Atlas Copco Tensor STB User manual

User Guide
Tensor STB
Wireless tool for the Power Focus tightening controller
Atlas Copco Tools and Assembly Systems
9836 3043 01
Software version 10.3
Edition 1.9
2010-06

2 (30) 1.9 9836 3043 01
Copyright Atlas Copco Tools and Assembly Systems
Note! This manual can be altered without further notice.
For further information log in to Atlas Copco www.atlascopco.com

Introduction
9836 3043 01 1.9 3 (30)
Contents
1Introduction...........................................................................................................4
1.1 Radio Frequency Exposure ........................................................................................4
2System overview...................................................................................................6
2.1 Functionality................................................................................................................7
2.1.1 System functionality...................................................................................................7
2.1.2 Tool functionality........................................................................................................7
2.2 Technical data ............................................................................................................8
2.2.1 Memory capacity .......................................................................................................8
2.2.2 Battery .......................................................................................................................8
2.2.3 IRC.............................................................................................................................9
3System setup.......................................................................................................11
3.1 Hardware setup ........................................................................................................11
3.2 IRC-B hardware setup..............................................................................................11
3.2.1 Serial Port Adapter..................................................................................................11
3.2.2 Antenna placement..................................................................................................11
3.3 Tool preparation........................................................................................................12
3.4 Power Focus software setup ....................................................................................12
3.5 Getting started with IRC-B........................................................................................12
3.6 Getting started with IRC-W.......................................................................................13
3.7 Getting started with Standalone................................................................................13
3.8 Connecting tool with Power Focus (Pairing).............................................................14
3.9 Connecting tool with ToolsTalk Service (Docking) ...................................................16
3.10 Other settings ...........................................................................................................18
4Parameters, relays and events...........................................................................19
4.1 Parameter list............................................................................................................19
4.2 Digital outputs (relays)..............................................................................................19
4.3 Event codes..............................................................................................................20
5FAQ ......................................................................................................................22
6Appendix..............................................................................................................23
6.1 Docking station setup ...............................................................................................23
6.1.1 Connecting to PC ....................................................................................................23
6.2 Cross-over Ethernet connection...............................................................................27

Introduction
4 (30) 1.9 9836 3043 01
1 Introduction
This manual describes the Atlas Copco Tensor STB nutrunner.
For complete technical data, see Product Instructions for each tool.
For software and hardware compatibility between tool and controller, see Tensor STB release notes.
For an updated list of functionality, see Tensor STB release notes.
See also the Power Focus User guide, 9836 3123 01.
1.1 Radio Frequency Exposure
The Serial Port Adapter and the Tensor STB contain a small radio transmitter and receiver. During
communication all IRC products receive and transmit radio frequency (RF) electromagnetic fields
(microwaves) in the frequency range for the ISM band (2.4GHz).

System overview
6 (30)
2 System overview
Tensor STB is battery powered and communicates with the Power Focus tightening controller system
through wireless digital communication built on Industrial Radio Communication (IRC) technology.
Figure 1 System overview
A Tensor STB system includes the following parts.
Tool
Tensor STB tool
Tool battery
Battery charger
Docking station with power supply and USB cable, for configuration of IRC-W.
Controller options
IRC Focus Power Focus 4000 or 3100
Serial Port Adapter
Serial cable for Power Focus
SW version 7.4 and older:
Plug for STB tool SW version 7.5: Power cable for Serial Port
Adapter
RBU (Bronze, Silver or Gold)
Software
Tensor STB software
Power Focus software
ToolsTalk Service, for configuration of IRC-W
For compatibility between software versions, see Tensor STB release notes.
1.9 9836 3043 01

System overview
2.1 Functionality
2.1.1 System functionality
The Power Focus sends the Parameter set (Pset) and the batch size to the tool where it is stored and
executed, and the tightening result is sent back to the Power Focus. See schematic figure below.
The STB tool family has the same basic functionality as other ST tools, but due to the nature of the
wireless communication where the tightening data is stored in the tool, all features in the Power Focus SW
may not be available in STB. For a complete list, see Tensor STB release notes.
Remote start is not available, for safety reasons.
9836 3043 01 1.9 7 (30)
Pset
Result
Figure 2 System functionality
2.1.2 Tool functionality
Figure 3 STB tool
1 Scanner on bus
connector
2 Buzzer
3 LEDs
4 Function button
5 Battery
6 Direction ring
7 Tool trigger
The Tensor
STB tool is equipped with a buzzer and blue LEDs that can be configured as outputs to
indicate a series of events, similar to the relays on Power Focus. In addition, STB has the following LEDs.

