Atlas Copco POWER FOCUS 4000 Quick Manual
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Atlas Copco POWER FOCUS 4000 Quick Manual

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POWER FOCUS
QUICK GUIDE
SAFETY INSTRUCTIONS
When using electric products, basic precautions should be followed:
❑ THIS EQUIPMENT MUST BE EARTH GROUNDED
❑ Always disconnect the equipment from the mains, by pulling the
plug, before opening it for installation, service etc
❑ Do not use this product near water

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Summary of Contents for Atlas Copco POWER FOCUS 4000

  • Page 1 POWER FOCUS QUICK GUIDE SAFETY INSTRUCTIONS When using electric products, basic precautions should be followed: ❑ THIS EQUIPMENT MUST BE EARTH GROUNDED ❑ Always disconnect the equipment from the mains, by pulling the plug, before opening it for installation, service etc ❑ Do not use this product near water...

  • Page 2: Table Of Contents

    CONTENTS GETTING STARTED – Putting together the Tensor system – Mounting and connecting – The Compact user interface – The Graph user interface – ToolsTalk PF STRATEGIES – Setting up the normal two-stage tightening – Monitoring the first stage of your tightening –...

  • Page 3: Putting Together The Tensor System

    PUTTING TOGETHER THE TENSOR SYSTEM Power Focus 4000 is the electric tool controller replacing the 3100 generation, as the control and monitoring system for Atlas Copco’s Tensor and ETX electrical tools. This advanced fastening system consists of: – a Power Focus controller. Two different hardware versions are...

  • Page 4: Mounting And Connecting

    MOUNTING AND CONNECTING Wall Lock Controller 1) Open the locking mechanism 2) Open the controller slowly towards you 3) Connect the tool cable, power cable etc. (see picture below) 4) Connect the RBU 5) Check that the GFI (Ground Fault Interruptor) is switched on 6) Close the controller and lock it 7) Connect the power cable to a power supply (115/230 V) 8) Turn the power on...

  • Page 5: The Compact User Interface

    THE COMPACT USER INTERFACE 2. NOK 3. Alarm 4. AutoSet 5. n x OK 6. Job OK STAT 8. Prog Control 1. OK The tightening result is within specified limits 2. NOK The tightening result is outside of specified limits 3.
  • Page 6 THE COMPACT USER INTERFACE Button Functionality Question mark Pressing it will show RBU type (Au = Gold, Ag = Silver etc), installed software release, connected tool type, active Pset and Job Press F (Function key) to display functions. To display function F1 press F once, to display function F2 press F twice etc.

  • Page 7: The Graph User Interface

    THE GRAPH USER INTERFACE The color display offers easy monitoring and programming. It can be configured to show information from any Power Focus within a cell. The display is fully configurable - the picture below shows only one example. Job no. Pset (P) or Multi- Batch count Channel...

  • Page 8: Toolstalk Pf

    TOOLSTALK PF Connect via USB 1) Turn on your PC and the PF , then 2) con- nect the USB cable. Your PC should detect the PF , which makes it possible to start TTPF and connect to the PF using the ”serial” option.
  • Page 9 TOOLSTALK PF Connect via Ethernet continued...

  • Page 10: Setting Up The Normal Two-Stage Tightening

    SETTING UP THE NORMAL TWO-STAGE TIGHTENING Torque Control / Angle Monitoring – Two Stage To quickly get started, either make the basic settings using AutoSet a) On the Compact, this is done by i) pressing the ”arrow” button, ii) confirming by pressing Enter, iii) entering the final torque target with the ’+’...

  • Page 11: Monitoring The First Stage Of Your Tightening

    MONITORING THE FIRST STAGE OF YOUR TIGHTENING The Power Focus offers several ways to control and monitor the rundown of the screw cycle. The rundown is the rotation before snug level (where the screw head starts compressing the joint). Rundown Monitoring: monitor the angle between cutting the first thread and a settable torque level monitor torque during an angle window PVT Selftap:...

