Atlas Copco Tensor STB Wireless Tightening Tool Deployment Guide



Atlas Copco Tensor STB Wireless Tightening Tool: A Complete Deployment Guide from Pairing to Troubleshooting

In automobile assembly, aviation assembly, and large-scale machinery manufacturing, the range of activities of operators often exceeds the constraints of wired tools and cables. Traditional electric tightening tools are limited by cable length and drag wear, which not only affects work efficiency but also poses a risk of downtime caused by cable breakage. The Tensor STB wireless tightening tool launched by Atlas Copco is based on industrial radio communication (IRC) technology and works with the Power Focus 4000/3100 controller to achieve high freedom assembly of battery power supply and wireless data transmission. However, pairing wireless systems, frequency band selection, battery management, and fault diagnosis often become new challenges for on-site engineers. This article is based on the Tensor STB user manual, systematically reviewing its system architecture, selection and configuration of two IRC standards (IRC-B and IRC-W), pairing and connection processes, standalone mode applications, common parameters, and event codes, providing assembly line engineers with a practical guide that can be implemented.

System Overview: The "Freedom" and "Rules" of Wireless Tightening

Tensor STB is the only battery powered wireless tightening tool in Atlas Copco Tensor series, which is suitable for scenarios requiring large-scale movement or frequent tool change. Its core architecture is as follows:

Tool body: includes torque/angle sensor, brushless motor, lithium battery, Bluetooth/Wi Fi communication module (depending on IRC type), directional ring function button, status LED (connection, batch, battery, alarm), and buzzer.

Communication link: Through IRC technology, bidirectional digital communication is carried out with the Power Focus controller - the controller sends Pset (parameter set) and Batch size to the tool, and the tool performs tightening and returns the results. The built-in memory of the tool can cache up to 25 tightening results, and can continue working even if temporarily out of communication range, automatically uploading after reconnection.

Controller side: RBU (at least Bronze level) and corresponding Serial Port Adapter (IRC-B) or network infrastructure (IRC-W) need to be configured. The Power Focus software version requires W7.4 or higher.

The system provides two IRC standards, and engineers need to choose based on the on-site wireless environment:

Features IRC-B (Bluetooth based) and IRC-W (Wi Fi based)

Frequency band 2.4GHz ISM, 79 1MHz channels 2.4GHz ISM, 13 22MHz channels

Anti interference adaptive frequency hopping (AFH), automatically avoiding fixed channels such as Wi Fi, requires frequency planning

Delay/anti multipath low delay, high anti multipath medium

Low power consumption (more suitable for battery power supply) and high power consumption

Deployment requirements do not require IT support, plug and play requires network administrators to allocate IP and encryption keys

Experience: If there is already a dense Wi Fi network on site, it is recommended to use IRC-B (adaptive frequency hopping can avoid conflicts); If the factory requires unified Wi Fi management and can accept high power consumption, IRC-W can be selected.

Hardware installation and antenna layout

2.1 IRC-B configuration steps

Turn off the power of Power Focus.

Connect the Serial Port Adapter to the RS232 (2) port of PF via a crossover cable and provide power to it (taking power from PF).

After power on, the antenna of the adapter should be placed in an unobstructed line of sight position, such as above the shelf or top of the equipment. The antenna can be adjusted from multiple angles to obtain the best signal.

2.2 IRC-W pre configuration

The IT department needs to open a network firewall, allow UDP communication with tool MAC addresses, and obtain encryption types (WEP64/128, WPA-PSK, WPA2-PSK, etc.) and keys.

The tool is connected to the PC through a Docking Station and uses ToolsTalk Service software to write network parameters (remote IP, port, encrypted information).

2.3 Charging Preparation

Be sure to fully charge the lithium battery before use. The battery life is about 500 charge discharge cycles, and the capacity drops to 75%. Charging time: 18V/2.6Ah for about 60 minutes, 30V/2.6Ah for about 90 minutes. The number of times it can be tightened when fully charged depends on the torque and the hardness of the joint (soft joints consume more power). Please refer to the curve chart in the manual for details.

Core configuration: Pairing and Connection

3.1 IRC-B pairing process

Pairing is a crucial step in establishing a unique correspondence between a tool and a controller, which only needs to be performed when a new tool or controller/adapter is replaced.

Tool side operation:

Ensure that the battery is charged but not installed.

Insert the battery while holding down the trigger, and release the trigger after all LEDs have turned off.

Press the trigger again, wait for the LED to light up again, and then release it (at this point, the tool enters pairing mode, and after about 10 seconds, the dual LEDs flash).

Controller side (Power Focus) operation:

Compact model: Press the F key 10 times (F10), then press Enter to confirm.

Graph model: Go to PROG → Tool → Configuration → Connection → IRC Pairing, press the soft key 'Start'.

ToolsTalk PF: In the PF Map, go to Tool → Configuration → Radio → IRC pairing.

After successful pairing, the blue connection LED of the tool and the LED on the adapter are both constantly lit, and the controller generates event codes E559 (pairing completed) and E550 (connection established). Attention: Pairing must be completed within 30 seconds after the tool enters pairing mode, otherwise timeout will occur.

3.2 IRC-W Docking

The IRC-W tool needs to be connected to a PC through a Docking Station and configured using ToolsTalk Service

Install ToolsTalk Service and select the corresponding STB model (angle or pistol style).

Set the communication port to a USB device, connect the base, and use the software recognition tool.

Enter the IP address and port number of PF in the configuration interface (default 6677, consistent with controller parameter T293).

