Atlas Copco ACTA 3000 Guide

Edition 2 Atlas Copco Tools AB - 9836 1818 01
Page 1 (197)2002-04
A Guide to Using
ACTA 3000
Atlas Copco Tools AB

Contents
3
Contents
1. Safety Instructions...................................................................................................................9
2. System Overview ...................................................................................................................11
2.1 General........................................................................................................................ 11
2.1.1 ACTA 3000 Basic............................................................................................ 11
2.1.2 ACTA 3000 Quality Control........................................................................... 11
2.1.3 ACTA 3000 Advanced Analysis...................................................................... 12
2.1.4 ToolsTalk ACTA............................................................................................. 13
3. Installation and startup.........................................................................................................15
3.1 Out of the Box............................................................................................................. 15
3.1.1 Installation....................................................................................................... 15
4. Quick Programming..............................................................................................................17
4.1 General........................................................................................................................ 17
4.2 Operating Quick-guide ............................................................................................... 17
4.3 Quick programming .................................................................................................... 18
4.4 Your Measurement Results using Quick Programming............................................ 21
5. Keys and Indicators...............................................................................................................23
5.1 Front Panel.................................................................................................................. 23
5.1.1 Status (LED) Indicators................................................................................... 24
6. Measurement Dialog boxes...................................................................................................27
6.1 General........................................................................................................................ 27
6.2 The Different Measurement Dialog boxes................................................................. 27
6.2.1 The “Basic” Measurement Dialog box .......................................................... 28
6.2.2 The “Custom” Measurement Dialog Box...................................................... 28
6.2.3 The “Trace” Measurement Dialog Box......................................................... 29
6.3 Measurement Dialog box / Menu Block Setup Combinations .................................. 30
6.3.1 Basic ................................................................................................................ 30
6.3.2 Quality Control (QC)....................................................................................... 30
6.3.3 Advanced Analysis (AA) ................................................................................. 31
7. Programming Tree................................................................................................................33
7.1 General........................................................................................................................ 33
7.2 Using the programming tree....................................................................................... 33
7.2.1 Menu Blocks ................................................................................................... 33
7.2.2 Pop-up Menu................................................................................................... 34
7.2.3 Data Input Dialog box...................................................................................... 35

Contents
4
7.3 Programming tree ACTA 3000 Basic......................................................................... 36
7.4 Programming tree ACTA 3000 Quality Control........................................................ 37
7.5 Programming tree ACTA 3000 Advanced Analysis................................................... 39
8. Programming the ACTA 3000.............................................................................................41
8.1 General........................................................................................................................ 41
8.2 Ready to program........................................................................................................ 41
8.3 Configuration (Conf.)................................................................................................... 42
8.3.1 User interface .................................................................................................. 44
8.3.2 Tightening operation interface........................................................................ 45
8.3.3 Port Interface................................................................................................... 49
8.3.4 Calibration....................................................................................................... 50
8.3.5 Diagnostics ...................................................................................................... 51
8.3.6 Transducer memory ........................................................................................ 51
8.3.7 Product information......................................................................................... 52
8.3.8 Options ............................................................................................................ 53
8.4 Quick Programming (Q.Prog.).................................................................................... 53
8.5 Calibration (Cal.)......................................................................................................... 53
8.5.1 Setting up your non-Atlas Copco memory type transducer............................ 53
8.6 Database (Datab.)........................................................................................................ 55
8.6.1 New Tool.......................................................................................................... 55
8.6.2 Select Tool....................................................................................................... 56
8.6.3 Delete Tool...................................................................................................... 57
8.6.4 Clear all measurements................................................................................... 58
8.6.5 Backup tool...................................................................................................... 58
8.7 Select Tool (Select)..................................................................................................... 59
8.8 Program (Prog.)........................................................................................................... 60
8.8.1 Tool type setup................................................................................................ 63
8.8.2 Measurement setup ........................................................................................ 66
8.8.3 Extended Measurement Setup ....................................................................... 67
8.8.4 Statistical setup................................................................................................ 69
8.8.5 Display setup ................................................................................................... 74
8.9 Speed (Speed).............................................................................................................. 79
8.10 User (User).................................................................................................................. 79
8.11 Sequence number (Seq. No.)....................................................................................... 80
8.12 View (View).................................................................................................................. 80
8.13 Manual input (Man.In)................................................................................................ 81
8.14 Communication (Com.) ............................................................................................... 82

