Power MACS 4000

Quick Guide

POWER MACS 4000 QUICK GUIDE | 1

Contents
TC Interface................................................................................ 3
Software Installation................................................................. 5
Changing IP-address.................................................................. 6
Download software to TC......................................................... 9
Connect PC to TC..................................................................... 10
Basic Programming................................................................. 11
Help function...................................................................... 11
Create a new setup............................................................ 11
Add new program.............................................................. 13
Delete program.................................................................. 13
Add a step........................................................................... 13
Cut, copy or delete a step.................................................. 14
Set up problems................................................................. 15
Test bolt............................................................................... 16
Checks, Restrictions and Monitoring..................................... 17
Checks................................................................................. 18
Restrictions......................................................................... 19
Monitoring.......................................................................... 19
Advanced programming......................................................... 20
Create a new program by copying an existing................ 20
Quick set.............................................................................. 21
DynaTork............................................................................. 23
Reject Management........................................................... 24
Reporters.................................................................................. 26
Cycle data........................................................................... 26
Event log............................................................................. 27
Traces.................................................................................. 28
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TC Interface
Indicator lamps
OK
NOK
ALARM
ALL OK (TC-P only)
PRIM (TC-P only)
E-STOP (TC-P only)

Text display
TC node address
IP-address
Error messages
Software version
Torque & Angle display

Push buttons
Toggle between
displayed information
Set IP-address
Reset E-stop button
(TC-P only)

POWER MACS 4000 QUICK GUIDE | 3

TC Interface

E-stop in
Digital input and MACS IO E-stop out and
(TC-P only) MACS IO

Power connector
D-sub MACS
I/O (TC-P only)
Dip switch for
MACS I/O
D-sub and RS485
RS232/RS485 termination
(TC-P only) (TC-P only)

D-sub HD
RS232/RS485 QST Spindle
(TC-P only) Connector

External Ethernet Digital output

(TC-P only) (TC-P only)

Internal Ethernet
24V input
Ethernet Switch Anybus slot,
Power supply Fieldbus card
Interface (TC-P
only)

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Software Installation
Power MACS
To communicate with PM 4000 ToolsTalk PM has to be instal-
led on your PC. To run ToolsTalk PM, Multiprog PLC editor is
needed.

Multiprog
Install MultiProg PLC Editor on your PC
Accept all default answers
Restart the computer when prompted

ToolsTalk PM
Install ToolsTalk PM Software
Answer next to all questions
Launch the program when prompted

Since the Multiprog PLC program is an integrated part of

ToolsTalk Power MACS, both setup files are needed to run
the system. That means that every setup consists of two
files:

Example:
Demo_1sp.pm4
Demo_1sp.zwt2

POWER MACS 4000 QUICK GUIDE | 5

Changing IP-address
The only way to connect your computer to Power MACS
4000 is via Ethernet.

The Primary Tightening Controller (TC-P) has two Ethernet

ports, each with its own IP-address. The external port is for
the factory network. The internal port is for internal
communication and uses local addressing.

Connect your Ethernet cable to the switch on the backplane

of the TC-P.

The TC ID number shown on the TC and TC-P display and

TC-P is the last part of the IP address. This number needs to
be changed to a unique number if there is more than one
TC in the system.

The IP-address and TC ID number can be viewed on the

display and set via using buttons on the front of the TC.
The IP-address can also be set through the computer with
ToolsTalk PM.

1. Set the IP-address of the TC.

Use the buttons on the front of
the TC to toggle between the
menus.
a. Select Setup and enter the
Basic setup
b. Toggle to IP Setup and push
Select
c. Toggle to IF1 IP and push
change. Change the IP-adress
by using the buttons on the TC
d. Go back to the Basic setup
e. Toggle to TC number in order to
change the last part of the IP-adress. This number
needs to be unique for every TC in a system
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2. Change IP-address and Subnet mask on your PC.
a. Turn on your PC and open: Start/Control Panel/
Network connections/Local area connection
b. Click on Properties
c. If you use a VPN client. De-select the check box
Checkpoint SecuRemote
d. Scroll down and double click
Internet Protocol (TCP/IP)
e. Select Use the following IP-address
f. Enter the IP address 192.168.0.250 and Subnet
mask 255.255.255.0. Click OK

3. Use ipconfig to verify that the computer has

changed the IP-address
a. Go to Start and select Run
b. Type cmd and click OK
c. Type ipconfig and check that the IP-address is correct

POWER MACS 4000 QUICK GUIDE | 7

4. Use Ping to verify communication between your
computer and the TC-P in Power MACS 4000.
a. Go to Start and select Run
b. Type cmd and click OK
c. Type ping + IP-address of TC and check that the
TC is connected

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Download software to TC
The software version of the TC can be viewed on the TC
display or in ToolsTalk PM.

