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Atlas Copco PowerMACS 4000, User Manual

The Atlas Copco PowerMACS 4000 user manual is available for free download on manualshive.com. This manual provides comprehensive guidance on operating and maintaining your PowerMACS 4000 power tool. Get the manual now and unleash the full potential of your tool with easy-to-follow instructions and troubleshooting tips.

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Appendix 

626 

9836 3521 01 

Code 

Comp 
Code 

Type 

Severity  Event string 

604 

21 

System 

Error 

Bolt %d is connected to invalid spindle %d 

605 

22 

System 

Error 

ST: signal from undefined spindle 

606 

23 

System 

Error 

ST: signal from undefined bolt 

607 

24 

System 

Error 

ST: Data structures inconsistent 

608 

25 

System 

Error 

ST: Telegram %d received in wrong state %d from proc %d 

609 

26 

System 

Error 

Start is impossible since station has no contact with spindle %d 

610 

27 

System 

Error 

Start is impossible since station has no contact with PLC 

611 

28 

System 

Error 

Start is impossible since station has no contact with Test Bolts 

612 

29 

System 

Error 

Unexpected Cycle End when running RM 

613 

30 

System 

Error 

Invalid Bolt number from spindle 

614 

31 

System 

Error 

ST: DB read error %d for bolt %d 

615 

32 

Emergency stop 

Warning 

ST: emergency stopped 

616 

33 

Emergency stop 

Warning 

ST: machine stopped 

617 

34 

System 

Error 

Start is impossible since stations has no contact with syinit 

618 

35 

Setup 

Error 

Cycle data too big, bolt %d not stored 

619 

419 

General 

Info 

Cycle start disabled 

620 

425 

Setup 

Error 

Start is impossible since bolt %d and %d both uses TC %d 

621 

434 

System 

Error 

Station failed to reach TC. Bolt is disconnected (OK) 

622 

435 

System 

Error 

Station failed to reach TC. Bolt is disconnected (NOK) 

623 

436 

System 

Error 

Station starts the cycle even though %d spindles could not be 
reached 

624 

437 

System 

Error 

Station failed to init servo. Bolt is disconnected (OK) 

625 

438 

System 

Error 

Station failed to init servo. Bolt is disconnected (NOK) 

626 

439 

System 

Error 

Station failed to read which cycle data that is wanted 

627 

445 

System 

Error 

Start is impossible since there are conflicting TCs in the station 

628 

477 

Setup 

Info 

Cycle data dropped since no bolt reached report threshold 
torque limit 

629 

544 

Setup 

Error 

ST: BoltControl from PLC has bad value (%d) in mode %d 

630 

545 

Setup 

Error 

ST: Found no program for mode %d in mode table to run for the 
bolt 

631 

552 

System 

Error 

Start is impossible since station has no contact with Station 
service 

632 

560 

General 

Warning 

PLC BOLTCTRL2 cmd %d ignored since no bolts are selected 

633 

561 

General 

Error 

PLC BOLTCTRL2 cmd %d ignored since station is not idle 

634 

562 

General 

Error 

PLC BOLTCTRL2 cmd %d ignored since there is no cycle data 

Summary of Contents for PowerMACS 4000

Page 1: ...User guide PowerMACS 4000 Atlas Copco Tools and Assembly Systems 9836 3521 01 2010 11 Edition 10 3 0...

Page 2: ......

Page 3: ...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...

Page 4: ...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...

Page 5: ...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...

Page 6: ...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...

Page 7: ...rol 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...

Page 8: ...k 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 P...

Page 9: ...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 7 SPC and Statistics 401...

Page 10: ...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 vers...

Page 11: ...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 Alle...

Page 12: ...ndCDQueue 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...

Page 13: ...erties 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...

Page 14: ...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 Surv...

Page 15: ...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 a...

Page 16: ...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 tra...

Page 17: ...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 p...

Page 18: ...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 PM4...

Page 19: ...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 prese...

Page 20: ...lication 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...

Page 21: ...folder ToolsTalk PM4000 Gauging is installed with the file PM4000 10 X X ToolsTalk Gauging exe located in the folder ToolsTalk Gauging After installing ToolsTalk PowerMACS you have up to 90 days to re...

Page 22: ...For more information on differences between these products see Tightening and Gauging Until registered ToolsTalk PowerMACS will display an extra status bar at the bottom of the main window showing you...

Page 23: ...itecture 2 1 System Architecture Overview This section describes the architecture of the PowerMACS 4000 system It includes the descriptions of the hardware components including computers and devices t...

Page 24: ...sTalk If you need to display data from two or more stations at the same time you must design them in one system Multiple PowerMACS systems may be networked together in a single facility but are limite...

Page 25: ...or more torque sensors One or more angle sensors ToolsTalk ToolsTalk PowerMACS is a Windows application used to set up a PowerMACS 4000 system It is not needed for automatic running but it can option...

Page 26: ...bes the hardware structure of a PowerMACS 4000 system i e how hardware components are used Digital I O Sp 1 Sp 2 TC 1 primary TC 2 secondary TC n secondary Sp n Factory Network Ethernet Field bus Seri...

Page 27: ...r more information on how to configure a TC as a System TC and set its IP address Chapter Configure Target System describes a tool for detecting overlapping systems that is several System TCs trying t...

Page 28: ...System Architecture 28 9836 3521 01 The TC board has the following layout Flash PROM RAM CPU Local I O ST bus Serial MACS I O Emerg Stop SRAM Ethernet Battery RTC...

Page 29: ...of set ups traces cycle data etc 2 MB ST bus St bus 2 ch ST bus 1 is for communication with the drive and the spindle located in the tool connector ST bus 2 is for communication with ST based accesso...

Page 30: ...ightening performed by the PTC was NOK ALARM is lit red when a servo or spindle hardware or system error has been detected on the PTC To acknowledge the alarm the PLC variable RESET can be used an att...

Page 31: ...5 MACS I O 9 pole D sub Dig In 10 pole Phoenix 4 Digital inputs Em Stop In 12 pole Phoenix Emergency stop in and MACS I O Relay Out 12 pole Phoenix 4 Relay Outputs 24V input 2 pole Phoenix 24 V input...

Page 32: ...mmon with the LEDs found on PTCs OK is lit green when last cycle tightening performed by the TC was OK NOK is lit red when last cycle tightening performed by the TC was NOK ALARM is lit red when a ser...

Page 33: ...input and output sockets on the TC Em Stop In 12 pole Phoenix Emergency stop in 24V Input 2 pole Phoenix 24 V input Int Eth RJ45 Internal Ethernet ES 2 pole JST Power Supply for Ethernet Switch only...

Page 34: ...system Default Menu The default menu contains two view items you can select which view by pressing the up down buttons the two middle soft buttons Press the Setup button to go to the Setup menu and th...

Page 35: ...n the settings press the Up Down buttons To edit a setting press the Change button when editing it is possible to Store the new value or Cancel the editing The picture below shows an example editing t...

Page 36: ...Default gateway for interface 2 PTC only Note It is possible to lock the display from the system node in the system map in ToolsTalk PowerMACS If the display is locked it is not possible to use the di...

Page 37: ...enu is grouped by TC Servo and Spindle Information Menu Description TC Info System Type System Type PowerMACS Tightening Appl Ver PowerMACS Application Version Boot Ver PowerMACS Boot Version PCB PCB...

Page 38: ...ict with software versions 7 3 0 or higher the Automatic download function takes care of that problem and the messages shown is as described in the chapter Automatic Download If a Spindle TC with soft...

Page 39: ...is 10Base TX i e twisted pair max length 100 m By use of commercially available products it is possible to build a network with optically isolated components Via a router other computers in the facto...

Page 40: ...device Communication via serial protocols Communication via fieldbus interface Communication from an external PC based application using the PowerMACS API Application Programmers Interface Except for...

Page 41: ...th a TC that has different software loaded and to automatically update the software in that TC with the same as the rest of the system 2 4 2 General function The purpose of the Automatic Download func...

Page 42: ...ses Yes the following control text appears on the TC panel Fig 2 Yes No Version conflict Press Yes if this TC should be updated Press No to return to the previous level Ver Conflict Update Software If...

Page 43: ...lid setup the System TC continues to check for any software version conflict among TC3 TCN If one or several Spindle TCs are found with a different software version the above described dialog appears...

Page 44: ...servo is automatically updated with the newer version During the update of the servo software the following message is shown on the TC panel Updating Servo software Updating Indicates that the TC is...

Page 45: ...ng the update of the spindle software the following message is shown on the TC panel Updating Spindle software Updating Indicates that the TC is updating the spindle software It is also possible to do...

Page 46: ...System Architecture 46 9836 3521 01...

Page 47: ...Basic Functions 9836 3521 01 47 3 Basic Functions 3 1 Basic Functions Overview This part covers the basic functions like how to handle windows and screen security help etc...

Page 48: ...w the title bar there is a menu bar When selecting one of the menus it drops down and you can see a set of menu items or menu choices Tool bar Below the menu bar you have a tool bar This contains butt...

Page 49: ...hat belongs together Button Carries out a command when pressed Check box Represents parameters of Boolean type that is that either are True or False Radio button Represents multiple choices from which...

Page 50: ...e the factory default view from here and save your own view configuration If you have a number of windows on the screen at the same time you can get these rearranged in a structured way Use the menu c...

Page 51: ...will automaticly display detailed help about certain items you are working on For example it will automaticly show the help text for the selected step in the tightening window Help menu It is also pos...

Page 52: ...are also used in connection with setups Handling setups are described in chapter Set Up and Maintenance Page setup and Print is used for printing of setups See chapter Printing Security Login and Logo...

Page 53: ...ows previous setups that has been opened recently Select one of these to get an instant opening of it instead of using the Open item Use Exit to shut down the ToolsTalk PowerMACS application If you ha...

Page 54: ...s window it is possible to select Create a new setup to begin working on a new setup in disconnected mode select Open an existing setup to open an already saved setup from disk The option Select a tar...

Page 55: ...1 Make sure your console computer is connected to the network of the system in question 2 Press the Connect button on the toolbar To connect to a specified system This is how you start up ToolsTalk P...

Page 56: ...displayed Select Write to TC to transfer the setup currently loaded in ToolsTalk PowerMACS to the target system The target will wait for any ongoing cycles to be completed before the setup is loaded...

Page 57: ...use of the menu View or by pressing one of the corresponding buttons on the tool bar 3 6 1 Assembly Overview The Assembly Overview displays current status of the system its stations and bolts using a...

Page 58: ...ll be green and disconnected NOK bolts will be red For bolts only If you want more information on the stations or bolts expand the box by clicking on the box of interest The information that is displa...

Page 59: ...he bolt boxes background color is updated to show the status of the finished cycle Note The station box is still yellow to indicate that the complete tightening cycle is not yet finished and that ther...

Page 60: ...the PLC station output variable MODE see Station variables If a cycle is running when the Mode number changes the Station View is not changed until the cycle is finished If the Mode number changes to...

Page 61: ...l parts but also as a navigation tool within the system The default location for the System Map is on the left side of ToolsTalk PowerMACS but it can be placed anywhere on the screen When first starte...

Page 62: ...e Blue Bolt is disconnected This color is only used if the checkbox Display disconnected bolts with blue color in the Options form is checked If not checked then disconnected OK bolts will be green an...

Page 63: ...Basic Functions 9836 3521 01 63 Problems with equipment hardware or devices are indicated with a red cross over the icon For certain devices Online info is shown below the Details window...

Page 64: ...em TC If the Advanced button is pressed you can specify the format settings by pressing the Layout button if you want to present just specific cycles press the Settings button the following frame will...

Page 65: ...s where at least one bolt has executed the selected program Cycle data can be saved to file when pressing the Get cycledata button Select a file to save the data to or type a new file name The data wi...

Page 66: ...am With the cursor you can mark a specific part of the trace to zoom in Place the mouse pointer on the upper left corner of the area you want to enlarge Press the left mouse button and drag the mouse...

Page 67: ...rm trend If Cp or Cpk is not presently within limits a warning message is presented If you select Histogram you will be presented the following view This form displays the frequency distribution of th...

Page 68: ...r each individual bolt s tightening cycle a trace can be generated and recorded The maximum length of a trace is 20 seconds If a trace is recorded for longer time than 20 seconds the oldest values wil...

Page 69: ...e Views the recorded angle values Current Views the recorded current values Current as T Views the recorded current values scaled as torque using the values of the spindle setup parameters Gear Ratio...

Page 70: ...it for each trace can be found in the identity list This list is displayed by clicking on the button Identity The second torque and angle channels are only available when the following conditions are...

Page 71: ...As dialogue where you specify the name and the format of your file Chose extension trc Trace Files to save it in PowerMACS internal format or extension txt Text Files to save the trace as a text file...

Page 72: ...e area to zoom in and release the mouse button This will cause the graph to be redrawn displaying only the selected area Click on the right mouse button to zoom out Scroll When the graph is zoomed in...

Page 73: ...on the graph The point on a curve that is nearest to the mouse pointer is selected and marked with a black dot The information that belongs to the actual curve is displayed with black text Other infor...

Page 74: ...ill having several others displayed Change the selected trace to highlight another trace This makes it possible to browse through all traces viewing them one by one Show Tightening limits and paramete...

Page 75: ...ts are displayed when Torque over Time curves are viewed angle limits are displayed when Angle over Time curves are viewed monitoring limits and other checks that measure torque vs angle are displayed...

Page 76: ...is used on either a vertical axis or the horisontal axis you can select to show the step angle instead of the cycle angle with the checkbox Show Step Angle The step angle starts at zero degrees at the...

Page 77: ...cle Data If you select View Extras Show cycle data the lower part of the window is expanded and displays more data Press the Layout button to set up the layout of the cycle data This will invoke the T...

Page 78: ...onditions If you select Torque matching will be done where the traces have reached the same level of torque The level is specified in in the field next to the alternative If you e g specify 50 the tra...

Page 79: ...ange color of many traces at the same time hold down the CTRL key and click on the traces to select them Then click on one of the selected traces colored button to the left Note It is only possible to...

Page 80: ...ent colors Normally traces are from the most recent cycles Traces that are tagged for save will be saved indefinitely The save tag can be switched on and off by use of the Save Unsave buttons for any...

Page 81: ...akes it more easy to see how reject management procedures affected a cycle To display the tightening path for a cycle either select a cycle data by pressing the Select Cycle Data button or select one...

Page 82: ...or 8 Internal communication errors etc Ext com error 9 No response to many retransmissions etc when communicating with external equipment SPC 10 SPC events 7 up 7 down etc Setup 11 Erroneous configura...

Page 83: ...d to a particular bolt Optional The Angle Channel if relevant for restriction check and monitoring events Possible values are M Monitoring C Control 1 2 Channel number Optional The Torque Channel if r...

Page 84: ...red check mark in the leftmost column If you press the Setup button the Event Log Setup window is opened where you can specify which event types and or Severities to display You can also include just...

Page 85: ...rMACS is connected you can display the current status of all digital inputs and output connected to a particular TC Use menu choice View IO to open the IO Map form You can also open it from the Hardwa...

Page 86: ...lk PowerMACS The files are placed in special directories depending of the type of reporter For example API reporters are placed in the directory ToolsTalk PowerMACS install dir Reporters API and scree...

Page 87: ...k PowerMACS requires ToolsTalk PowerMACS to be connected Excel File sent to an Excel file via ToolsTalk PowerMACS requires ToolsTalk PowerMACS to be connected Printer to be printed on a line printer d...

Page 88: ...CS is running on If Excel cannot be started the data is written to a text file with extension txt instead This text file is formatted in a format suitable for Excel To import the text file from Excel...

