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Atlas Copco
Power Tool
PowerMACS 4000
Atlas Copco PowerMACS 4000 User Manual
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PLC
248
9836 3521 01
Inputs:
Variable
Type
Use
DEVCMD_STS
INT
Overall execution status of the DEVCMD command:
ï‚·
0: Idle and OK. Command completed OK.
ï‚·
1: Idle and NOK. Command failed.
ï‚·
2: Busy executing the command.
Note!
The operation is not complete until this signal is 0 (or 1 if
it fails). After issuing a DEVCMD command you should wait
one PLC scan before evaluating DEVCMD_STS.
247
249
Table of Contents
Default Chapter
3
Table of Contents
3
1 Introduction
15
Introduction - Overview
15
Toolstalk Powermacs, the Friendly User Interface
16
Intelligent Tightening Controllers, Tcs
16
Tightening and Gauging
18
Gauging Functions
18
Gauging Applications
18
Torque to Turn Gauging Application
19
Valve Lash Gauging Application
20
Installing Toolstalk Powermacs
21
2 System Architecture
23
System Architecture - Overview
23
System Structure
24
Hardware Structure
26
Tightening Controller
27
PTC Description
30
TC Description
32
The TC HMI Menu System
34
Version Conflict Message
38
Console Computer (CC)
38
Ethernet
39
Peripheral Devices
40
Automatic Update of TC, Servo and Spindle
41
Automatic Update Overview
41
General Function
41
Replacement of the System TC and Backup TC
43
Replacement of TC3 - Tcn
43
Updating a System with New Software
43
Troubleshooting
43
Automatic Update of Servo Software
44
Automatic Update of Spindle Software
45
3 Basic Functions
47
Basic Functions - Overview
47
Windows
48
Help
51
The File Menu
52
How to Start up
54
Viewing
57
Assembly Overview
57
Station Views
60
System Map
61
View Cycle Data
64
View Statistics
66
View Trace
68
Select Which Trace to Display
69
View of Trace Curves
72
Select Trace
80
View Tightening Path
81
View Event Log
82
View I/O Signals
85
Reporter
86
Predefined Reporter Settings
86
New Reporter
87
Remove Reporter
90
Edit Reporter
91
Adding Cycle Data Variables
93
Layout of Cycle Data
95
Cycle Data Layout Example
98
Reporter Preview
103
Advanced CD Settings
104
Advanced Event Settings
104
Security
106
Registering Groups
106
Registering Users
107
Login and Logout
108
Printing
110
4 Set up and Maintenance
111
Set up and Maintenance - Overview
111
Setups and How to Handle Them
112
Backwards Compatibility
113
PLC Conversion
114
Compatibility between PM4000 Tightening and Gauging
115
Upgrade of PLC Environment
115
Set up of a New System
116
Creating a New System Using the Set up Wizard
116
System Map
124
Logical View
125
Station Node
126
System Node
126
Bolt Node
128
Programs Node
128
Reporters Node
129
Hardware Node
130
TC Node
131
Spindle Node
133
Other Device Nodes
134
Station Set up
135
Advanced Station Settings
137
Multiple Identifiers
138
Work Piece Identifier
138
Conversion Table
142
PLC Event Handling
142
Spindle Set up
145
General Page
145
Calibration Page
146
Application Page
147
Application External Equipment
148
Angle Channels Page
149
Angle Double Transducer Check
149
Torque Channels Page
151
Torque Double Transducer Check
151
Diagnostic Page
153
Static Zero Offset
153
Dynamic Zero Offset and Angle Count
154
Flying Zero Offset
154
Order of Execution
155
Motortune Page
156
Automatic Transducer Protections
157
I/O
158
Local I/O
161
ID Device Set up
162
Assembly Overview Set up
163
PLC Parameters Set up
167
Sram
168
Options
169
Set Customer Step Names
171
Set Customer Error Codes
172
Setup Problems
174
Table Export and Import
175
Table Copy
177
Handling of the Setup in the Target System
178
Backup of the Setup
178
Replacement of Tcs
180
Maintenance
181
Select Target System
184
Test Bolts
186
Calibration Procedures in Powermacs
190
General
190
Torque
192
Angle
194
Wind up Coefficient
195
Current (Torque)
197
Event Statistics
198
Service Log
199
Replace ID String
200
Configure Target System
201
Advanced Mode
202
Information Fields
203
Restart of Tc's after Download
203
Prepare TC for Download of Software
207
Change Net Data
209
Clear Data
210
Compare Programs
211
Check for System Conflicts
213
TC Crash Log
214
5 Plc
215
