Atlas Copco PowerMACS 4000 User manual

User guide
PowerMACS 4000
Atlas Copco Tools and Assembly Systems
9836 3521 01
2010-11
Edition 10.3.0

Contents
9836 3521 01 3
Contents
1Introduction .......................................................................................................................................15
1.1 Introduction - Overview ....................................................................................................................... 15
1.1.1 ToolsTalk PowerMACS, the friendly user interface................................................................. 16
1.1.2 Intelligent tightening controllers, TCs....................................................................................... 16
1.2 Tightening and Gauging....................................................................................................................... 18
1.2.1 Gauging Functions .................................................................................................................... 18
1.2.2 Gauging Applications................................................................................................................ 18
1.2.2.1 Torque To Turn Gauging Application ....................................................................... 19
1.2.2.2 Valve Lash Gauging Application............................................................................... 20
1.3 Installing ToolsTalk PowerMACS ....................................................................................................... 21
2System Architecture..........................................................................................................................23
2.1 System Architecture - Overview .......................................................................................................... 23
2.2 System Structure................................................................................................................................... 24
2.3 Hardware Structure............................................................................................................................... 26
2.3.1 Tightening Controller................................................................................................................ 27
2.3.1.1 PTC Description......................................................................................................... 30
2.3.1.2 TC Description........................................................................................................... 32
2.3.1.3 The TC HMI Menu System ....................................................................................... 34
2.3.2 Version conflict message........................................................................................................... 38
2.3.3 Console Computer (CC)............................................................................................................ 38
2.3.4 Ethernet ..................................................................................................................................... 39
2.3.5 Peripheral Devices..................................................................................................................... 40
2.4 Automatic update of TC, Servo and Spindle........................................................................................ 41
2.4.1 Automatic update Overview...................................................................................................... 41
2.4.2 General function........................................................................................................................ 41
2.4.3 Replacement of the System TC and Backup TC....................................................................... 43
2.4.4 Replacement of TC3 –TCn....................................................................................................... 43
2.4.5 Updating a system with new software....................................................................................... 43
2.4.6 Troubleshooting ........................................................................................................................ 43
2.4.7 Automatic Update of Servo software ........................................................................................ 44
2.4.8 Automatic Update of Spindle software ..................................................................................... 45
3Basic Functions..................................................................................................................................47
3.1 Basic Functions - Overview ................................................................................................................. 47
3.2 Windows............................................................................................................................................... 48
3.3 Help ...................................................................................................................................................... 51
3.4 The File menu....................................................................................................................................... 52
3.5 How to Start up..................................................................................................................................... 54
3.6 Viewing ................................................................................................................................................ 57

Contents
4 9836 3521 01
3.6.1 Assembly Overview.................................................................................................................. 57
3.6.1.1 Station Views............................................................................................................. 60
3.6.2 System Map............................................................................................................................... 61
3.6.3 View Cycle Data ....................................................................................................................... 64
3.6.4 View Statistics........................................................................................................................... 66
3.6.5 View Trace................................................................................................................................ 68
3.6.5.1 Select which trace to display...................................................................................... 69
3.6.5.2 View of trace curves .................................................................................................. 72
3.6.5.3 Select Trace................................................................................................................ 80
3.6.6 View Tightening Path................................................................................................................ 81
3.6.7 View Event Log ........................................................................................................................ 82
3.6.8 View I/O signals........................................................................................................................ 85
3.7 Reporter................................................................................................................................................ 86
3.7.1 Predefined reporter settings....................................................................................................... 86
3.7.2 New reporter.............................................................................................................................. 87
3.7.3 Remove reporter........................................................................................................................ 90
3.7.4 Edit reporter .............................................................................................................................. 91
3.7.4.1 Adding Cycle Data Variables .................................................................................... 93
3.7.4.2 Layout of Cycle Data................................................................................................. 95
3.7.4.3 Cycle Data layout example ........................................................................................ 98
3.7.4.4 Reporter Preview ..................................................................................................... 103
3.7.4.5 Advanced Event settings.......................................................................................... 104
3.7.4.6 Advanced CD settings.............................................................................................. 104
3.8 Security............................................................................................................................................... 106
3.8.1 Registering groups................................................................................................................... 106
3.8.2 Registering users ..................................................................................................................... 107
3.8.3 Login and Logout.................................................................................................................... 108
3.9 Printing............................................................................................................................................... 110
4Set Up and Maintenance.................................................................................................................111
4.1 Set Up and Maintenance - Overview.................................................................................................. 111
4.2 Setups and How to handle them ......................................................................................................... 112
4.2.1 Backwards compatibility......................................................................................................... 113
4.2.1.1 PLC conversion........................................................................................................ 114
4.2.1.2 Compatibility between PM4000 Tightening and Gauging....................................... 115
4.2.1.3 Upgrade of PLC environment.................................................................................. 115
4.3 Set up of a new system ....................................................................................................................... 116
4.3.1 Creating a new system using the Set Up Wizard..................................................................... 116
4.4 System Map........................................................................................................................................ 124
4.4.1 Logical view............................................................................................................................ 125
4.4.1.1 System node............................................................................................................. 126
4.4.1.2 Station node ............................................................................................................. 126