Page 89: ...hat If predefined reporter settings files exists in the directory for the currently selected reporter type see Predefined reporter settings you have the option to select predefined settings for the ne...

Page 90: ...6 3521 01 3 7 3 Remove reporter You can remove a reporter by menu item Reporter Remove Select a reporter and press Remove You can also delete reporters by right clicking on them in the system map and...

Page 91: ...r All stations if data generated by all stations should go to the device Use the Binary Printable combo box to select if the data should be formatted as binary or printable output The controls grouped...

Page 92: ...to include all traces with bolt status NOK only reporters capable of traces Check Disconnected bolt included if you want such bolts to be included in the output For presentation on devices that can h...

Page 93: ...ut it is also possible to browse freely for any predefined reporter settings If the chosen predefined reporter settings contain parameters that are not available or configurable for the currently conf...

Page 94: ...als Specifies the number of decimals to print Only valid for variables of numerical type and when format is Printable Data Printable selected Width Defines the width of the field in number of characte...

Page 95: ...uded in the result However this does not automatically mean that the variable will be measured Most of the variables correspond to values measured by bolt monitoring and step checks Whether these chec...

Page 96: ...he internal ordinal bolt number and not using the user defined bolt number A particular variable is always printed at the same position for a given bolt regardless if the cycle result contains data fo...

Page 97: ...and time formats is displayed in the status bar at the bottom of the Reporter form For reporters configured to format the result binary Data Binary selected you can also Control byte order of all num...

Page 98: ...box on the Step data tab Select Execution order to print the steps in the order that they are executed and Step number to have them ordered in ascending step number order 3 7 4 3 Cycle Data layout ex...

Page 99: ...2 4 A 125 Step No 2 Peak T 15 2 A 310 Bolt No 2 Bolt T 2 5 Bolt A 436 Status OK Step No 1 Peak T 2 5 A 124 Step No 2 Peak T 15 2 A 312 Station Stn 01 Time 011030 09 40 22 Status OK Bolt No 1 Bolt T 15...

Page 100: ...11030 09 40 58 OK 1 15 1 435 OK 1 2 4 125 2 15 1 310 2 15 2 436 OK 1 2 5 124 2 15 2 312 Stn 01 011030 09 41 10 OK 1 15 1 435 OK 1 2 4 125 2 15 1 310 2 15 2 436 OK 1 2 5 124 2 15 2 312 Station Time Sta...

Page 101: ...ak T A 1 15 1 435 OK 1 2 4 125 2 15 1 310 2 15 2 436 OK 1 2 5 124 2 15 2 312 Station Stn 01 Time 011030 09 40 58 Status OK 1 15 1 435 OK 1 2 4 125 2 15 1 310 2 15 2 436 OK 1 2 5 124 2 15 2 312 Station...

Page 102: ...h Dec Text Station 8 yes Time 24 yes Status 9 yes New Line Bolt variables Variable Width Dec Text Bolt No 8 yes New Line Bolt T 7 1 yes New Line Bolt A 7 yes New Line Gives the following print out for...

Page 103: ...reporters it is possible to preview how the generated data will be formatted It is possible to adjust the preview according to a station and mode number It is possible to hoover with the mouse above...

Page 104: ...erity included frame check the severities you want to pass to the device controlled by this reporter See View Event Log for a description of event types and severity In the Data included for event whe...

Page 105: ...cters to be sent to the Reporter AFTER the main data you can specify character strings that will surround each cycle data result printed Here you may also include non printable characters Typing their...

Page 106: ...Read access Read and write access 3 8 1 Registering groups Use menu item File Security Groups to register a new group ot to check or change data for an existing group By default every setup contains o...

Page 107: ...n possible to select access level for each ToolsTalk PowerMACS window by selecting the access level in the Form Access list 3 8 2 Registering users Use menu item File Security Users to register a new...

Page 108: ...access preferable the group No Access should be used 3 8 3 Login and Logout When a new user is about to start to work with the system he should log in This can be done in either of the following ways...

Page 109: ...on the Console for ten minutes the system will make an automatic log out If you have made changes to the system and you log out you will automatically be asked to enter a message in the Service Log Y...

Page 110: ...y clicking on these while holding down the CTRL key on the keyboard Press Select all to select all tables of the selected type Press Select changed to print all tables that have been changed since las...

Page 111: ...ntain the system Note Be careful when changing data in setups If you are connected and your system is running a change will affect the system immediately when you press the Apply button in the current...

Page 112: ...e system or uploaded for storing or modification Most items on the File menu handle setups Use the New item to create a completely new setup This is described in chapter Set up of a new system With th...

Page 113: ...later version by clicking Convert in the File menu Both the setup and the PLC program can be converted to a later version It is only possible to convert the PLC program if the newer PLC environment is...

Page 114: ...re 7 5 0 setup to version 7 5 0 or newer the following rules apply for moving PLC variables from the shared area Inputs 1 Variables mapped by any I O device a If name starts with SI_ variable is left...

Page 115: ...e Shared_Variables group and removed from the Fieldbus mapping This means none of the signals in the array will be available after the conversion If wanted the whole array can be moved back to the fie...

Page 116: ...and downloads the setup Note You should take as a rule to always create a new setup using the Wizard since it automatically generates a setup that not only is valid but also contains a PLC program 4...

Page 117: ...es in the Station Enter in Default Spindle type that you have in your system If you have more than one type select the alternative you have most of You can later individually change these values Press...

Page 118: ...TC corresponding to it Press Next If you specified fewer spindles than bolts in the second wizard dialog you will be displayed the following dialog Use the combo boxes in the Spindle column to select...

Page 119: ...ber of modes selected You can select predefined programs located in the installation directory for ToolsTalk PowerMACS under the subdirectory Programs Checking the Generate SPC Setup check box will co...

Page 120: ...t of the system like printers fieldbuses etc In the listbox all stations and devices are presented If you want to change the name or any other parameter for a device select the device and press Edit T...

Page 121: ...orter data for just This station or for All stations If predefined reporter settings files exists in the directory for the currently selected reporter type see Predefined reporter settings you have th...

Page 122: ...ctory for the reporter in question By default this dialog is not displayed Press Next to display the last wizard dialog Mark boxes if you want a Checklist on printer or Checklist on file In the latter...

Page 123: ...and angle for each of the bolts A reporter for the ToolsTalk PowerMACS screen and a printer connected to the CC A PLC project containing one POU Program Organization Unit and one resource with one tas...

Page 124: ...ta for the selected item for more complicated items an Open button is displayed that will open an item specific dialog You drag and resize place the Details window as you feel most comfortable Data in...

Page 125: ...doing major structural changes to your system 4 4 1 Logical view The nodes under System displays the logical items in the setup The System is displayed in a tree structure with the System node as the...

Page 126: ...get System When Unlock TC panel is checked it is possible to use the TC panel to make settings and changes otherwise the panel is locked and it is only possible to view information If Backlight auto o...

Page 127: ...Set Up and Maintenance 9836 3521 01 127 See chapter Station Set Up for a description of the parameters...

Page 128: ...disconnected In the latter case you can also chose if it should be reported as OK or NOK Bolt type is a free text that identifies the type of the bolt This information is used for the result variables...

Page 129: ...am to remove a program right click and select Remove Program 4 4 1 5 Reporters node Clicking on the Reporters node will in fold unfold a list of all reporters defined in the system A reporter can be o...

Page 130: ...ardware node The Hardware node of the System Map contains all hardware in the system this node is the primary resource when configuring or monitoring the hardware configuration The tree level below Ha...

Page 131: ...network If downloaded to several TC s all will get the same external IP address which will lead to an address conflict in the network Note 2 There can only be one gateway specified in a TC If a corre...

Page 132: ...a predefined Reporter exists for the device type added you will be offered to choose one of them see Predefined reporter settings for how to add your own If a reporter is added it must also be configu...

Page 133: ...e Spindle This name will identify the Spindle in cycle data reports etc and may be up to 20 characters long Use the Spindle type combo box to change the type of the used spindle Note Changing spindle...

Page 134: ...the selected device type For most devices all parameters are displayed in the Details window Devices that have many parameters make use of a specific form to access these For such devices an Open butt...

Page 135: ...o 20 characters long The Advanced Reject Management if settings are described in the functional description for Tightening see chapter Advanced RM Actions Normally the Hold Torque step stop condition...

Page 136: ...e to a communication error Ethernet or a servo error Set Max no of bolts to disconnect to the maximum number of bolts that may be disconnected automatically due to communication or servo errors Possib...

Page 137: ...the System Map when the selected node is a Station alternatively it is possible to right click on a station and select Advanced Station Settings from the popup menu From this form you can set up which...

Page 138: ...By adding a Conversion table you may have the identifier string automatically translated to a numerical value or code This code is then available to the PLC as the input IDCODE and can for example be...

Page 139: ...not possible to use an id device or the six PLC outputs PLCx_IDTYPE_STR together with an AudiXML device If the station has an AudiXML device attatched possible input sources for the identifier types...

Page 140: ...d to the Types if they are ambiguously defined The Identifier types included in the Work Order must be received in the order that they are listed to be accepted If there is at least one Type in the Wo...

Page 141: ...dentifier Types are cleared when a cycle is started from the PowerMACS PLC That is accepted identifiers can only be used once To include them in a following cycle their respective source must be initi...

Page 142: ...unobserved events in the Event Log This information is available via the inputs xxxEVENT SPCEVENT ACCESSEVENT etc See View Event Log for a description of the different Event types and the PLC chapter...

Page 143: ...RegularExpr Expression OptExpression OptExpression Expression OptExpression NOTHING Expression See table below OptRangeCheck TagRef RelOp IntegerValue OptRangeCheck NOTHING TagRef N where N is a numb...

Page 144: ...ck Example A Conversion table with Significant positions set to 1 10 24 and the following Significant string Code pairs Significant string Code L 1 11 L 2 12 S 1 21 S 2 22 AB ddd ddd 1 300 2 700 1 AB...

Page 145: ...spindle in the System Map The controls on the Spindle Set Up form is divided in several pages Each of these is described in the following subsections 4 6 1 General page The General page holds the most...

Page 146: ...in controls the measuring on Torque Channel 1 Normally a spindle with a 50Nm transducer should have a scalefactor of 50 at Gain 1 0 If the spindle has a second torque channel equipped it is possible t...

Page 147: ...ecting one of the items PLC P1 to PLC P5 which corresponds to the PLCs Station variables output GENOUT_1 to GENOUT_5 respectively If the selected PLC output is set to 1 then the spindle will run forwa...

Page 148: ...e checked when an external gearbox or similar equipment is connected to the spindle The following frame appears when external equipment is enabled Use the checkbox Equipment Inverses Direction if the...

Page 149: ...ossible to configure the double transducer check here This page shows basic properties for each equipped angle channel it is possible to Disable the secondary Angle channel if equipped 4 6 4 1 Angle D...

Page 150: ...pecify your own limits The Spindle defined limits are only displayed when ToolsTalk PowerMACS is connected to a system It is possible to override the spindle configured transducer check for specific s...

Page 151: ...ws basic properties for each equipped torque channel including the Current channel it is possible to disable any channel here by unchecking the Enabled checkbox Filter Hz is the cut off frequency of t...

Page 152: ...ACS is connected to a system It is possible to override the spindle configured transducer check for specific steps by using the Torque Difference restriction Note The torque diff check is not executed...

Page 153: ...test These limits are stored in the physical spindle To make a change enter wanted values and press Store to spindle 4 6 6 1 Static Zero Offset To a large extent you can eliminate torque measuring er...

Page 154: ...diagnostic step is started but first after that the Time from cycle start to measuring has elapsed The average value is calculated during Measuring time The absolute value of the measured offset shoul...

Page 155: ...the backward direction Measure average torque and angle pulses in both directions IF Dynamic Zero Offset test THEN Check the measured Dynamic Zero Offset Save as Zero Offset compensation value if with...

Page 156: ...ervice enabled ToolsTalk PowerMACS it is possible to Motortune a spindle Press Start Motortune to begin the motortune operation note that the spindle will run at a very high speed so it is absolutely...

Page 157: ...ests are always considered Fatal Transducer overload protection Spindle Protection This test supervises that the torque measured on the monitoring channel does not exceed the maximum allowed torque fo...

Page 158: ...8 8 chan Digital output module 1 8 chan Digital output module max 8 8 chan The maximum configuration on the local I O bus is six nodes Each node can have a maximum of 64 inputs and 64 outputs However...

Page 159: ...ing eight inputs or outputs If you have one block specify 1 8 signals If you have two blocks specify 9 16 signals and so on Beside every input or output signal there is a combo box With this you can s...

Page 160: ...here is one Name of signal 828 891 if there is one 4 No default is set up No default is set up 5 No default is set up No default is set up 6 No default is set up No default is set up Note The PLC sign...

Page 161: ...p the local I O add an I O device to the setup and open the I O form The Local I O is mapped by selecting PLC signals in the comboboxes in the form like for the other I O nodes As default I O node 1 i...

Page 162: ...nformation read from an ID device may be added to the tightening data as the station level result variable Wp ID or the Multiple identifier result variables ID Res x See description of Work piece iden...

Page 163: ...ked using the Set Up Assembly Overview menu item When selecting the Set Up Assembly Overview item two forms are displayed First the Assembly Overview Set Up form and secondly the Assembly Overview for...

Page 164: ...combo boxes on the Station Box tab to define which result variables to display in the Station box The combo boxes on the Bolt Box tab controls which of the result variables that are displayed in the...

Page 165: ...commended to enable these settings Do so only if you have problems to get an existing set up to work as you want Enabling Use Station View 1 for unmapped Mode numbers including Mode number 0 will caus...

Page 166: ...x When the mouse pointer changes to a vertical arrow pointing upwards press the left mouse button and reposition the box To change the sizes of a box move the mouse pointer to the lower right corner o...

Page 167: ...The form contains 190 rows on which either a parameter or label can be defined Labels are used only to make the layout of the form easier to read they are not accessible from the PLC For each row you...

Page 168: ...m amount that can be stored given the selected settings The checkbox Use only TC1 for CycleData Storage is used for backward compatibility and disables the distributed storage if checked Press the Def...

Page 169: ...a so called Language file To add support for a new language you just have to copy a file supporting the language in the same directory as your ToolsTalk PowerMACS is installed in The file should have...

Page 170: ...or long cycles e g for gauging More samples will though decrease number of traces saved in the trace memory Use Date format and Time format to select the standard for how date time variables should be...

Page 171: ...t setups Their respective default values are English and not checked 4 12 1 Set Customer step names Click on Set Customer step names to display a window where customer specific step names can be defin...

Page 172: ...eries specified in the step pointed to by the result variable Failing Step number that is used for the conversion Only the errors that occurred during that step is used not any additional errors that...

Page 173: ...le ends OK or OKR and Code to use when cycle ends NOKRM to specify these respectively To always be able to determine if the cycle ended OK or not a value must be specified for the OK OKR case if any e...

Page 174: ...umber of messages are displayed Every message is a classified as either an error or a warning If Show only errors is checked only the messages classified as errors are displayed Note that the window i...

Page 175: ...or example a bolt a reporter etc A table can be moved from one setup to another by using the Table Export and Import functions by first exporting it from the first setup and then importing it into the...

Page 176: ...lay the Import Table form First select the type of table to import using the Table combo Use the Source frame to specify which table file to import Specify in the Destination frame exactly to which in...

Page 177: ...type of table to copy Depending on type of table you can then in the Source frame specify which table you want to copy Use the fields in the Destination frame to specify where to copy the table data F...

Page 178: ...ting them with the latest setup manually A backup copy of the setup is always kept on TC 2 in a system in case the System TC needs to be replaced 4 16 1 Backup of the setup The purpose of the backup f...

