POWER FOCUS 6000

POCKET GUIDE

Release 2.3

Overview of the Power Focus 6000

and Tensor STR System

POCKET GUIDE TO POWER FOCUS 6000 SYSTEM

SYSTEM OVERVIEW ............................................................................................. 6

Power Focus 6000 Controller ......................................................................... 6

Intelligent Application Module (IAM) ............................................................. 7

Display .............................................................................................................. 9

Communication ............................................................................................. 10

Audio .............................................................................................................. 10

Connections ................................................................................................... 10

IAM ..................................................................................................................11

POWER FOCUS 6000 SOFTWARE ..................................................................... 12

Menu Overview ............................................................................................. 12

Tightening Menu ........................................................................................... 12

Batch Sequence Menu .................................................................................. 12

Settings Menu................................................................................................ 13

Basic Programming ....................................................................................... 14

Open Protocol ................................................................................................ 15

CONTENTS

POCKET GUIDE TO POWER FOCUS 6000 SYSTEM

FUNCTIONALITY MANAGEMENT SYSTEM ..................................................... 16

Introduction .............................................................................................. 16

Main benefits ............................................................................................ 16

Order and distribute licenses to customer portal ..................................... 17

TIGHTENING STRATEGIES ................................................................................ 20

Turbo Tight

Tightening Strategy ................................................................. 20

Sustainability ................................................................................................ 22

How are cycle times reduced? ................................................................ 22

How is reaction force reduced? ............................................................... 22

How come set-up is so easy? .................................................................. 22

Stop Stage ..................................................................................................... 28

Soft Stop ........................................................................................................ 29

POCKET GUIDE TO POWER FOCUS 6000 SYSTEM

VIRTUAL STATIONS ............................................................................................ 30

Introduction ............................................................................................. 30

Setting up a Virtual Station ........................................................................ 31

Key Benefits .............................................................................................. 31

STR TOOL............................................................................................................. 32

Overview ........................................................................................................ 32

Models ............................................................................................................ 33

Tool Modules ................................................................................................. 33

Handle module ......................................................................................... 33

HMI ........................................................................................................... 33

Motor ........................................................................................................ 34

Torque transducer ..................................................................................... 34

Gears and Angle head ............................................................................... 34

ETT front part ............................................................................................ 34

Service/Maintenance Intervals ................................................................. 37

STR TOOL ACCESSORIES ................................................................................... 38

Local customization .................................................................................. 39

CONTENTS

POCKET GUIDE TO POWER FOCUS 6000 SYSTEM

CABLE MANAGEMENT ...................................................................................... 40

Use of a cable clamp bracket .................................................................... 41

Smaller bending radius for greater accessibility. ...................................... 43

Innovative ‘Cable Twist’ design ................................................................. 43

Centralized strain relief to prevent lead damage....................................... 44

FIELDBUS ............................................................................................................ 45

TOOL TALK 2 ........................................................................................................ 46

Dashboard ................................................................................................ 49

Traceability ................................................................................................ 49

Tool Service Information ........................................................................... 50

SYSTEM OVERVIEW

The core Power Focus 6000 systems consist of the following parts:

• Power Focus 6000 controller

• Intelligent Application Module (IAM)

• Tensor STR tool

globe for their outstanding tightening capabilities. The

platform meets the need to enhance error-proofing,

connectivity and flexibility, and is the first to introduce

software ergonomics to the industry. This won the

Power Focus 6000 the prestigious Red Dot design

award in 2012. Learn more about the functionality

of the software or the hardware connections in the

respective chapter.

The intelligent Application Module (IAM) stores all the

controller to another. The module is located on the inside of the door to the

controller and is available in three different versions:

• IAM Critical control

• IAM Process control

• IAM Process+ control

For a complete overview of the included functionality please see respective

chapter.

The Atlas Copco Tensor STR tool is a complete tool designed to work with

optimal performance together with the Power Focus 6000 controller.

since 1987 and has unrivaled experience in the

field. Flexibility and durability have steadily

improved since the introduction of the

company’s first generation cables,

resulting in today’s optimum

cable performance.

Atlas Copco’s flat-cable

design combines

maximum flexibility

has full connectivity with our QIF offerings and software products such as

ToolsNet 8 or ToolsNet 4000 and ToolsTalk 2.

The system also communicates with interfaces such as Fieldbus, Open

Protocol or customer specific protocols, creating a seamless integrated

solution in the customer environment.

POWER FOCUS 6000 HARDWARE

Power Focus operates on a single-phase 115 or 230 VAC line voltage.

