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Pulsor C - Edlo Sales & Engineering

1. By choosing Save To File the results are saved to a text file By clicking Open In Excel the results are opened in Microsoft Excel if installed 16 6 Trace There are three different ways to open the Trace section Select window in the main menu and then click activate trace Use the PF Map Double click trace Click the trace icon on the toolbar Select which type of chart to view Relative torque over time Angle over time Torque over time Final torque and final angle over time Torque over angle Pulse pressure over time Vmin and Vmax over time 9836 4841 21 117 235 Monitors Additionally when performing a Tool Setup you can activate trace by pressing the Traces button in the Tool Setup Monitor In this trace only Torque value over time 1s available This trace updates automatically but no other option of the options below are available fa trace PulsorF Name Not Defined EN Peet 1 1990 01 03 19 12 25 B00 Time m e Auto update Redraw XK Close Humber of traces fi Lirnits Ge Read With Auto update selected the charts will automatically update as new tightening data arrives With auto update deselected the user must press Read to see the latest tightening The Limits function allows the user to see the min and max limits for torque and or angle With Number of traces it is possible to superimpose up to 5 consecutive tightenings It is possible to see a single pulse value
2. cccccsececceeeeeceeeeeeceseeceueeecsausesseuseesseeessaneessaaeees 12 4 PUSO GOMPDOMEMIS urraca oia 14 o PUSO ACCESSONMES iaa 16 2 Connecting and installing the Pulsor C SySteM ooooonccconnncccononnnnonannnnnnaanennnnans 17 2 1 Required hardware and SO WAare cccconcnccccnnncccccocononononannnononcnnnnnnennonnnnnnnnrnnonanennnnos 17 2 2 Connect the physical parts of the SySteM connccccccnconccccoccnnncnncnncnnonnnncnnannnnnonanennnss 18 23 install the Tools Talk PulsOr C SOW ane iaa did 19 2 4 Initial connection of Tools Talk PulSor neci i a 19 2 4 1 Gomecing WIT USD odios 19 2 4 2 COMMECTING serial catas tds 19 2 4 3 Connecting over Ethene ersinnen 20 2 5 Exchange of tools Hot SWAD Mievritrinta a AAA 20 3 Introducing the Pulsor system s user interface oooncooncconncococeconconnnonarenanonannnnnos 21 Sl signal lIgnts On Ne tO0l ns ia 21 3 2 Tool Gontrol Box buttons and NIGMS scott 21 320 PUISOr FOCUS TON PANG iuris is 22 3 35 INGIGATOF NON Scudo 23 332 KOY enano e e enore aa ia ar 24 3A Tools TAK PUISOF acin e a a a A A E 25 4 Tool Control Box and tool introduction cooncccnnccononicnnnccnanconancnnanonnancenanennanos 27 AT The FOO SOM TODO onori ae Meunier T 27 4 1 1 a e A O a a 27 4 1 2 TSAI HOSE TM os AS 27 4 1 3 Starting Air Hose Test from Tool Control BOX oocccccccccccconcccnnnccccnnnaoncnnnnncnononanonens 28 O ay ee eee 28 4 1 5 A O a 28 4 1 6 EOCKTUINCUONAM Mustaine 28 de TINETO ne ie 2
3. otie a Battin comicos feria pork errvulators Floppy dick controlar r gt IDE ATAJATAPE controller i Al Ted r rd ori a keer a Ty Mee and other pointing devices i Lo Moderns Bl Monihors MN hrk adopters FOMCLO adapters Ports COMA ET OF Conmnurecations Port COML AF Printer Port LETH a F rt The USB interface is now set up and ready to use It is used exactly as if you were using a serial cable In the rest of this manual wherever text 1s referring to serial communication this applies to USB communication as well Go to chapter 6 2 Starting ToolsTalk Pulsor for more information on how to use serial communication together with ToolsTalk Pulsor 6 1 2 Connecting via serial cable Connect your computer to the Pulsor Focus with an Atlas Copco serial cable The serial port can be found on the backside of the Pulsor Focus serial port 2 No special installation has to be done Go to chapter 6 2 Starting ToolsTalk Pulsor for more information on how to use serial communication together with ToolsTalk Pulsor 6 1 3 Connecting via crossover Ethernet cable Connect your computer to the Pulsor Focus with a crossover Ethernet cable The PF needs to be set up 1 e be given an IP address etc before it can be used over Ethernet If the PF is not set up yet use a serial or USB cable to connect to the Pulsor Focus follow the instructions in 6 2 Starting ToolsTalk Pulsor and then set up the Pulsor