  • Page 12: Yield Control

    YIELD CONTROL Using Yield control as tightening strategy gives higher clamp force out of the same screw, than with Torque control. A problem joint could benefit from a change of strategy, or it can be redesigned into smal- ler dimensions and lower weight, while meeting the same clamping requirements.

  • Page 13: Detecting A "Rehit

    DETECTING A ”REHIT” At hand-held applications, there is always a risk that the operator starts a tightening on an already tightened bolt. This can disturb the station’s batch counting. Power Focus has a rehit detection based on tool speed in the first stage, and tightening angle in the final stage.
  • Page 14 SETTING UP AN ACCESSORY IN W07 The setup of an accessory is very easy, using ToolsTalk PF W07 . If you click your way past Accessories in the PF Map, then I/O bus, then right-click on Configuration, you will be led through the neces- sary steps by the program.
  • Page 15 SETTING UP AN ACCESSORY IN W07 How do I trouble-shoot the Accessory? To find out whether Power Focus has established communication with the Accessory, go to the I/O bus Information window. There, you can e.g. see to which Device address the unit is set. There is no longer a need to open the Accessory to check the rotary switch.
  • Page 16 LOGIC CONFIGURATOR Assumption: You want to use the green lamp on the Stacklight to signal a Job OK. The lamp should light up at Job OK and should come off only when you push the Stacklight button. Solution: Create a Logic Configurator that controls the described ”process” . It should have two Inputs –...
  • Page 17 LOGIC CONFIGURATOR Go to Accessory setup and program the Stacklight. The illustration shows that the output signal of our Logic Configurator sheet is called Logic Relay 1. We give the ”button push” signal the name Logic digin 1, see below. Back to the Logic Configurator sheet, where we now program the second input signal, for the ”R”...
  • Page 18 LOGIC CONFIGURATOR Now store your program to the Power Focus and test it by working the Job. You might not be quite happy with the result. Why? 1. The Job OK signal is a ”long” internal signal, staying active until the next Job is activated.
  • Page 19 LOGIC CONFIGURATOR Comment: Compare the Job OK signal, marked ”Tracking” in the Configurator sheet, with the OK signal, marked ”Pulse” . The OK signal is already a 0,1 s long pulse, and would not need the conversion with the help of a Timer gate.
  • Page 20 STATION CONTROL USING LOGIC CONFIGURATOR Assumption You want to control a work station, to fixture the work piece with a pneumatic cylinder until the Job is OK. See the following logical wiring scheme and flow chart.
  • Page 21 STATION CONTROL USING LOGIC CONFIGURATOR Å The mechanical blocking device might require an additional, manual two-hand trigger, for personal safety reasons. The station must be realized in line with local safety regulations.
  • Page 22 STATION CONTROL USING LOGIC CONFIGURATOR Solution Denote the external signals (2 position sensors, 1 key switch) on the digital inputs with logical names, as well as the relay signal we want to create (for the air cylinder).
  • Page 23 STATION CONTROL USING LOGIC CONFIGURATOR Create the Logic Configurator for the air cylinder on Relay 1. It will need one input to activate the cylinder and two inputs to deactivate it (one for the key switch and one for Job OK).
  • Page 24 STATION CONTROL USING LOGIC CONFIGURATOR Create a second LoCo. With this LoCo, we simply want to trigger the Job, using the ”Work piece fixtured” signal. Create a third LoCo, that uses the key switch signal as input (like LoCo 1 above) to abort the Job. Store the Logic Configurators to the PF4000.
  • Page 25 Note that some of the procedures described only can be performed by an Atlas Copco authorized service provider. See also the Product Instruction for the controller and the tool. The events are grouped according to the table below.
  • Page 26 Event Event Description Procedure A C K Cntrl- Tool Code name ready ready E052 Sensor mecha- Sensor wheel nical error mechanical error. Replace tool. E053 Sensor signal Angular sensor error signal fault. If frequent con- tact service. 22.2.1.1 TCB and hose related errors (Pulsor C only) Event Event Description...

