to configure the MTF 400 controller and TPS. Depending
on the type of operation you may need to set the inputs and outputs to other values.
1. Check that the digital I/O cable is connected to the TPS and the MTF 400.
2. Check that a PC with the ToolsTalk MT software installed is connected to the MTF 400.
In ToolsTalk MT
1. Click I/O state to display the status of the controller I/O signal. A new window appears.
2. Set input and output signals as seen in the figure below.

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3. Click Save to controller to store all selected values in the controller.
In TPS Control
1. Go to Menu>Setup>Input Configuration and set the input signals matching the output signals set up
in ToolsTalk MT.
2. Press VAL to confirm the selection.
3. Press ESC to leave the menu.
4. Go to Output Configuration and set the output signals matching the input signals in the tool con-
troller.
5. Press VAL to confirm the selection.
6. Press ESC to leave the menu.