PLC - Overview
215
General
216
System Globals
218
Station Variables
218
Loosening Cycles
225
Bolt Variables
231
ID Device Variables
235
Multiple Identifier Variables
236
GM Devicenet Variables
238
DC PLUS Variables
240
Globals
243
Bolt Specific Commands
244
Device Commands
247
Programming the PLC
249
PLC Console
254
PLC Parameters
256
Display PLC Status
257
6 Tightening
258
Tightening - Overview
258
Create a New Tightening Program
259
The Tightening Program Form
260
Tightening Program Step Operations
262
The Mode Table Form
264
Tightening Program
266
Program Properties
268
Program Common Properties
268
Program User Variables
268
Program Settings
270
Step - Control
273
DT - Run until Dyna-Tork
274
DT2 - Run until Dyna-Tork
276
TM , Method 2
276
DT3 - Run until Dyna-Tork
277
TM , Method 3
277
T - Run until Torque
278
TC - Run until Torque with Current Control
279
AO - Run until Angle with Overshoot Compensation
280
A - Run until Angle
282
Y1 - Run until Yield Point, Method 1
283
Y2 - Run until Yield Point, Method 2
284
LT - Loosen until Torque
285
RA - Release Angle
287
PA - Run until Projected Angle
289
TD - Run until Torque Has Decreased
290
E1 - Run Engage Method 1
291
E2 - Run Engage Method 2
291
NS - Run until Next Step
291
TI - Run until Time
291
GS - Run Gear Shift
292
PLC - Run PLC Step
292
JOG - Run until Digital Input Goes High / Low
293
W - Wait
293
TA - Run Torque-Angle with no Stop
294
SR - Socket Release
300
ADT-Angle Delta Torque
301
SG - Snug Gradient
303
D - Diagnostic Step
304
BCT - Backlash Correction (Only Available for Gauging)
305
POS - Run to Position (Only Available for Gauging)
305
Step - Restriction
307
Fail Safe Torque
308
Fail Safe Time
309
Fail Safe Angle
310
Min Torque Restriction
311
Gradient
313
Cross Thread and Gradient
315
Torque Profile
316
Angle Difference
318
Torque Difference
319
Step - Check
320
Result Values from Checks
321
Check Peak Torque
322
Check Torque in Angle Window
324
Check Torque in Time Window
325
Check Mean Torque
326
Check Angle
327
Check Post View Torque
329
Check T/T3 (Current as Torque)
331
Check Shut off Torque
332
Check Torque Rate
333
Check Zero Crossing (Only Available for Gauging)
336
Check Time
338
Check Yield Point Angle
338
Check Stick Slip
340
Delta T (Only Available for Gauging)
342
Check Position (Only Available for Gauging)
343
Low Spot Torque (Only Available for Gauging)
343
Check Backlash Angle (Only Available for Gauging)
344
Check External Input (Only Available for Gauging)
344
Step - Rejects
345
Checking the Bolt Status
346
Deciding What to Do
347
Configuring Reject Management
350
Advanced RM Actions
352
Cycle RM
353
Reject Management States
355
Reject Management Examples
361
Step - Ramps & Other
363
Ramps & Other - Ramps
364
Ramps & Other - Other
365
Ramps & Other - Store Position (Only Available for Gauging)
366
Ramps & Other - Signals at Step Start and End (Only Available for Gauging)
367
Zones (Only Available for Gauging)
368
Bolt Monitoring
369
Monitoring Check - Final Peak Torque
372
Monitoring Check - Angle
373
Monitoring Check - Torque Rate
376
Monitoring Check - Monitoring Yield Point Torque and Angle
379
Result Variables
382
Statuses
382
Station Level Result Variables
383
Bolt Level Result Variables
385
Errors
390
Warnings
394
Step Level Result Variables
395
Servo and Spindle Protections
399
Stall Protection
399
How to Avoid the Problems
399
7 SPC and Statistics
401
SPC - Overview
401
SPC, Statistical Process Control
402
Data Collection
402
Calculations for Subgroups
403
Calculations and Checks
403
SPC Constants
407
SPC Set up
408
Shift Reports and Shift Set up
410
Shift Set up
411
8 Peripheral Devices
413
Peripheral Devices - Overview
413
Add a Device
415
Status of a Device
417
Standard Accessory Devices
418
Stacklight
418
Indicator Box
419
Operator Panel
421
I/O Device
423
Printer on TC
424
Printer or File on CC
424
Plc
425
ID Device
429
Type Specific Parameters
430
Barcode Scanner
430
Pepperl + Fuchs Escort Memory
431
Allen Bradley Escort Memory
432
Omron Escort Memory
433
Euchner Card Reader
435
Toolsnet
436
Ethernet Protocols
439
Open Protocol
442
Automatic/Manual Mode