Contents
9836 3521 01 5
4.4.1.3 Bolt node.................................................................................................................. 128
4.4.1.4 Programs node ......................................................................................................... 128
4.4.1.5 Reporters node......................................................................................................... 129
4.4.2 Hardware node ........................................................................................................................ 130
4.4.2.1 TC node.................................................................................................................... 131
4.4.2.2 Spindle node............................................................................................................. 133
4.4.2.3 Other device nodes................................................................................................... 134
4.5 Station Set Up..................................................................................................................................... 135
4.5.1 Advanced Station Settings....................................................................................................... 137
4.5.1.1 Work piece identifier ............................................................................................... 138
4.5.1.2 Multiple identifiers................................................................................................... 138
4.5.1.3 PLC Event handling................................................................................................. 142
4.5.1.4 Conversion table ...................................................................................................... 142
4.6 Spindle Set Up.................................................................................................................................... 145
4.6.1 General page............................................................................................................................ 145
4.6.2 Calibration page ...................................................................................................................... 146
4.6.3 Application page ..................................................................................................................... 147
4.6.3.1 Application External Equipment.............................................................................. 148
4.6.4 Angle Channels page............................................................................................................... 149
4.6.4.1 Angle Double Transducer Check............................................................................. 149
4.6.5 Torque Channels page............................................................................................................. 151
4.6.5.1 Torque Double Transducer Check .......................................................................... 151
4.6.6 Diagnostic page....................................................................................................................... 153
4.6.6.1 Static Zero Offset..................................................................................................... 153
4.6.6.2 Dynamic Zero Offset and Angle Count ................................................................... 154
4.6.6.3 Flying Zero Offset.................................................................................................... 154
4.6.6.4 Order of execution ................................................................................................... 155
4.6.7 Motortune page ....................................................................................................................... 156
4.6.8 Automatic transducer protections............................................................................................ 157
4.7 I/O....................................................................................................................................................... 158
4.7.1 Local I/O ................................................................................................................................. 161
4.8 ID device Set Up ................................................................................................................................ 162
4.9 Assembly Overview Set Up ............................................................................................................... 163
4.10 PLC Parameters Set Up ...................................................................................................................... 167
4.11 SRAM................................................................................................................................................. 168
4.12 Options ............................................................................................................................................... 169
4.12.1 Set Customer step names......................................................................................................... 171
4.12.2 Set Customer error codes ........................................................................................................ 172
4.13 Setup Problems................................................................................................................................... 174
4.14 Table Export and Import..................................................................................................................... 175
4.15 Table Copy ......................................................................................................................................... 177

Contents
6 9836 3521 01
4.16 Handling of the setup in the target system.......................................................................................... 178
4.16.1 Backup of the setup................................................................................................................. 178
4.16.2 Replacement of TCs................................................................................................................ 180
4.17 Maintenance ....................................................................................................................................... 181
4.17.1 Select Target System............................................................................................................... 184
4.17.2 Test Bolts ................................................................................................................................ 186
4.17.3 Calibration procedures in PowerMACS.................................................................................. 190
4.17.3.1 General................................................................................................................... 190
4.17.3.2 Torque.................................................................................................................... 192
4.17.3.3 Angle...................................................................................................................... 194
4.17.3.4 Wind Up Coefficient.............................................................................................. 195
4.17.3.5 Current (torque) ..................................................................................................... 197
4.17.4 Event Statistics........................................................................................................................ 198
4.17.5 Service Log ............................................................................................................................. 199
4.17.6 Replace ID String.................................................................................................................... 200
4.17.7 Configure Target System......................................................................................................... 201
4.17.7.1 Advanced mode ..................................................................................................... 202
4.17.7.2 Restart of TC’s after download .............................................................................. 203
4.17.7.3 Information fields................................................................................................... 203
4.17.7.4 Prepare TC for download of software.................................................................... 207
4.17.7.5 Change Net Data.................................................................................................... 209
4.17.8 Clear data ................................................................................................................................ 210
4.17.9 Compare programs.................................................................................................................. 211
4.17.10 Check for System Conflicts................................................................................................ 213
4.17.11 TC Crash Log..................................................................................................................... 214
5PLC...................................................................................................................................................215
5.1 PLC - Overview.................................................................................................................................. 215
5.2 General ............................................................................................................................................... 216
5.3 System Globals................................................................................................................................... 218
5.3.1 Station variables...................................................................................................................... 218
5.3.1.1 Loosening cycles...................................................................................................... 225
5.3.2 Bolt variables .......................................................................................................................... 231
5.3.3 ID device variables.................................................................................................................. 235
5.3.4 Multiple identifier variables.................................................................................................... 236
5.3.5 GM DeviceNet variables......................................................................................................... 238
5.3.6 DC PLUS variables................................................................................................................. 240
5.3.7 Globals .................................................................................................................................... 243
5.3.8 Bolt specific commands .......................................................................................................... 244
5.3.9 Device commands ................................................................................................................... 247
5.4 Programming the PLC........................................................................................................................ 249
5.5 PLC Console....................................................................................................................................... 254