4. ON em gt Q S RBU did not respond to command from Pulsor Focus 436 RBU filesystem warning There has been a repairable fault in the RBU file system e g Power ACK off or other interruption during download es es 437 RBU filesystem corrupt The RBU file system has too many faults An attempt will be made to ACK repair it by means of erasing the RBU RBU file mismatch A file with incorrect name or size was returned to a read request RBU no files A file type is not present in the RBU at start up 441 RBU access too busy RBU has answered to the poll but Pulsor Focus is too busy to receive ACK the reply 442 RBU no such file A file has not been localized in the RBU C The RBU is corrupt or not present E444 RBU packet rejected RBU responds with an answer not matching the last request This is probably due to duplicates sent when the Pulsor Focus does not acknowledge packages gt gt ajo ae LL w m A gt UI 00 es tH gt gt O 7 RBU delete error Delete operation failed ACK E449 RBU flush error Flush operation failed ACK i Fieldbus mailbox message fault Fieldbus dip switch error The software tries to configure the value of node address or baud rate but the address switch on the FieldBus module is not in the right position to enable software setting Set switches in the right position and then turn on the power Fieldbus offline The FieldBus went from online to offline T
5. i A V Show VIN in result Serial auto connection on startup The first checkbox in Automatic functionality OYE SS HE activates deactivates Auto collapse tree views Auto Store Pulsor Focus to file on disconnect If Serial Ethernet Auto connection on start up Auto Store Pulsor Focus Filename is checked ToolsTalk will try to connect to the Pulsor Focus via serial Ethernet Sore Verau rectory communication immediately on start up Path Eoo Sept If the Auto store PF to file on disconnect box 1s checked ToolsTalk will store PF to file Set background color _ clBtnFace gt when disconnecting The last field allows you to set the path for X Cancel Default directory Log files and auto stored PF files will be saved to this directory ControlerBackup pf3 6 6 3 Settings Printout The Printout tab contains printout Se E settings 2 ommunication Application dt If you enter text in the Printout footer it p s will appear on every printed paper Pe If you use the A4 Printout format Printout forma ee Color select A4 format otherwise select een f ies Default format Printout Colors is only applicable if you use a color printer x Cancel 9836 4841 21 51 235 Working with ToolsTalk Pulsor 6 6 4 Settings PF List From the PF List tab you can manage the PF available list You can add modify and remove items An item is a Pulsor Focus unit with
6. Connector Connector RJ45 standard Ethernet connector is used 1 A 224 235 9836 4841 21 Troubleshooting 31 Troubleshooting Use the following table to get possible solutions to problems that may arise when using the Pulsor C system The tool is weak and the pulse frequency Not enough oil in the pulse unit Fill the pulse unit with more oil is higher than normal many more pulses than usual are needed to reach the target The tool is weak the pulse frequency Tool engine is defect Service tool normal or lower aa Air pressure low Feed the Pulsor system Tool Control Box with the correct air pressure Pset pressure too low Increase Pset pressure Large torque spread first pulses high Pset pressure too high Lower Pset pressure This will ensure the torque is increased in smaller steps E Tool size too large for application Adjust the trim valve on the air outlet of the tool clockwise This will reduce air flow preventing overshoots in the first pulses while still maintaining much of the tool performance later in the tightening Invalid torque and or angle values The tool spins because of lack of oil Fill the pulse unit with more oil Soft joint lower end of tools torque range Try reducing Pset pressure otherwise smaller tool model may be needed 31 1 Tips and tricks Very hard joints In order to reduce the force in the first pulses the rundown speed must be lowered This can be done b