Page 179: ...hen the system starts using the copied setup 3 Ok Empty First the setup is copied from the System TC to TC 2 Then the system starts using setup originally stored on the System TC 4 OK OK and identical...

Page 180: ...you should make sure that the setup stored of the new TC is cleared before it is inserted in the system especially when replacing the System TC or TC 2 Clearing the setup stored in a TC is done using...

Page 181: ...current and angle measuring see Calibration Event Statistics gives you an overview of the most frequent alarms Service Log opens a logbook Use it to log all your service actions Replace ID String dis...

Page 182: ...o each other Programs that have different names are not compared to each other The differences are displayed using different colors and text style as follows with item can be a step a check or a param...

Page 183: ...rogram currently loaded This means that the result presented not necessarily correspond to the exact sequence of changes done by the operator For example if the operator first have deleted a step of t...

Page 184: ...ystem TCs that for some reason are logically grouped together Each PowerMACS system in the network is identified with the IP address of its System TC and free textual description The main purpose of t...

Page 185: ...icate with the System TC first TC in a system so therefore only one selection need to be made Choose TC Simulator if you do not have a real target system to connect to but still want to demonstrate th...

Page 186: ...The hardware Emergency input is inactive for the TC that executes the station PLC station input EMERGSTOPIN True The selected stations PLC output DISABLE_TESTBOLT is set True See also the description...

Page 187: ...Torque Angle or Current Use the controls in the Run conditions frame to define the direction and speed to use when executing the step Speed can also be specified as target If so then the bolt s will r...

Page 188: ...ntinue to alternate cycles between Program 1 and Program 2 Press Stop to stop any on going execution Running a program produces Cycle Data and Statistics just as if the bolts where executed by the Pow...

Page 189: ...bo boxes are filled with the modes that are relevant with respect to the currently selected Bolt If All is selected they will include all modes without Program from PLC of the station If a specific bo...

Page 190: ...thod 3 The joint is not a real screw joint It could be a mechanical part with a welded bolt head or similar Method 4 1 Program a torque x Nm and the speed 0 zero rpm Apply a torque wrench to the inlin...

Page 191: ...arget value Reset the statistics Click on the Start button If you use the Stop function the spindle will stop and a Machine Stop will be generated in the Event Log Note When you use the single run fun...

Page 192: ...Mode Using the Mode option is similar to the Program one The difference is that in the Mode option it is possible to run different tightening programs for different spindles As we normally recommend...

Page 193: ...ean final torque Xmean Xmeanref SXrefn n where n is the number of tightenings Xmean SXn n where n is the number of tightenings Adjust the spindle parameter Scale factor for channel Torque 1 Ts see Spi...

Page 194: ...trace capability for example an Atlas Copco IRTT transducer with ACTA There are two methods of checking the angle measuring 1 Rotating the spindle in the air Program a set angle value in the Test Bolt...

Page 195: ...t cases not necessary to change Calibration of the Wind Up Coefficient It is fairly simple to check and to calibrate the Wind Up Coefficient Create a simple tightening program that has a Diagnostic st...

Page 196: ...ng like the example shown below As you can see now is there a lash in the socket of about 0 8 deg and then the torque increases to 45 Nm without moving the bolt and this is the goal Note When external...

Page 197: ...tor for all current control The unit of the T C factor is torque_unit A and a theoretical value based on the motor data is used as default setting The value of the T C Factor can not be changed since...

Page 198: ...One bar is displayed for each event code of which there is at least one error For a list of possible event codes see chapter List of events The event statistics are stored in the system in accumulator...

Page 199: ...be stored both on disk and in the target system When you open the Service Log the titles of all existing logs are listed in the top list box labeled Title while the text box labeled Message displays c...

Page 200: ...by the system just as if it was scanned using the barcode scanner This means that it is automatically sent to the Station and its PLC visible as CURRIDSTRING see Station variables and is stored in the...

Page 201: ...conds and results in a list of TCs that where reached by ToolsTalk PowerMACS For each TC the following information is always displayed The current IP address on both interfaces The current Status of t...

Page 202: ...d again 4 17 7 1 Advanced mode When not in advanced mode the form shows only the most basic functions Advanced mode is reached by clicking the Advanced button on the toolbar Advanced mode makes the fo...

Page 203: ...formation fields The information fields are divided into groups Default Spindle SW Spindle Info Servo TC SW TC HW and IP Addresses When klicking on a group in the View menu the list is refreshed to on...

Page 204: ...l no Sp HW ver Sp cycles Sp cycles since service Sp cycles to next service Servo Servo SW Servo SW in TC Servo boot Servo HW ver Servo serial no TC SW TC SW TC boot Telnet IP addresses Internal net ma...

Page 205: ...egardless of their IP address configuration However this does not mean that you can connect to or send all configuration commands to all TCs displayed in the list The reason for this is that the norma...

Page 206: ...the TC must be restarted Turning the power off and on again is the normal way to do this But if at least one TC accepts the request you will be offered the possibility to restart those TCs remotely Yo...

Page 207: ...ot loader is duplicated to increase the safety when updating the boot loader part This gives each TC dual boot loaders named Boot 1 and Boot 2 At start up Boot 1 is responsible for checking that Boot...

Page 208: ...ote It is important that you do not interrupt the download process when started If that happens by accident while downloading boot software you should not restart the TC Restarting it may cause the bo...

Page 209: ...manually ensure that the Default Gateway belongs to same network as all the TCs Click OK to send the new values to the TCs The result of this request is displayed in the Configure Target System form...

Page 210: ...n a individual TC The SPC data for a bolt is stored on the TC that controls the spindle used to tighten the bolt Trace data on all TCs or on a individual TC The Trace data for a given bolt is stored o...

Page 211: ...nt names are not compared to each other The differences are displayed using different colors and text style as follows with item can be a step a check or a parameter of these An item that exists in Se...

Page 212: ...used for comparing the two programs strives to find the smallest edit script needed to change the program on disk to become equal to the program currently loaded This means that the result presented n...

Page 213: ...rently connected to and only when connected ToolsTalk PowerMACS continuously listens for telegrams multicast sent from a TC System TC or Spindle TC that has detected a version conflict that is a Syste...

Page 214: ...e Target System describes for how to download new TC System Software Prepare TC for download of software and how to configure a TC as a System or a Spindle TC The TC HMI Menu System 4 17 11 TC Crash L...

Page 215: ...and interface to the PowerMACS system is given in the next two chapters General and System Globals The basics on how to write a program are given in the Programming the PLC chapter while a small but...

Page 216: ...PLC program and the ToolsTalk PowerMACS application running on the Console Computer See chapter PLC Console for a detailed description of it From Digital I O the PLC can read digital inputs push butt...

Page 217: ...PLC 9836 3521 01 217 The Cycle Data interface makes it possible to read data produced as cycle data result See the description of PLC in chapter Peripheral Devices for how to enable this function...

Page 218: ...ad the cycle data without delay This might be useful for external devices that need to know when they can expect the result of the last cycle is available SYSTEMSTATUS INT Indicates system errors The...

Page 219: ...nput is True when there is unobserved SPC events in the event log see View Event Log ACCESSEVENT BOOL This input is True when there is unobserved Access events in the event log see View Event Log POWE...

Page 220: ...ive bits have the following meaning bit 0 is the least significant 0 value 1 Servo NOK 1 value 2 Communication NOK 2 value 4 Over temperature 3 value 8 Spindle not ready 4 value 16 TC out of order 5 v...

Page 221: ...OF DINT Reports number of cycles before service should take place DEVICE_CTRL ARRAY 0 31 OF DATAHOLD DATADROP Controls device queue DataHold DataDrop Result False False Cycle data is saved for this de...

Page 222: ...Variable Type Use PLC_DI_1 10 BOOL These signals can be set at specific times directly from the tightening programs e g at step start or zone end See Ramps Other Signals at step start and end only av...

Page 223: ...Next positive edge on START will start a new cycle MONSTART BOOL Start monitoring Set to True to start monitoring of the spindles This signal is ignored if the station is not idle MONEND BOOL End moni...

Page 224: ...ToolsTalk PowerMACS Test Bolt form for this station See also chapter Test Bolts ACKACCESSEVENT BOOL Set this output True to mark all events of type Access as observed see View Event Log and PLC Event...

Page 225: ...events are not generated INTERMEDSTART BOOL In each step it will be possible to select if the station shall continue with the next step directly at step end or if it shall wait for the PLC to continue...

Page 226: ...e standard PLC program that is generated by the wizard contains signals outputs and functions to support this It is off course possible to alter the PLC program to use other means or input rather than...

Page 227: ...PARAM_ARR This is an array of 130 parameters of type INT 16 bit signed integer defined and modified using the ToolsTalk PowerMACS forms PLC Parameters Set Up and PLC Parameters They can be used to mak...

Page 228: ...nt flags are set Use this variable together with STATIONSTATE as an alternative to the STATIONSTATUS input STATIONSTATE STATION_STATE_ TYPE This variable indicates the current state of the station It...

Page 229: ...API device in the system is erroneous IDDEV True if any ID device device in the system is erroneous PRINTER True if any TC printer device in the system is erroneous TOOLSNET True if any ToolsNet devi...

Page 230: ...lable in CycleData_Var It can be set False by the PLC program to be able to check when new cycle data has arrived UPDATE_EXTCO_2 BYTE When this variable is written with a positive flank 0 1 all variab...

Page 231: ...rted bolt errors for each of the bolts The respective bits have the following meaning bit 0 is the least significant 0 value 1 THM Torque High Monitoring 1 value 2 TLM Torque Low Monitoring 2 value 4...

Page 232: ...the first case the bolt will be reported with the given status and in the latter nothing is reported for the bolt In neither case will the bolt start when the station is started The outputs BOLTCONTR...

Page 233: ...ble is an array of 50 elements of type BOLT_STATUS_EXT_TYPE Each element indicates the status of the last tightening for a bolt The BOLT_STATUS_EXT_TYPE is a structure containing the following BOOL fl...

Page 234: ...ted normally and is idle that is it is not disconnected or ordered not to run and is not executing a cycle RUNNING True if the bolt is running a cycle that is it is not idle This includes running reje...

Page 235: ...replace the ID string currently known by the station with the value of IDSTRING If the station is connected to an ID device this device will be used to generate a corresponding IDCODE The written valu...

Page 236: ...CODE INT Code generated by the Conversion table defined for Identifier Type 1 IDTYPE_WO_STATE BYTE Work Order State A number between 0 and 4 indicating the latest accepted item in the Work Order list...

Page 237: ...er sequence to its initial state IDTYPE_WO_STATE 0 IDTYPE_RESET_LAST BOOL A positive edge resets the last accepted Identifier Type This will clear the string corresponding to the Identifier Type IDTYP...

Page 238: ...de 1 8 mapped to Mode bit 0 value 1 PARSET2 Parameter set code 1 8 mapped to Mode bit 1 value 2 PARSET3 Parameter set code 1 8 mapped to Mode bit 2 value 4 REVERSE Reverse tool cycle Uses mode 9 for t...

Page 239: ...Parameter set code 1 8 confirmation Mapped to Mode bit 0 value 1 PARSET2 Parameter set code 1 8 confirmation Mapped to Mode bit 1 value 2 PARSET4 Parameter set code 1 8 confirmation Mapped to Mode bi...

Page 240: ...Talk PowerMACS Set to TRUE for station type SAW and to FALSE for the other types Only available for backward compatibility reasons it is recommended to use PLUS_STATIONTYPE instead PLUS_STATIONTYPE IN...

Page 241: ...ING will have the letters PN or KN added as a prefix to the string received from PLUS If Station Type in the PLUS device is different from SAW WIS nothing is sent to PLUS Instead the string in PLUS_BA...

Page 242: ...cycle data is removed from the Cycle data queue for the PLUS device used for the station PLUS_DROP BOOL If PLUS_DROP is high when cycle data is stored for a cycle no data is written in the Cycle data...

Page 243: ...e global variables Variable Type Use SYSTEMGLOBAL INT For communication between PLCs on different stations The variables are declared as a shared memory and can therefore both be read and written to b...

Page 244: ...station is idle that is not executing a cycle The current cycle data must also include at least one result record for each of the bolts selected In addition to the general result values the following...

Page 245: ...NOTIMPL Command not implemented unknown value of BOLTCTRL2_CMD 4 STNNOTIDLE Station is not idle many commands may only be executed when the station is not running a cycle Note Values are only returned...

Page 246: ...one either since the retightening of bolt B1 and B2 ended OK or that no more attempts are allowed releases the produced cycle data by setting DATAHOLD to FALSE The cycle data produced using the above...

Page 247: ...ARRAY 1 1000 OF BYTE Additional command parameter data Layout and usage depends on the targeted device and command See table below for specification Currently only devices of type Printer are supporte...

Page 248: ...us of the DEVCMD command 0 Idle and OK Command completed OK 1 Idle and NOK Command failed 2 Busy executing the command Note The operation is not complete until this signal is 0 or 1 if it fails After...

Page 249: ...the PowerMACS setup file It has the same name as the setup file but the extension ZWT2 instead of PM4 For a two station system the PLC project tree displayed when the PowerMACS PLC editor is opened w...

Page 250: ...s executed by the resource The variables defined on Global_Variables are divided in the following groups Default and Global_Variables Consists of a number of PLC internal variables that can be used fo...

Page 251: ...is given two examples of this After editing the program you must compile it before it can be downloaded This is done using the item Make in the menu Build If your program contains any errors you will...

Page 252: ...odifications you can download the program from inside the PLC This is done using the following sequence Open the Project Control dialog from the Online menu Stop the execution of the PLC by pressing t...

Page 253: ...e project from inside the PowerMACS PLC does not implicate cause the PLC project to be saved together with your setup on disk To do that you must you choose Save or Save As from the WinTC File menu No...

Page 254: ...puts and outputs in the PLC as described in the tables below See also the Station variables chapter PLC In Type Connected to PLC Input Cons In 1 BOOL CONS_IN_1 Cons In 2 BOOL CONS_IN_2 Cons In 3 BOOL...

Page 255: ...te The set values will remain in the PLC until next time they are changed or the PLC is restarted Closing the PLC Console window will not clear any values If you as an example connect Cons In 1 to the...

Page 256: ...PLC application The difference is that the PLC Parameters are stored in non volatile memory and therefore will survive a restart of the PLC while all changes made using the PLC Console will vanish The...

Page 257: ...untime kernels in the system The list contains the name of the station and the state of the PLC runtime kernel Possible state for the PLC is Synchronizing new PLC program Blue synchronization has begu...

Page 258: ...dit an existing program To understand how the tightening process is actually performed within a PowerMACS system you should be familiar with all parts that make up the tightening process 1 The PLC sta...

Page 259: ...ams folder in the System Map and selecting Add Program Start by entering a proper name for the new program in the Program name field If you want to create a new program based on another program check...

Page 260: ...ram chapter You can edit more than one program simultaneously by opening more programs using the System Map it is also possible to drag drop steps between programs Programs are displayed on the left s...

Page 261: ...block to view program settings in the Detail window Collapsed step block Select a step block to view the settings in the Detail window Number of Restrictions in step Number of Checks in step Expanded...

Page 262: ...on while dragging an existing step from the same or another program to a new location this will create an identical copy of the step A copy operation is indicated by a small plus sign when the mouse i...

Page 263: ...rogram User Variables Definition of program user variables and values Settings Trace monitoring and report limit settings for the program The information for steps is divided in the following groups T...

Page 264: ...lt in the station On the top row labeled Name you can specify a symbolic name for each mode This name may be included in the cycle data as the station level result variable Mode The remaining rows are...

Page 265: ...ly in the cells but it is probably easier to use the copy function to the right It is used as follows 1 Mark the program you want to copy in the Tightening Program list 2 Mark the cells in the mode ta...