System overview
8 (30)
Connection, blue LED: Indicates connection to Power Focus
Batch, green LED: Indicates Batch done
Battery, yellow LED: Indicates battery status (flashing light for low, and
fixed light for empty battery)
Alarm, red LED: A tool event is detected, for example Tool overheated
The function button, situated on the direction ring, can be configured as an input similar to the inputs on
Power Focus. It can generate different inputs depending on the position of the direction ring, clockwise
(CW) or counter clockwise (CCW).
External accessories can be mounted directly on the tool. Connected to the bus connector, the accessories
communicate with the Power Focus using the same data link as the tool. The tool accessory bus is
configurable to work in different modes depending on the connected device.
2.2 Technical data
For complete technical data, see Product Instructions for each tool.
2.2.1 Memory capacity
The result from up to 25 tightening can be stored in the STB.
2.2.2 Battery
Tensor STB is equipped with a Lithium-Ion battery.
Figure 4 Number of tightening
The capacity is dependent on the battery type and joint, softer joints gives less tightenings. Figure 4
Number of tightening illustrates the number of tightening between re-charge for different tools and
different types of joints (rundown angle in degrees) at the maximum torque for the tool.
1.9 9836 3043 01

System overview
2.2.3 IRC
The Industrial Radio Communication (IRC) technology
operates on the free 2.4 GHz ISM band.
The Tensor STB tool is available in two different versions
for the different IRC standards:
IRC-B
IRC-W
The table below gives an overview of the different standards.
Technique Latency Immunity Multipath Immunity Interference Immunity Power Consumption
IRC-B High High High Low
IRC-W Moderate Moderate Moderate High
The performance of IRC-W is highly dependent on the infrastructure at the site.
Latency defines the delay times of the communication link i.e. when transferring tightening results. The
multipath immunity indicates how well the reflections in the environment are handled, for example against
walls or equipment. The interference immunity indicates how well other radio sources are avoided.
IRC-B
79 (1 MHz) channels.
IRC-B features dynamic Adaptive Frequency Hopping (AFH).
No frequency planning needed.
Figure 5 IRC-B with AFH avoids collisions on the 2.4 GHz ISM band, for example Wi-Fi
More information at: www.bluetooth.com.
9836 3043 01 1.9 9 (30)

System overview
10 (30)
IRC-W
13 (22 MHz ) channels.
1 fixed channel used for communication.
Frequency planning needed
Installation support from IT department needed.
Figure 6 IRC-W, three channels occupying the 2.4GHz ISM band.
More information at: www.wi-fi.org.
1.9 9836 3043 01

System setup
3 System setup
This section describes how to connect the Power Focus and STB.
The STB tool is compatible with standard Power Focus 4000 and 3100 controllers with all
available RBU-types.
3.1 Hardware setup
Setup the Power Focus system according to the local network recommendation.
If using a Serial Port Adapter, the connection with ToolsTalk Power Focus must go through Ethernet as
the serial port 2 is required for the adapter. In case there is no network available, the connection between
Power Focus and the PC running ToolsTalk Power Focus is made with a cross-over Ethernet cable
according to the instructions in section 6.2 Cross-over Ethernet connection.
3.2 IRC-B hardware setup
Tools using IRC-B need to setup the Serial Port Adapter.
3.2.1 Serial Port Adapter
If using a Serial Port Adapter, connect it according to the following instructions.
1. Turn off the Power Focus.
2. Connect an Atlas Copco crossover cable between
the Serial Port Adapter and the Power Focus serial
port 2, called RS232 (2).
3. Connect power cable between the Serial Port
Adapter and the Power Focus.
4. Turn on the Power Focus.
Figure 7 Serial Port
Adapter connection Figure 8 Serial Port
connection
3.2.2 Antenna placement
The antenna must be located with free line of sight to
the tool, for example above pallets and other
equipment.
The antenna on the serial port adapter can be
adjusted to optimize performance.
In IRC Focus, the antenna is built-in behind the front
panel. Place the controller in free line of sight to the
tool.
Figure 9 Antenna placement
9836 3043 01 1.9 11 (30)