  • Page 27: Configuration

    Event Event Description Procedure Cntrl- Tool Code name ready ready E067 Tool control "Air hose not box air shutoff connected error TCB- >tool or TCB unable to shut off air. Check that the tool hose is fit bet- ween the TCB and tool.
  • Page 28 22.2.2 E100-E199 Event related errors Event Event Description Procedure Cntrl Tool Code name ready ready E102 Rundown prohibi- "An attempt "Depending ted due to Lock on to make a on C210 Lock Reject tightening on reject con- is made and figuration, either tightenings unlock the tool...
  • Page 29 Event Event Description Procedure Cntrl Tool Code name ready ready E107 Rundown prohi- "A Job using Unlock the tool bited due to Line line control is with one of the Control, batch not selected with following digital enabled parameter input functions: Use J330 line Line control start control.
  • Page 30 Event Event Description Procedure Cntrl Tool Code name ready ready E117 Tool locked - can- "The controller "Acknowledge not access RBU cannot com- the event. municate with Turn off the con- RBU. The con- troller and check troller must be that the RBU is restarted to correctly con-...
  • Page 31 Event Event Description Procedure Cntrl Tool Code name ready ready E122 Open end posi- Open end Remove the tioning failure positioning tool from the failed due joint. Restart the to too much positioning. torque during positioning phase. E125 Alarm on This event is "Redo the tighte- timeout / Alarm...
  • Page 32 Event Event Description Procedure Cntrl Tool Code name ready ready E127 PVT shut off This event In the Trace indicates that the monitor, check the drive was shut off result and change in the selftap or the settings ac- prevail phase of cordingly.
  • Page 33 Event Event Description Procedure Cntrl Tool Code name ready ready "(logically or electrically) tool is done. For Pulsor, the tool may be disconnected from the Tool Control Box and/or the Tool Control Box is disconnected from the controller. Additional parame- ter information: First integer para- meter: 0=locked...
  • Page 34 Event Event Description Procedure Cntrl Tool Code name ready ready E133 Tool locked by "The tool is prohibi- "Unlock the Tools Talk ted via ToolsTalk. tool by Additional parame- • sending an ter information: “Enable tool” First integer para- message via meter: 0=locked ToolsTalk proto- during tightening,...
  • Page 35 Event Event Description Procedure Cntrl Tool Code name ready ready E137 Tool locked by "The tool is locked "Unlock the fieldbus by FieldBus. Ad- tool by ditional parameter • sending an information: “Enable tool” First integer para- message via meter: 0=locked fieldbus or during tightening, •...
  • Page 36 Event Event Description Procedure Cntrl Tool Code name ready ready E140 Insert user ID "The tool is locked; Insert a valid ID card to release the user must card. tool insert his ID card in the card reader to release the tool. Additional parame- ter information: First integer para-...
  • Page 37 Event Event Description Procedure Cntrl Tool Code name ready ready E145 Tool locked by The tool is locked by "Unlock the tool Timer enable digital input Timer enable with digital input tool tool when the Job was Timer enable tool. not started within the If applicable, set time set in J320 Max...
  • Page 38 Event Event Description Procedure Cntrl Tool Code name ready ready E151 Job in OFF It is not possible to "In the Job moni- mode select a new Job. The tor, clear the Job controller in Job OFF off check box. mode.
  • Page 39 Event Event Description Procedure Cntrl Tool Code name ready ready E156 Job members "When running a Cell "Check cables and lost Job, this is displayed connections to the by the Job reference lost Job client. when it has lost contact In the Controller with one of the Job menu of the lost Job...
  • Page 40 Event Event Description Procedure Cntrl Tool Code name ready ready In the Select source view, check the settings for C201 Job. E161 Line Control The line control has For information Alert 1 been activated, and the only. first control alert limit has been reached.
  • Page 41 Event Event Description Procedure Cntrl Tool Code name ready ready E168 ST scanner Issued at ST scanner For information settings not power-on if scan only. production engine settings are default not the same as production defaults. E169 ST scanner Issued at ST scanner For information settings not power-on if scan engine...