Page 266: ...anagement Defines how to do an automatic repair in case of a step failure Speed Defines which speed to use during the step Other Used for setting up start delays stop conditions etc Bolt monitoring De...

Page 267: ...Tightening 9836 3521 01 267...

Page 268: ...s mandatory when program from PLC is used as the PLC configures which program to run using the Pgm No Program Name The name of the program Comment Any comment about the program 6 5 1 2 Program User va...

Page 269: ...Peak Torque check is within 3 of the target torque in order to have an OK cycle Then we can create one program with user defined variables we call this program Tighten One variable is defined TargetT...

Page 270: ...bles one operation and one parameter is allowed Examples TargetTorque 1 3 Target1 3 6 5 1 3 Program Settings Trace Settings Trace Start When trace collection should start the options are Cycle Start o...

Page 271: ...must manually enter the resolution of the buffer in the edit field to the right of it In this case the oldest recorded data will be overwritten when buffer limit is reached resulting in that the last...

Page 272: ...ntrol function before the backlash is finished This means that a step will not end even if the target torque is reached during the backlash It also means that all angle measurements will start when th...

Page 273: ...ing into the monitor buffer If restarted everything recorded before this step is erased See also the description of Bolt Monitoring Most step that run the spindle have a Speed parameter and a step Dir...

Page 274: ...T and DT are converted to corresponding motor currents using the spindle parameters T C Factor T C Correction Factor and Gear ratio When the step starts the current that corresponds to T is set as cur...

Page 275: ...switched to DT DT Mean T is the mean torque measured during the second time interval TI2 Relax A relaxation angle is the angle that the bolt moves during the time interval TI1 TI2 Trace Torque T is s...

Page 276: ...r makes it is possible to Dyna Tork TM at a lower level than the target Note To avoid overheating of the spindle it is strongly recommended to never run Dyna Tork TM to more than 40 of the maximum tor...

Page 277: ...ol When the torque measured on the torque transducer used for control reaches T the step switches to current control using the current that corresponds to DT as set point for the motor servo This curr...

Page 278: ...ction Function Run spindle in DIR direction until torque is T Diagram Angle Torque T Target Torque T Step Trace Torque T is shown as a horizontal line from step start to step stop in trace when Torque...

Page 279: ...onding motor current using the spindle parameters T C Factor T C Correction Factor and Gear ratio This current is then set as reference to the motor servo The step is stopped when the servo reaches it...

Page 280: ...that is from its shut off Any overshoot will be included in this step If the overshoot is larger than A the step will be signaled ready immediately Overshoot is defined as the angle measured between s...

Page 281: ...Shut off point A Target Angle A2 A OS actual angle movement in this step OS Overshoot in previous step Trace Angle A is shown as a horizontal line from step start to step stop in trace when Angle vs T...

Page 282: ...art condition Function Run spindle in DIR direction until angle A has passed Diagram Angle Torque A Angle A Step Trace Angle A is shown as a horizontal line from step start to step stop in trace when...

Page 283: ...nce in average torque values Tn Tn 2 are continuously calculated and the max difference is stored The yield point is considered reached when the calculated difference is less than TDIFF of the current...

Page 284: ...s calculated with linear regression over the RNOS points After that new average values are continuously calculated over NOS degrees The actual slope is calculated with linear regression over the last...

Page 285: ...inue to run for Mask2 seconds in the DIR direction During this time the step is not shut off regardless of the measured torque From this point continue to run in the DIR direction until the measured t...

Page 286: ...que Mask1 Time 1 Mask2 Time 2 Step Mask1 time Mask2 time Peak T T Release Angle Trace Torque T is shown as a horizontal line from step start to step stop in trace when Torque vs Time is selected Contr...

Page 287: ...continue to run for Mask2 seconds in the DIR direction During this time the step is not shut off regardless of the measured torque From this point continue to run in the DIR direction until the measu...

Page 288: ...0 3 Shut off point Mask2 Time 2 Step Mask1 time Mask2 time Peak T Release Angle Peak T 0 3 T Trace Torque T is shown as a horizontal line from step start to step stop in trace when Torque vs Time is s...

Page 289: ...s calculated This procedure is repeated after INC angle degrees A straight line is calculated through the two calculated torque average values and down to the x axis The projected angle starts from th...

Page 290: ...s reached The rotation continues but from that point the torque is measured The step stops when the measured torque is less than or equal to T Diagram Angle Torque A Angle T Torque Step A T Trace Torq...

Page 291: ...m step start to step stop in trace when Current vs Time is selected Control parameters must be enabled in the trace form see View of trace curves 6 5 2 16 E2 Run Engage method 2 Step type Id 15 Parame...

Page 292: ...nds before the gear is changed Trace There are no control parameters for this step type in trace 6 5 2 19 PLC Run PLC step Step type Id 18 Parameters DIR PLC output STEPTYPE PLC output STEPVAL Functio...

Page 293: ...until low value is detected Should the digital input be low at step start the step is finished immediately High The step runs until high value is detected Should the digital input be high at step sta...

Page 294: ...waits until all other bolts running in parallel have reached the next synchronization point If the check box Hold Position is checked the spindle tries to hold the position of the bolt during the wait...

Page 295: ...Angle is reached The switch from torque to angle control is done On The Fly that is without stopping in between The two parts can be programmed with different speeds and if so the speed will be chang...

Page 296: ...Tightening 296 9836 3521 01 If parameter Falling edge is marked the search for the TC threshold is done on falling torque TC on falling edge Angle TC Torque TC A Target angle TC A Step...

Page 297: ...on until torque has been larger than Torque TC and the angle has been larger than Angle Parameter A start cond controls from where Angle is measured See description on following page for possible valu...

Page 298: ...in DIR direction until the first of either Torque TC or Angle is reached Parameter A start cond controls from where Angle is measured See description on following page for possible values Diagram Angl...

Page 299: ...ers A start cond and Angle torque start controls from which point the angle Angle is measured Possible values are Start condition Description AS1 Normal Angle measurement starts at the angle of the cu...

Page 300: ...erforms the same function as a A Run until Angle step with Start condition set to AS1 except from that nothing that this step does is recorded by the Bolt Monitoring function Diagram Angle Torque A Ta...

Page 301: ...til the torque Tlast Delta Torque is reached 5 Shut off the step The same speed and speed ramps are used both when running in the backward and the forward directions If Check angle is used it will rep...

Page 302: ...ta T Delta Torque A Angle Step x 1 A Tlast T Delta T Step x Trace Torque T is shown as a horizontal line from step start to step stop in trace when Torque vs Time is selected Control parameters must b...

Page 303: ...the torque level TcMAX is passed without finding the Snug point the step is aborted and an event is generated Diagram Angle Torque TcMax Max Torque ASG Angle run TcMin Min Torque DeltaA Delta angle TS...

Page 304: ...the spindle functional test as the first step in every tightening program to compensate torque measurements The spindle takes care of zero offset compensation if this is not sufficient you can select...

Page 305: ...be reset by the BCT step Result var This step produces the step level result variable BCT A which is the angle from the end of the wait time to torque TC This angle is used for backlash transportation...

Page 306: ...on the Ramps Other tab If Automatic slow down is used the slow down angle is automatically calculated so the speed reaches 1 rpm just before the target position Trace There are no control parameters f...

Page 307: ...when a step shall be interrupted A restriction stops a running step immediately A restriction can be considered repairable or fatal All restriction checks except for the Fail Safe Torque limit starts...

Page 308: ...entire step including the post step check time Note The torque restriction is supervised also during the Torque Spike Elimination phase Diagram Angle Torque FsTorque Fail safe torque Angle Fail safe a...

Page 309: ...step overshoot time Time measurement starts at step start after start delay for step and end when the step has ended and post step check time has elapsed The measured time must be less than the fail s...

Page 310: ...AS1 or from the point where the configured Torque start level has been reached The measured angle must be less than the fail safe angle limit No check is made until the selected start condition has b...

Page 311: ...s below the level MinT The restriction is only active until the control function of the step has shut off since the torque normally drops when the spindle is stopped Note that the restriction is not a...

Page 312: ...que Limit TStart MinT Restriction active Alarms Min Torque Restriction MTR if the torque drops below MinT Trace MinT is showed in trace as a horizontal line from TStart to step stop when Torque vs Ang...

Page 313: ...millisecond The calculated gradient is compared against the limits and stored in trace as a gradient curve One or both of the gradient limits can be left empty If both are empty no restriction check...

Page 314: ...step level result variable Grad which is the lowest gradient measured during the restriction or the gradient that violated the high limit of the restriction Alarms Gradient high restriction GHR and G...

Page 315: ...em must be configured Diagram T1 T2 Angle Torque T1 Torque Level T1 Amin Angle min T2 Torque Level T2 Amax Angle max A Measured angle from T1 to T2 Step Amax Amin A Alarms Cross thread restriction CRO...

Page 316: ...parameter is used TnStart AnStart and or AnStop may be left empty Leaving AnStart empty corresponds to the beginning of the step while an empty AnStop corresponds to the end of the step TnHigh and or...

Page 317: ...ction produces the step level result variables Tp1 Peak T Tp2 Peak T and Tp3 Peak T which is the highest torque measured in the respective interval Alarms Torque in window n too high TnHR and or Torqu...

Page 318: ...equipped on the spindle Select if you want to use the spindle s stored limits or configure your own limits Max difference Maximum difference in degrees Number of samples For how many samples millisec...

Page 319: ...t to use the spindle s stored limits or configure your own limits Max difference Maximum difference in Nm and Number of samples For how many samples milliseconds Max difference is allowed If a torque...

Page 320: ...erated Should the check have one or more limits defined then the corresponding error bits are set as well and the status of the checks is set to Fatal independent of the configuration An example of su...

Page 321: ...start Check Delta T Step or Zone Step start Zone start Zone started Low Spot T Step or Zone Step start Angle Zone start Angle Zone started Check Position Step Step start 6 5 4 1 Result values from ch...

Page 322: ...peak position to Null position register only available for Gauging Set peak position Store peak position to Peak position register only available for Gauging Function The peak torque from check start...

Page 323: ...off point Peak Torque Result var Peak T Peak T1 Peak T2 Peak T3 Peak torque Alarms Step peak torque high PTH and step peak torque low PTL Trace TH and TL are shown in trace as horizontal lines from s...

Page 324: ...r the torque spike elimination phase and that angle Astop is reached If not and at least one limit is specified the steps status is set to Fatal and the error bit of respective limit is set Diagram An...

Page 325: ...the torque spike elimination phase and that time Stop time is reached If not and at least one limit is specified the steps status is set to Fatal and the error bit of the respective limit is set Diag...

Page 326: ...result value is still calculated and reported This check requires that at least one sample is collected after the torque spike elimination phase If not and at least one limit is specified the steps s...

Page 327: ...dient for a description Zone start Angle at zone start Stop condition Value used as end angle F Final The final angle AE1 measured when the Overshoot time has passed after shut off SO Shut Off The ang...

Page 328: ...angle prev A_Snug Start cond Snug point A_Tstop Stop cond Angle at Tstop Angle Previous step AS1 AS2 AS3 TStart A_Tstart Shut off point F SO P SOP TStop A_Tstop AL AH Step x Step x 1 Shut off point A...

Page 329: ...The angle windows are measured from the last point where the torque reached TC The torque values used in the check are filtered using a sliding window average algorithm The mean torque value is calcu...

Page 330: ...Distance TC Torque Check Level TC AdistH AwinH TH AdistL Step Result var None Alarms Post view torque too high PVTH and post view torque too low PVTL Trace TH and TL are shown in trace as horizontal l...

Page 331: ...sables the check but the result value is still calculated and reported This check requires that at least one sample is collected after the torque spike elimination phase If not and at least one limit...

Page 332: ...spike elimination phase If not and at least one limit is specified the steps status is set to Fatal and the error bit of the respective limit is set Diagram Time SOTL SOTH SO T SOTH Shut Off Torque Hi...

Page 333: ...Start is left empty then Astart is measured from the start of the step Leaving Astart empty is equal to setting Astart to zero Leaving Torque Stop and or Astop empty deactivates the respective check...

Page 334: ...is specified the steps status is set to Fatal and the error bit of the respective limit is set The paramters Falling Edge Type are only available for Gauging In Tightening rising edge and type Two poi...

Page 335: ...p Step Tstart T2 Tstop T1 Astart Astop A1 A2 Dev TRH TRL Result var TR step torque rate and TR Dev step torque rate deviation Alarms Torque rate too low TRL Torque rate too high TRH and Too big deviat...

Page 336: ...lculated torque rate line in the torque rate check T TR A m to calculate the zero crossing point i e the angle there the toque is zero The zero crossing ZC is calculated as ZC m TR The angle used is t...

Page 337: ...in the torque rate check Angle Torque A1 Check Zero Crossing A2 Step x Step x 1 ZC ZCL ZCH Result var Zero Cr A Zero Cr A1 Zero Cr A2 measured zero crossing Alarms Zero Crossing high ZCH Zero crossin...

Page 338: ...them blank disables the check but the result value is still calculated and reported Diagram Time Torque TIH TIL TIL Time Low OSHT Overshoot time TIH Time High Step Shut off point OSHT Step time Resul...

Page 339: ...ent is less than DIFF Maximum gradient The DIFF value is specified as a percentage of the maximum gradient The angle to use as end angle is controlled by the parameter Stop condition There are three d...

Page 340: ...point and the end angle Alarms Yield Point Angle High YAH and Yield Point Angle Low YAL Trace No limits are shown in trace 6 5 4 14 Check Stick Slip Parameters Trigger mode Max drops Trigger level Th...

Page 341: ...detections of stick slip the counter of the drops below TTrig is reset if a too long angle has been run since the last drop The counter is reset if the angle since the latest drop is larger than the...

Page 342: ...que vs Angle is selected 6 5 4 15 Delta T only available for Gauging Parameters TH Maximum delta torque TL Minimum delta torque Function The difference between the peak torque and the low spot torque...

Page 343: ...p level the last sample is taken at the shut off point of the step If Set null position or Set low position is set the low position that is the angle where the low spot torque was found is stored in t...

Page 344: ...ngle high BAH and Backlash angle low BAL Trace No limits are shown in trace 6 5 4 19 Check external input only available for Gauging Parameters Digital Input Signal Value Function The selected Digital...

Page 345: ...iled steps Most of the RM settings for a step can be found in the Rejects group When a failed step is detected the RM performs the following 1 Checks bolt status 2 Decides what to do 3 Starts repair 4...

Page 346: ...h synchronized step all bolts will be assigned a status This status is the result of all checks made in the step comprising the restriction tests the step checks hardware checks etc The resulting over...

Page 347: ...with the next step The bolt will first wait for any Terminate and Repair sequences to finish Retry The bolts should execute their Retry action s The bolt will first wait for any Terminate sequences to...

Page 348: ...or have finished their repair are not affected The following Failure during repair alternatives are available in the main program Failing bolts Failing group Other bolts Terminate Terminate Terminate...

Page 349: ...settings If there are any bolts remaining with Repairable errors after running the terminate sequence they will be executed according to the First failure or Failure during repair settings as above S...

Page 350: ...to the Retry in the step from which the repair was started Note 4 Bolts that end their cycle at a CE step in the repair part of the program reenters state Running Normal when the CE step is reached Th...

Page 351: ...eft blank execution resumes at the next step after the step where the Retry was ordered and repair is ready Terminate with step The number of the step to jump to when ordered by the station to Termina...

Page 352: ...is running in state Normal That is whenever the First failure alternative is at hand When more than No of reject groups in step erroneous groups have been detected in the current synchronization inter...

