Atlas Copco Power Focus 4000 Configuration and Troubleshooting Manual

Job and multi-step tightening management

When there are multiple bolts with different torque requirements on the workpiece, the Job function can be used to combine multiple Psets or Multistage in sequence.

Job creation: Create a new job in ToolsTalk PF, add it from the list of available Psets, and set the Batch size (number of repetitions) for each Pset. Job supports "forced order" (must be in list order) and "free order" (can be chosen arbitrarily).

Job selection source: can be selected through digital input, Ethernet/serial port, recognizer (barcode), or Fieldbus.

Job Monitoring: Through Job Monitor, you can view the current progress, perform operations such as "bypass", "increase or decrease batch count", "restart", etc.

Common problem: If the Job cannot start, check if the Job select source [C201] is set correctly and if the Pset referenced in the Job exists. If the tool is locked and displays "E152 PF locked in Job mode", it means that in the forced sequence job, the current controller is not in the turn to operate and needs to wait or manually select the correct Pset.

Sync synchronization tightening (RBU Gold exclusive)

The Sync function is used for simultaneous tightening of multiple axes (such as wheel bolts), supporting up to 10 axes. Synchronization is achieved through I/O bus for time critical communication, while Ethernet is used for non real time configuration.

Configuration steps: First, connect all participating PFs in Sync to the same cell, set the Sync reference IP [C317] as the IP of the Sync reference controller, and each member points the Sync reference IP to that address.

Sync group creation: In the Sync menu of ToolsTalk PF, add members from the available PF list and select the tightening strategy (Stage or SynchroTork). SynchroTork is designed specifically for PF4000 and can continuously adjust the speed of each axis in the final stage to minimize torque differences.

Operation and diagnosis: Sync reference controller triggers startup, and all members start simultaneously. If some axes are not started, check if the member has set Tool start select source [T200] to "Sync start" and if the I/O bus wiring is intact.

Fieldbus Integration and Data Interaction

PF4000 supports multiple fieldbuses (ProfiBus DP, DeviceNet, InterBus, ModBusPlus, EtherNet/IP, etc.) to achieve efficient data exchange with PLCs.

Configuration focus: Select the bus type in the Fieldbus menu of ToolsTalk PF, set the node address, baud rate, and data length (From PF and To PF). Ensure that the data length and byte order (Motorola or Intel Endian) on the PF side and PLC side are consistent.

Common mapping items: can output status bits such as "Cycle complete", "OK/NOK", "Torque value" from PF; Control commands such as "Select Pset", "Abort Job", "Tool disable" can be written from the PLC.

Troubleshooting: If Fieldbus communication is interrupted, check for node address conflicts, bus terminal resistance settings, and cable shielding layer grounding. Event codes E466 (Fieldbus offline) and E465 (DIP switch position error) are common prompts.

Identifier and Traceability

By scanning the barcode/QR code, it is possible to bind the VIN (Vehicle Identification Number) of the workpiece to the tightening result. PF4000 supports single identifier (Type 1) and multiple identifier (Type 2-4) modes.

Configuration steps: Define the input source (serial port, Fieldbus, Ethernet, etc.), effective character length, and saliency position (i.e. extract key fields from the entire string) in the Identifier menu. Type 1 can be associated with Pset/Job selection, while other types only store additional information.

Work Order: The order in which identifiers are received can be set. If "Tool locked during work order" is activated, the tool will be locked after receiving the first identifier until all expected identifiers have been received before unlocking.

Result storage: By adjusting the memory configuration (Controller → Memory), the number of "Identifier result parts" can be increased (up to 4), and different identifier fragments can be stored in each tightening record.

Tool configuration and maintenance

8.1 Tool parameter calibration

Motor tuning: It must be performed after using new tools or replacing the motor to ensure optimal control circuit. Click on 'Do motor tuning' in ToolsTalk PF's Tool → Maintenance section, then press the tool trigger until complete (approximately 5 seconds). For Sync groups, it is necessary to use 'Sync motor tuning' and trigger from Sync reference.

Open End tool tuning: used for tube nut tools, requires performing "Open End tuning" to measure gear ratio and backlash.

8.2 Maintenance Indicator

PF4000 can record the total number of tightening times of the tool, the number of times since the last maintenance, service intervals, etc. When the set number of times or wear threshold is reached, E502 (service interval expiration) or E504 (wear alarm) is triggered. By using 'Service counter reset', the counter can be cleared and the latest service date can be updated.