Power MACS 4000 Quick Guide - Atlas Copco

Power MACS 4000
Quick Guide
POWER MACS 4000 – QUICK GUIDE | 1

Contents
TC Interface ...............................................................................3
Software Installation ................................................................5
Changing IP-address .................................................................6
Download software to TC.........................................................9
Connect PC to TC .................................................................... 10
Basic Programming ................................................................ 11
Help function ..................................................................... 11
Create a new setup ........................................................... 11
Add new program .............................................................13
Delete program .................................................................13
Add a step ..........................................................................13
Cut, copy or delete a step ................................................. 14
Set up problems ................................................................15
Test bolt ..............................................................................16
Checks, Restrictions and Monitoring ....................................17
Checks ................................................................................18
Restrictions ........................................................................ 19
Monitoring ......................................................................... 19
Advanced programming ........................................................20
Create a new program by copying an existing ...............20
Quick set .............................................................................21
DynaTork ............................................................................23
Reject Management ..........................................................24
Reporters .................................................................................26
Cycle data ..........................................................................26
Event log ............................................................................27
Traces .................................................................................28
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TC Interface
Indicator lamps
– OK
– NOK
– ALARM
– ALL OK (TC-P only)
– PRIM (TC-P only)
– E-STOP (TC-P only)
Text display
– TC node address
– IP-address
– Error messages
– Software version
– Torque & Angle display
Push buttons
– Toggle between
displayed information
– Set IP-address
– Reset E-stop button
(TC-P only)
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TC Interface
Digital input
(TC-P only)
D-sub MACS
I/O (TC-P only)
D-sub
RS232/RS485
(TC-P only)
D-sub HD
RS232/RS485
(TC-P only)
External Ethernet
(TC-P only)
Internal Ethernet
Ethernet Switch
Power supply
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E-stop in
and MACS IO E-stop out and
MACS IO
Anybus slot,
Fieldbus card
Interface (TC-P
only)
Power connector
Dip switch for
MACS I/O
and RS485
termination
(TC-P only)
QST Spindle
Connector
Digital output
(TC-P only)
24V input

Software Installation
Power MACS
To communicate with PM 4000 ToolsTalk PM has to be installed
on your PC. To run ToolsTalk PM, Multiprog PLC editor is
needed.
Multiprog
• Install MultiProg PLC Editor on your PC
– Accept all default answers
– Restart the computer when prompted
ToolsTalk PM
• Install ToolsTalk PM Software
– Answer next to all questions
– Launch the program when prompted
Since the Multiprog PLC program is an integrated part of
ToolsTalk Power MACS, both setup files are needed to run
the system. That means that every setup consists of two
files:
Example:
Demo_1sp.pm4
Demo_1sp.zwt2
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Changing IP-address
The only way to connect your computer to Power MACS
4000 is via Ethernet.
The Primary Tightening Controller (TC-P) has two Ethernet
ports, each with its own IP-address. The external port is for
the factory network. The internal port is for internal
communication and uses local addressing.
Connect your Ethernet cable to the switch on the backplane
of the TC-P.
The TC ”ID number” shown on the TC and TC-P display and
TC-P is the last part of the IP address. This number needs to
be changed to a unique number if there is more than one
TC in the system.
The IP-address and TC ID number can be viewed on the
display and set via using buttons on the front of the TC.
The IP-address can also be set through the computer with
ToolsTalk PM.
1. Set the IP-address of the TC.
Use the buttons on the front of
the TC to toggle between the
menus.
a. Select Setup and enter the
”Basic setup”
b. Toggle to “IP Setup” and push
”Select”
c. Toggle to ”IF1 IP” and push
”change”. Change the IP-adress
by using the buttons on the TC
d. Go back to the ”Basic setup”
e. Toggle to ”TC number” in order to
change the last part of the IP-adress. This number
needs to be unique for every TC in a system
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2. Change IP-address and Subnet mask on your PC.
a. Turn on your PC and open: Start/Control Panel/
Network connections/Local area connection
b. Click on “Properties”
c. If you use a VPN client. De-select the check box
“Checkpoint SecuRemote”
d. Scroll down and double click
“Internet Protocol (TCP/IP)
e. Select “Use the following IP-address”
f. Enter the IP address 192.168.0.250 and Subnet
mask 255.255.255.0. Click “OK”
3. Use “ipconfig” to verify that the computer has
changed the IP-address
a. Go to “Start” and select “Run…”
b. Type cmd and click “OK”
c. Type ipconfig and check that the IP-address is correct
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4. Use Ping to verify communication between your
computer and the TC-P in Power MACS 4000.
a. Go to “Start” and select “Run…”
b. Type cmd and click “OK”
c. Type ping + “IP-address of TC” and check that the
TC is connected
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Download software to TC
The software version of the TC can be viewed on the TC
display or in ToolsTalk PM.