System setup
12 (30)
3.3 Tool preparation
The battery must be charged before proceeding.
3.4 Power Focus software setup
The Power Focus can be programmed from ToolsTalk Power Focus or directly on Power Focus Graph.
Power Focus Graph:
1. Press
PROG > Tool > Configuration > Connection to access the radio and connection parameters.
2. Proceed to section 3.5 Getting started with IRC-B or 3.6 Getting started with IRC-W depending on
connection type.
ToolsTalk Power Focus:
1. Establish an Ethernet connection with program control from ToolsTalk.
2. Open
Power Focus Map > Tool > Configuration > Connection to access the radio and connection
parameters.
3. Proceed to section 3.5 Getting started with IRC-B or 3.6 Getting started with IRC-W depending on
connection type.
Figure 10 Tool configuration
3.5 Getting started with IRC-B
In ToolsTalk Power Focus do the following settings:
1. Set parameter
T290 Primary tool to IRC-B .
2. Set
T294 Serial port to Serial 2 if a Serial Port Adapter is used or internal on the IRC Focus.
3. Reboot the Power Focus.
4. Continue to section 3.8 Connecting tool with Power Focus (Pairing).
1.9 9836 3043 01

System setup
3.6 Getting started with IRC-W
IRC-W connection requires the following settings.
Network settings: The network administrator must open the network for UDP traffic for the MAC
address of the STB tool, and submit data to enter in ToolsTalk Service.
Supports IEEE 802.11 b/g
Encryption and authentication standards supported:
WEP: 64
WEP 128
WPA/WPA2-PSK (TKIP)
WPA/WPA2-PSK (AES/CCMP)
LEAP-WPA2
LEAP-WEP128
In ToolsTalk Power Focus do the following settings:
1. Set parameter
T290 Primary tool to IRC-W .
2.
T293 Power Focus IP port is default 6677 , and must be the same as in the tool.
3. Reboot Power Focus.
4. Continue to section 3.9 Connecting tool with ToolsTalk Service (Docking).
3.7 Getting started with Standalone
The STB power tool can be used in standalone mode, i.e., without being connected to the controller.
To setup the tool in standalone mode follow this instruction:
1. Start by pairing the tool and controller.
2. In the PF Map Tool branch, double-click on Maintenance and then click Standalone to view the
Standalone settings.
3. To edit the standalone parameters click Set stand
alone parameters.
4. In the
Set Stand Alone Parameters dialog box
select the
Use standalone check box, and then
select type of accessory.
•None: Only one Pset can be used.
•ST Selector: Up to four Psets are
available. The ST Selector must be set to
mode 1. To set up the ST Selector,
please refer to the Power Focus User
guide.
•GPIO: Up to four Psets are available.
5. Select a Pset for each position.
6. Click
OK when finished to store the standalone
configuration to tool.
Figure 11 Standalone parameter settings
Standalone mode is indicated by the flashing blue Connection LED on the tool.
9836 3043 01 1.9 13 (30)