Contents
9836 3521 01 7
5.6 PLC Parameters.................................................................................................................................. 256
5.7 Display PLC Status............................................................................................................................. 257
6Tightening.........................................................................................................................................258
6.1 Tightening - Overview........................................................................................................................ 258
6.2 Create a new Tightening Program...................................................................................................... 259
6.3 The Tightening Program form............................................................................................................ 260
6.3.1 Tightening Program step operations........................................................................................ 262
6.4 The Mode Table form......................................................................................................................... 264
6.5 Tightening Program............................................................................................................................ 266
6.5.1 Program Properties.................................................................................................................. 268
6.5.1.1 Program Common properties................................................................................... 268
6.5.1.2 Program User variables............................................................................................ 268
6.5.1.3 Program Settings...................................................................................................... 270
6.5.2 Step –Control ......................................................................................................................... 273
6.5.2.1 DT - Run until Dyna-TorkTM ................................................................................... 274
6.5.2.2 DT2 - Run until Dyna-TorkTM, method 2................................................................. 276
6.5.2.3 DT3 - Run until Dyna-TorkTM, method 3................................................................. 277
6.5.2.4 T - Run until Torque ................................................................................................ 278
6.5.2.5 TC - Run until Torque with Current Control ........................................................... 279
6.5.2.6 AO - Run until Angle with overshoot compensation............................................... 280
6.5.2.7 A - Run until Angle.................................................................................................. 282
6.5.2.8 Y1 - Run until Yield point, method 1 ...................................................................... 283
6.5.2.9 Y2 - Run until Yield point, method 2 ...................................................................... 284
6.5.2.10 LT - Loosen until torque........................................................................................ 285
6.5.2.11 RA - Release angle................................................................................................. 287
6.5.2.12 PA - Run until Projected angle............................................................................... 289
6.5.2.13 TD - Run until Torque has decreased..................................................................... 290
6.5.2.14 TI - Run until Time................................................................................................ 291
6.5.2.15 E1 - Run Engage method 1 .................................................................................... 291
6.5.2.16 E2 - Run Engage method 2 .................................................................................... 291
6.5.2.17 NS - Run until next step......................................................................................... 291
6.5.2.18 GS - Run Gear Shift............................................................................................... 292
6.5.2.19 PLC - Run PLC step............................................................................................... 292
6.5.2.20 JOG - Run until digital input goes high / low ........................................................ 293
6.5.2.21 W - Wait................................................................................................................. 293
6.5.2.22 TA –Run Torque-Angle with no stop ................................................................... 294
6.5.2.23 SR –Socket Release .............................................................................................. 300
6.5.2.24 ADT-Angle Delta Torque...................................................................................... 301
6.5.2.25 SG - Snug Gradient................................................................................................ 303
6.5.2.26 D - Diagnostic Step................................................................................................ 304
6.5.2.27 BCT –Backlash correction (only available for Gauging)...................................... 305