443
Supported Message Types
445
TC Status Record Formats
448
TC Result Record Formats
449
Daimlerchrysler PFCS
451
PFD Result Record Formats
452
Supported Message Types
452
Fsh
453
Supported Message Types
454
TC Result Record Formats
455
DC Plus
456
Parameters for PDT
457
Parameters for PQD
459
Handling of PN, KN and LI, in Protocol Version PDT
461
Handling of QO and FP
462
Saw / Wis
463
Sps
465
Vba
466
Sse
467
TC Result Formats for PDT
468
TC Result Format for PQD
470
Selecting the Data to Report
472
Mapping of Data
473
I-P.M
473
Value Sent as Maintenance Sequence (AFO-Number)
475
Possible Error Codes
476
Characteristic Identifications
477
Parameter Identifications
477
Audi XML
478
Fieldbus Interface
480
Access to PLC Data
485
PLC Areas
487
Complex Data Types
488
Set up Shared Variables
491
Fieldbus Form
495
Access to Process Data
498
Using the Extended Format
504
Fieldbus Specific Information
506
Devicenet
506
Profibus DP and DP-V1
510
Profinet IO
514
Modbus TCP
518
Ethernet/Ip
523
CC-Link
526
Serial Communication
529
Accesses from External Communication Device
530
Access to PLC Data
532
Access to Process Data
534
Serial Communication Protocol Information
534
Jbus
536
Siemens 3964R
537
Telemechanique UNI-TE
538
SATT Comli
540
Allen-Bradley Data Highway (Plus)
541
API, Application Programmers Interface
542
Subscriptions
546
Object Model
547
Enumerators Exported by the API
548
Api Object
550
Properties
550
Getplcboolex
551
Setplcboolex
551
Getplcbyteex
552
Setplcbyteex
552
Getplcintex
553
Setplcintex
553
Getplcrealex
554
Setplcrealex
554
Getplcstringex
555
Setplcstringex
555
Getplcbool
556
Setplcbool
556
Getplcbyte
557
Setplcbyte
557
Getplcint
558
Setplcint
558
Getplcreal
559
Setplcreal
559
Getplcstring
560
Getcycledata
561
Getcycledatabin
561
Getlastcycledata
562
Getlastcycledatabin
562
Getcycledatabyid
562
Subscribecd
563
Recnewcd
563
Getevent
564
Geteventex
565
Geteventobj
565
Subscribeevent
566
Recnewevent
566
Gettrace
567
Gettraceex
567
Getlasttrace
567
Subscribetrace
568
Recnewtrace
568
Subscribeststatus
569
Recnewststatus
569
Getsetup
570
Setsetup
570
Getsetupitem
571
Setsetupitem
571
Getsystemdesc
572
Getstationdesc
572
Getdateandtime
573
Setdateandtime
573
Gettime
574
Settime
574
System Object
575
Properties
575
Item
576
Properties
576
Stations Object (Collection)
576
Exists
577
Properties
578
Station Object
578
Bolts Object (Collection)
579
Item
579
Properties
579
Exists
580
Bolt Object
581
Properties
581
Properties
582
Tracedata Object
582
Channels Object (Collection)
583
Item
583
Properties
583
Exists
584
Channel Object
585
Getsamplevalueno
585
Getsamplevaluetime
585
Properties
585
Getsamplevalues
586
Item
587
Properties
587
Stepbounds Object (Collection)
587
Exists
588
Properties
589
Stepbound Object
589
Eventdata Object
590
Properties
590
How to Use the API
591
GM Devicenet
596
Interface Definition Input
598
Interface Definition Output
600
Indication Schema
601
Acta 3000
604
Process Data
606
Data Types
608
Layout of Cycle Data in Process Data
608
Layout of Events in Process Data
609
Layout of Traces in Process Data
610
Layout of Setup Item Descriptions
611
Bolt
612
Spindle, Parameters
613
Spindle, Channel Data
614
Program, General Data
615
Program, Trace Data
616
Program, Monitoring Data
617
Sequence and Program, Step, Control Data
618
Sequence and Program, Step, Speed Data
618
Sequence and Program, Step, Speed, Ramp down Data
619
Sequence and Program, Step, Other Data
620
Layout of Setups
621
Sequence and Program, Step, Surveillance Data
621
9 Specification
623
Requirements Toolstalk PC
624
10 Appendix
625
List of Events
625
Toolstalk Powermacs Command Line
653
Cycle Data Storage
654
Store 5000 Cycle Data
654
Storing and Retrieving Cycle Data
655
Configuration of the Conversion Box
657
Fatal Software Errors
660
11 References
663
References to External Documents
663
12 Glossary of Terms
665
Glossary
665
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Atlas Copco PowerMACS 4000 Specifications
General
Brand
Atlas Copco
Model
PowerMACS 4000
Category
Power Tool
Language
English
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