  • Page 42 Event Event Description Procedure Cntrl Tool Code name ready ready E180 Euchner Ident The protocol settings System only for the serial COM supports Sie- port 1 is not set to mens 3964R 3964R, it is not pos- protocol sible to use the Euch- ner Ident System with this configuration.
  • Page 43 The cause of this may be technical problems with the sensor or a bad air sensor tuning. Air sensor tuning is performed by Atlas Copco Tools service personnel. E193 Too many More than the tightenings maximum 50 performed in...
  • Page 44 Event Event Description Procedure Cntrl Tool Code name ready ready E194 Setup The tool was aborted due exchanged during to exchange Tool Setup or Mo- of tool nitoring Setup. E195 Monitoring Monitoring Setup setup contains contains tighten- invalid ings with invalid tightening result for one or parameter...
  • Page 45 Event Event Description Procedure Cntrl Tool Code name ready ready E199 Not possible If You try to store the Make new tighten- to store Refe- Reference Trace (In ings and find a new rence Trace Multiple Traces menu), Reference Trace and but it does not exist press store again.
  • Page 46 22.2.3 E200-E299 User input events Event Event Description Procedure Cntrl Tool Code name ready ready E206 Pset number "An attempt was Check parameter invalid made to do a C200 Pset and tightening with the select a Pset wrong Pset. Ad- from the correct ditional parameter source.
  • Page 47 Event Event Description Procedure Cntrl Tool Code name ready ready E212 Pset/Multis- "Event displayed For information tage stored every time a Pset only. or Multistage is stored or restored. Additional parame- ter information: First integer parameter: Pset or Multistage number Second integer parameter 0=Pset, 1=Multistage"...
  • Page 48 Event Event Description Procedure Cntrl Tool Code name ready ready E208 Not Ok to It is not allowed to "Proceed in select new select new Pset the Job order Pset when a Pset is al- until the Job is ready autoselected finished.
  • Page 49 Event Event Description Procedure Cntrl Tool Code name ready ready E220 Fastener Displayed if fastener "Ensure that more broken (screw or nut) breaks than one compa- during yield control. rison is obtained before yield is reached. In ToolsTalk, open the trace monitor and analyze the tightening.
  • Page 50 Event Event Description Procedure Cntrl Tool Code name ready ready E234 Start final "This event code is "Change the value angle range displayed when an for P120 Start Final error attempt is made to Angle to a value tighten with a P120 within tool limits.
  • Page 51 Event Event Description Procedure Cntrl Tool Code name ready ready E237 Strategy "No valid control "Change control configuration strategy was chosen strategy valid for error for the stored Pset. used tool. Additional parameter Check that the information: Pset parameters First parameter: Pset are correct and number Second para- store the Pset."...
  • Page 52 Event Event Description Procedure Cntrl Tool Code name ready ready E251 Max time to This message is "If needed, open PF complete Job displayed and the Map > Job run out Job aborted if it > Timer and change is not completed the parameter J321 within the speci- Maxtime to complete...
  • Page 53 Event Event Description Procedure Cntrl Tool Code name ready ready E287 All Result All Result Parts "Make sure that the Parts can not can not be stored. Job Master and all be stored of the Job Members have the same number of Result Parts in the configuration.
  • Page 54 22.2.4 E300-E399 Statistical events Event Event Description Procedure Code name E300 Xucl relative The last subgroup relative torque mean value torque is larger than the upper control limit. E301 Xlcl relative The last subgroup relative torque mean value torque is lower than the lower control limit. E302 Rucl relative The last subgroup range relative torque value...
  • Page 55 Event Event Description Procedure Code name E311 7below Trend deviation alarm, the subgroup relative x relative torque mean value has been below the av- torque erage mean value of the average of the last ten subgroups 7 times consecutively. E312 7above r Trend deviation alarm, the subgroup relative relative...
  • Page 56 Event Event Description Procedure Code name E322 7inc x line Trend deviation alarm , the subgroup pressure line pressure mean value has in- creased 7 times consecutively. E323 7dec x line Trend deviation alarm , the subgroup pressure line pressure mean value has de- creased 7 times consecutively.