Contents
8 9836 3521 01
6.5.2.28 POS - Run to Position (only available for Gauging).............................................. 305
6.5.3 Step –Restriction .................................................................................................................... 307
6.5.3.1 Fail Safe Torque....................................................................................................... 308
6.5.3.2 Fail Safe Time.......................................................................................................... 309
6.5.3.3 Fail Safe Angle ........................................................................................................ 310
6.5.3.4 Min Torque Restriction............................................................................................ 311
6.5.3.5 Gradient ................................................................................................................... 313
6.5.3.6 Cross Thread and Gradient ...................................................................................... 315
6.5.3.7 Torque Profile.......................................................................................................... 316
6.5.3.8 Angle Difference...................................................................................................... 318
6.5.3.9 Torque Difference.................................................................................................... 319
6.5.4 Step –Check ........................................................................................................................... 320
6.5.4.1 Result values from checks........................................................................................ 321
6.5.4.2 Check peak torque.................................................................................................... 322
6.5.4.3 Check torque in angle window................................................................................. 324
6.5.4.4 Check torque in time window .................................................................................. 325
6.5.4.5 Check mean torque .................................................................................................. 326
6.5.4.6 Check angle.............................................................................................................. 327
6.5.4.7 Check Post view Torque.......................................................................................... 329
6.5.4.8 Check T/T3 (Current as Torque).............................................................................. 331
6.5.4.9 Check shut off torque............................................................................................... 332
6.5.4.10 Check torque rate................................................................................................... 333
6.5.4.11 Check Zero Crossing (only available for Gauging) .............................................. 336
6.5.4.12 Check time ............................................................................................................. 338
6.5.4.13 Check Yield Point Angle ....................................................................................... 338
6.5.4.14 Check Stick Slip..................................................................................................... 340
6.5.4.15 Delta T (only available for Gauging)..................................................................... 342
6.5.4.16 Low Spot Torque (only available for Gauging) ..................................................... 343
6.5.4.17 Check Position (only available for Gauging)......................................................... 343
6.5.4.18 Check Backlash angle (only available for Gauging).............................................. 344
6.5.4.19 Check external input (only available for Gauging)................................................ 344
6.5.5 Step –Rejects.......................................................................................................................... 345
6.5.5.1 Checking the bolt status........................................................................................... 346
6.5.5.2 Deciding what to do................................................................................................. 347
6.5.5.3 Configuring Reject Management............................................................................. 350
6.5.5.4 Advanced RM Actions............................................................................................. 352
6.5.5.5 Cycle RM................................................................................................................. 353
6.5.5.6 Reject management states........................................................................................ 355
6.5.5.7 Reject management examples.................................................................................. 361
6.5.6 Step –Ramps & Other ............................................................................................................ 363
6.5.6.1 Ramps & Other –Ramps ......................................................................................... 364

Contents
9836 3521 01 9
6.5.6.2 Ramps & Other –Other ........................................................................................... 365
6.5.6.3 Ramps & Other –Store Position (only available for Gauging)................................ 366
6.5.6.4 Ramps & Other –Signals at step start and end (only available for Gauging).......... 367
6.5.7 Zones (only available for Gauging)......................................................................................... 368
6.6 Bolt Monitoring.................................................................................................................................. 369
6.6.1 Monitoring Check –Final Peak Torque.................................................................................. 372
6.6.2 Monitoring Check –Angle...................................................................................................... 373
6.6.3 Monitoring Check –Torque Rate............................................................................................ 376
6.6.4 Monitoring Check –Monitoring Yield point torque and angle............................................... 379
6.7 Result variables .................................................................................................................................. 382
6.7.1 Statuses.................................................................................................................................... 382
6.7.2 Station level result variables.................................................................................................... 383
6.7.3 Bolt level result variables........................................................................................................ 385
6.7.3.1 Errors ....................................................................................................................... 390
6.7.3.2 Warnings.................................................................................................................. 394
6.7.4 Step level result variables........................................................................................................ 395
6.8 Servo and spindle protections............................................................................................................. 399
6.8.1 Stall protection ........................................................................................................................ 399
6.8.2 How to avoid the problems ..................................................................................................... 399
7SPC and Statistics............................................................................................................................401
7.1 SPC - Overview.................................................................................................................................. 401
7.2 SPC, Statistical Process Control......................................................................................................... 402
7.2.1 Data Collection........................................................................................................................ 402
7.2.2 Calculations for subgroups...................................................................................................... 403
7.2.3 Calculations and checks .......................................................................................................... 403
7.2.4 SPC constants.......................................................................................................................... 407
7.3 SPC set up .......................................................................................................................................... 408
7.4 Shift Reports and Shift Set Up............................................................................................................ 410
7.4.1 Shift Set Up............................................................................................................................. 411
8Peripheral Devices...........................................................................................................................413
8.1 Peripheral Devices - Overview........................................................................................................... 413
8.2 Add a device....................................................................................................................................... 415
8.3 Status of a device................................................................................................................................ 417
8.4 Standard Accessory Devices............................................................................................................... 418
8.4.1 Stacklight................................................................................................................................. 418
8.4.2 Indicator Box........................................................................................................................... 419
8.4.3 Operator Panel......................................................................................................................... 421
8.5 I/O Device .......................................................................................................................................... 423
8.6 Printer on TC...................................................................................................................................... 424
8.7 Printer or File on CC .......................................................................................................................... 424
8.8 PLC..................................................................................................................................................... 425
8.9 ID device ............................................................................................................................................ 429