Page 353: ...ject management is done Bolts that have been terminated before they reach the CE step will not participate in Reject Management executed on the CE step Bolts that have status NOK before the Monitoring...

Page 354: ...that never reach a CE step for example due to that it is terminated will use the Monitoring checks defined on the CE step it would have reached if the execution should have continued normally As an ex...

Page 355: ...olts that never entered the repair sequence for example due to that they had Wait or Continue as reject action and bolts that are already ready with the repair sequence are not involved Note 2 The Fat...

Page 356: ...there is at least one bolt to terminate All bolts ready with repair Evaluation of all bolts using First and Fatal failure gives that there is no bolt to terminate but at least one bolt to repair Eval...

Page 357: ...er the synchronization interval from which it entered this state as the Failing synchronization interval see the picture of the below example This information is used when the bolt determines if it is...

Page 358: ...g synchronization interval has been run The bolt failed running one of the steps in the failing synchronization interval This causes an immediate First try evaluation that affects all not terminated b...

Page 359: ...t 1 to finish repair Retry ordered when repair ready Run Retry as configured in step 3 1 Bolt transfer from state RUNNING NORMAL to RUNNING REPAIR 3 Bolt 2 waits for bolt 1 to finish repair Run Next o...

Page 360: ...TE 4 End of cycle at RE Monitoring checks according to step 8 Bolt doesn t participate in cycle RM as it is Terminated Bolt 2 runs OK but is ordered to Retry and Terminate when bolt 1 fails 1 2 3 4 5...

Page 361: ...Repair which is an implicit synchronization mark This ends the Loosen with step sequence Since Restart from step is set to 1 for the step 3 the bolt will jump to step 1 when it receives the next start...

Page 362: ...bolt reports step status and that it has reached cycle end and RM end If there was an error when running step 11 it is handled with Failure during repair settings If there are other bolts still runni...

Page 363: ...Tightening 9836 3521 01 363 6 5 6 Step Ramps Other The Ramps Other group contains parameters related both to speed ramping of the step Ramps and other options Other...

Page 364: ...oothened ramps Straight ramps Up to five speed changes can be made during a step These are defined as Ramp data entries When to change speed can be triggered by one of the following conditions Angle r...

Page 365: ...e disregarded for control Note The torque restriction see chapter Fail Safe Torque is active also during the Torque Spike Elimination phase Use the Customer step name combo to select the customer erro...

Page 366: ...his has happened If the evaluation of any checks fails for a spindle that run Continue rotation the motor will be switched off and the spindle will roll out to a stop The same will also happen if anot...

Page 367: ...nes in the same step Digital signal at step start Output signal specifies the signal to use With the combobox Change at it is possible to select if the signal shall be set directly at step start or wh...

Page 368: ...run during the whole step or only during one specific zone see Step Check for more information All zones within one step use the same Angle channel as selected in the Common paramters for the zones It...

Page 369: ...s started The buffer has a fix length of 8192 elements but its resolution i e the length that each element represents can be configured by editing the settings for a program Note It is possible to use...

Page 370: ...is not terminated the evaluation is done on reset monitoring measurement values which causes Fatal errors for all checks that have configured limits Monitoring can also be stopped when a step fails To...

Page 371: ...uffer that is used for all monitoring checks The monitoring checks are added as regular checks on any CE step The checks are described in detail in the following sub chapters If the parameter Ignore m...

Page 372: ...al Leaving them blank disables the check but the result value is still calculated and reported Unless Fatal is checked a value outside the specified limits is considered to be a repairable error If a...

Page 373: ...l Tstart Tstop Torque Level Tstop Torque falling below Tstop Function This function checks that the angle A is within the specified limits AH and AL Angle A is measured from the point where the torque...

Page 374: ...ssed the found positions when a step is run in backward direction If both Tstart and Tstop are empty the angle will be measured from monitoring start to monitoring end That is Astart is defined as the...

Page 375: ...stop2 AL AH Astop1 Result var Bolt A Bolt A2nd measured on the second monitoring buffer and Bolt A Thresh T the programmed value of Tstart Alarms Angle too high AHM AHM2 Angle too low ALM ALM2 and Thr...

Page 376: ...when the torque reaches final torque that is the end of the monitoring buffer This point is used only if both T Stop and A Stop are empty T Start T Stop A Start and A Stop are all optional If T Start...

Page 377: ...e specified limits is considered to be a repairable error If a value cannot be calculated and at least one limit is specified for the check in question it is always considered Fatal This is the case i...

Page 378: ...M Torque rate in interval 2 too high TR2HM Torque rate in interval 2 too low TR2LM Too big deviation in interval 1 DEV1M Too big deviation in interval 2 DEV2M Trace TRH and TRL are shown in trace as l...

Page 379: ...or Yield point starts when the torque value has reached the trig level TC From this point the average torque is measured over NOS degrees TNOS This procedure is repeated after each INC degrees When th...

Page 380: ...tion checks that Bolt YP T is within the limits YTH and YTL and that Bolt YP A is within the limits YAH and YAL Note that YTH and YTL can be negative All limits that is YTH YTL YAH and YAL are optiona...

Page 381: ...Bolt YP A Alarms Yield torque high YTHM If Bolt YP T YTH Yield torque low YTLM If Bolt YP T YTL Yield angle high YAHM If Bolt YP A YAH Yield angle low YALM If Bolt YP A YAL Trace YAH and YAL are shown...

Page 382: ...n the value NOT_DEFINED is reported for it A NOT_DEFINED value is printed as blanks spaces when reported as text and the value 32768 when reported in binary format 6 7 1 Statuses Stations and bolts ha...

Page 383: ...tect missing cycles Station The name of the station See System for how to set or change the name of a station Max 20 ASCII characters Station No The number of the station The first station in the syst...

Page 384: ...A variable specific for the PLUS protocol The variable will only have a valid value if a PLUS device is defined The value is taken from Station AB in the PLUS device ID Res 1 Multiple identifiers resu...

Page 385: ...les that this bolt has run during the current shift See Shift Reports and Shift Set Up for a description of shifts Total NOK Total number of NOK and TERMNOK cycles that this bolt has run during the cu...

Page 386: ...ned the bolt Compact Errors 2 This is a compact version of the Errors result variable It may list the following errors TLM Torque Low Monitoring bit 0 value 1 THM Torque High Monitoring bit 1 value 2...

Page 387: ...is missing and 0 if not Bolt Id Bolt ID Program version A unique program version string Can be used to check if two programs are equal or not Audi FAP Tag A variable specific for the Audi XML protoco...

Page 388: ...g buffer is appended with 2nd Variable name Description Bolt T Bolt T 2 nd Peak Torque for the cycle See Monitoring Check Final Peak Torque for how it is defined Bolt A Bolt A 2 nd Cycle Angle Either...

Page 389: ...t T will always correspond to the last used of these variables Bolt A try 1 Bolt A try 2 Bolt A try 3 Bolt A try 4 Bolt A try 5 Bolt A for each evaluation of the monitoring Bolt A try 1 is from the fi...

Page 390: ...only first 8 bytes are included that is errors 0 to 63 Possible errors Mnemonic Bit no Description ANGDIAG 0 Angle count test failed during a diagnostic step SPFUNCTEST 1 Spindle functional test fail...

Page 391: ...TIL 28 Time low alarm from check CH 29 Current high alarm from check CL 30 Current low alarm from check SOTH 31 Shut off torque high from check SOTL 32 Shut off torque low from check T IH 33 Torque T...

Page 392: ...d using the Run reverse before retry parameters on the Step Rejects tab failed TRH 65 Torque rate too high from check TRL 66 Torque rate too low from check DEV 67 Deviation too high from check TTNOTRM...

Page 393: ...gle high limit exceeded YAL 94 Yield angle low limit exceeded OTHER2 95 This is bit is set if any error bit s in the range 96 127 are set and only the first 12 bytes are included That is Type in the r...

Page 394: ...Error bit no 63 56 55 48 47 40 39 32 Possible warnings Warning Bit no Description NZS 0 Not zero speed FLYZODIAG 1 Flying zero offset failed during a diagnostic step BUFOVFLM 2 Monitoring Overflow in...

Page 395: ...ps control part See the definition of the respective step type Step Control for which parameters that are printed and in which order Note This variable always prints 10 values If fewer parameters are...

Page 396: ...in the time window Produced by the Check torque in time window check Ti Win Lo T Ti Win Lo T1 Ti Win Lo T2 Ti Win Lo T3 The lowest torque measured during time window Measured by Check torque in time w...

Page 397: ...3 Maximum torque rate deviation Produced by the Check torque rate check Gradient Gradient T1 Gradient T2 Gradient T3 The gradient measured by the Gradient restriction Delta T Delta T2 Delta T2 The dif...

Page 398: ...Pos A The distance to the Low position after the current step only available for Gauging Zero Cr A Zero Cr A1 Zero Cr A2 The Zero crossing measured by the Zero Crossing check Fail Safe T Fail Safe T1...

Page 399: ...ratio of the spindle for some examples see the table below If the motor run slower than this the stall protection is activated Depending on the current level the protection works in different ways Be...

Page 400: ...Tightening 400 9836 3521 01...

Page 401: ...first introduction to SPC is given in the next chapter SPC Statistical Process Control SPC Set Up opens the SPC set up form with which the SPC is configured Shift Set Up opens Shift Set Up form Use it...

Page 402: ...ations and checks to suit most needs 7 2 1 Data Collection Data is collected only for those variables that have been set up for collection Data are collected in two main ways As subgroups for the SPC...

Page 403: ...or deviation values are calculated for subgroups built from the data in the short Term trend buffer starting with most resent value Which variables to collect are set up uniquely for each bolt spindl...

Page 404: ...D D and A B B see table X X R R X X S S 2 2 4 3 3 3 4 3 2 4 3 3 4 3 Check and alarm if enabled if following happens with Average or Range or Standard deviation one value outside control levels One ou...

Page 405: ...be collected Cam is not applicable to standard deviation An error event is generated if the value of Cam Cp or Cpk is out of limit When SPC is wanted for a station not for its individual bolts the cal...

Page 406: ...StdDevStn VarStn Var XStn NoBolt 1 2 1 ij j subgroup for station for the deviation standard The j subgroup for station for the varians The i bolt for j subgroup for varians The j subgroup for station...

Page 407: ...1 03 0 24 1 76 10 3 08 0 973 0 31 0 22 1 78 0 98 0 28 1 72 11 3 17 0 975 0 29 0 26 1 74 0 93 0 32 1 68 12 3 26 0 978 0 27 0 28 1 72 0 89 0 35 1 65 13 3 34 0 979 0 25 0 31 1 69 0 85 0 38 1 62 14 3 41 0...

Page 408: ...e to calculate on See chapter Data Collection for a description of the parameters In the Variables to collect frame add those variables you want to check Select Station Bolt and or Spindle Program Var...

Page 409: ...ble if cam can be calculated Check one or more of the check boxes in the Trend Deviation Alarms frame to have the SPC and TDA data monitored for any of the following deviations One out One point outsi...

Page 410: ...e ToolsTalk PowerMACS screen or sent to a printer connected to it Preview and print are invoked from the Statistics menu The report contains the following information per station Total No of cycles ex...

Page 411: ...using 24 h notation i e as 00 00 to 23 59 Check Automatic clear at shift start to have all shift statistics variables erased when a new shift starts Clearing the shift statistics will reset the follow...

Page 412: ...ollowing Station level result variables must be included in at least one reporter in the system see chapter Edit reporter for how to configure a reporter Total Total OK Total NOK To have the SPC data...

Page 413: ...t of a PowerMACS system The devices can be both of simple type like printers and of more complex type like a fieldbus a serial communication protocol and the PowerMACS API interface CC Console Compute...

Page 414: ...LC output of cycle data events and traces read write Setups Serial port on TC Fieldbus Interface Data to from PLC output of cycle data events and traces read write Setups Fieldbus interface board Tool...

Page 415: ...click and select Add Device from the popup menu This will bring up a list of devices that can be added You will be asked to give the new device a name This name will later be referred to when you cre...

Page 416: ...f data Port Usage Signal Interface Serial 1 General serial communication RS 232 RS 485 Serial 2 General serial communication RS 232 RS 422 ST Bus CAN I O port I O Device communication CAN with DeviceN...

Page 417: ...l Devices 9836 3521 01 417 8 3 Status of a device During performing its task each device checks for errors or malfunction The result is shown in the System Map Devices not working OK are shown with a...

Page 418: ...klight To access the stacklight configuration window add a stacklight device and double click on it in the system map Select the correct MAC Id for the Stacklight When a new Stacklight device is added...

Page 419: ...ion etc It is possible to select the number of lamps on the indicator box by selecting the None value as Component type When connected to a system the form will show show the signal values in realtime...

Page 420: ...e exactly which of the lamps should have a specific function Configure the Indicator Box by selecting the component you wish to edit lamp or digital input in the property grid on the right side or by...

Page 421: ...ded Configure the Operator Panel by selecting the component you wish to edit lamp buzzer or button in the property grid on the right side or by clicking on the component in the operator panel image On...

Page 422: ...Peripheral Devices 422 9836 3521 01 When connected to a system the form will show show the signal values in realtime...

Page 423: ...p see chapter I O The I O device as well as Stacklight Indicator Box and Operator Panel can map all boolean signals located in the Digital_In_Out group and in the Shared_Variables group Boolean outsig...

Page 424: ...orter How to do this and connect it to your Printer device is described in the New reporter chapter How to make the Reporter format the result as you wish is described in chapter Edit reporter 8 7 Pri...

Page 425: ...it requires no additional hardware to be connected to the system Secondly you must create New reporter and connect it to the PLC device Use the reporter to select what result variables to include in...

Page 426: ...Bolt No 1 I2 Bolt T 2 F Bolt A 3 F Status 4 I2 You must also enable and configure the drivers used for accessing the PLC data This is done using the IO_Configuration worksheet for station in question...

Page 427: ...data This is done using the I O Configuration dialogue which is invoked by double clicking on the icon for IO_Configuration worksheet of station in question in the Project Tree In the O Configuration...

Page 428: ...esses Length so that it corresponds to the size of your cycle data in this case 22 The Start and End addresses shown here 4000 and 4021 are logical meaning that a PLC variable later mapped to the logi...

Page 429: ...tion See chapter Add a device for how to add an ID device Use Type to specify the type of ID device to use Currently the following ID device types are supported Barcode Barcode scanner any brand that...

Page 430: ...e ID device The data read from an ID device is also available to the PowerMACS PLC making it possible to process it as wished When the device is connected to a Station the data read from it is also av...

Page 431: ...scanned Enter as End character the character that marks the end of returned string Non printable characters are entered using their hexadecimal code enclosed between a pair of and for example 09 for...

Page 432: ...ere to write cycle data to Use the two pairs of Start address and Stop address to do this The first address in the tag has address zero 0 RF field strength controls the power of the signal transmitted...

Page 433: ...1 one is supported Reading an ID string For Omron devices the ID String may consist of two different parts the main part and an optional number part Parameters Start address and Stop address defines t...

Page 434: ...lting ID String is ABCDE0047 This string is sent to the station and PLC as a response to an IDREAD PLC output request Writing result data Start address and Stop address defines the address area of the...

Page 435: ...reader has a card When a card is inserted in the reader the 24V signal goes high This triggers PowerMACS to start communicating with the card reader and fetch the data from the card Whenever the sign...

Page 436: ...et device you may report cycle data and or traces to an Atlas Copco ToolsNet server over the Ethernet To enable this function you must first add a ToolsNet device as described in chapter Add a device...

Page 437: ...ACS trace that are sent to the Toolsnet server It can be set to a value in the range 100 2000 and the default value is 752 Use Select Protocol to select which version to use Auto detect or specific ve...