7. Parameter Overview General Setup F100 Fieldbus Type General Setup DewviceWNet General Setup FrotiBus DF From PF Setup InterBus HModBusPlus Sep Modhus TCP Ethernet 1P None Get fieldbus into 9836 4841 21 107 235 FieldBus 15 1 1 Parameters in General setup The table below shows the a available for the selected FieldBus type F104 From PF Global DataLength F105 To PF Global DataLength F110 Set node address and baudrate from F131 Process DataLength F140 Set source address from EOS EM E xo px a a See chapter 30 FieldBus configuration appendix for specific FieldBus type data 108 235 9836 4841 21 FieldBus 15 2 From To PF setup By selecting From PF Setup the bitmap that is sent out from the Pulsor Focus can be configured By selecting To PF Setup the bitmap that is sent in to the Pulsor Focus can be configured 15 2 1 Add item When the Add item key is clicked a selection list is activated On the right side of the item list see information about highlighted item Click Hide details button if you do not need this help text Highlight the item you want and double click on it or click the Add item button The item will then be entered to the item list on the first available line ER FieldBus PF 3 PF1 al 51 Parameter Overview To PF Setup a Nr Name i Bute 0 General Setup qe A lalala 1 a FieldBus Add Items Eeeh lo A From PF Setup To PF Se
8. Ul6 2 bytes Binary representation Decimal 0 65535 CycleComplete Indicates that a tightening is finished Bit 1 bit 0 Not used Do not care about the result 1 Cycle complete 1 4 DigIn 1 Mimic the status on a DigIn in Pulsor Bit 1 bit 0 Input Off Focus or I O Expander The input 1 Input On must be configured to FieldBus DigIn X There are four different Items ErrorCode Shows error code Ul6 2 bytes Binary representation Decimal 0 65535 FieldBusHandShakeAck Indicates handshake from PLC Bit 1 bit 0 Not used received by Pulsor Focus 1 Handshake FinalAngle Final angle result Ul6 2 byte Binary representation Decimal 0 65 535 Final torque Torque result Fixed point 4 byte Binary representation 2 byte integer part 2 byte decimal part 9836 4841 21 199 235 FieldBus configuration appendix Items From PF Description Data type String Value length JobDoneStatus Job OK done or NOK done or Character 1 byte O OK aborted reset ASCII N NOK A Aborted Bit Field Bit Field 00 Not used 01 OK 10 NOK 11 Aborted JobDoneStatusJobAborted Shows Job aborted Bit 1 bit 0 Not used 1 NOK JobDoneStatusOK nxOK Job is OK nxOK 0 Not used 1 OK JobID Gives the number of the selected Bit field 2 8 bits 0000 0001 Job 1 JOB in the 0001 0000 Job 16 same byte U16 16 bits in 00 0001 Job 1 one word 00 1000 Job 8 JobRunning A Job is selected and
9. D930 The line pressure entered when air sensor tuning were performed D931 Air senor tuning performed Date and time when air sensor tuning was performed D95x Tool board info D950 Tool board revision The hardware revision of the tool s built in electronics D951 Tool board serial number The serial number of the tool s built in electronics 9836 4841 21 169 235 Digital inputs and outputs 23 5 Identifier 23 5 1 11xx Identifier setup 110x General setup Parameter Parameter Name Description Default setup Number 1100 Identifier input source Defines what source 1s to be accepted when a VIN number is to be Off read Available options Off Scanner Ethernet Serial and Ethernet Serial amp Scanner 1101 Significant numbers This parameter is a string of integers that tells the Pulsor Focus which positions to look at in the Identifier string The string can have maximum 25 characters 1104 VIN filter This parameter is a string of integers that tells the Pulsor Focus All which positions in the scanned barcode that shall NOT be considered as VIN I20x Card reader setup Parameter Number Description 1200 Card reader type Defines the type of identifier reader connected to the Pulsor Focus Available options None and Euchner ident system 23 6 FieldBus Parameter Parameter Name Description Default value Number F100 FieldBus type This parameter shall be selected first It includes the types None DeviceNet Profi
