Atlas Copco ACTA 4000 Torque Analyzer Operation and Calibration Guide

Atlas Copco ACTA 4000 Torque Analyzer: A Complete Operating Guide from Basic Measurement to Advanced Analysis

In the quality control of bolt assembly, the accuracy and traceability of torque measurement are directly related to product safety and process stability. Atlas Copco's ACTA 4000/3000 torque analyzer, as a portable torque measurement and statistical analysis platform, covers the whole scenario requirements from simple torque inspection to complex SPC process control, tool calibration and ISO 5393 performance test. The three functional levels - Basic, Quality Control, and Advanced Analysis - respectively meet the different levels of maintenance workshop, production line quality control, and in-depth analysis. This article is based on the ACTA 4000/3000 user manual (version 3.21), which systematically outlines the core functions and operating points of the instrument from startup configuration, fast programming, synchronous measurement, calibration process to statistical analysis, providing a practical technical guide for quality engineers and maintenance personnel.

System Overview and Version Function Layering

The ACTA series currently mainly includes two hardware models, ACTA 4000 (color display, USB/Ethernet interface, larger storage) and ACTA 3000 (black and white display, RS232 interface), which share the same operating logic and menu tree, but differ in storage capacity and interface.

The core capabilities of the three functional versions are as follows:

ACTA Basic (Basic Edition): Suitable for simple torque checks - measuring direct drive, pulse, and residual torque tools, calculating mean and 3 σ, single tool storage, automatic calibration and self checking, automatically identifying Atlas Copco sensors with storage chips.

ACTA Quality Control: Added functions such as tool/measurement/historical database, real-time SPC statistics, process capability index (CM/CMK), and tool calibration report printing on the basic version.

ACTA Advanced Analysis: Added functions such as displaying and scaling the tightening curve (Trace), saving and transferring the curve to ToolsTalk QAT software on the basis of the QC version.

On site engineers can choose the version according to actual needs, and the hardware supports connecting to a PC through USB, RS232, or Ethernet, combined with ToolsTalk QAT software to achieve deep data management and report output.

Key points for startup and initial configuration

2.1 Sensor Connection and Automatic Recognition

ACTA supports multiple torque sensors, including Atlas Copco's IRTT series with storage chips, Atlas Microtorque/Microtec, and third-party sensors. Ensure that there is no load on the sensor when starting up, otherwise automatic calibration may fail. After connection, ACTA automatically reads the calibration data stored in the sensor (sensitivity, calibration torque, serial number, etc.) and briefly displays the calibration dialog box on the screen.

For non Atlas Copco sensors, it is necessary to manually configure the sensitivity (mV/V), bridge resistance, calibration torque, angle encoder parameters, etc. of the sensor by entering Conf → Diagnostics → Transformer. Up to 10 sets of sensor configurations can be stored.

2.2 Interface Navigation and Language Settings

ACTA adopts a dialog style menu structure, with the bottom soft keys corresponding to different functional blocks (Qprog, Stat, Conf, Datab, Prog, A.lyse). Switch pages using the left and right arrow soft keys, and select from the list using the up and down arrows. Supports 10 languages including English, German, French, Spanish, Italian, Swedish, Portuguese, Polish, Czech, and Japanese.

It is recommended to go to Conf → Interface → User for personalized settings when using it for the first time:

Language: Choose a language

Date/Time: Set the date and time (automatically synchronized after connecting to ToolsTalk QAT)

Torque unit: default Nm, optional lbf.ft, lbf.in, kgf.cm, etc

Result header: Select to display tool name, application name, or both

Buzzer: configurable to sound every time tightened, NOK tightened, or batch completed

Quick Programming - Core Features to Get Started in Five Minutes

Quick Programming (Qprog) is one of the most practical features of ACTA, allowing users to quickly establish measurement tasks without a deep understanding of the meaning of each parameter. Q. Prog covers three major scenarios:

3.1 Tool measurement (without controller synchronization)

Select the tool type in Qprog:

Direct drive: Dynamic measurement of direct drive tools

Pulse: Pulse tool for dynamic measurement (filter frequency needs to be set, usually 850Hz)

Wrench: Static torque check of torque wrench (Peak or Static installed torque strategy can be selected)

Click wrench: Set wrench release torque check

After selecting the type, ACTA automatically applies the default parameters (target torque=0.75 x sensor calibration torque x range ratio), and the user can start tightening the measurement.

3.2 Synchronous measurement (in conjunction with the controller)

When it is necessary to simultaneously record the displayed values of the controller and the actual values of the sensor, use Qprog → Synchronize, which supports the following controller types:

None: No controller, manually input target value

Other controller: Non Atlas Copco controller, manually input controller readings

Focus2000/PF2000: Automatic Reading via RS232

DS/DL: DS/DL series controllers

PF3000/PF4000: Automatic reading via RS232 or Ethernet (ACTA 4000)

PowerMACS: Automatically read via RS232 or Ethernet

In synchronous mode, ACTA displays both sensor values and controller values after each tightening, and calculates the difference (Diff) to verify the deviation between the tool and the sensor.