Check software version

1. Go to the Maintenance menu and select
Configure target system
2. Click Scan to view all available TC
3. Read the Software version in the column labelled Version

Download new software

To download new software to the TC, follow the
instructions below.

1. Go to the Maintenance menu and select Configure target

system Highlight the TC to be upgraded
2. Click Download
3. Browse for the Power MACS 4000 Folder and select
TC System software
4. Select the .mx file and click Open
5. Restart the TC once the new software has been downloaded
successfully

POWER MACS 4000 QUICK GUIDE | 9

Connect PC to TC
Make sure you have a Set-up before you connect. To create a
Set-up, see page 11.

1. Start ToolsTalk Power MACS and select the desired

system as described below.
a. Open the Maintenance menu and select
Select Target System
b. Click Scan to scan for new TC
c. Select the TC-P to connect to and click OK. The new
TC is marked green in the list. See picture below

2. Click Connect to connect ToolsTalk PM to the TC

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Basic Programming
Help function
Help texts can be reached
from the Help menu by
pushing F1 or from the
Help tab in the
Dynamic tool window.

Create a new setup

A set up is needed for saving and running a program.
The set up must be created before the program is built.

Make sure the TC is disconnected.

1. The Wizard for creating a new setup can be started either

from the Start page when opening ToolsTalk PM (See
picture below) or by selecting the File menu and the
New menu item

P O W E R M A C S 4 0 0 0 Q U I C K G U I D E | 11
2. In the New setup wizard the settings for the system,
station, spindles and bolts are entered. Follow the Wizard
to finish the setup

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Add new program
After the Set up is created programming can start. To add a
program the TC has to be disconnected.

1. Under the Tightening menu. Select New program

Name the new program and click OK

Delete program
1. Open System map and Select Program
2. Right click on the program that shall be deleted
3. Choose Remove program and OK

Add a step
1. To add a step, drag the step from the Dynamic tool win-
dow and drop it on the desired location in the program.
It is also possible to right click between two steps and
select Add step from the pop up menu

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2. Change the values in Settings under the menu
Control. For more detailed programming, see page 17

3. Click Apply to save the new settings in the setup

If a warning is displayed when clicking Apply this

indicates an error when programming. A description of
this is displayed in Set up problems. See page 15

Cut, copy or delte a step

1. Right click on the step and select cut, copy or delete from
the pop-up menu
2. To insert a copied step, right click where you want the
new step to be inserted and select Paste

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Set up problems
When applying new settings, during programming, a
warning message will appear if settings are missing or
incorrect.
These errors or warnings are viewed in the Set up
problems window and also at the step where the error
occurs.

To open this window go to the View menu and select

Set up problems

Unlike warnings, errors must be corrected before the system

can continue to run.

P O W E R M A C S 4 0 0 0 Q U I C K G U I D E | 15
Test bolt
Test bolt is used for running the Spindle(s) from the PC.
It is possible to run a Single run, Program or Mode.

To run a Program, follow the instructions below.

1. Click correct to correct the PC to the TC

2. Go to the Maintenance menu and select Test bolt
3. Click Program to run the created Programs
4. Under Settings, select the programs to run
5. Adjust the No. of cycles tol be carried out
6. Click Start to run the programs

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Checks, Restrictions and Monitoring

By using checks, restrictions and monitoring, the tightening

process can be monitored, controlled and evaluated.

Programming of checks, restrictions and monitoring.

1. Right click on the step or drag the selected item from the
Dynamic tool window to the step.
Note: Monitoring can only be added to Cycle End (CE)

2. Set the parameters for each item in the setting window

In the Program...

checks are marked with a yellow dot

restrictions are marked with a red dot

monitoring is marked with a blue dot

P O W E R M A C S 4 0 0 0 Q U I C K G U I D E | 17
Checks
Checks are used to define the variables that are to be
measured and the limits to check in the tightening step. All
checks can be set to Repairable or Fatal. If set to Fatal, the
tightening can not be automatically repaired.

If repairable, the Reject Management can try to re-tighten

the bolt (see Reject Management page 24). Select the Fatal
box if you want the incorrect tightening to be considered
Fatal.