Contents
5
8.15 Parameters (Param.).................................................................................................... 84
8.16 Analyse (A.lyse).......................................................................................................... 85
8.16.1 To Zoom in....................................................................................................... 85
8.16.2 To Zoom out .................................................................................................... 85
8.16.3 Adjust position................................................................................................. 86
8.16.4 Save trace ........................................................................................................ 86
8.17 Print (Print).................................................................................................................. 87
8.17.1 To select a print command.............................................................................. 88
8.18 Statistics (Stat.)............................................................................................................ 89
8.18.1 All Tightening operations................................................................................ 91
8.18.2 Statistics torque ............................................................................................... 91
8.18.3 Statistics Angle ................................................................................................ 93
8.18.4 Statistic no. of Pulses....................................................................................... 94
8.18.5 History............................................................................................................. 96
9. Measuring Strategies.............................................................................................................99
9.1 General........................................................................................................................ 99
10. Measurement Results..........................................................................................................103
10.1 General...................................................................................................................... 103
10.2 Basic Measurement Window.................................................................................... 103
10.3 Custom Measurement Window................................................................................ 105
10.4 Trace Measurement Window.................................................................................... 108
10.5 Batch Result window................................................................................................. 111
10.5.1 Within Limits ................................................................................................. 112
10.5.2 Outside Limits............................................................................................... 112
11. Calibration...........................................................................................................................113
11.1 Calibrating the ACTA 3000...................................................................................... 113
11.2 Calibrating Transducers with the ACTA 3000......................................................... 115
11.2.1 Calibration..................................................................................................... 116
11.2.2 Linearity check.............................................................................................. 117
11.2.3 Saving and printing the new calibration value............................................... 118
11.3 Tool calibration.......................................................................................................... 120
11.3.1 Non-controlled tool calibration...................................................................... 122
11.3.2 Other controller calibration........................................................................... 123
11.3.3 DS calibration................................................................................................. 124
11.3.4 Power Focus 2000 calibration....................................................................... 126
11.3.5 PowerFocus 3000 calibration....................................................................... 127
11.3.6 PowerMac calibration.................................................................................... 129
11.3.7 Example, how to perform a calibration.......................................................... 130

Contents
6
12. Printouts from the ACTA 3000..........................................................................................133
12.1 General...................................................................................................................... 133
12.2 Tool Rundowns.......................................................................................................... 135
12.3 Transducer Info......................................................................................................... 136
12.4 Tool Setup ................................................................................................................. 137
12.5 Tool Statistics............................................................................................................ 138
12.5.1 Page 1 ............................................................................................................ 138
12.5.2 Page 2 ............................................................................................................ 139
12.6 All Tool Rundowns .................................................................................................... 140
12.7 All Tool Set-ups......................................................................................................... 140
12.8 All Tool Statistics ...................................................................................................... 140
12.9 Tool calibration.......................................................................................................... 141
12.10Database Summary.................................................................................................... 142
12.11Trace.......................................................................................................................... 143
13. ToolsTalk ACTA.................................................................................................................145
13.1 General...................................................................................................................... 145
13.2 The Tool Database.................................................................................................... 146
13.3 The Supplier Database.............................................................................................. 147
13.4 The Tightening Database.......................................................................................... 148
13.4.1 Tightening operation Traces......................................................................... 149
13.4.2 Tightening Statistics...................................................................................... 150
13.5 Automatic Calibration and Maintenance Reminder................................................. 151
13.6 Program your ACTA 3000........................................................................................ 152
13.7 More About ToolsTalk ACTA ................................................................................. 152
14. Guide to Statistics................................................................................................................153
14.1 General...................................................................................................................... 153
14.2 How to estimate the variation................................................................................... 155
14.3 Capability studies...................................................................................................... 157
14.3.1 Six-Sigma Improvement Program................................................................. 158
14.4 Control charts............................................................................................................ 159
14.4.1 Using control charts ...................................................................................... 160
14.4.2 X-bar charts ................................................................................................... 161
14.4.3 R charts.......................................................................................................... 162
15. Technical Specifications......................................................................................................163
15.1 Dimensions and Weights........................................................................................... 163