Page 438: ...to set up what data to report to ToolsNet The ToolsNet reporter is somewhat different from reporters used for other devices since you can only select what variables to include not format them Certain...

Page 439: ...To enable this function you must first add an Ethernet protocol device as described in chapter Add a device Add the device to a TC that has a PLC i e the first TC in a station With the exception of D...

Page 440: ...er for the new ToolsNet device using the New reporter form Set up which Ethernet Type of protocol to use and which IP address the server has A new Reporter is created automatically for the Ethernet pr...

Page 441: ...s also described what functions are included and how they are mapped on PowerMACS functions The Ethernet protocol device does not require any additional hardware to be connected to the TC since it use...

Page 442: ...as not been able to send Retry Timeout specifies the timeout between retries Keep Alive Timeout is the timeout used to detect the absence of a client If no telegram has been received within the timeou...

Page 443: ...sages MID 0018 Select Parameter set MID 0042 Disable tool MID 0043 Enable tool MID 0050 Vehicle Id Number download request When these are received in a state when they are not wanted according to the...

Page 444: ...omatic Manual mode state PowerMACS sends this message whenthe stations mode slection is changed also when it changes to from zero When entering Manual mode the following the following actions are exec...

Page 445: ...s sent to station ModeNo NOT_DEFINED 32768 test bolt not mode view is not reported as parameter set change and mode is reset to original mode in station when the test bolt cycle has run 0040 Tool data...

Page 446: ...cknowledges all events in PM regardless of specified error number TC sends this message when an event subscribed on has been marked observed in PM If command mark all as observed is used event code 0...

Page 447: ...data unsubscribe See document Open Protocol MID for PowerMACS data for more information 0240 User data download See document Open Protocol MID for PowerMACS data for more information 0241 User data su...

Page 448: ...a unique Id for each sync tightening result Each individual result of each spindle is stamped with this Id The tightening Id is incremented after each sync tightening 5 ASCII digits Max 65 535 Report...

Page 449: ...limit 08 6 The torque min limit is multiplied by 100 and sent as an integer 2 decimals truncated The torque min limit is six byte long and is specified by six ASCII digits 0 9 Bolt T Min limit from t...

Page 450: ...Reports 0 when station status is NOK TERMNOK or NOKRM Spindle status 18 18 Number of spindles Bytes 1 2 Ordinal bolt number 01 99 Bytes 3 4 Spindle number 01 99 Byte 5 Reports 0 when bolt status is N...

Page 451: ...chine ID is the identification that is sent first in all telegrams to the server and which identifies the source of all telegrams Vehicle Data Timeout is the timeout used when transmitting Vehicle Dat...

Page 452: ...8 11 2 2 PFD Result Record Formats The tightening results are reported to PFCS according to the specification with following additional information Field Implementation VIN Last 6 characters of the ID...

Page 453: ...in Port No which port to use in the FSH default is 4242 The Station No is the identification of the TC in the FSH this is sent in all telegrams and identifies the source of all telegrams In the follo...

Page 454: ...ndown Packet Request 4 TC Rundown Packet 5 FSH Rundown Packet Acknowledge 6 TC No Rundown Packet 7 FSH Reset Buffer Request 8 TC Reset Buffer Acknowlwdge 15 FSH Communication Parameters Packet 16 TC C...

Page 455: ...onitor function Angle Low Limit Bolt Angle Min limit from the Monitor function Angle High Limit Bolt Angle Max limit from the Monitor function Status Bits Completion Torque Status Torque Spec Angle St...

Page 456: ...QD The PLC variables used to control this device are described in chapter DC PLUS variables Press the Open button on the Details form to to open the Advanced DC PLUS settings form The different parame...

Page 457: ...z when sending tightening results to PLUS Station AB The value to use as AB Anlagen betreiber for all bolts when sending cycle data to PLUS Will also be included in the cycle data as the result variab...

Page 458: ...SA to use are specified in this table with one row for each mode If no values are specified for a mode cycle data produced when running this mode will not be sent to the PLUS server The values specifi...

Page 459: ...lts as OK With the selection G ALL bolts are reported as NOK even the bolts that was really OK For the originally OK bolts the string specified in Group NOK error code will be used in the field FE Feh...

Page 460: ...cycle data as the result variables Station QO Strings entered in the columns US if ok US if OKR and US if NOK for a specific mode are used in the cycle data US field US is part of the bolt data US is...

Page 461: ...werMACS sends result data to the PLUS server the value to use for PN or KN is sampled from the Wp ID field in the result VIN number type controls if Wp ID shall be treated as PN or KN see also the tab...

Page 462: ...QO if Use QO from PLC is unchecked If Use QO from PLC is checked the value of the PLC system global PLUS_QO is used instead If the value of PLUS_QO is not a valid QO an event is generated to inform th...

Page 463: ...e data TC 2 Switch TC 3 TC 1 Workflow 1 The PN KN or LI number is read by the barcode scanner or automatic scanner and sent to the TC 2 The TC sends a request for TMU to PLUS with the PN KN or LI that...

Page 464: ...and sends a positive edge to PLUS_GETTMU 3 When the PLUS server has sent an answer PLUS_GETTMU_OK will be set to TRUE PLUS_MODE contains the mode number to use for the tightening The received TMU is c...

Page 465: ...the cycle data is sent to PLUS PLC program The PowerMACS PLC program will be very similar to the program used in the SAW station 1 The line PLC sends mode number and PN or KN to PowerMACS PLC through...

Page 466: ...E is copied to MODE by the PowerMACS PLC This mode is started and CURRIDSTRING will be included as Wp Id in the cycle data NSCR If PLUS sends the telegram NSCR it means that no tightening shall be mad...

Page 467: ...ogram will be very similar to the program used in the SAW station 1 The barcode is scanned and the value is put in CURRIDSTRING in the PowerMACS PLC 2 The PowerMACS PLC copies the value in CURRIDSTRIN...

Page 468: ...ET Bolt data Field Implementation EINZELERGEBNIS NR EN Bolt number from ToolsTalk PowerMACS setup EINZELERGEBNIS IDENT EI Bolt name from ToolsTalk PowerMACS setup The bolt number will be added at the...

Page 469: ...Step level data This table describes the data sent to PLUS if step level data is reported All the step data will come from the same step PI Description Value sent PW Comment 001 Torque SO T Shut off...

Page 470: ...Id In the cycle data Q AUSSAGE ART AA Always SC Bolt data Field Implementation Q AUSSAGE IDENT QI Bolt Id from WinTC setup Q AUSSAGE QA Bolt status for this tightening IO OK is sent for status OK and...

Page 471: ...mit Only sent if limits for Bolt T is selected in the reporter RW Redundancy angle This value is not possible to send ZW Time No value is sent PH Step number 0 The step number will always be 0 to indi...

Page 472: ...Grad is selected in the reporter 8 11 4 11 Selecting the data to report Only one angle value and one torque value can be sent for each tightening Bolt T and Bolt A are reported in OK cycles and SO T...

Page 473: ...r of the I P M server shall normally be 1 8 11 5 1 Mapping of data The I P M implementation is done following version 3 1 11 of the I P M specification with the following additional information Telegr...

Page 474: ...number from the spindle setup if it is specified Unit Carrier ID 10 Result variable Id res 2 only the 10 first characters are used Type 10 Result variable Id res 3 only the 10 first characters are us...

Page 475: ...is controlled by the settings in the I P M reporter The station name is put first in the maintenance sequence the value of the field width in the reporter sets the number of characters to use If widt...

Page 476: ...Test1234 Spindle Number 12 Bolt Number 17 Program Number 21 The maintenance sequence will be Test12012 21 8 11 5 3 Possible error codes Value sent Meaning Corresponding PowerMACS error 1 MD max THM to...

Page 477: ...value angle Bolt A Grad MI Actual value torque Bolt T Nm GI Actual values gradient Bolt TR1 Nm Gr TI Actual value time Only sent as trace data S MR Redundancy Torque Bolt A 2 nd Grad WR Redundancy ang...

Page 478: ...Manual start enabled is checked it is possible to run cycles from the PLC If Master PC enabled is checked cycle data is sent to the Master PC If VW Variant is checked the VW version of the protocol is...

Page 479: ...from the Master PC otherwise it is only reset if the MID in the RST telegram is 0 If Use only Port B is checked the Port A connection is not used In this case the IP address of the Application server...

Page 480: ...i e the first TC in a station A PowerMACS PLC can only access a fieldbus interface that is mounted on the same TC as the PLC is running on Note The DeviceNet GM is a special case in the sense that it...

Page 481: ...e bus The data on the bus is divided in cyclic and acyclic transfer Cyclic transfer occurs on a regular basis between the master and the PowerMACS 4000 fieldbus Cyclic data is typically PLC data Acycl...

Page 482: ...Data Read Write 0 1 0 0 0 Max Write Cyclic Data 256 152 244 a 256 256 c 256 d Min Write Cyclic Data 0 0 0 0 0 Max Read Cyclic Data 256 152 244 a 256 256 c 256 d Min Read Cyclic Data 0 0 0 0 0 Max Acy...

Page 483: ...483 Because the size of the areas is limited you must specify the size of each area individually using the parameters PLC bytes In PLC bytes Out Data bytes In Data bytes Out Fast bytes In and Fast by...

Page 484: ...Outputs from the PowerMACS PLC Size Fast bytes Out Used as Process Data output e g the requested cycle data Size Data bytes Out Filedbus side Filedbus side Note You should not configure the respectiv...

Page 485: ...e respective LED is specific to the fieldbus type being used See chapter Fieldbus specific Information for a description 8 12 1 Access to PLC data For ToolsTalk to be able to move around variables in...

Page 486: ...Peripheral Devices 486 9836 3521 01...

Page 487: ...having prefix SO_ Digital input signals Address 1600 1791 Can in ToolsTalk be mapped only for I O Digital output signals Address 1600 1791 Can in ToolsTalk be mapped only for I O Shared input signals...

Page 488: ...user defined data types and arrays defined in SHARED_MEMORY_TYPE Both a complex data type and each element in the complex data type can be declared in the Global_Variables sheet PM4000 calculates the...

Page 489: ...es occcupied by the complex variable are hidden from the user When a complex variable is moved in TTPM all variables declared on addresses occcupied by the complex variable are moved as well When mapp...

Page 490: ...hin mBOLT_DATA_ARRAY_SHORT and are therefore also declared on addresses starting with 30003 These variables SO_Running_Bolt_1 SO_OK_Bolt_1 SO_NOK_Bolt_1 SO_Running_Bolt_2 etc are not available when ma...

Page 491: ...les sheet in the PLC can be shared between I O and fieldbus Signals under the group Fieldbus_Variables represent the fieldbus mapping When converting a setup older than version 7 5 0 the PLC will not...

Page 492: ...itten and read as Big Endian values commonly referred to as Motorola format When the variables are declared you are free to refer them from any POU Program Organization Unit you have or will declare i...

Page 493: ...es button The group name has no functionality therefore the group can be named anything Change the value of Logical addresses Length so that it corresponds to the size of your fieldbus data declared a...

Page 494: ...erties button The group name has no functionality therefore the group can be named anything Set up address length and driver parameter the same way as for the input driver For both input and output dr...

Page 495: ...Peripheral Devices 9836 3521 01 495 8 12 1 4 Fieldbus form The fieldbus form is reached by pressing the Open button in the system map or by double clicking the fieldbus directly in the map...

Page 496: ...nk to the reporter form is available on the command bar Only monitoring is available for the data bytes Mapping of signals When not connected to a TC PLC signals is added either by dragging them from...

Page 497: ...the shared area in the PLC when pressing Apply Monitoring When connected to a TC fieldbus data is monitored in the form A snapshot of the fieldbus data is taken once a second and sent to TTPM from th...

Page 498: ...o a TC and when the fieldbus form is open On disconnection from the TC the TC will reset the force list automatically Only the PLC bytes can be forced 8 12 2 Access to Process data Accesses to the Pro...

Page 499: ...1 STS Least Significant Byte 2 2 3 Data Data TO FROM PowerMACS PowerMACS Data bytes In 1 Data bytes Out 1 The first word in the IN area is used as Command CMD The fieldbus master writes commands in th...

Page 500: ...so after that this command has been issued S Skip Set one 1 to skip reading of the current data item in the data queue selected with DataType Next reading will return next data item or the first part...

Page 501: ...esult and negative values a failure Currently the following status codes are defined Status code Description 0 Success 1 Illegal process data specified 2 Illegal size of the process data area 3 Device...

Page 502: ...hat the low byte bit 7 0 of the STS word is zero This indicates that the command was executed successfully If reading the output data is now valid 7 When finished with reading of data and or the STS w...

Page 503: ...the output area is not free then it will be lost It will not be written automatically when the area becomes free again An automatically written cycle data is formatted exactly the same way as if the f...

Page 504: ...ommand word I e Process data should be laid out as below Process Data 0 Target Addr MSB 1 Target Addr LSB 2 3 Message Data m bytes m 1 The layout of Message Data depends on whether the targeted data i...

Page 505: ...write the ten characters ID code ABCDEFGHIJ to the PLC input starting at address 2010 the following should be written to the fieldbus process data input 0 0x48 CMD MSB 1 0x00 CMD LSB 2 0x00 Target Add...

Page 506: ...ee chapter Fieldbus Interface for a description on PLC bytes In PLC bytes Out Data bytes In and Data bytes Out The parameter Fast bytes In defines the size in bytes of the input data that is transferr...

Page 507: ...0xA2 Acyclic Data Input 1 0 63 0x05 0x05 2 64 127 0x06 0x05 3 128 191 0x07 0x05 118 7488 7551 0x7B 0x05 119 7552 7615 0x7C 0x05 120 7616 7679 0x7D 0x05 Outputs from PowerMACS that is the AnyBus IN are...

Page 508: ...66 81 1 7 Data byte Out 8 23 1 126 Data byte In 127 142 62 68 Data byte Out 69 84 62 127 Data byte In 128 143 Acyclic data block 1 64 bytes Class id A2 Inst id 06 Attrib id 05 63 69 Data byte Out 70...

Page 509: ...llows LED Function Indicates 1 Network status Steady off Not Online No Power Steady Green On line one or more connections established Steady Green 1 Hz On line no connections established Steady Red Cr...

Page 510: ...that is transferred as cyclic or real time IO data on the ProfiNet IO network Max value is PLC bytes In Data bytes In Leaving the parameter blank will make all input data transfererred as cyclic IO da...

Page 511: ...l be generated ANYBUS TC d Error Module version x does not support Extended Mode and the module has to be replaced When using the 368 bytes data mode there is a limitation of max 244 bytes input or ou...

Page 512: ...ta byte In 66 81 1 7 Data byte Out 8 23 1 126 Data byte In 127 142 62 68 Data byte Out 69 84 62 127 Data byte In 128 143 Acyclic data block 1 64 bytes Slot No 4 Index 4 63 69 Data byte Out 70 85 Acycl...

Page 513: ...unction of the respective LED is as follows LED Function Indicates 1 Operation Mode Steady off Not online No Power Steady Green On line data exchange Flashing Green On line clear Flashing Red 1 flash...

Page 514: ...ce max 64 modules can be used Alignment also controls the maximum size of data that can be transferred as cyclic IO data see table below See chapter Fieldbus Interface for a description on PLC bytes I...

Page 515: ...de it must be done in the following order 1 All data sent from the master to PowerMACS 2 All data sent from PowerMACS to the master Acyclic data Inputs to PowerMACS are sent with Write record commands...

Page 516: ...n 26 41 41 5 Data byte Out 6 21 REAL TIME IO Data 21 26 Data byte In 27 42 42 6 Data byte Out 7 22 0 27 Data byte In 28 43 43 7 Data byte Out 8 23 1 88 Data byte In 89 104 104 68 Data byte Out 69 84 6...