10. Internal info Internal info appearing only in event log Of interest mainly to design department See Subinformation for event codes section 22 4 4 E799 if this error info occurs frequently 22 3 11 Software events E805 PF Model unknown This event is displayed after start up when the RBU is missing or when the RBU revision can not be supported by the controller or when the RBU license file is missing or can not be read by the boot code E808 Error condition detected by software An error condition was detected by software E822 No Job ACK from control Tightening initialization phase failed Hardware failure 150 235 9836 4841 21 Digital inputs and outputs E840 Feature Not Available In Software This event is displayed if the tool software version contains functionality Revision not supported by the controller software version or an attempt is made to store a Pset with a Pset id larger than the max number of Pset SW function not available for this tool This event is displayed if the tool software version is lower than needed type for corresponding controller functionality e g loosening Connection with Tools Net server lost The connection with the Tools Net server was lost the Pulsor Focus is trying to reconnect The Tools Net server might be down or it might be an Ethernet cable problem E a E856 Router unreachable The router programmed in the configuration setting could not be reached Check the n
11. Pulsor C System manual Atlas Copco Tools and Assembly Systems 9836 4841 21 Software release 5 5 2010 04 Edition 2 0 Atlas Copco Contents chapter overview Part I Getting started with Pulsor C BR WO N e e O Par 6 Z 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Introduction to Pulsor C Connecting and installing the Pulsor system Introducing the Pulsor system s user interface Tool Control box and tool introduction Performing Tool Setup II Working with Pulsor C Working with ToolsTalk Pulsor Pset and batch count Tightening and monitoring Performing a Monitoring Setup Job Config Tool Control Box Diagnostics and service Identifier FieldBus Monitors Statistics Cell and Net ToolsNet Accessories Configurable memory Part II Reference information on Pulsor C 22 23 24 23 26 27 28 29 30 31 32 33 34 Event codes Parameter list RBU information Pulsor Focus hardware description Tool Control Box hardware description Digital inputs and outputs Connector descriptions Pulsor Quick Guide FieldBus configuration appendix Troubleshooting Abbreviations General safety instructions for Pulsor Focus unit EC declaration of conformity 9836 4841 21 Contents chapter overview 3 235 Contents Contents 1 IMTFOGUCTION TO PUISOR iuris AATA AEREA 12 1 1 Conventions used in THIS MANUAl iia 12 L sADOUETAIS OACI Murtas 12 1 3 Overview of the Pulsor system
12. Pulsor Focus calculates recommended values for UCL and LCL The operator can then choose if he wants to use these values or enter another value Subgroup size Subgroup frequency and Number of subgroups parameters are used in the calculations 17 6 Calculation of xand R Pulsor Focus calculates recommended values The operator can then choose if he wants to use these values or enter another value Subgroup size Subgroup frequency and Number of subgroups parameters are used in the calculations 17 7 Calculation formulas When a stat display is requested the whole memory will be calculated This will also be done when shifting Pset Pulsor Focus controls the lowest and highest values If some of these drop out from