Check software version
1. Go to the “Maintenance” menu and select
“Configure target system”
2. Click “Scan” to view all available TC
3. Read the Software version in the column labelled “Version”
Download new software
To download new software to the TC, – follow the
instructions below.
1. Go to the “Maintenance” menu and select “Configure target
system” – Highlight the TC to be upgraded
2. Click “Download”
3. Browse for the Power MACS 4000 Folder and select
“TC System software”
4. Select the .mx file and click “Open”
5. Restart the TC once the new software has been downloaded
successfully
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Connect PC to TC
Make sure you have a Set-up before you connect. To create a
Set-up, see page 11.
1. Start ToolsTalk Power MACS and select the desired
system as described below.
a. Open the “Maintenance” menu and select
“Select Target System”
b. Click “Scan” to scan for new TC
c. Select the TC-P to connect to and click “OK”. The new
TC is marked green in the list. See picture below
2. Click “Connect” to connect ToolsTalk PM to the TC
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Basic Programming
Help function
Help texts can be reached
from the “Help” menu by
pushing F1 or from the
“Help” tab in the
“Dynamic tool” window.
Create a new setup
A set up is needed for saving and running a program.
The set up must be created before the program is built.
Make sure the TC is disconnected.
1. The Wizard for creating a new setup can be started either
from the Start page when opening ToolsTalk PM (See
picture below) or by selecting the “File” menu and the
“New…” menu item
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2. In the “New setup” wizard the settings for the system,
station, spindles and bolts are entered. Follow the Wizard
to finish the setup
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Add new program
After the Set up is created programming can start. To add a
program the TC has to be disconnected.
1. Under the “Tightening” menu. Select “New program…”
Name the new program and click “OK”
Delete program
1. Open “System map” and Select “Program”
2. Right click on the program that shall be deleted
3. Choose “Remove program” and “OK”
Add a step
1. To add a step, drag the step from the ”Dynamic tool” window
and drop it on the desired location in the program.
It is also possible to right click between two steps and
select ”Add step” from the pop up menu
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2. Change the values in “Settings” under the menu
“Control”. For more detailed programming, see page 17
3. Click “Apply” to save the new settings in the setup
If a warning is displayed when clicking “Apply” this
indicates an error when programming. A description of
this is displayed in “Set up problems”. See page 15
Cut, copy or delte a step
1. Right click on the step and select cut, copy or delete from
the pop-up menu
2. To insert a copied step, right click where you want the
new step to be inserted and select “Paste”
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Set up problems
When applying new settings, during programming, a
warning message will appear if settings are missing or
incorrect.
These errors or warnings are viewed in the “Set up
problems” window and also at the step where the error
occurs.
To open this window – go to the “View” menu and select
“Set up problems…”
Unlike warnings, errors must be corrected before the system
can continue to run.
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Test bolt
Test bolt is used for running the Spindle(s) from the PC.
It is possible to run a Single run, Program or Mode.
To run a Program, follow the instructions below.
1. Click ”correct” to correct the PC to the TC
2. Go to the “Maintenance” menu and select “Test bolt”
3. Click “Program” to run the created Programs
4. Under “Settings”, select the programs to run
5. Adjust the “No. of cycles” tol be carried out
6. Click ”Start” to run the programs
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Checks, Restrictions and Monitoring
By using checks, restrictions and monitoring, the tightening
process can be monitored, controlled and evaluated.
Programming of checks, restrictions and monitoring.
1. Right click on the step or drag the selected item from the
”Dynamic tool” window to the step.
Note: Monitoring can only be added to Cycle End (CE)
2. Set the parameters for each item in the setting window
In the Program...
…checks are marked with a yellow dot
…restrictions are marked with a red dot
…monitoring is marked with a blue dot
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Checks
Checks are used to define the variables that are to be
measured and the limits to check in the tightening step. All
checks can be set to Repairable or Fatal. If set to Fatal, the
tightening can not be automatically repaired.