Contents
10 9836 3521 01
8.9.1 Type specific parameters......................................................................................................... 430
8.9.1.1 Barcode scanner....................................................................................................... 430
8.9.1.2 Pepperl + Fuchs escort memory............................................................................... 431
8.9.1.3 Allen Bradley escort memory .................................................................................. 432
8.9.1.4 Omron escort memory ............................................................................................. 433
8.9.1.5 Euchner card reader ................................................................................................. 435
8.10 ToolsNet............................................................................................................................................. 436
8.11 Ethernet Protocols .............................................................................................................................. 439
8.11.1 Open Protocol.......................................................................................................................... 442
8.11.1.1 Automatic/manual mode........................................................................................ 443
8.11.1.2 Supported message types ....................................................................................... 445
8.11.1.3 TC Status Record Formats..................................................................................... 448
8.11.1.4 TC Result Record Formats..................................................................................... 449
8.11.2 DaimlerChrysler PFCS............................................................................................................ 451
8.11.2.1 Supported message types ....................................................................................... 452
8.11.2.2 PFD Result Record Formats................................................................................... 452
8.11.3 FSH ......................................................................................................................................... 453
8.11.3.1 Supported message types ....................................................................................... 454
8.11.3.2 TC Result Record Formats..................................................................................... 455
8.11.4 DC PLUS ................................................................................................................................ 456
8.11.4.1 Parameters for PDT................................................................................................ 457
8.11.4.2 Parameters for PQD ............................................................................................... 459
8.11.4.3 Handling of PN, KN and LI, in protocol version PDT........................................... 461
8.11.4.4 Handling of QO and FP ......................................................................................... 462
8.11.4.5 SAW / WIS............................................................................................................ 463
8.11.4.6 SPS......................................................................................................................... 465
8.11.4.7 VBA....................................................................................................................... 466
8.11.4.8 SSE......................................................................................................................... 467
8.11.4.9 TC Result Formats for PDT................................................................................... 468
8.11.4.10 TC Result Format for PQD .................................................................................. 470
8.11.4.11 Selecting the data to report................................................................................... 472
8.11.4.12 Selecting the data to report................................................................................... 472
8.11.5 I-P.M. ...................................................................................................................................... 473
8.11.5.1 Mapping of data..................................................................................................... 473
8.11.5.2 Value sent as Maintenance Sequence (AFO-number)............................................ 475
8.11.5.3 Possible error codes ............................................................................................... 476
8.11.5.4 Characteristic Identifications ................................................................................. 477
8.11.5.5 Parameter Identifications ....................................................................................... 477
8.11.6 Audi XML............................................................................................................................... 478
8.12 Fieldbus Interface ............................................................................................................................... 480
8.12.1 Access to PLC data ................................................................................................................. 485

Contents
9836 3521 01 11
8.12.1.1 PLC Areas.............................................................................................................. 487
8.12.1.2 Complex data types................................................................................................ 488
8.12.1.3 Set up shared variables........................................................................................... 491
8.12.1.4 Fieldbus form......................................................................................................... 495
8.12.2 Access to Process data............................................................................................................. 498
8.12.2.1 Using the extended format ..................................................................................... 504
8.12.3 Fieldbus specific Information.................................................................................................. 506
8.12.3.1 DeviceNet .............................................................................................................. 506
8.12.3.2 Profibus DP and DP-V1......................................................................................... 510
8.12.3.3 ProfiNet IO............................................................................................................. 514
8.12.3.4 Modbus TCP.......................................................................................................... 518
8.12.3.5 Ethernet/IP ............................................................................................................. 523
8.12.3.6 CC-Link ................................................................................................................. 526
8.13 Serial Communication........................................................................................................................ 529
8.13.1 Accesses from External communication device...................................................................... 530
8.13.2 Access to PLC data ................................................................................................................. 532
8.13.3 Access to Process data............................................................................................................. 534
8.13.4 Serial Communication Protocol Information .......................................................................... 534
8.13.4.1 JBUS...................................................................................................................... 536
8.13.4.2 Siemens 3964R ...................................................................................................... 537
8.13.4.3 Telemechanique UNI-TE....................................................................................... 538
8.13.4.4 SATT Comli........................................................................................................... 540
8.13.4.5 Allen-Bradley Data Highway (Plus)...................................................................... 541
8.14 API, Application Programmers Interface ........................................................................................... 542
8.14.1 Subscriptions........................................................................................................................... 546
8.14.2 Object model........................................................................................................................... 547
8.14.3 Enumerators exported by the API ........................................................................................... 548
8.14.4 Api object................................................................................................................................ 550
8.14.4.1 Properties ............................................................................................................... 550
8.14.4.2 GetPLCBoolEx ...................................................................................................... 551
8.14.4.3 SetPLCBoolEx....................................................................................................... 551
8.14.4.4 GetPLCByteEx ...................................................................................................... 552
8.14.4.5 SetPLCByteEx....................................................................................................... 552
8.14.4.6 GetPLCIntEx.......................................................................................................... 553
8.14.4.7 SetPLCIntEx .......................................................................................................... 553
8.14.4.8 GetPLCRealEx....................................................................................................... 554
8.14.4.9 SetPLCRealEx ....................................................................................................... 554
8.14.4.10 GetPLCStringEx .................................................................................................. 555
8.14.4.11 SetPLCStringEx................................................................................................... 555
8.14.4.12 GetPLCBool......................................................................................................... 556
8.14.4.13 SetPLCBool ......................................................................................................... 556