System setup
14 (30)
7. To the left in the Tool Maintenance dialog box, click Disconnect tool .
Figure 12 Disconnect tool
8. To disconnect the tool, click
Disconnect tool , and then click Ok in the Disconnect tool dialog box.
9. Pair the tool to upload results and/or change standalone configuration.
3.8 Connecting tool with Power Focus (Pairing)
The Power Focus and the tool need to be paired together in order to establish the IRC-B connection.
1. Disconnect the (charged) battery from the tool.
2. Press the tool trigger while reattaching the battery.
3. When the tool LEDs are off, release the tool trigger.
4. When the tool LEDs are on again, press the tool trigger.
5. When the tool LEDs are off again, release the tool trigger. Both LEDs start
to flash (after approximately 10 seconds).
Figure 13 LED on
Do not start the Power Focus procedure before both LEDs on tool are flashing. Initiate
pairing within 30s or the tool might time out.
Power Focus Compact or IRC Compact:
1. Press the F-button 10 times (
F10 ).
2. Press the return-key to confirm the selection.
Power Focus Graph or IRC Graph:
1. Press
PROG > Tool > Configuration > Connection > IRC Pairing > right arrow
1.9 9836 3043 01

System setup
2. Press the soft key marked Start to confirm the selection.
3. Press
OK to exit setup.
ToolsTalk Power Focus:
•Select
Power Focus Map > Tool > Configuration > Radio > IRC pairing
Wait a few seconds until the blue connection LEDs on the
tool and the Serial Port Adapter (if used) are on.
The pairing is consistent until the tool or the
Serial Port Adapter is replaced.
Figure 14
Connection LED on
tool Figure 15
Connection LED on,
Serial Port Adapter
Event E559 indicates a successful pairing completed and event E550 indicates connection with the tool.
The connection to Power Focus is established within one minute.
9836 3043 01 1.9 15 (30)

System setup
16 (30)
3.9 Connecting tool with ToolsTalk Service (Docking)
1. Connect the tool to the docking station. For instructions on how to connect the tool, see section 6.1
Docking station setup.
2. In ToolsTalk Service, open
Options > Settings .
3. Select
Port and USB
device.
4. Click
OK .
Figure 16 TTS settings
5. Click the Connect icon when the
tool is connected to the Tensor
STB docking station.
The tool stays connected during the
session with ToolsTalk Service.
Figure 17 Connect icon
6. Open Configuration > IRC-W . Set parameters 106402 Remote IP Address to the IP address of the
Power Focus, and
106403 Remote Port to the port number same as the controller parameter T293
Power Focus IP port
, default 6677 .
7. Enter the settings for
IRC Hardware parameters.
1.9 9836 3043 01

System setup
Figure 18 IRC Hardware settings
8. Enter the settings for the IRC-W parameters. The data for Encryption type and key is submitted by
the network administrator.
Figure 19 IRC-W settings
9836 3043 01 1.9 17 (30)

System setup
18 (30)
Figure 20 Encryption Key dialog
9. Save the settings and click the
Disconnect icon.
10. Remove the tool from the docking station and attach the battery. The tool is automatically
connected to Power Focus.
3.10 Other settings
Open Power Focus Map > Tool
> Configuration > Radio
The following settings are
available.
Figure 21 Radio settings
T270 Power save timeout: Tool turns off after this time, if inactive. To restart, press trigger once.
Connection takes approximately 10 seconds.
T271 Start condition: The start condition if using IRC connection for tool.
None: Up to 25 tightenings can be performed if IRC connection is lost (Blue LED off).
Connected: IRC connection must be established (Blue LED on) to run tool.
Start request: IRC connection must be acknowledged before start of each tightening.
T272 Link timeout : If the tool looses IRC connection it is considered offline and the connection LED (blue)
on the tool turns off after the link timeout time.
T276 Max sender power. See Parameter list.
T290 Primary tool . Note that Power Focus needs to be restarted after changing primary tool setting.
Press
Store to save the settings.
1.9 9836 3043 01