memory once it is full first in first out the entire memory will be recalculated The formula for group range is calculated after each completed subgroup 9836 4841 21 121 235 Statistics The formulas for the statistic parameters used by Pulsor Focus are as follows X value n number of tightenings Min minimum value from all the tightenings in the test series Max maximum value from all the tightenings in the test series minl minimum acceptable value maxl maximum acceptable value Range R Max Min O Ss E NS Maxl Minl Cp Maxl Minl 7 6 0 CPK min Maxl X X Minl 3 oO SO Tightenings Xy X X Xy Xs Xs X7 Xs Xy Xoo Xi Xir Ajo Xirs Xi Xis Xie Aj 7 Xis Xiro
13. i Show controller error info in ToolsT alk ON Advanced i Show controller warming into in ToolsT alk Log file Log txt Serial setup Com port Com 1 z Baud rate 3600 r Ethernet setup Portnumber 16543 Controller IP 10 140 24 fag Pulzor Focus available list C ls NetMaster C ls CellMaster f s Controller Connect the Pulsor Focus by clicking on the connect button i lt Open Remote com in the Config window Set the IP address of the connected Pulsor Focus to a unique number within the network Set the Subnet mask according to network partitioning Default router is optional Click Store to save settings Restart the Pulsor Focus unit T Config PulsorF Station 1 E Ioj xj een Remote com C301 IP address 110 40 165 96 gt ae E C302 Subnet mask ps 255 252 Jo 1 0 setup E Communication C303 Default router 110 20 164 E Remote com C304 Netmaster IP address fo fo ff fo E a C305 Cellmaster IP address fo fo fo o io Serial ports setup ee Pintora C306 Jobreference IF address E o o o Advanced com C310 Cell keep alive le Sec Serial ports setup C320 Serial 1 baudrate seno C321 Seral 1 protocol fasc C322 Serial 2 baudrate seno y X Close Read sa Store 126 235 9836 4841 21 Cell and Net 18 2 Cell and Net configuration via ToolsTalk Pulsor Open the Remote Com window Config Communication Remote Com Se
14. 1 Gar box E 2 E Pa Job F Config 4 Tool Control Box 3 Diagnostic MI Identifier 2 FieldBus E Monitors L4 Trace El pl Statistic E q Offline Name Not Defined 6 5 1 Creating a new Pset Each type of joint has its own characteristics If you want to use the tool on different joints you therefore need one Pset for each type of joint Proceed as follows to create a new Pset Create a new Pset by clicking the right mouse button on Pset in the PF Map A Ta Nhe Ue Select Create new Pset a Ethemet EP 10 46 24 224 E 2 Create new Pset pe Config on Tool Control Box D Diagnostic M Identifier co Fieldbus H E Monitors LA Trace lh Statistic EE Offline ff Mame Not Defined Give the Pset an ID from the list or accept the suggested ID Station 1 Create new Pset AS and if required give the new Pset a name Click on OK E A o E New Pset Name Gear box Jf OK X Cancel Select the Pset in the Selection panel in ToolsTalk File Edit Focus Options Window Help Pulsor This last step will activate the Pset Note that seecteaconater HT Staton z Running the Pset can not be used until a Tool Setup has been S to Te Ye a M See dy Y Y Y o il IATA performed for the Pset 10 x 2 1 Gear box none N 48 235 9836 4841 21 6 6 Settings in ToolsTalk Pulsor This section describes the Settings functionality in ToolsTalk Pulsor Select Sett
15. AnyBus S modules that is based on the CIP 1 e DeviceNet and ControlNet the same vendor specific objects are being implemented together with new objects for servicing and monitoring the IT functionality EtherNet module IP address Do not configure the module to use any of them Devices on an EtherNet network are not 0 x x x allowed to be configured to the IP TRE addresses listed in left column X X x 0 X X X 255 ModBus TCP Data address 000h I 1 0 1 From PF This address is based on words 400h 1 1 0 1 To PF The data length is in PF limited to 122 bytes ModBus TCP and EtherNet IP standard allows 1024 bytes data 0000h I 1 0 1 From PF This address is based on Bits 4000h I 1 0 1 To PF The data length is in PF limited to 122 bytes