Set the encryption type and key (provided by IT), disconnect the base after saving, install the battery, and the tool will automatically connect to PF.

3.3 Offline mode

When real-time data feedback is not required at certain workstations, the standalone mode can be enabled, allowing the tool to run independently of the controller. Configuration method:

First, in the normal pairing state, enter Tool → Maintenance → Standby through ToolsTalk PF.

Check 'Use standalone' and select the attachment type (None only supports a single Pset, ST selector or GPIO supports up to 4 Psets).

Assign Pset to each location and click "Store" to save to the tool.

Then execute the 'Disconnect tool' logic to disconnect and physically remove the tool. At this time, the blue connection LED flashes, indicating offline mode.

In standalone mode, the tool can execute pre stored Psets, with the results temporarily stored internally (up to 25 entries), and automatically uploaded after re pairing.

Battery management and energy-saving settings

The tool has a built-in "Power save timeout" parameter (T270), which automatically shuts down after 30 minutes of inactivity to save power. The adjustable range is 1-120 minutes. Restarting only requires pulling the trigger, but reconnecting takes about 10 seconds.

When the battery is low, the yellow LED flashes; When the power is empty, it is fixed to light up and the tool is automatically locked. Automatically unlock after replacing the new battery. If low battery alarms frequently occur, check if the torque and speed parameters in Pset are too high, causing excessive energy consumption.

Quick search of commonly used parameters (unique to STB)

Parameter number name description default value

T270 Power save timeout No operation Automatic shutdown time (minutes) 30

T271 Start condition Connection conditions: Off (can run without connection), Connected (must have blue light on), Start request (connection confirmation required for each start) Off

T272 Link timeout determines offline time after losing connection (ms) 5000

T276 Max sender power only IRC-B, transmit power (Full/High/Medium/Low) Full

T290 Primary tool Main tool type: Cable or IRC-B/IRC-W Cable

T293 PF IP port IRC-W communication port 6677

T294 Serial port IRC-B Serial port position (Serial 2 or internal) Serial 2

T470 Use standalone to enable offline mode No

T472 Accessory Offline Attachment Type (None/ST selector/GPIO) None

Important reminder: Changes made to T290s must restart PF in order to take effect.

Event codes and troubleshooting

Tensor STB introduces a series of exclusive event codes related to wireless communication, which can quickly locate problems:

Meaning and Handling of Event Code Names

E550 tool can access connection establishment and normal information

E551 tool inaccessible connection lost, check adapter power supply, antenna obstruction, distance (within 100m of open space), or re pair

E552 communication error occasional interference, can be ignored; Adjust the antenna position frequently

E553 pairing failure tool did not enter pairing mode or timed out, re execute pairing process

E554 command not executed (tool unreachable): The tool goes offline during batch processing operation. Please reconnect and retry

E555 condition change not reflected (tool unreachable) When switching Pset, the tool goes offline and automatically synchronizes after reconnection

E556 battery low, ready to replace battery

E557 battery empty battery replacement, tool automatically unlocks

The E558 software version does not match the tool and PF protocol version, and the lower software needs to be upgraded

E559 pairing completed successfully message

E561 tool lock (Standalone not stored) enables Standalone but does not execute "Store Standalone", configuration needs to be saved

E562 condition change not reflected (tool offline) is the same as E555, but for standalone mode, it needs to be modified in the offline interface

E601 system voltage is low, STB battery voltage is low, replace battery; PF checks the input power supply

E620 tool blockage check connection (STB is associated with E601)

E623 safety current monitoring error: The torque sensor and current estimation are inconsistent and require repair

E624 battery malfunction: The battery has an internal fault and cannot be used anymore. Please contact for recycling

E721 tool internal error (LED board disconnected) needs to be sent for repair

E808 software exception: PF end may close unnecessary connections due to excessive external program subscriptions; STB software error needs to be repaired

Typical troubleshooting scenario:

Tool unable to connect: First, check if the Serial Port Adapter is powered and if the antenna is vertical; Attempt to re pair; If it still doesn't work, check if T290 of PF is set to IRC-B/IRC-W and restart PF.

Frequent communication interruptions: reduce metal barriers between tools and adapters; For IRC-W, check if the Wi Fi channel conflicts with other APs and switch channels.

Tightening result lost: Ensure that the tool memory is not full (up to 25 entries), if exceeded, the earliest result will be overwritten; After going offline, it will automatically upload when going back online.

Practical Cases and Best Practices

Case 1: In an assembly line of a bus factory, operators need to tighten multiple points around the body of the vehicle, and wire tools frequently break cables. Using 4 sets of Tensor STBs (IRC-B) in combination with PF4000. After initial installation, the tool frequently displays E551. On site investigation found that the Serial Port Adapter antenna was obstructed by a metal fence. After being moved to the upper bracket, communication became stable, and T276 was adjusted to Low to reduce transmission power and minimize interference with other devices.

Case 2: A powertrain factory adopts the IRC-W scheme and requires real-time data upload. After deployment, E558 appeared because the PF software version was W7.2 and the tool was the latest firmware. Upgrading PF to W7.5 is compatible.

Best practice recommendations:

It is best to complete the pairing operation before the first use of the tool and backup the configuration to RBU.

Set T271 to "Connected" and ensure that the blue light is on before each tightening to avoid failure to upload results due to communication loss.

Regularly check the number of battery cycles and replace spare parts in advance after reaching 400 cycles.

When using the standalone mode, it is necessary to upload cached data in a timely manner after the tool is re paired to avoid memory overflow.