If repairable, the Reject Management can try to re-tighten
the bolt (see “Reject Management” page 24). Select the Fatal
box if you want the incorrect tightening to be considered
Fatal.
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Restrictions
A Restriction stops a running step immediately if the limits
have been exceeded. A restriction can be set to Fatal if you
do not want to retry.
Monitoring
Monitoring is set at the Cycle End. The Monitoring function
is used to examine the result of an entire tightening cycle.
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Advanced programming
Create a new program by combining an existing
program
1. Select ”Tightening” menu
2. Select ”New Program…” menu item
3. Name the new program
4. Click the check box “Build a new tightening program by
combining existing programs”
5. Select the program you want to reuse
6. Click the “Add” button and then “OK”
7. The new program is now added in the System Map under
Programs
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Quick set
Quick set is a function for creating a program where all
parameters can be changed quickly and easily.
1. Make sure the “Program settings” is highlighted
2. In the “Settings” menu – select “User variables” and
click “Add”
3. Name the variable
4. Enter a value and unit
5. Click “Apply” and the variable is added to the Program
settings
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6. When programming a step – under “Settings” and
“Control”, use the programmed Variable when entering
the targets of the step
7. When programming Checks
and Restrictions set the max.
and min. levels to a percent of
the Variable
Note: If the Value of the Variable
is changed in the Program settings,
the value will change in all places
were the Variable is used.
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DynaTork
DynaTork is a method patented by Atlas Copco designed to
overcome relaxation in the joint. When the target torque is
reached the DynaTork function holds the torque (current) in
oreder to compensate for joint relaxation.
1. IOn order to add a step, type ”DT – Run until DynaTork”
2. Fill in the values for “Torque”, “Times” and “Current
percentage” (If you are unsure about what values to fill in,
use the Help function to get more information)
3. Add “Checks” and “Restrictions” as described earlier
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Reject management
Reject Management is a function for automatically repairing
tightenings in station and avoiding more time consuming repairs
later in the process. When programming Reject Management,
a step to loosen the bolt is added and the program
is set to go back to an earlier step and retighten the bolt.
For examples/illustrations – see next page.
1. Add two steps at the end of the program.
a. To loosen the bolt, add a “Run to Angle” step and set
the direction to “Backwards”.
b. After this step, add a “Return from repair” step.
2. Click the step where the Reject Management functionality
is to be added.
a. Add the desired ”Checks” to evaluate if the tightening
is OK or NOK
b. In the “Settings” window under “Rejects” enter the
following settings for the Reject Management:
Retry
Loosen with step: Enter the “Run to Angle” step for
loosening the bolt
Start from step: Enter the step that shall start the
retightening of the bolt
First failure
Failing bolts – set to “Retry”
Other bolts – set to “Wait”
3. Click Apply to activate the new settings
For a more detailed guide to Reject Management use the
help function in ToolsTalk PM.
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Reporters
When analysing a tightening, several tools are available in
ToolsTalk PM. Cycle data for viewing the results, Event log
for viewing errors that have occurred and Trace for a graphic
picture of what is happening in the joint.
Cycle data
After a tightening cycle has been completed, variable data
can be displayed in the ”Cycle data” window.
“Cycle data” is opened by clicking the “Cycle data” icon on
the Toolbar.
To change the values viewed in “Cycle data”. Open the
”Reporters” menu and select ”1 Screen...” or select the
”reporters-Screen” from the ”System Map”.
1. Click “Variables”
2. Choose Station, Bolt and Step variables by dragging them
from the “Dynamic Tool” window
3. By highlighting the variables the parameters can be
modified
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Use the Help function (F1) for more information.
Event log
After a tightening, is finalised reported events are displayed
in “Event log”. Brief message about the error is displayed.
To open this window – go to the “View” menu and select
“Event log…”
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Traces
Using the Trace function, the tightening can be viewed in a
graph that can, in turn, be used for analysing the program
and optimise the process. Traces can also be compared with
a reference trace for finding deviations in the tightening
process.
View trace
1. Click the “Trace” icon in the Toolbar to open the “Trace”
window
2. Open the “View” menu in the “Trace” window.
3. Select “Latest” to view the latest tightening
4. Set the preferred units for “Bottom axes”, “Right axes”
and “Left axes” to adjust the layout of the trace
Save trace
1. Go to the “Trace” menu and select “Save to file”
2. Save the trace
3. Select the “View” menu and “Selected”
4. Select trace and click “OK” to view the selected Trace
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