ModBus TCP and EtherNet IP standard allows 1024 bytes data EtherNet IP Assembly Instance Input 100 output 150 configuration 5 and size 0 This is used to configure a EtherNet IP module Data to PF total length 0 122 bytes Must be the same in PF and PLC The data length is in PF limited to 122 bytes ModBus TCP and EtherNet IP standard allows 9836 4841 21 221 235 FieldBus configuration appendix re es ta Lu AA Data from PF total length 0 122 bytes Must be the same in PF and PLC The data length is in PF limited to 122 bytes ModBus TCP and EtherNet IP standard allows 1024 bytes data FieldBus connectors The module uses standard Ethe
16. Byte0 Convert to PF data pot P a na 30 2 3 Integer Unsigned16 is a 16 bit integer and Unsigned32 is a 32 bit integer U32 HMW is a special case of Unsigned32 which is used in Intel Endian Motorola Endian Type Word Byte Bit Lengt Unsignedib O 0 O 16 Unsigneda2 1 0 O Je Unsigned32 0 MSB IU o was ose 9836 4841 21 197 235 FieldBus configuration appendix Intel Endian Type Word Byte Bit Lenat Byte 1 Byte O Unsignedib O 0 16 Unsigned32 1 1 U te 032 HAN 3 1 O Usignedi Ot op sime 1 foma Jr fo fos CS mw sofas oa fo 198 235 9836 4841 21 FieldBus configuration appendix 30 3 Items From PF In this section follows a description of the possible items to select when data from the Pulsor Focus is configured Items From PF Description Data type String Value length AngleStatus Status Angle result Character ASCII Bit 2 bits 00 Not used 01 OK 10 High 11 Low AngleStatusHIGH Angle result is above max limit Bit 1 bit 0 Not used 1 High 1 Low 1 OK OK or NOK 1 bit 0 Not completed 1 Done Batch OK done or NOK reset Character 1 byte O OK ASCII N NOK Bit 2 bits 00 Not used 01 OK 10 NOK BatchStatusNOK Batch is NOK batch aborted BatchStatusOK nxOK Batch is OK nxOK B Bit 1 bit 0 Not used 1 NOK it Completed batch Displays current completed batch Bit Field 1 bit 0 Not used 1 OK 00000000 0 11111111 255
17. To change the address first loosen the four screws on the front panel of the stacklight Then open the lid and turn the address switch Possible addresses are between 1 15 0 9 A F Select I O expander for option C210 Device 8 and click Set 9836 4841 21 Accessories Relay Timer Digital Input 1 Of 2 Of Select High for Relay 1 This output is connected to light 1 Select OK for relay 2 This output is connected to light 2 Select Low for relay 3 This output is connected to light 3 Select NOK for relay 4 This output is connected to light 4 Select NOK for relay 8 Set the relay timer to 3 seconds This output is connected to the buzzer Select Ack error message for digital input 3 This input is connected to the push button Select Batch increment for digital input 5 This input 1s connected to the left key switch State Select Reset batch for digital input 6 This input is connected to the right key switch State Click OK Y To next tight To next tight 3 Ack error message 4 Off 5 Batch increment 6 Reset batch POr 8 Off To next tight To next tight a ee 4 aia aiaiadane 4 4 fa ie lle lle loe lle Select I O expander for option C211 device 9 and click Set Select Tool locked for relay 1 This output 1s connected to the buzzer Click OK Click Store to save settings 9836 4841 21 137 2
18. ToolsNet These instructions assume that ToolsNet has already been installed Proceed as follows to enable Pulsor reporting to ToolsNet Find out the IP address and port of the ToolsNet server Start Config by either double clicking on Config in the PF Map in ToolsTalk Pulsor or by selecting the function from the toolbar and then select ToolsNet setup under Protocols from the navigation area m Parameter Overview ToolsTalk setup C400 Port 16543 System setup 10 setup Communication Protocals C411 IP address 110 140 124 1148 ToolsT alk setup C412 Port 16570 ToolsNet setup C410 ToolsMet on fa Toolset setup Multicast setup Open protocol setup C420 Multicast on C421 IP address C422 Port C423 Results C427 Event code E Open protocol setup C451 Port 4545 C454 Seral cable