Contents
7
15.2 Electrical.................................................................................................................... 163
15.3 Battery....................................................................................................................... 163
15.3.1 Charging ........................................................................................................ 163
15.4 Connectors ................................................................................................................ 164
15.4.1 Transducer Pin Description.......................................................................... 164
15.5 Barcode Reader........................................................................................................ 165
15.6 Default Setups ........................................................................................................... 166
15.6.1 New ACTA 3000 ........................................................................................... 166
15.6.2 Direct Driven Tool........................................................................................ 167
15.6.3 Pulse Tool...................................................................................................... 169
15.6.4 Wrench........................................................................................................... 171
15.6.5 Click Wrench................................................................................................. 173
15.6.6 Synchronise.................................................................................................... 175
16. Maintenance.........................................................................................................................195
16.1 Cleaning..................................................................................................................... 195
16.2 Service....................................................................................................................... 195
16.3 Software Upgrade ...................................................................................................... 195
17. Accessories, Parts................................................................................................................197
17.1Accessories............................................................................................................... 197

Safety Instructions
9
1. Safety Instructions
Important
All locally legislated rules with regard to installation, operation and maintenance must be observed
at all times.
Warning!
§When using electrical equipment, basic precautions should always be taken, including the
following:
§Read all instructions before you begin using the equipment.
§Before operating the equipment, please make sure that the operating voltage (indicated on the
type plate on the base of the unit) is identical to the voltage of your local power supply.
§When replacing the battery, always disconnect the equipment from the mains by unplugging it.
§The unit is equipped with an internal fan to reduce the build-up of heat. However, the unit
should only be used in an area where there is adequate ventilation and it must be kept away
from sources of excessive heat (radiators or other equipment which produce heat).
§Do not expose the unit to excessive moisture (dripping or splashing water), and do not use it
near water (near a wash basin or in a wet basement) or other liquids.
§The equipment should not be subjected to continuous or excessive shocks or vibration.
§For minimal electrical interference, use the equipment well away from possible sources of
electrical noise (arc-welding equipment, etc.).
§There are no user-serviceable parts inside the unit. Under no circumstances should you open
or attempt to repair the unit. Doing so will invalidate all warranties. Refer all service needs to
your local Atlas Copco Tools service personnel.
Caution
Danger of explosion if a replacement battery is incorrectly connected. Replace only with the same or an
equivalent type of battery recommended by the equipment manufacturer. Discard used batteries
according to the manufacturer’s instructions.

System Overview
11
2. System Overview
2.1 General
Introducing the ACTA 3000; combining premium tightening analysis functionality with
integrated tools management and SPC in a compact, portable and extremely user-
friendly configuration.
The ACTA 3000 is available in three different versions to cater for all needs:
§Basic
§Quality Control (QC)
§Advanced Analysis (AA).
2.1.1 ACTA 3000 Basic
The ACTA 3000 Basic measures torque and angle on direct driven, residual torque and pulse
tools, and counts the number of pulses on pulse tools. Basic is the entry level version designed
for simple torque checking in a repair shop or directly on the production/assembly line.
It has the following functionality:
§Measures Torque / Angle / Pulses
§Mean / 3 Sigma
§Single Memory Position
§Flash Memory
§Auto Cal. and Self Test
§Auto Cal. on AC Memory Transducers
§Print Statistics
§Transducer database for non-Atlas Copco transducers.
2.1.2 ACTA 3000 Quality Control
Quality Control is the next step up from Basic. It includes a database withsufficient memory
capacity to organise and store more than 500 tools or up to 9,000 tool tightening operations.
It also includes advanced statistical functions and is ToolsTalk ACTA compatible.