3.3 ISO 5393 standard performance testing

ISO 5393 is an international standard for evaluating torque dispersion of tightening tools. ACTA has built-in testing process:

Select ISO 5393 → Standard/Custom in Qprog

Tighten each of the four test joints 25 times in sequence (high torque hard joint, high torque soft joint, low torque hard joint, low torque soft joint)

ACTA automatically calculates the combined mean torque, mean offset, and combined torque dispersion

Print or export ISO 5393 report

This test is of great value for tool procurement acceptance and regular performance verification.

Advanced Programming - Customized Measurement Parameters

For measurement tasks with specific requirements, it is necessary to enter the Program menu for detailed configuration.

4.1 Measurement Strategy

Peak (DD): The default strategy measures the peak torque during the tightening process. Suitable for direct drive tools and clutch tools, reset time can be set to ignore clutch noise.

Static installed torque: used for static inspection of torque wrenches, ACTA automatically recognizes the moment when the bolt head starts to rotate (inflection point), without the need for the operator to stop accurately.

Multistage: Used for automatic calibration of scenes, the ACTA control controller completes multi-stage measurements of "forward twist → reverse 720 ° → reverse target angle" to obtain high-precision angle values.

Break away: Used for online measurement of preset wrenches, storing peak values before slip torque occurs.

Peak (Pulse): Used for pulse tools to simultaneously measure peak torque and pulse number/frequency.

4.2 Key parameter settings

Cycle start [torque]: Tighten the cycle start threshold

Cycle complete [torque]: Cycle end threshold

Start angle [torque]: the starting point for angle measurement

Measure angle to: selectable to peak torque, peak angle, or cycle complete

End time [ms]: The waiting time after the cycle is completed, and if it exceeds the time limit, it is determined that the cycle has ended

Slip torque: Break away strategy defines' how much torque drop is considered released '

4.3 Statistics and Batch Settings

In Prog → Statistical setup:

Batch size: defines the number of tightening cycles for a single batch, and ACTA displays the batch result (OK/NOK) after completion

Subgroup size/frequency: grouping parameters used for SPC control charts

Torque/Angle Min/Max: Qualified product torque/angle upper and lower limits

LCLx/UCLx: Control upper and lower limits of subgroup mean

LCLr/UCLr: Control upper and lower limits of subgroup range

CM/CMK>: Minimum Requirements for Process Capability Index

When the batch result pops up, if a parameter exceeds the standard, the corresponding value will flash and prompt. The operator can click on Torque/Angle/Pulse to enter the corresponding statistics window to view details.

Database and tool management

The QC and AA versions have built-in tool databases that support:

New tool: Create a new tool and copy all the settings of the current tool

Select tool: Select the current measurement tool from the list

Delete tool: Delete the selected tool and all its measurement data

Clear all measurements: Clear all tool measurement data (automatically archive historical statistics to History)

Backup tool: Before adjusting the tool, backup the current tool data (including all tightening records and history), add the suffix "[#]" to the backup tool name, and it cannot be used for measurement

Information: View the total number of tools in the database, the number of tools containing measurement data, remaining/total memory, etc

The History function saves the historical records of mean (X), range (R), and standard deviation (σ) after clearing measurement data each time. Each tool can store up to 5 sets of historical data for tracking tool performance trends.

Tool calibration - closed-loop quality assurance

The tool calibration function of ACTA is used to compare the deviation between the tool/controller combination and the reference sensor, and calculate new calibration coefficients.

6.1 Manual Calibration Process

Connect ACTA with the target tool/controller to complete synchronization settings

Select the tool to be calibrated in Datab → Select tool, press SHIFT+CI to clear old data

Perform at least 25 tightening cycles (recommended quantity) and record the results

Go to Conf → Calibration → Tool to view the mean deviation

Select Read (read current coefficient), Edit (manually modify coefficient), or Store (store new coefficient) based on the controller type

The system automatically creates a backup tool (original tool name+[0]), and retains the original data for comparison

6.2 Automatic Calibration (Fixture Application)

For fixed axis tools controlled by Power Focus or PowerMACS, ACTA can automatically control the tightening process through RS232 or Ethernet:

Complete synchronization settings, select target Pset and batch size

Enter Conf → Communication → Start Batch, ACTA automatically executes multi-stage measurements

After calibration is completed, adjust the tool coefficients in the same way as manual calibration

6.3 Sensor Calibration (Dead Weight Method)

ACTA supports the use of weights and force arms for sensor calibration:

Place the sensor in the dead weight device and connect it to ACTA

Enter Conf → Calibration → Deadweight

Record the mV/V output values of unloaded and loaded with known torque in sequence (at least 3 times)

Perform linearity check (at least 2 times)

ACTA calculates new calibration values. If using Atlas Copco sensors with storage chips, the new values can be directly written into the sensor memory

Print calibration report and mark the new calibration date on the sensor

Attention: ACTA body calibration needs to be conducted in a certified laboratory, and it is recommended to do it once a year.