loss detection E Multicast setup Enter the values for enabling ToolsNet reporting Check the ToolsNet on option Enter the IP address of the ToolsNet server Keep the default setting for Port 6570 Save by clicking Store The enabling of ToolsNet reporting is now complete Verify that results are stored by making a few tightenings and check that the Pulsor Focus unit and results are shown in the ToolsNet web reporter interface The Pulsor Focus unit is found under the PowerFocus folder in the ToolsNet web reporter tree view See the ToolsNet User Manual for detailed information on how to use ToolsN
19. WII Identifier FieldBus Monitors Result Monitor _ Operator Monitor E Tracking Results LA Trace g Statistic Tracking Results Monitor Pset Over all status i T T o T la x be T T o T fz x T T o T o x T T o gr la x me T T T la x T T l Relative Torque Torque Yalue Lost Trigger Tightening Angle No Of Pulses Tightening Time TE Tt iit TAP ol w a ola im oOo a w iilh Bili PI mn ho hop hi oo Rundown Time EE Pp 119 5 lo 0 o 4 ooo ee a 117 4 118 6 6 3 6 3 6 3 0 0 0 0 6 2 6 5 a E FEO PA Pulse Frequency PF pressure TAF om orn Pulse Pressure ho Ol to amp TCE pressure Tightening ID iti TT Batch count d The following are displayed in the Tracking Results window Rejected tightenings are shown by NOK in red For rejected tightenings the parameter s that lie above the activated limits are marked in red whereas the parameters that are below the limit values are marked in yellow Trigger lost is marked in yellow if it is monitored Parameters that have invalid values are shown in purple If batch count is used 1t is presented in the last row Examples of things that may cause invalid parameter values are for example a disturbance of sensor reading during the final pulse spin in the tool or too few pulses making pulse frequency impossible t
20. configured in branch I O Setup In addition to the internal I O ports it is possible to connect up to 15 external I O devices to the Pulsor Focus I O Bus Communication Pulsor Focus communicates by both Ethernet and Serial communication links RS232 and USB and can communicate with ToolsTalk Pulsor and database applications such as ToolsNet IP address and baud rate etc are set up in this window Protocols Pulsor Focus communicates through a number of protocols This window contains the settings for each communication protocol 9836 4841 21 79 235 Config 11 2 System setup System Setup contains basic Pulsor Focus features such as name and display options 11 2 1 Password and Name Select the Password and Name tab under Sai Config Pulscct Sse AS l0l x 1 1 1 Parameter Overview System setup in the navigation area AT e E System setup Enter the appropriate values see below for Password and name a a details i Display setup 2 Options Click on Store to save eee Printer setup C105 Ch ID number Configurable memory setup C106 PF name Pulsor tool config Tool lock C107 Cell ID number 140 setup C108 Cell name Not Used Communication E Protocols Set date and time X Close gt Read sg Store C100 C101 Password and Password entry scope 1s used when you want to limit access to the Pulsor Focus When the function 1s enabled the corresponding password setting butto
21. n e Posa s Powa 9 Not used 28 4 Ethernet Connector Shielded RJ45 for 10 baseT connection Function 10 Mbit Ethernet communication Fin Fonction CU Sl 6 mo le a A 28 5 RBU Connector 15 pin DSUB female Function For connection of Atlas Copco RBU The RBU unlocks the software you need and works as a backup memory for your Pulsor Focus setup data The pin configuration is propriety information for Atlas Copco This connector cannot be used for other purposes 186 235 9836 4841 21 Connector descriptions 28 6 Tool connector Connector 16 4 pin Function For connection of Atlas Copco Tensor electric tools Pn poenos B Not Used D housea p sess 9836 4841 21 187 235 Connector descriptions 28 Digital inputs Connector 10 pin detachable screw terminal Mating connector Phoenix MCVR 1 5 10 ST 3 81 or compatible Function Isolated opto coupled digital input Logical function is set in the configuration of the Pulsor Focus Electrical data High input 10 40 VDC Current needed to activate input 1s 5 mA at 24 V This input can be connected to run both positive and negative logic active high or active low Isolated 24 VDC output 19 V 30 V 1 A maximum load This output can be used to feed external equipment such as Stack lights and buzzers Atlas Copco I O Bus accessories are also powered from this output Fin ro 3 Disati 15 Disia mp2 16 Dis