Contents
12 9836 3521 01
8.14.4.14 GetPLCByte......................................................................................................... 557
8.14.4.15 SetPLCByte.......................................................................................................... 557
8.14.4.16 GetPLCInt............................................................................................................ 558
8.14.4.17 SetPLCInt............................................................................................................. 558
8.14.4.18 GetPLCReal......................................................................................................... 559
8.14.4.19 SetPLCReal.......................................................................................................... 559
8.14.4.20 GetPLCString....................................................................................................... 560
8.14.4.21 SetPLCString ....................................................................................................... 560
8.14.4.22 GetCycleData....................................................................................................... 561
8.14.4.23 GetCycleDataBin................................................................................................. 561
8.14.4.24 GetLastCycleData................................................................................................ 562
8.14.4.25 GetLastCycleDataBin .......................................................................................... 562
8.14.4.26 GetCycleDataById............................................................................................... 562
8.14.4.27 SubscribeCD ........................................................................................................ 563
8.14.4.28 RecNewCD .......................................................................................................... 563
8.14.4.29 FlushCDQueue..................................................................................................... 563
8.14.4.30 RewindCDQueue................................................................................................. 563
8.14.4.31 GetEvent .............................................................................................................. 564
8.14.4.32 GetEventEx.......................................................................................................... 565
8.14.4.33 GetEventObj ........................................................................................................ 565
8.14.4.34 SubscribeEvent .................................................................................................... 566
8.14.4.35 RecNewEvent ...................................................................................................... 566
8.14.4.36 FlushEventQueue................................................................................................. 566
8.14.4.37 RewindEventQueue ............................................................................................. 566
8.14.4.38 GetTrace............................................................................................................... 567
8.14.4.39 GetTraceEx.......................................................................................................... 567
8.14.4.40 GetLastTrace........................................................................................................ 567
8.14.4.41 SubscribeTrace..................................................................................................... 568
8.14.4.42 RecNewTrace....................................................................................................... 568
8.14.4.43 FlushTraceQueue ................................................................................................. 568
8.14.4.44 RewindTraceQueue.............................................................................................. 569
8.14.4.45 SubscribeStStatus................................................................................................. 569
8.14.4.46 RecNewStStatus................................................................................................... 569
8.14.4.47 GetSetup............................................................................................................... 570
8.14.4.48 SetSetup ............................................................................................................... 570
8.14.4.49 GetSetupItem ....................................................................................................... 571
8.14.4.50 SetSetupItem........................................................................................................ 571
8.14.4.51 GetSystemDesc.................................................................................................... 572
8.14.4.52 GetStationDesc .................................................................................................... 572
8.14.4.53 GetDateAndTime................................................................................................. 573
8.14.4.54 SetDateAndTime.................................................................................................. 573

Contents
9836 3521 01 13
8.14.4.55 GetTime ............................................................................................................... 574
8.14.4.56 SetTime................................................................................................................ 574
8.14.5 System object .......................................................................................................................... 575
8.14.5.1 Properties ............................................................................................................... 575
8.14.6 Stations object (collection)...................................................................................................... 576
8.14.6.1 Properties ............................................................................................................... 576
8.14.6.2 Item........................................................................................................................ 576
8.14.6.3 Exists...................................................................................................................... 577
8.14.7 Station object........................................................................................................................... 578
8.14.7.1 Properties ............................................................................................................... 578
8.14.8 Bolts object (collection) .......................................................................................................... 579
8.14.8.1 Properties ............................................................................................................... 579
8.14.8.2 Item........................................................................................................................ 579
8.14.8.3 Exists...................................................................................................................... 580
8.14.9 Bolt object............................................................................................................................... 581
8.14.9.1 Properties ............................................................................................................... 581
8.14.10 TraceData object ................................................................................................................ 582
8.14.10.1 Properties ............................................................................................................. 582
8.14.11 Channels object (collection)............................................................................................... 583
8.14.11.1 Properties ............................................................................................................. 583
8.14.11.2 Item...................................................................................................................... 583
8.14.11.3 Exists.................................................................................................................... 584
8.14.12 Channel object.................................................................................................................... 585
8.14.12.1 Properties ............................................................................................................. 585
8.14.12.2 GetSampleValueNo ............................................................................................. 585
8.14.12.3 GetSampleValueTime.......................................................................................... 585
8.14.12.4 GetSampleValues................................................................................................. 586
8.14.13 StepBounds object (collection) .......................................................................................... 587
8.14.13.1 Properties ............................................................................................................. 587
8.14.13.2 Item...................................................................................................................... 587
8.14.13.3 Exists.................................................................................................................... 588
8.14.14 StepBound object ............................................................................................................... 589
8.14.14.1 Properties ............................................................................................................. 589
8.14.15 EventData object................................................................................................................ 590
8.14.15.1 Properties ............................................................................................................. 590
8.14.16 How to use the API ............................................................................................................ 591
8.15 GM DeviceNet.................................................................................................................................... 596
8.15.1 Interface definition input......................................................................................................... 598
8.15.2 Interface definition output....................................................................................................... 600
8.15.2.1 Indication schema .................................................................................................. 601
8.16 ACTA 3000........................................................................................................................................ 604