System Overview
12
It incorporates all the following functionality (including all features of Basic):
§CP / CPK
§Real Time SPC
§Databases for Tools, Measurements and History
§ToolsTalk ACTA Compatible
§Print SPC -for an entire tool / tool tightening database
§Tool calibration.
2.1.3 ACTA 3000 Advanced Analysis
Advanced Analysis is the top of the range version. It employs a detailed graphic display
function to allow you to perform advanced analysis of the tightening characteristics of various
tools or joints.
It has the following functionality (including all features of Basic and Quality Control):
§Tightening Traces with Zoom-In
§Print Traces
The ACTA 3000 can easily be upgraded thanks to its flash memory, which allows
software updates straight from a PC.
All ACTA 3000 versions have an integral battery that ensures up to 3.5 hours of
continuous use for convenient tests on the production/assembly line.
The ACTA 3000 is also equipped with a PC port allowing quick upgrades and PC
integration through ToolsTalk ACTA, as well as a Printer Port and an Analogue Output
to further enhance documentation capability and quality analysis.
Setup is easily accomplished. The Atlas Copco memory transducers communicate
calibration data instantly to the ACTA 3000 at startup. Just connect and start
measuring.
The programming logic is based on read-at-a-glance menus and all programmable
parameters are divided into logical blocks with pop-up menus.
The ACTA 3000 also has a quick programming function to minimise
programming work when performing simple torque checks.

System Overview
13
2.1.4 ToolsTalk ACTA
In addition to its built-in functionality, the ACTA 3000 Quality Control and Advanced
Analysis can be supplemented with the PC program ToolsTalk ACTA to create a
complete quality management system.
With ToolsTalk ACTA you have a complete tool database, tightening database
and supplier database for easy storage and access to all the information you
might need about your tools, along with traces*and detailed statistical data.
You are also able to attach maintenance and service instructions for all your tools and
keep a record of work in progress. Best of all, ToolsTalk ACTA can even keep
track and remind you of maintenance and service intervals. Read more in the
ToolsTalk ACTA section.
*ACTA 3000 Advanced Analysis version required

Installation and startup
15
3. Installation and startup
3.1 Out of the Box
When purchasing any version of ACTA 3000, the following should be included:
§V AC Power Supply Cable
§Manual /ASL
§Calibration Certificate.
Please keep the calibration certificate as it might be useful ID when servicing your
ACTA 3000 in the future.
3.1.1 Installation
The ACTA 3000 is a stand-alone portable product. Therefore, no particular
installation is necessary. Simply follow the safety instructions and observe the
following recommendations:
§Place the ACTA 3000 on a firm, flat surface or hold it securely in your hand
§Connect your Atlas Copco memory transducer
§Connect the power supply cable
§Start the ACTA 3000 by pressing and holding the ‘On’ button until the
buzzer sounds.
The first time you charge the battery, please charge it for 12 hours and then use
the ACTA 3000 in battery mode until the battery is totally drained.
The ACTA 3000 features an internal charger which can be used during charging
if connected to a V AC outlet.

Installation and startup
16
Power Supply Port Transducer Port
To install other accessories, such as a printer, oscilloscope etc., or find out how to
connect them to a PC, see the connector diagram in the Technical Information
section.
Startup
When you start the ACTA 3000, the following will appear in the display dialog
box:
•The Atlas Copco logo flashes
•The Measurement dialog box appears
•The Calibration dialog box flashes (if an Atlas Copco memory transducer is
connected)
•The Measurement dialog box resumes.
The ACTA 3000 initialises and performs a self-test. The calibration dialog box
appears in order to indicate that the ACTA 3000 is communicating with the
Atlas Copco memory transducer and performing an automatic setup. It reads
the transducer’s serial number and calibration data, which it stores in its
memory.
Note!
The ACTA 3000 can operate with most types of transducer. If you use an Atlas Copco
non-memory transducer or other brand, refer to the Technical Specifications section on
how to set up your transducer before continuing with Quick Programming in the next
section.
Connector Panel
For a complete technical
specification of the
connectors, see the
Technical Specifications
section