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Restrictions
A Restriction stops a running step immediately if the limits
have been exceeded. A restriction can be set to Fatal if you
do not want to retry.

Monitoring
Monitoring is set at the Cycle End. The Monitoring function
is used to examine the result of an entire tightening cycle.

P O W E R M A C S 4 0 0 0 Q U I C K G U I D E | 19
Advanced programming
Create a new program by combining an existing
program

1. Select Tightening menu

2. Select New Program menu item
3. Name the new program
4. Click the check box Build a new tightening program by
combining existing programs
5. Select the program you want to reuse
6. Click the Add button and then OK
7. The new program is now added in the System Map under
Programs

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Quick set
Quick set is a function for creating a program where all
parameters can be changed quickly and easily.

1. Make sure the Program settings is highlighted

2. In the Settings menu select User variables and
click Add
3. Name the variable
4. Enter a value and unit
5. Click Apply and the variable is added to the Program
settings

POWER MACS 4000 QUICK GUIDE | 21

6. When programming a step under Settings and
Control, use the programmed Variable when entering
the targets of the step

7. When programming Checks

and Restrictions set the max.
and min. levels to a percent of
the Variable

Note: If the Value of the Variable

is changed in the Program settings,
the value will change in all places
were the Variable is used.

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DynaTork
DynaTork is a method patented by Atlas Copco designed to
overcome relaxation in the joint. When the target torque is
reached the DynaTork function holds the torque (current) in
oreder to compensate for joint relaxation.

1. IOn order to add a step, type DT Run until DynaTork

2. Fill in the values for Torque, Times and Current
percentage (If you are unsure about what values to fill in,
use the Help function to get more information)
3. Add Checks and Restrictions as described earlier

POWER MACS 4000 QUICK GUIDE | 23

Reject management
Reject Management is a function for automatically repairing
tightenings in station and avoiding more time consuming re-
pairs later in the process. When programming Reject Mana-
gement, a step to loosen the bolt is added and the program
is set to go back to an earlier step and retighten the bolt.

For examples/illustrations see next page.

1. Add two steps at the end of the program.

a. To loosen the bolt, add a Run to Angle step and set
t he direction to Backwards.
b. After this step, add a Return from repair step.

2. Click the step where the Reject Management functionality

is to be added.
a. Add the desired Checks to evaluate if the tightening
i s OK or NOK
b. In the Settings window under Rejects enter the
following settings for the Reject Management:

Retry
Loosen with step: Enter the Run to Angle step for
loosening the bolt
Start from step: Enter the step that shall start the
retightening of the bolt

First failure
Failing bolts set to Retry
Other bolts set to Wait

3. Click Apply to activate the new settings

For a more detailed guide to Reject Management use the

help function in ToolsTalk PM.

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POWER MACS 4000 QUICK GUIDE | 25
Reporters
When analysing a tightening, several tools are available in
ToolsTalk PM. Cycle data for viewing the results, Event log
for viewing errors that have occurred and Trace for a graphic
picture of what is happening in the joint.

Cycle data
After a tightening cycle has been completed, variable data
can be displayed in the Cycle data window.

Cycle data is opened by clicking the Cycle data icon on

the Toolbar.

To change the values viewed in Cycle data. Open the

Reporters menu and select 1 Screen... or select the
reporters-Screen from the System Map.

1. Click Variables
2. Choose Station, Bolt and Step variables by dragging them
from the Dynamic Tool window
3. By highlighting the variables the parameters can be
modified

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Use the Help function (F1) for more information.

Event log
After a tightening, is finalised reported events are displayed
in Event log. Brief message about the error is displayed.

To open this window go to the View menu and select

Event log

POWER MACS 4000 QUICK GUIDE | 27

Traces
Using the Trace function, the tightening can be viewed in a
graph that can, in turn, be used for analysing the program
and optimise the process. Traces can also be compared with
a reference trace for finding deviations in the tightening
process.

View trace
1. Click the Trace icon in the Toolbar to open the Trace
window
2. Open the View menu in the Trace window.
3. Select Latest to view the latest tightening
4. Set the preferred units for Bottom axes, Right axes
and Left axes to adjust the layout of the trace

Save trace
1. Go to the Trace menu and select Save to file
2. Save the trace
3. Select the View menu and Selected
4. Select trace and click OK to view the selected Trace

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 Jetlag / tta.45 Tryckeri AB, 2011:1
9833 1761 01

www.atlascopco.com
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