Contents
14 9836 3521 01
8.17 Process data........................................................................................................................................ 606
8.17.1 Data types................................................................................................................................ 608
8.17.2 Layout of Cycle data in Process data ...................................................................................... 608
8.17.3 Layout of Events in Process data ............................................................................................ 609
8.17.4 Layout of Traces in Process data............................................................................................. 610
8.17.5 Layout of Setup Item Descriptions.......................................................................................... 611
8.17.5.1 Bolt......................................................................................................................... 612
8.17.5.2 Spindle, Parameters................................................................................................ 613
8.17.5.3 Spindle, Channel data ............................................................................................ 614
8.17.5.4 Program, General data............................................................................................ 615
8.17.5.5 Program, Trace data............................................................................................... 616
8.17.5.6 Program, Monitoring data...................................................................................... 617
8.17.5.7 Sequence and Program, Step, Control data............................................................ 618
8.17.5.8 Sequence and Program, Step, Speed data .............................................................. 618
8.17.5.9 Sequence and Program, Step, Speed, Ramp down data ......................................... 619
8.17.5.10 Sequence and Program, Step, Other data............................................................. 620
8.17.5.11 Sequence and Program, Step, Surveillance data .................................................. 621
8.17.6 Layout of Setups...................................................................................................................... 621
9Specification.....................................................................................................................................623
9.1 Specification....................................................................................................................................... 623
9.2 Requirements ToolsTalk PC............................................................................................................... 624
10 Appendix...........................................................................................................................................625
10.1 List of events ...................................................................................................................................... 625
10.2 ToolsTalk PowerMACS command line.............................................................................................. 653
10.3 Cycle Data Storage............................................................................................................................. 654
10.3.1 Store 5000 Cycle Data............................................................................................................. 654
10.3.1.1 Storing and retrieving cycle data............................................................................ 655
10.4 Configuration of the Conversion Box................................................................................................. 657
10.5 Fatal Software Errors.......................................................................................................................... 660
11 References.........................................................................................................................................663
11.1 References to external documents ...................................................................................................... 663
12 Glossary of Terms............................................................................................................................665
12.1 Glossary.............................................................................................................................................. 665

Introduction
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1 Introduction
1.1 Introduction - Overview
The PowerMACS 4000 system is the seventh generation of tightening systems from Atlas Copco Tools
and Assembly Systems. It is the perfect solution for all tightening applications in your assembly plant,
however complex.
Building on the successfull PowerMACS concept the PowerMACS 4000 delivers even more performance
and benefits to customers by increased intelligence in tightening controllers and simplified configuration
through the new ToolsTalk PowerMACS software.
PowerMACS 4000 supports all known tightening and process monitoring methods and builds further on
the proven PowerMACS concept to deliver even more performance using the new intelligent QST
spindles.
PowerMACS 4000 is not only the most productive, cost-effective and user-friendly tightening system on
the market today, it also offers an impressive new level of installation flexibility.