Power rating 1500 W

100-120 / 200-240 VAC (50-60 Hz) Power Focus has a function for sensing the

FUNCTIONALITY MANAGEMENT SYSTEM

Atlas Copco Functionality Management System (FMS) is our new licensing

platform and it is a completely new way of delivering and administering

functionality available on Power Focus 6000 controllers. FMS is meant as

a way to simplify the way that functionality is added and removed from a

controller based on the actual needs on a station.

• Flexible rebalancing

• Customizable and upgradable

• Instant delivery

• Trial licences

There are two ways to distribute features and licenses to the customer

portal, electronic or physical delivery. The electronic delivery is made

automatically once the order is put in the local CC system and the features

is automatically linked to the customer account in the customer portal. The

physical delivery is carried out from PTD as a physical license paper from

(physical way). The network based solution is meant for production facilities

where it is needed to re-balance and move functionality quickly and

efficiently between virtual stations. The physical way is the FMS USB license

device solution and is perfect for customers where an IP-based network is

not available and the need for rebalancing is not as big.

The Atlas Copco FMS functionality is built into ToolsTalk from start making

it the best way to distribute virtual stations and features to the individual

controllers. ToolsTalk is also the best way of managing and programming

multiple controllers.

have the controllers networked and do not have any need for ToolsTalk

and plant level management of their controllers. With the Atlas Copco

USB license device it is possible to load and distribute virtual stations and

features to individual controllers.

After the USB device has been registered on the Atlas Copco customer

portal and the capability file has been downloaded, move the license file

to the USB device. The USB device will be used for transporting the virtual

stations and features to the controller. Plug in the USB to the controller that

needs to have additional virtual stations and features. After the device has

been inserted an icon will appear on the top right of the controller screen

another one just plug in the same USB stick as the one that was used to add

it originally and move it back to the USB device. Now the device contains

this functionality and it can be moved to a different virtual station.

TIGHTENING STRATEGIES

Select tightening strategy by choosing the method for applying clamping

force (or preload) to the joint. Different joints require different strategies for

applying the desired clamping force and to minimize unwanted in-service

effects.

The Turbo Tight

®

Quick prog, see section Strategy. The Quick step, Two step, and Three step

strategies enable the choice of tightening towards a Target torque or a Target

angle value, see section Target.

All tightening strategies require that you set either Target torque or Target

max speed). This strategy only requires Target torque to be set in order to

perform the tightening. Depending on the joint properties, for example if the

Note! The Turbo Tight

®

strategy is only available when using the Tensor STR

tools.

If the Turbo Tight

strategy gives unwanted results, we recommend you to

®

in the Tightening step resulting in an overshoot. This is even more important

if the joint is very stiff.

Turbo Tight

®

tightening maintaining reliable accuracy. The results are:

• Possibility to remove bottlenecks,

• Possibility to rebalance assembly lines due to increased

cycle rate,

• Improved operator comfort during tightening,

Reduced need for reaction absorbing devices in certain situations, giving

less cost and reduced tool weight.

Turbo Tight

®

just need to set the target torque and you’re ready to go. Exceptions are

discussed in the following chapters. In such cases please contact your local

Atlas Copco Tools representative for support. The results are:

• Time savings during set-up,

POCKET GUIDE TO POWER FOCUS 6000 SYSTEM

speeding up the tightening phase, but remember: the big savings come

from standby.

tightening without excessive overshoot. Comparing it to a traditional Two

Turbo Tight

torque rate and the remaining torque of the joint. Since all these parameters

are dynamically calculated during the tightening, the only user input

required is the target torque.

Atlas Copco has been ISO 14001 certified since 2010, ensuring the planning,

execution, control and optimization of continuous improvement processes

for all Atlas Copco Industrial Technique products. If we compare the energy

consumption of a Power Focus 4000 running a Tensor ST tool with a Two

Step set-up, with the energy consumption of a Power Focus 600/6000

adjoining surfaces and will have greater effect on new parts than on reused

ones due to the smoothening of surfaces which will reduce embedment.

STR TOOL

When running on a Power Focus 4000:

• Tools are generally running on a slightly lower max

speed around 90% of maximum.

• Turbo Tight

®

Power Focus 4000.

• When connecting the ETT tool to a Power Focus

4000 the front trigger can only be programmed to

cooler. This increases the life length of grease and in the long run the

internal mechanical parts. IP54 classification (ETV and ETD) is another factor

that highly contributes to the increased durability, since the tool is better

sealed and protected for intrusion of dust and fluids.

ETV and ETD are the full featured STR tools. ETT is missing the IP

classification and gyroscope. ETP is of an older base design but offers the

The STR concept uses modules to increase quality and flexibility. Different

diameter so modules can be interchangeable between different sizes.

module concept also makes it easier to replace parts. All electronic modules

use connectors to make assembly and service fast and simple, no soldering

movements of the tool down to 1 degree.