Page 517: ...ntroller established IO Controller in STOP State 2 Module status Steady off No power applied to module or module I SETUP state Steady Green Normal operation Green 1 flash Diagnostic event present Gree...

Page 518: ...ut The parameter Fast bytes In defines the size in bytes of the input data that is transferred as cyclic or real time IO data on the ProfiNet IO network Max value is PLC bytes In Data bytes In Leaving...

Page 519: ...ut from the client input to the PowerMACS The Modbus TCP IN and OUT areas can be configured to a maximum size of 8192 bytes The input and output areas of the PowerMACS fieldbus device are available fr...

Page 520: ...4201F 0x61FF 0x61FF0 0x61FF1 0x61FF2 0x61FF3 0x61FF4 0x61FFE 0x61FFF Special address map PM4000 uses Anybus CC modules as fieldbus interfaces The address map for this seen from the fieldbus is differe...

Page 521: ...1 16 words Addr 4200 Reg 3 15 4 Data word Out 5 12 1 16 Data word In 17 24 0 17 Data word In 18 25 1 17 Data word Out 18 25 14 18 Data word Out 19 26 Acyclic data block 1 16 words Addr 8200 Reg 3 15...

Page 522: ...ollows LED Function Indicates 1 Network Status Off No power or no IP address Green Module is in Process Active or Idle state Flashing Green Waiting for connections Red Duplicate IP address or FATAl ev...

Page 523: ...set to EtherNet IP Specify with IP address the address the AnyBus CC board should have on the network seen from a client Also specify the Subnet mask and the IP address of an optional Gateway See chap...

Page 524: ...resented in the System Map If the extended numbering is wanted and the version is 2 03 or older please contact Atlas Copco to get a description on how to upgrade the AnyBus board firmware to a newer v...

Page 525: ...Peripheral Devices 9836 3521 01 525 Steady Red Major fault EXCEPTION state FATAL error 3 Link Activity Off No link no activity Steady Green Link established Flickering Green Activity...

Page 526: ...rwarded to the CC Link master as normal PLC Data Use Name to specify the name of the device Fieldbus Type should be set to CC Link The PLC bytes In and PLC bytes Out are read only and calculated autom...

Page 527: ...6 words 44 44 192 bits 32 words 88 88 384 bits 64 words 176 176 3 96 bits 12 words 36 36 160 bits 24 words 68 68 320 bits 48 words 136 136 640 bits 96 words 256 256 1 4 128 bits 16 words 48 48 224 bit...

Page 528: ...Data bits X63 bit 63 8 9 PLC word AT 3308 Word 1 10 11 PLC word AT 3310 Word 2 22 23 PLC word AT 3322 RWr Data word registers Word 8 Two LED s on the AnyBus module indicate the status of the CC Link T...

Page 529: ...ccess the following PowerMACS functions Read and write PLC signals Read cycle data events and traces Read and write complete setups PLC Reporter Process Data Events Traces Setup Tightening Controller...

Page 530: ...ead Write 0 999 Variables in PLC area 1 Length of area as defined by drivers EXTCOM_in and EXTCOM_out on the IO_Configuration worksheet R W 1000 Cycle data 2 Max R W 2000 Events 2 Max R W 3000 Traces...

Page 531: ...ldest value data item available in the central SRAM storage 1 32767 Here value is interpreted as an earlier received device specific sequence number DataNo to which the queue should be re winded When...

Page 532: ...a area from the PowerMACS PLC is configured in two steps First you must configure how the respective area should be used by defining variables Secondly must configure the EXTCOM and or EXTCO2 driver s...

Page 533: ...e external communication device to the PLC and vice versa This is done using the I O Configuration dialogue which is invoked by double clicking on the icon for IO_Configuration worksheet of station to...

Page 534: ...The external device accesses the Process Data areas by normal read and writes accesses Since Process Data quite often is bigger than what can be transferred using a single read or write operation all...

Page 535: ...Devices 9836 3521 01 535 Write five integers at address 0 9 i e PLC input area address 2000 2009 External device is indicated with XD PowerMACS with PM Data that are irrelevant for PowerMACS are indi...

Page 536: ...ess 0 XD PM Comment XD PM Comment 0x00 Slave no 0x00 Slave no 0x03 Read command 0x10 Write command 0x01 Address MSB 0x00 Address MSB 0xF4 Address LSB 0x00 Address LSB 0x00 Size in words MSB 0x00 Size...

Page 537: ...t 0x02 STX 0x02 STX 0x10 DLE 0x10 DLE 0x00 0x00 0x00 0x00 0x45 E 0x41 A 0x44 D 0x44 D 0x01 Address MSB 0x00 Address MSB 0xF4 Address LSB 0x00 Address LSB 0x00 Size in words MSB 0x00 Size in words MSB...

Page 538: ...een the master and PowerMACS For Read and Write object the supported segments and types are Segment 0x68 Type 0x07 internal word number Segment 0x68 Type 0x08 internal double word number Checksum is c...

Page 539: ...0 Category 0x68 Segment 0x68 Segment 0x07 Type 0x07 Type 0xF4 Address LSB 0x00 Address LSB 0x01 Address MSB 0x00 Address MSB 0x05 Length LSB 0x05 Length LSB 0x00 Length MSB 0x00 Length MSB 0xD2 Checks...

Page 540: ...mand 2 0x30 Write command 0 0x30 Address digit 1 0 0x30 Address digit 1 0 0x31 Address digit 2 1 0x30 Address digit 2 0 0x46 Address digit 3 F 0x30 Address digit 3 0 0x34 Address digit 4 4 0x30 Addres...

Page 541: ...ddress 0 XD PM Comment XD PM Comment 0x10 DLE 0x10 DLE 0x02 STX 0x02 STX 0x02 DST 0x02 DST 0x01 SRC 0x01 SRC 0x01 CMD 0x08 CMD 0x00 STS 0x00 STS 0x05 TNS LSB 0x05 TNS LSB 0x00 TNS MSB 0x00 TNS MSB 0xF...

Page 542: ...eding to know the details on how they are performed Today the PowerMACS API exports functions for performing the following tasks Read and write PLC signals from to the PowerMACS station PLC Read cycle...

Page 543: ...e with having the API implemented as an ActiveX component is that it provides a standardized way of describing its public interface This makes it possible for a developer to use more or less any of th...

Page 544: ...a areas that this device accesses is the same as the area accessed via the API interface If you use these simultaneously you must co ordinate the use of the cells to avoid unwanted collisions If you w...

Page 545: ...data Events Traces Setup Tightening Controller Queues Consol Computer API API IF External SPC Package Remote Client Application Storing data Write Read OUT IN API device server PLC Process area data...

Page 546: ...ions the application can take care of the received data The parameters of the ActiveX event functions vary depending on type of subscribed data Subscribed Data Parameters Cycle Data Station Id Event E...

Page 547: ...s 9836 3521 01 547 8 14 2 Object model The below picture describes how the objects of the PowerMACS API are related to each other Api Stations Station Bolts Bolt System TraceData Channels Channel Step...

Page 548: ...specified IP address eRetWrongPlcAddress 56 Incorrect PLC address check parameters Address and or Bit eRetNoData 57 The data requested Cycle data Event Trace or Setup is not available eRetNotSupporte...

Page 549: ...tatusStopTerminateNOK 3 Stop and Terminate not OK eStatusNOKRM 4 Not OK by Reject Management RunStatusEnum This enumerator is used to indicate the status for a station or bolt when it is running Const...

Page 550: ...ct to the TC on which the station in question runs The following methods do only function if connected to the System TC If called when not connected to a System TC they will return eRetCmdNotAllowed G...

Page 551: ...cant bit and 7 is the Most significant bit Value Boolean Out Returns the result True if the read bit is 1 False otherwise 8 14 4 3 SetPLCBoolEx Description This method writes a Boolean value to the PL...

Page 552: ...n Specifies the offset in the PLC area of the Byte to read Range 0 999 Value Byte Out Returns the result Range 0 to 255 8 14 4 5 SetPLCByteEx Description This method writes a BYTE value to the PLC inp...

Page 553: ...the first byte of the Integer to read Range 0 999 Value Integer Out The read data interpreted as an Integer Range 32768 to 32767 8 14 4 7 SetPLCIntEx Description This method writes an Integer value t...

Page 554: ...LC area of the first byte of the Real to read Range 0 999 Value Single Out The read data interpreted as a Real Range 1 18 10 38 8 14 4 9 SetPLCRealEx Description This method writes a Real value to the...

Page 555: ...x Station Address Value Obj Arg Type Dir Description object Api The Api object to operate on Station Integer In Specifies which stations PLC to access Range 0 15 where 0 correspond to the station conn...

Page 556: ...bit and 7 is the Most significant bit Value Boolean Out Returns the result True if the read bit is 1 False otherwise 8 14 4 13 SetPLCBool Description This method is replaced with the SetPLCBoolEx met...

Page 557: ...n Specifies the offset in the PLC area of the Byte to read Range 0 999 Value Byte Out Returns the result Range 0 to 255 8 14 4 15 SetPLCByte Description This method is replaced with the SetPLCByteEx m...

Page 558: ...the first byte of the Integer to read Range 0 999 Value Integer Out The read data interpreted as an Integer Range 32768 to 32767 8 14 4 17 SetPLCInt Description This method is replaced with the SetPL...

Page 559: ...LC area of the first byte of the Real to read Range 0 999 Value Single Out The read data interpreted as a Real Range 1 18 10 38 8 14 4 19 SetPLCReal Description This method is replaced with the SetPLC...

Page 560: ...n Specifies the offset in the PLC area of the first byte to read Range 0 999 Value String Out The read data interpreted as a string 8 14 4 21 SetPLCString Description This method is replaced with the...

Page 561: ...o receive the read cycle data then Size is set to 0 and eRetBufferToSmall is returned Return type A RetCodeEnum value Syntax object GetCycleData Buf Size Obj Arg Type Dir Description object Api The Ap...

Page 562: ...eDataBin but data is returned even if it has already been read Return type A RetCodeEnum value Syntax object GetLastCycleDataBin Buf Size Obj Arg Type Dir Description object Api The Api object to oper...

Page 563: ...hat will be called when new cycle data arrives and subscription is switched on Return type Syntax Event RecNewCD Station Id Obj Arg Type Dir Description Station Integer In Station number Id Long In Cy...

Page 564: ...A device unique sequence number This number is incremented by one for each event reported over this device SeqNo Long Out A global sequence number This number is incremented by one for each event gene...

Page 565: ...umber is incremented by one for each event generated by the system Ts Long Out Date and time for event Expressed as no of seconds since 1970 01 01 00 00 00 Code Integer Out Event code see List of even...

Page 566: ...eX event function that will be called when TC Event arrives and subscription is switched on Return type Syntax Event RecNewEvent EventObj Obj Arg Type Dir Description EventObj Event Data In Event data...

Page 567: ...data in Buf 8 14 4 39 GetTraceEx Description Call this method to read the next Trace from the FIFO queue for the API device The data is returned as a TraceData object The FIFO queue can hold max 100 t...

Page 568: ...escription OnOff Integer In Set 1 to switch subscription on Set 0 to switch off 8 14 4 42 RecNewTrace Description Format for ActiveX event function that will be called when Trace arrives and subscript...

Page 569: ...e Syntax object SubscribeStStatus OnOff Obj Arg Type Dir Description OnOff Integer In Set 1 to switch subscription on Set 0 to switch off 8 14 4 46 RecNewStStatus Description Format for ActiveX event...

Page 570: ...ceive the uploaded setup Size Long In Out At call Max length of Buf At return The length of the returned data in Buf 8 14 4 48 SetSetup Description This method downloads a setup in binary form to the...

Page 571: ...operate on Item String In The string specifying which parameter to read see Layout of Setup Item Descriptions Value Single Out The value of the read parameter 8 14 4 50 SetSetupItem Description This...

Page 572: ...operate on SysDesc System Out A reference that can hold the returned System object Is set to Nothing null if error 8 14 4 52 GetStationDesc Description This method returns a Station object that descri...

Page 573: ...ported Date IDL data type DATE Long Will return the date and time as number of seconds since 1970 01 01 00 00 00 8 14 4 54 SetDateAndTime Description This method sets the current date and time of the...

Page 574: ...n the date and time as number of seconds since 1970 01 01 00 00 00 8 14 4 56 SetTime Description This method sets the current date and time of the target system Compatible with VisualStudio NET Return...

Page 575: ...stem object Property Name Return Type Description Name String The name of the system as entered for the System object using the System form Stations Stations The collection of all Station objects that...

Page 576: ...8 14 6 2 Item Description Returns a specific Station object in the collection either by position or by the Name property of the Station object If the value provided as IndexKey does not match any exis...

Page 577: ...the object exists else False Syntax object Exists IndexKey Obj Arg Type Dir Description object Stations The Stations object to operate on IndexKey Variant In An expression that specifies the position...

Page 578: ...of the Station as entered for the Station object using the System form Number Integer The number of the station within the system 1 15 IpAddress String The IP address of the station as dotted decimal...

Page 579: ...an object of type Bolts 8 14 8 2 Item Description Returns a specific Bolt object in the collection either by position or by the Name property of the Station object If the value provided as IndexKey do...

Page 580: ...f the object exists else False Syntax object Exists IndexKey Obj Arg Type Dir Description object Bolts The Bolts object to operate on IndexKey Variant In An expression that specifies the position of a...

Page 581: ...Name String The name of the Bolt as entered using the System Map Number Integer The number of the bolt within the station 1 100 First bolt is always 1 UserBoltNo Integer The bolt number assigned to th...

Page 582: ...taNo Integer A device unique sequence number This number is incremented by one for each trace reported over the device DateAndTime Data Timestamp of trace in Data format PgmName String Name of program...

Page 583: ...11 2 Item Description Returns a specific Channel object in the collection either by position or by the Name property of the Channel object If the value provided as IndexKey does not match any existing...

Page 584: ...the object exists else False Syntax object Exists IndexKey Obj Arg Type Dir Description object Channels The Channels object to operate on IndexKey Variant In An expression that specifies the position...

Page 585: ...ion that evaluates to an object of type Channel 8 14 12 2 GetSampleValueNo Description Give sample time as parameter and get sample number as reply Return type A Long value Sample number possible valu...

Page 586: ...collected for the channel Return type A RetCodeEnum value Syntax object GetSampleValues Buf Size Obj Arg Type Dir Description object Channel The Channel object to operate on Buf Single Out Array of S...

Page 587: ...operties of the StepBounds object is as follows object PropertyName 8 14 13 2 Item Description Returns a specific StepBound object in the collection by position If the value provided as IndexKey does...

Page 588: ...lean value True if the object exists else False Syntax object Exists IndexKey Obj Arg Type Dir Description object StepBounds The StepBounds object to operate on IndexKey Variant In An expression that...

Page 589: ...object Property Name Return Type Description StepNo Long The step number that the start and stop times apply to StartTime Single The time difference from Ts to when the step started StopTime Single T...

Page 590: ...nt type see View Event Log Station Integer Station on which the event occurred 0 if not relevant Bolt Integer Bolt for which the event occurred 0 if not relevant Observed Boolean TRUE if event is obse...

Page 591: ...t Set up your Visual Basic environment according to the following PowerMACSAPI must be installed on the computer PowerMACSAPI must be checked in the project references dialog Do not create more than i...

Page 592: ...Here we just do one call to see if there are any cycle data waiting for us Private Sub cmdGetCd_Click Abstract Get cycle data from API server and display it On Error GoTo ErrorHandler Dim Size As Long...