Introduction
16 9836 3521 01
1.1.1 ToolsTalk PowerMACS, the friendly user interface
The new improved ToolsTalk PowerMACS (TTPM) builds on the experiences from the earlier WinTC and
with increased simplicity and flexibility make the user experience more rewarding without loosing any
functionality.
Simplicity has been greatly increased by the introduction of the Basic and Advanced concepts into
ToolsTalk PowerMACS, most functionality is hidden for inexperienced users but available at a mouse-click
for more those who feel they need the extra functionality.
Increased user friendliness by drag & drop functionality.
Full reporting ToolsTalk PowerMACS offers full reporting of tightening results, set values and limits. An
easily adapted annunciator shows the tightening results in read-at-a-glance graphics. The combined
SystemMap shows the tightening status of the bolts and the status of all equipped hardware. The system
provides reports for any chosen parameters, trace curves, and advanced SPC and log files.
User guides Accessible via Hyperlinks, the software includes SetUp Wizards, Tutorials, Tightening
Templates which guide you through the most common tightening sequences, Spare Parts Lists with
drawings and article numbers, service, fault-finding and FAQ functions, and a complete on-line manual.
If you need to configure the system for Ethernet or Fieldbus communication, the PowerMACS 4000 Set
Up Wizards make the task simple.
API for easy access ToolsTalk PowerMACS includes the popular Application Program Interface (API)
enabling the engineer to access data from the Tightening Controller. For example: read and write PLC,
cycle and trace data and store cycle data to media. All internal and external communications are via
Ethernet TCP/IP thin wire 100 Mbit/s.
PowerMACS 4000 can be tailored to any assembly process. A built-in PLC (IEC 61131-3), fully
programmable using the ToolsTalk interface, supports various in-station control requirements.
1.1.2 Intelligent tightening controllers, TCs
PowerMACS 4000 is modular in concept, utilizing the new improved intelligent Tightening Controller (TC)
with state-of-the-art software and a wide range of peripheral support and communication possibilities. The
TC is designed for IP43 and is easy to integrate into a production line as a stand-alone unit or integrated
in a panel.
Even more expanded capacity than it‟s predecessor it is an attractive piece of industrial design, the
PowerMACS 4000 TC is equipped with an impressive amount of memory, more than enough to handle
the Real- Time Operative System, Application Programs and the PLC program.
Tightening controllers are now separated in the Primary Tightening Controller (TC) featuring more
connectability and external communication possibilities and the more basic tightening controller (TC).
One Primary TC (PTC) is configured as a System TC and the rest as Spindle TCs. In a system all Spindle
TCs can be replaced without needing to download the setup once again. One system can include a
maximum of 15 stations. Up to 50 TC's can be connected in one system, controlling 50 nut runners.

Introduction
9836 3521 01 17
Full interchangeability means fewer spare parts are required, maintenance time is reduced and availability
is increased.
All common interfaces All PTC's are designed to interface with Ethernet, the most common Fieldbuses,
and industrial PLCs. The Application Program Interface (API) ensures easy external access to the system.
Peripherals simply added A wide range of peripherals can be connected to the PowerMACS 4000 TC
including printers, bar code readers, operator table, operator annunciators, etc.
Flexible installation The plug-and-play modular design of the TC means maximum installation flexibility.
Series communication in line control and data collection enables the PowerMACS TC's to be discreetly
integrated into the production line by the connection of two cables. The appropriate reporting system and
suitable operator interface can be mounted next to the work area.

Introduction
18 9836 3521 01
1.2 Tightening and Gauging
There are two types of PM4000 products:
PM4000 Tightening
PM4000 Gauging
PM4000 Tightening contains all functions needed for normal tightening of bolts. It can read and write
Tightening setups on disk or a TC. It cannot read or write a Gauging setup.
PM4000 Gauging has all the functions of PM4000 Tightening but also additional functions for gauging
applications. It can read a Tightening setup from file and convert it to a Gauging setup but not vice versa.
1.2.1 Gauging Functions
The following functions are only avaliable if you run PM4000 Gauging:
Step BCT
Step Run to Position
Step Wait, PLC signal addition
Check Delta T
Check Low Spot
Check Pos
Check Peak T, additions
Zones (within step)
Store positions
Backlash compensation
1.2.2 Gauging Applications
PM4000 Gauging can be used for applications where turning and measuring of torque and angle with high
precision is needed. Examples:
Torque To Turn
Valve lash
Indexer
Hub nuts

Introduction
9836 3521 01 19
1.2.2.1 Torque To Turn Gauging Application
An example of a Torque To Turn application is when an engine manufacturer wants to rotate the crank or
cam shaft under controlled conditions for the first time. Metal chips, burrs, sharp edges (spot distortions)
may cause excessive drag and eventually lead to early bearing shell failure and warranty repairs.
With PM4000 Gauging it is easy to create a program that rotates the shaft 360 or 720 degrees and
continuously monitor the torque and angle.
1
2
The curve present torque vs. time. There are two critical points.
1. Break-Away
2. Low Torque Rotation Test
To check break-away the torque is gently increased without rotation. If the torque reaches a preset limit
before any rotation starts the test stops immediately, preventing any damage.
If the break-away torque is within limits the rotation starts and the torque is monitored for the full rotation at
slow speed. Any friction out of limit indicates mechanical problems that should be corrected.
The combination of the two tests will show up any mechanical problems at a very early stage, before the
motor has been built into e.g. a vehicle. This eliminates the risk that the motor later experience expensive
service warranties.

Introduction
20 9836 3521 01
1.2.2.2 Valve Lash Gauging Application
In a Valve Lash application a bolt and a nut should be rotated and locked to each other to achieve a
specific valve lash. This can be done with a special coaxial spindle, e.g. QMX 42-2RT.
It is easy to create a program that operates the two spindles in a controlled way to make up perfectly
adjusted valve lash.