  • Page 57 Event Event Description Procedure Code name E331 2sigma r Trend deviation alarm, the last subgroup line line pres- pressure range average is outside Rline-bar- sure bar - 2 sigma. E333 Not allowed The requested statistic subscription is not Change the subscription. subscrip- allowed.
  • Page 58 Event Event Description Procedure Code name E345 Cpk tq The torque Cpk is lower than 1,33 See E340 Xucl tq E346 7inc x tq Trend deviation alarm, the subgroup See E340 Xucl tq torque mean value has increased 7 times consecutively E347 7dec x tq...
  • Page 59 Event Event Description Procedure Code name E360 Xucl ang The last subgroup mean angle value is See E340 Xucl tq larger than the upper control limit. E361 Xlcl ang The last subgroup mean angle value is See E340 Xucl tq lower than the lower control limit.
  • Page 60 Event Event Description Procedure Code name E371 7below x ang Trend deviation alarm, the subgroup angle See E340 Xucl tq mean value has been below the average mean value of the average of the last ten subgroups 7 times consecutively. E372 7above r ang Trend deviation alarm, the subgroup angle...
  • Page 61 Event Event Description Procedure Code name E387 7dec x cm Trend deviation alarm, the subgroup See E340 Xucl tq CM mean value has decreased 7 times consecutively. E388 7inc r cm Trend deviation alarm, the subgroup See E340 Xucl tq CM range value has increased 7 times consecutively.
  • Page 62 22.2.5 E400-E499Communication events Event Event Description Procedure Cntrl Tool Code name ready ready E401 Duplicate Two IO devices "Acknowledge the device ID:s with the same ID event. on IO bus are present on the Make sure that I/O Bus. all of the devices on the bus have a unique ID."...
  • Page 63 Event Event Description Procedure Cntrl Tool Code name ready ready E417 Too many There are too many Wait until the other commu- connections at the sessions are done nication same time (ToolsTalk, and close their con- sessions at ToolsNet, Operator nection.
  • Page 64 Event Event Description Procedure Cntrl Tool Code name ready ready E437 RBU file RBU file system fault. "Acknowledge system An attempt will be the event. Re- corrupt made to repair it by boot controller. means of erasing Replace the the RBU. RBU."...
  • Page 65 Event Event Description Procedure Cntrl Tool Code name ready ready E446 RBU read RBU read operation "Acknowledge the error failed. event. Try read again. Reboot controller. Replace the RBU." E447 RBU write RBU write opera- "Acknowledge the error tion failed. event.
  • Page 66 Procedure Cntrl Tool Code name ready ready E463 Fieldbus Error detected Contact the gen com in initialization of Atlas Copco fault FieldBus. service repre- sentative. E464 Fieldbus The FieldBus Acknowledge hardware module is broken the event. fault and has to be Contact the replaced.
  • Page 67 E469 Fieldbus Error detected Contact the init error in initialization of Atlas Copco FieldBus. service repre- sentative. E470 Fieldbus InterBus PCP "Check the length error. length of the error...
  • Page 68 Event Event Description Procedure Cntrl Tool Code name ready ready E473 Fieldbus Communication buffer "Check if there commu- full due to too many is a frequent nication input signals or incor- input signal, or if buffer rect fieldbus update F200 FB Update alarm interval.
  • Page 69 Event Event Description Procedure Cntrl Tool Code name ready ready E482 The application code "In the cell version not version differs from members, open compatible the cell reference. To PF Map with cell be able to run the cell > Controller > functionality, ensure Information and that all members in...
  • Page 70 22.2.6 E500-E599 Hardware events (tool) Event Event Description Procedure Cntrl Tool Code name ready ready E500 New tool A new tool has been connected connected to the drive E501 Tool over- "The tool is too hot and "Let the tool rest heated the drive is disabled.
  • Page 71 Event Event Description Procedure Cntrl Tool Code name ready ready E505 Tool rebuilt Tool redesigned. For information to/from E.g. angled tool type only. OE- type redesigned to an OE- tool type. E506 Tightenings Tool locked due to in- Change to a RBU prevented curred software release that supports the...
  • Page 72 Event Event Description Procedure Cntrl Tool Code name ready ready E513 Tool A checksum error has Acknowledge the EEPROM occurred in the tool event. Reprogram the checksum memory handling. tool and restore the error memory, using Tools Talk service. E514 Motor- "Checksum indicates "Acknowledge the...