Quick Programming
17
4. Quick Programming
4.1 General
This section focuses on how you can start measuring in minutes with the Quick Programming
function using Atlas Copco Torque/Angle memory transducers.
All versions of the ACTA 3000 feature a Quick Programming function that allows you to set
up a measurement session without extensive programming. It is ideal with the ACTA 3000
Basic or for quick and simple torque checks.
4.2 Operating Quick-guide
After initialisation and transducer setup the ACTA 3000 is ready for programming.
To operate the ACTA 3000, use the softkeys as explained below.
Measurement Dialog Box
. This is your
measurement dialog boxwindow which
displays your results. (ACTA Basic
version window is shown here)
View, Print etc. Menu Blocks. Represent
programming tree functions or arrows.
Soft Keys. Correspond to and control
menu block or arrow above. Using these
you can movealong the programming
tree and select different functions.
Enter

Quick Programming
18
4.3 Quick programming
1. Select menu block Q.Prog. on the display by pressing the softkey below it.
A pop-up menu appears with five alternatives:
Q. Prog
1 Direct driven
2 Pulse
3 Wrench
4 Click wrench
5 Synchronise-------- 1 None
2 Other controller
3 Focus 2000/PF2000--------
1 Manual input
2 RS232
4 DS--------------------------
-- 1 Manual input
2 Infrared
3 RS232
5 PF3000 1 Manual input
2 Infrared
3 RS232
6 PowerMacs 1 Manual input
2 RS232
2. Select the type of tool you are using by using the arrows to highlight your
choice. Press ‘Enter’. You can also select the tool type by pressing the
number shown for each tool type on the keypad.
Direct driven Used when testing all types of direct driven tools dynamically.
Pulse Used when testing all types of direct driven tools dynamically.
Wrench Used when checking installed torque in an already tightened joint.
Click wrench Used when checking the release torque on a Click Wrench.

Quick Programming
19
3. You are now asked if you want to use default programming.
Note!
If Pulse is selected, an input menu appears in the ACTA display asking for the
filter frequency. Enter the frequency and press ‘Enter’.
If Wrench is selected, a list menu appears where you can select between Peak
torque or Static installed torque.
Read more about strategies in Chapter 0.
Note!
Shaded areas are only available in QC & AA.
4. When using “Synchronise”, the ACTA 3000 will be programmed to
measure the torque similar to the controller. After each tightening operation
the ACTA 3000 will either ask the operator for or read the tightening
values directly from the controller, depending on the programming (manual
input, infrared or RS232).
Note!
If “none” or “other” controller is selected, a pop-up menu appears where the type of tool can be
selected. For “none” controlled tool an input menu appears requesting the target torque. For “other”
controller tool the calibration torque should be input. Select Pulse tool and another question appears
requesting the filter frequency. Select Wrench and another question appears requesting the measure
strategy.
Note!
If infrared or RS232 is selected, the ACTA 3000 will try to communicate with the controller and read
the settings. Therefore, make sure that this is possible, either by connecting an Atlas Copco serial cable
between the controller and the ACTA 3000 (RS232) or by pointing the ACTA 3000 towards the
controller display (infrared).
DS infrared:
DS drive will start to blink “--“, “ -- “. Press the ‘Enter’ button (the arrow) until the display
starts to blink “Ir”.
PF3000 Compact infrared:
PF drive will start to blink “-Ir-“, “ “. Press the ‘Enter’ button (the arrow) until the display
starts blinking “-Ir-“, “ Ir “.

Quick Programming
20
PF3000 Graph infrared:
A text window on the screen says:
“IR connect requested from ACTA 3000 on local channel 0. Press ‘OK’ to acknowledge,
wait or cancel to refuse.”
Press ‘OK’ on the PF. A new message appears:
“IR connect requested from ACTA 3000 on local channel 0. Press ‘OK’ to acknowledge,
wait or cancel to refuse.”
The selected tool in the ACTA 3000 will then be programmed with the settings
from the controller.
Note!
If Focus 2000/PF2000 automatic tool calibration (Q.Prog.-5-3-2) is selected,
an input menu requesting the unit ID appears in the ACTA 3000 display. Enter
the controller unit ID and press ‘Enter’.
5. Use the arrows again to highlight OK and press ‘Enter’ or simply press the
‘OK’ button on the keypad.
6. Another dialog box flashes confirming that default programming is now
being used. Programming is complete –you are ready to start measuring.