Parameters, relays and events
4 Parameters, relays and events
4.1 Parameter list
The following parameters are relevant for Tensor STB tools. See the Power Focus user
manual for a description of all parameters in Power Focus.
Parameter
number Parameter name Description Default setup
T270 Power save
timeout Tool will turn off automatically if inactive for this period of time.
Unit: Minutes. Min value: 1. Max value: 120. 30
T271 Start condition Tool radio start condition
Alternatives: Off, Connected, Start request Off
T272 Link timeout After this timeout the tool is considered offline.
Unit: Milliseconds. Min value: 5000. Max value: 60000. 5000
T276 Max sender power Max sender power on the IRC module. Only IRC-B. Full
T290 Primary tool Expected primary tool connection. Cable or IRC. Cable
T292 IRC pairing When selected, IRC pairing starts if tool is in pairing mode and tool
connection is IRC-B.
T293 Power Focus IP
port Port number for IRC-W tool connection. 6677
T294 Serial port Serial port where IRC-B device is connected. Serial 2 or internal. Serial 2
T470 Use standalone Defines if the tool is used as standalone.
T472 Accessory Specifies the attached tool accessory.
None, ST selector, GPIO None
T473 Pset position 1 Only available Pset if no accessory is selected, or used when
accessory is in position 1.
T474 Pset position 2 Selected when accessory is in position 2.
T475 Pset position 3 Selected when accessory is in position 3.
T476 Pset position 4 Selected when accessory is in position 4.
T477 Start select source Same function as T200, and overrides it when in standalone mode. Tool trigger
T478 Power save
timeout Same function as T270, and overrides it when in standalone mode. 30 min
4.2 Digital outputs (relays)
The following outputs are relevant for Tensor STB tools. See the Power Focus user manual
for a description of all available inputs/outputs and how to set up.
Name Description
String
length Value Set signal / Reset signal
Time To next tightening Tracking Blue LED Sound (time duration for all)
Battery empty Indicates tool battery
empty 1 bit 0=not used 1=battery
empty
Tool battery empty / no
signal X X X
Battery low Indicates tool battery
low 1 bit 0=not used 1=battery
low
Tool battery low / no
signal X X X
9836 3043 01 1.9 19 (30)

Parameters, relays and events
20 (30) 1.9 9836 3043 01
Tool connected Indicates connection
established between
tool and controller
1 bit 0=not used
1=tool
connected
Tool is connected / no
signal X X X
No tool
connected Indicates controller has no connection
with tool
1 bit 0=not used
1=tool not
connected
Controller has no
connection with tool /
no signal
X
4.3 Event codes
The following Power Focus event codes are associated with STB.
Event
code Event name Description Procedure
Acknowledge PF ready Tool ready
E550 Radio contact with
tool established, tool
accessible
Radio contact with tool established,
tool accessible. For information only.
E551 Radio contact with
tool lost, tool
inaccessible
Radio contact with tool lost, tool
inaccessible. Re-establish connection.
E552 Communication
error with tool An intermittent communication disturbance between tool and
controller.
For information only.
If occurring frequently, then
reposition the Serial Port
Adapter.
If reoccurring, then contact
your Atlas Copco
representative.
E553 Pairing attempt with
wireless tool failed An attempt to pair the Power Focus with a wireless tool failed. Set the tool in pairing mode according to the pairing
procedure and perform another
pairing attempt.
If reoccurring, replace the tool.
E554 Command not
performed, wireless
tool inaccessible
A command (batch increment, reset
batch etc.) could not be performed and
was discarded because the tool was
currently inaccessible.
Re-establish connection.
Perform the action causing the
event again.
E555 Condition change not
reflected in tool,
wireless tool
inaccessible
A condition change in the controller
(Pset selection, Job selection, Job
aborted etc.) could not be reflected in
the tool. The tool was currently
inaccessible.
Re-establish connection.
The condition change is now
automatically transferred to the
tool.
E556 Tool battery low Tool battery voltage is low. Complete work and replace
battery.
E557 Tool battery empty Tool battery voltage is empty. Tool
locked Replace the battery.
The tool is unlocked
automatically.
E558 Tool software
version mismatch The implemented protocol version in Power Focus for connected tool differs
from the protocol version in tool.
Additional parameter information:
First parameter is Power Focus protocol
version second parameter is Tool
protocol version.
Upgrade the software in tool or
Power Focus.
E559 IRC pairing
completed An IRC paring sequence has been successfully completed. For information only.
E561 Tool locked, do
Store standalone
Tool locked since no Pset has been
actively stored in the tool.
Do Store Standalone or deselect
Standalone, parameter T470
Use Standalone.