  • Page 73 Event Event Description Procedure Cntrl Tool Code name ready ready E519 Tool Tool calibration value Acknowledge the calibration out of range, service event. Recalibrate the value out tool. tool, using ACTA. If of range the event reappears, replace the tool. E520 Wear indi- Data in tool memory...
  • Page 74 Event Event Description Procedure Cntrl Tool Code name ready ready E540 Calibra- Calibration not OK, Service the tool. tion not calibration value changed > 5% of CalVal max value since last changed calibration. > 5% of max value since last calibra- tion E541...
  • Page 75 If occurring error with disturbance between frequently, reposition tool tool and controller. Serial Port Adapter. If re-occurring, con- tact your Atlas Copco representative." E553 Pairing An attempt to pair Set the tool in pairing attempt the controllerwith a mode according to with wire- wireless tool failed.
  • Page 76 Event Event Description Procedure Cntrl Tool Code name ready ready E558 Tool "The implemented Upgrade the software software protocol version in in tool or controller to version controller for connec- match each other. mismatch ted tool differs from the protocol version in tool.
  • Page 77 Event Event Description Procedure Cntrl Tool Code name ready ready E565 Locked The controller has For information only. while locked the tool while updating updating the Pset/Job Pset/Job in the (for instance in tool wireless) tool. E566 Tool Tool switched off Switch on the tool switch because of user (push...
  • Page 78 Connect an external isolated 24V power source to the 24V DC input of the devices." E619 Drive DC drive deactivated Contact the Atlas Copco deactiva- during operation. service representative. E620 Tool stall Tool motor stall. "Check that the tool...
  • Page 79 Tool>Maintenance>Motor error from the tool. tuning and perform a motor tuning." E623 Safety The torque measu- Contact the Atlas Copco current red by the torque service representative. moni- transducer is in- toring consistent with the error torque estimated from the measured current.
  • Page 80 22.2.8 E700-E799 Hardware events Event Event Description Procedure Cntrl Tool Code name ready ready E700 This event code is For information only. started only visible in the event log and used when the controller is started. E701 Backup The backup bat- Replace the backup bat- tery level is low.
  • Page 81 Event Event Description Procedure Cntrl Tool Code name ready ready E723 Swivel There is a mismatch lock between swivel activated lock and tool start source E724 Wrong Wrong gear box is Mount the correct gear mounted on the tool gearbox. E799 Internal Internal info in event...
  • Page 82 Cntrl Tool Code name ready ready E822 No Job No Job ACK from Acknowledge the event. control Contact the Atlas Copco from service representative. control E823 No cali- No calibration result "Acknowledge the event. bration Check tool cable. result Reboot the controller."...
  • Page 83 Event Event Description Procedure Cntrl Tool Code name ready ready E833 Autoset Autoset tight NOK Acknowledge the event. tight result Program the Pset manually or by Quick result programming. E834 Autoset Autoset rejected "Program the Pset rejected Pset in CCW manually or by Quick Pset in direction...
  • Page 84 Reboot the controller. before effect If the event reappears, changes the PF is faulty. Contact take the Atlas Copco service effect representative." E858 IP address already Acknowledge the event. address in use Change the IP-address in already the controller.
  • Page 85 Event Event Description Procedure Cntrl Tool Code name ready ready E870 Sync Sync member "In the sync reference, member registration failure open PF Map > Sync > registra- Options > Sync group list tion dialog box, and check that failure all IDs are correct and unique.
  • Page 86 22.2.10 E900-E999 Events MMI Event Event Description Pro cedure Cntrl Tool Code name ready ready E901 Error in MMI Acknowledge the event. Start-up detected. Reboot the controller. Error 22.3 Subinformation for event codes Each event code is logged together with four integer parameters. For some event codes these parameters are used to store extra information about the event.
  • Page 92 www.atlascopco.com...

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