The cable connection has a new generation of pins and sleeves that

increases the wear resistance considerably compared to previous

generations.

The trigger is easily removed for better accessibility during cleaning.

The HMI module is where the tool and operator interact with each other. The

module has LED lights – yellow, green or red. There is also a blue LED and

a tightening direction indicator. The reverse ring is lockable and the module

also includes a speaker that can send sound signals to the operator.

The standard HMI and EHMI is available with or without a button on the

In the STR ETV/ETD range all motors have the same diameter. More

powerful motors are made longer.

Focus 6000.

RFID tag is included in the motor module. It will be determined at a later

point what will be included in the chip.

The torque transducer is a delicate part that should not be replaced if faulty.

The transducer shows a very accurate reading from 100% down to 20% of

the nominal torque. STR range is improved so that disturbance from the

motor has less effect on the signal, making the reading more exact resulting

in an improved tool accuracy.

after the angle gear and attached to the output shaft. This gives the ETT tools

an accuracy of 2,5% over 3s.

EC declaration can be found in the

Safety information appended to

the product. The declaration states

responsible manufacturer and shows

European product directives and

harmonized standards.

European product directives – This

is the European Union product

legislation. The directives contain high

the product during its life-cycle. The

The directives applicable to STR are:

The directives set out high level product requirements. These may be

difficult to interpret. A harmonized standard is generally a safety standard

that has been approved by the European Union authorities as compliant

with a product directive. In practice, the standards are used as the means for

measurement, control and laboratory use - Part 1: General requirements.

EN 61000-6-2:2005 Electromagnetic compatibility (EMC) - Part 6-2: Generic

standards - Immunity for industrial environments.

En 61326-1:2006 Electrical equipment for measurement, control and

laboratory use- EMC requirements Part 1: General requirements.

The EC declaration concerns directives required for CE marking. However,

there is more legislation that needs to be considered. E.g.

STR TOOL ACCESSORIES

The STR tool can utilize two different accessories at a time.

The accessories consist of two halves, upper and lower and can be

combined in different ways, for example a scanner and headlight can

be put together on the front bus.

CABLE MANAGEMENT

Cables are used in conjunction with all Atlas Copco tools and assembly

equipment, including: hand held tools, fixtured hand tools or when spindle

”motors only” are provided for incorporation into various types of machine

automation.

As with many industrial systems, cables are a main failure point – especially

in applications where the cables are subject to repetitive motion. Atlas

Copco has the knowledge to help the customer find effective solutions to

their facilities unique cable needs.

In the case of fastening equipment, cables connect the following functions:

application the whole web application was rebuilt from scratch, making it

possible to leverage on new modern technologies. In the base ToolsNet 8

still has the reliable data collection that has been developed by Atlas Copco

for almost 15 years.

Data buffers both on the controller itself but also on the ToolsNet 8

application server in case the database goes down which ensure high

security.

• Save favorite reports which increases the efficiency

when working with the application

• Export reports to Excel for further analysis

• Get detailed information about tightening results

• Simple access to all traces

POCKET GUIDE TO POWER FOCUS 6000 SYSTEM

events in production. All the events that are available in the Power Focus

and the PowerMACS controller can be setup as events in the notification

center of ToolsNet 8. After it has been setup, an email will go out to the

configured receiver as soon as there is an event, making it possible to

cut down response times and thereby reducing the time it will take to fix

production problems.

• Reducing down-time thanks to direct notification

about production problems

• Simple setup of notification means customers will

use it

Alarms based on statistical trends. Find material problems or process

The dashboard gives a direct overview of the production in the plant. Every

user can configure the dashboard in a way that best suits their needs. For

Available dashboard widgets are:

• Running SPC: Shows the real-time X-bar and range

charts for a configured application.

• Tool maintenance: Shows the tools that need service

or calibration, from all the Power Focus tools in

production (currently only support Power Focus

W10.6+ and W14 controllers).

• Latest results: Shows an overview of the latest results

from the chosen part of the of the tool structure.

ToolsNet 8 greatly increases the traceability in our customer’s production.

production making it possible to find tools that have not been serviced in a

long time or tools in need of calibration. You can also find information about

software version of connected tools and the number of rundowns that have

been performed since the last service.

• Keep service log of all tools in production

specific application

• Find information about tool software versions

• Get information about last service and calibration

of a specific tool

• Locate to which controller a tool is currently

connected by serial number

• Manage custom tool serial numbers in the plant

POCKET GUIDE TO POWER FOCUS 6000 SYSTEM