Page 593: ...mPowApi_RecNewCd Station As Integer Id As Long Abstract New Cycle data notification received from the API On Error GoTo ErrorHandler Dim Size As Long Dim Ret As RetCodeEnum Dim Buf As String Size 100...

Page 594: ...er Dim Ret As RetCodeEnum Dim Address As Integer Dim Value As Boolean If Val txtAddress 1 Or Val txtAddress 999 Then MsgBox Address must be between 1 and 999 txtAddress SetFocus Exit Sub End If Addres...

Page 595: ...isplay it On Error GoTo ErrorHandler Dim Ret As RetCodeEnum Dim Address As Integer Dim Value As Boolean If Val txtAddress 1 Or Val txtAddress 999 Then MsgBox Address must be between 1 and 999 txtAddre...

Page 596: ...s and receive result The device offers the following two interfaces A special configuration of the standard DeviceNet fieldbus the input and output maps are predefined and fixed A discrete I O using d...

Page 597: ...ame time If both are active then the corresponding input signals will be OR ed together Note 1 To ensure Operator Safety it is possible to disable all of the input bits from the DeviceNet interface as...

Page 598: ...just passed through to PowerMACS discrete I O interface local I O Red Light This signal is just passed through to PowerMACS discrete I O interface local I O Alarm Horn This signal is just passed thro...

Page 599: ...s until the cycle is completed and the result is presented Spindle Stop Disable Is used to stop the current cycle and to inactivate the spindles from any future cycle Must be 0 to permit a new cycle t...

Page 600: ...le Error Proofing Ready EPR DO_GM_EprOut 5 7 Spare 1 0 0 Spindle 1 Good Rundown Green Light DO_GM_Green_Sp1 1 Spindle 1 Remove Red Light DO_GM_Red_Sp1 2 Spindle 1 Low Torque Yellow Light DO_GM_Yellow_...

Page 601: ...e Indication schema below for a description of how this output is set Spindle x Remove See Indication schema below for a description of how this output is set Spindle x Low Torque See Indication schem...

Page 602: ...Depending on the outcome of the Monitoring result and the Control strategy of the used program the result for each bolt is indicated according to the following schemas Torque Control strategy TORQUE B...

Page 603: ...status of the bolt is OK ANGLE status Bit in Errors Low ALM Angle too low during monitoring see chapter Monitoring Check Angle High AHM Angle too high during monitoring see chapterMonitoring Check Ang...

Page 604: ...started from the PowerMACS PLC or the Test Bolts form using the PLC System Globals Station variables ACTA_ACTIVE and DISBALE_ACTA The PLC program created by default when no GM DeviceNet device is use...

Page 605: ...em global ACTAMODE will reflect the mode selected from the ACTA and it is possible to connect this to the output MODE Calculation of Torque Scale Factor The ACTA unit can calculate a new torque scale...

Page 606: ...ew data is available Since a process data item e g one cycle data often are bigger than what can be handled by a single read or write access it is accessed through successive reads or writes where eac...

Page 607: ...ll occur when the cycle data is requested all data is written in Hexadecimal notation A Cycle data Package returned by the first read request 0 0x41 A 0 0x00 1 0x42 B 1 0x01 SEQ 1 2 0x43 C 2 0x00 3 0x...

Page 608: ...d non zero True Short integer 2 bytes 16 bit 2 complement signed binary 32768 32767 Long integer 4 bytes 32 bit 2 complement signed binary 2 147 483 648 2 147 483 647 Time 4 bytes 32 bit long integer...

Page 609: ...Par 1 char 4 First parameter for the EventStr see below for a description 128 Par 2 char 4 Second parameter for the EventStr see below for a description 132 Par 3 char 4 Third parameter for the Event...

Page 610: ...s Long integer Number of angle samples 0 2000 34 NoCsamples Long integer Number of current samples 0 2000 38 Not used Long integer Always zero 0 42 PgmName char 21 Name of program used at the occasion...

Page 611: ...he following parts of a setup may be modified individually Bolt Spindle Parameters Spindle Channel data Programs General data Programs Monitoring data Sequences and programs Step Control data Sequence...

Page 612: ...no 1 Max station no bolt no 1 Max bolt no in that station parameter See table below parameter Data type Description OpMode Short integer Operation mode 0 Connected 1 Disconnected OK 2 Disconnected NO...

Page 613: ...an If torque channel difference test should be enabled TDiffUseSpindle Boolean If spindle s limits should be used TDiffChannels Short integer Channels to compare 1 Current compared to Torque Channel 1...

Page 614: ...p for Angle Channel 1 ExtWindUp2 Float External Equipment Replacement WindUp for Angle Channel 2 Example Spindle 1 Direction 8 17 5 3 Spindle Channel data Syntax Spindle spindle no Chan channel no par...

Page 615: ...s Use2ndMonBuf Boolean If true then 2nd monitoring buffer is used if there is more than one used torque or angle channel ReportTqLimit Float Report threshold torque limit If none of the bolts executed...

Page 616: ...race will start TraceStartQty Short integer Specifies an addition condition for when to start recording a trace Takes one of the following values 0 None 1 When the measured angle reaches the value Tra...

Page 617: ...when to end monitoring Takes the following values 1 At cycle end 3 When the measured torque reaches the value MonEndTorqueVal MonStartTorqueVal Float The torque value to reach before starting monitor...

Page 618: ...n by the order they are listed in chapter Step Control Example Program Pgm01 Step 1 Control Sync Program Pgm01 Step 1 Control Par 1 8 17 5 8 Sequence and Program Step Speed data Syntax Program pgm nam...

Page 619: ...rogram step no Step number 1 50 ramp Ramp number 1 5 parameter See table below and Step for a description parameter Data type Description Start Short integer Defines the quantity to monitor as start c...

Page 620: ...pikeAngle Float Torque spike elimination angle StopMethod Short integer How to stop Allowed values 1 Inertia break 2 Ramp down current 3 Hold Torque InitialStopValue Float The start level of the amper...

Page 621: ...Parameter number 1 12 as listed in the description Example Program Pgm01 Step 1 Surveillance 1 Par 1 8 17 6 Layout of Setups A Setup is a complete package of data containing all information necessary...

Page 622: ...Peripheral Devices 622 9836 3521 01...

Page 623: ...quency 1000 Hz Stations per system 1 15 Spindles per system 1 50 Delays in set values to servo 2 x sampling time Maximum time for a loop in the PLC program 5 Maximum number of cycle data stored in the...

Page 624: ...624 9836 3521 01 9 2 Requirements ToolsTalk PC Requirements for a ToolsTalk computer Windows XP or Windows 7 CPU clock frequency min 1 GHz Memory min 1 GB Disc with min 200 MB free Monitor resolution...

Page 625: ...System Established connection to TC d 104 12 Hardware Error System TC d is of wrong type 105 13 Hardware Error System Spindle TC d is configured as system TC 106 442 Hardware Error System TC d is of...

Page 626: ...nfo Cycle start disabled 620 425 Setup Error Start is impossible since bolt d and d both uses TC d 621 434 System Error Station failed to reach TC Bolt is disconnected OK 622 435 System Error Station...

Page 627: ...etup Error Step d Incorrect Torque spike elimination setup 713 49 Setup Error Step d Incorrect Pre step time 714 50 Setup Error Step d Incorrect Post step time 720 56 Check Error Step d Monitoring Fin...

Page 628: ...Setup Error Step d Restriction Incorrect FS Time 752 88 Setup Error Step d Restriction Incorrect Cross thread and gradient 753 89 Setup Error Step d Restriction Incorrect Torque profile 754 90 Check E...

Page 629: ...ncorrect Clamp Load 785 121 Setup Error Step d Check Incorrect Time 786 122 Setup Error Step d Check Incorrect Post view 787 123 Check Error Step d Check Post view Torque failed 788 504 Check Error St...

Page 630: ...f 822 157 Check Error Step d Check Torque at the corner f f 829 164 Setup Error Step d Check Shut Off Torque has bad configuration 830 165 Check Error Step d Check Shut Off Torque f f 831 166 Check E...

Page 631: ...d illegal Retry order in SP_RUN_STEPS from station Spindle running d 876 479 Check Error Step d Check Peak torque failed 878 481 Check Error Step d Diagnostic Static Zero Offset high on T2 abs f f 879...

Page 632: ...e transducer angle diff high 909 195 System Error Info Monitoring Overflow in recording buffer d 910 196 Hardware Error Step d Servo hardware failure Id d 911 197 Setup Error Incorrect Servo configura...

Page 633: ...to write process data 1507 886 Ext com Error ID read error on TC d port d Tot length of string was more than d chars 1508 887 Ext com Error ID read error TC d port d Start char was never received mus...

Page 634: ...p Item req Only allowed on TC 1 1906 242 System Info API on TC d failed to send answer cmd d ret d 2001 243 System Error CCH Error when receiving type d d1 d d2 d 2005 247 System Error CCH Unable to d...

Page 635: ...wed now d and d 3204 355 System Error PLC EXTCOM area input d output d is too big max d bytes 3205 356 Setup Error PLC ANYBUS variables defined but no Fieldbus device exists 3206 357 Setup Error PLC O...

Page 636: ...ldbus on TC d Configuration error d 3402 377 System Error ToolsNet Illegal message received error type d info d 3403 378 Ext com Info Toolsnet Connection to server established using protocol ver f 340...

Page 637: ...o d 3500 382 System Error SPC DB read error d 3501 383 System Error SPC Out of memory 3503 384 System Error SPC Variable does not exist Bolt d StepNo d Var d 3504 385 SPC Error SPC One out check faile...

Page 638: ...546 Ext com Error EPH Bad length of received TMU acctual d expected d 3817 508 Ext com Error EPH No response from PLUS server 3818 509 Ext com Error EPH Wp Id has bad layout Length d 3819 510 Ext com...

Page 639: ...3843 616 Ext com Info EPH Total length of IT and IW is d chars Truncated after d chars 3845 618 Ext com Error EPH Send data failed Wp ID must start with specified VIN number type 3846 619 Ext com Err...

Page 640: ...d by group d already is occupied 3869 738 System Error EPH Start failed since station d used by chan d already is occupied 3871 739 System Error EPH Start failed since groups does not have the same ba...

Page 641: ...d 4105 597 Ext com Info ACTA Torq SF changed for T1 on spindle d old f new f 4106 598 Ext com Info ACTA DATAHOLD or DATADROP used no cycle data will be avaliable for ACTA 4107 599 Ext com Warning ACT...

Page 642: ...TC d Simulated Spindle and Servo in use 4230 680 System Info TC d Replaced ramp down with i brake too short time between start stop 4231 903 General Info Conv Box TC d New box detected 4232 904 Gener...

Page 643: ...Error TC d Servo Motor parameters invalid 5004 754 Hardware Error TC d Servo Motortune parameters invalid 5005 755 Hardware Error TC d Servo software error Id d Code d 5006 756 Hardware Error TC d Se...

Page 644: ...unication Error WD d 5057 615 General Info TC d Not possible to start motortune cycle running or TC is emergency stopped 5070 786 Hardware Error TC d Spindle Software Warning 5071 787 Hardware Error T...

Page 645: ...815 System Error TC d Error reading motor temp from spindle Ref d Status d 5213 816 System Error TC d Error writing electronics temp to spindle Ref d Status d 5214 817 System Error TC d Error reading...

Page 646: ...d Status d 5234 837 System Error TC d Error reading motortune params from spindle Ref d Status d 5235 838 System Error TC d Error writing motor params to spindle Ref d Status d 5236 839 System Error...

Page 647: ...TC d Error writing bootloader to spindle Ref d Status d 5256 859 System Error TC d Error reading bootloader from spindle Ref d Status d 5257 860 System Error TC d Error writing application to spindle...

Page 648: ...tem Error TC d Error writing hardware revision to servo Ref d Status d 5316 879 System Error TC d Error reading hardware revision from servo Ref d Status d 5317 880 System Error TC d Error writing boo...

Page 649: ...Setup Error No step failed used customer step name in first CE step step d instead 5715 888 Setup Error Step d Control Local DI d cannot be used since TC type is not PTC 5716 912 Check Error Step d BC...

Page 650: ...5738 939 Pos reg Info Step d PosValid d Stored External Postion f 5739 940 Abs pos Info Acctual Internal position d Acctual External position f 5740 941 Setup Error Step d Store of position register...

Page 651: ...d was never started 5761 411 Check Error Step d Check Low spot torque failed start angle was never reached 5762 412 Check Error Step d Check Low Spot Torque High f f 5763 413 Check Error Step d Check...

Page 652: ...Appendix 652 9836 3521 01 Code Comp Code Type Severity Event string 8001 899 General Info TFTP Software update of TC d failed...

Page 653: ...f ToolsTalk PowerMACS should connect or not against the target system known by ToolsTalk PowerMACS If not specified the same on line state as ToolsTalk PowerMACS had when it was last closed is assumed...

Page 654: ...ame Warnings Limits Bolt T Station QO Compact Errors Limits Bolt A Station SA Bolt Name Station AB Cust Error Id Res 4 Amount of SRAM used for Cycle Data System with 2 bolts System with 8 bolts System...

Page 655: ...ower up the cache is empty an all requested cycle data has to be retrieved from each bolt It is possible to change TCs within a system and still be able to retrieve cycle data from them If however any...

Page 656: ...lt 02 0 OK 0 75 362 37 3 Bolt 03 0 OK 0 75 362 37 4 Bolt 04 0 OK 0 75 362 37 5 Bolt 05 0 OK 0 75 362 37 6 Bolt 06 0 OK 0 75 362 37 7 Bolt 07 0 OK 0 75 362 37 Data No Station 2 Station Stn 01 2008 03 0...

Page 657: ...r the spindle before it allows a cycle to be started This is indicated by the following events 4231 Conv Box TC n New box detected 4233 Conv Box TC n Motortune is required and calibration is recommend...

Page 658: ...spindle Ref 89 Status 50 5262 TC 1 Error reading reference from spindle Ref 90 Status 50 5262 TC 1 Error reading reference from spindle Ref 100 Status 50 5262 TC 1 Error reading reference from spindle...

Page 659: ...in the folder SpindleType which is located in the folder that TTPM was installed to normally C PM4000 7 4 2 By default this folder only contains files for QST spindles The files corresponding to QMR...

Page 660: ...x02 Out of space in user stack pool 0x03 Too many processes were created 0x11 Too large signal buffer requested 0x12 Out of space in kernel pool 0x1d An attempt to kill a static semaphore was made 0x1...

Page 661: ...n freed or is otherwise not owned by any process 0x58 An attempt was made to install an unreasonably small pool fragment 0x59 The tick system call was called concurrently by several processes 0x5b An...

Page 662: ...n breakpoint was encountered 0x105 An unknown interrupt was encountered 0x107 A prioritized or background process ended 0x108 Startup stack overflow 0x109 The CPU model is not recognized The kernel co...

Page 663: ...es 11 1 References to external documents 1 Functional and Technical Description PowerMACS 4000 TCs 2 Calibration with ACTA Atlas Copco Tools document No 9836 2086 00 3 Specification Open Protocol Atla...

Page 664: ...References 664 9836 3521 01...

Page 665: ...or Torque sensor Angle sensor Often one bolt is tightened with one spindle but it is possible to configure the system so several bolts are tightened with one spindle Program steps and sequences How th...

Page 666: ...000 system It is a Windows based program that executes on the console computer or any PC It is used to set up a PowerMACS 4000 system and can be used to monitor the system and to collect and present v...

Page 667: ...which are run completely separate from each other but have some form of relationship In case of reject management they are considered to belong to the same group and special actions can be specified...

Page 668: ...9836 3521 01 2010 11 Edition 10 3 0 www atlascopco com...

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