Curve analysis and data output

7.1 Curve Display and Scaling (AA Version)

Select View → Trace to enter the curve analysis mode, which displays:

Torque over angle curve

Torque over time curve

Angle over time curve

Torque&angle over time curve

By using A. lyse → Zoom in, you can zoom in up to 5 times continuously to observe the curve features of specific areas in detail. Adjust position allows for manual adjustment of the measurement point position (marked as manual input after adjustment). Save trace can save curves in low/medium/high resolution to the database.

7.2 Printing and Data Export

The printing of ACTA 4000 is implemented through ACTA 4000 Printer Service software (installed on PC), supporting report types:

Continuous: Print the tightening results continuously each time

Rundown: Print all tightening records of the selected tool

Tool Setup: Print the complete parameter configuration of the current tool

Tool Statistics: A statistical report of printing tools

Tool calibration: Print calibration report

ISO 5393: Printing ISO 5393 Performance Test Reports

Trace: Only ACTA 3000 supports direct printing of curves; ACTA 4000 needs to be printed through ToolsTalk QAT

The data can be transmitted to ToolsTalk QAT software via USB/RS232/Ethernet, achieving unified management of the tool database, measurement database, and supplier database, and can be accompanied by maintenance instructions and service records.

Principles and Applications of Statistical Process Control (SPC)

The built-in statistical function of ACTA is based on normal distribution and control chart theory, helping engineers monitor process stability in real time.

8.1 Core statistical parameters

X-bar: subgroup mean

R: Subgroup range (maximum minimum)

σ (standard deviation): measures the degree of data dispersion

CM (Equipment Capability Index)=Tolerance Zone/6 σ, typically required to be ≥ 1.33

CMK (Modified Equipment Capability Index)=min [(upper limit mean)/3 σ, (mean lower limit)/3 σ], typically ≥ 1.33

CAM: Improved Capability Index, based on subgroup range calculation

8.2 Control Chart (X-bar&R)

ACTA can generate X-bar control charts (monitoring process levels) and R control charts (monitoring process variations). The control limit (UCL/LCL) is calculated based on historical data:

UCL_X = X-bar-bar + A₂ × R-bar

LCL_X = X-bar-bar - A₂ × R-bar

UCL_R = D₄ × R-bar

LCL_R = D₃ × R-bar

The coefficients A ₂, D ∝, and D ₄ depend on the size of the subgroup (obtained from the table). When 7 consecutive points are on the same side or exceed the control limit, a statistical alarm is triggered, indicating possible tool wear or material changes.

Torque Supervisor Integration (ACTA 4000)

ACTA 4000 supports cooperation with Torque Supervisor software to execute preset testing routes:

Create a test route in Torque Supervisor and transfer it to ACTA 4000

Set communication parameters: Conf → Interface → Communication → TTQAT, select RS232/USB/Ethernet, client port 7502, server port 7503

Execute each test item in the route and switch through Datab → Select tool

Torque Supervisor automatically retrieves test results

Note: Importing the Torque Supervisor route will clear all existing tightening programs from ACTA memory, so be sure to back them up in advance.

Common troubleshooting

Possible causes and measures for handling the phenomenon

When starting up, the Microtorque sensor reported an error and initialization abnormality. The sensor was disconnected and reconnected

The sensor calibration values cannot be written to non Atlas Copco storage sensors, and new values cannot be manually recorded and automatically written to memory

Check the baud rate and protocol (RS232/Ethernet) for communication settings errors or wiring issues without a controller in synchronous mode, and ensure that Flow control is set to Hardware

Frequent occurrence of statistical alarms, insufficient process capability or tool wear inspection of CM/CMK values. If it is lower than the requirements, the tool or process needs to be adjusted

ISO 5393 report missing combination dispersion, incomplete tightening of all four types of joints, ensuring that each joint has been tightened 25 times

Short battery life, battery aging, or constant backlight on. Replace the battery or turn off the backlight (Conf → Interface → User → Backlight)

Maintenance and Calibration Reminders

Cleaning: After turning off, wipe with a damp cloth (water+neutral soap) to avoid oily/silicone cleaning agents

Battery: It takes 12 hours for the first charge and can be used normally thereafter; ACTA 4000 has a battery life of approximately 7 hours, while ACTA 3000 has a battery life of approximately 3.5 hours

Software upgrade: Contact a service representative to obtain the latest firmware

Calibration cycle: ACTA body is recommended to be calibrated once a year; Sensors are calibrated regularly based on their usage frequency; ACTA will automatically remind you 30 days before the calibration expires