22. you can set the parameter limits so that a rehit is detected tightening time tightening angle number of pulses Make a number of correct tightenings and then carry out a rehit on these to check which parameter s that 1s most suited for detecting the error Cross thread This means that the joint sticks in a non tightened position as a consequence of damaged threads or that the nut is cross threaded In the event of such faults the tightening angle is often different both lower and higher is possible compared to what it should normally be Self lock If there is a risk that prevailing torque nuts for example nyloc nuts are mistaken for standard nuts or vice versa this error can be captured using the rundown time The rundown time is often longer for prevailing torque nuts Test with a number of each type of nut and check 1f how the rundown time can capture the difference 9836 4841 21 65 235 Tightening and monitoring 8 9 Analysis of improvements Once the tool is adjusted and has been working for a while 1t may be appropriate to analyze how the tool and the monitoring have functioned With the help of Get all results found in the monitors dropdown menu all the parameters from the tightenings can be viewed E La bh Result Monitor E Job Monitor C Operator Monitor C Tracking Results 322 Get all results When the results are shown you can send the results to Excel There you can for example sort out all reje
23. 2 are used to set the baud rate and dips 3 to 8 are used to configure the node address Mac ID Dip 1 is the most significant bit on the DIP switch See table on the next page The Pulsor Focus DeviceNet module is implemented in compliance with the ODVA specification for a Communication adapter profile no 12 It acts as a group two only server on the DeviceNet network 210 235 9836 4841 21 Hardware LED 1 Not used LED 2 Network status LED 3 Module status LED 4 Not used On a fe fo fm fm fey en 1 Off 0 OF m LI LI LJ L i gt 3 4 5 7 8 Baud rate Mae ID Function ADO ADI AD2 AD3 AD4 AD5 BD2 BD1 Baud rate Bit sec Dip 1 2 125k 250k 500k Reserve SW setting CONTO a UPS 9836 4841 21 FieldBus configuration appendix 211 235 FieldBus configuration appendix Mac ID Node address If you want to set the Mac ID from ToolsTalk all DIP switches must be set to On 11 111 111 The Mac ID cannot be changed when the power is switched on FieldBus connector Connector 5 pin 5 08mm detachable screw terminal Pin Color code Description A V and V must come from a fully isolated power supply That means that the voltage cannot have any reference to ground This is to prevent the bus from interference caused by ground loop problems If V and V are connected from a Pulsor Focus internal 24VDC screw terminal the same connection shall only power on
24. Depending on the protection class and type of application other connector designs are also allowed Connector 9 pin female DSUB pn ime Fence O ousing Shield Connected to PE Nocomeed RT Not connected Positive RxD TxD according to RS485 specification S Request to send 5V BUS and GND BUS are used for bus termination Some devices like optical transceivers RS485 to fibre optics may require an external power supply from these pins GND BUS Isolated GND from RS484 side 5V BUS and GND BUS are used for bus termination Some devices like optical transceivers RS485 to fibre optics may require an external power supply from these pins 5V BUS Isolated 5V from RS484 side 5V BUS and GND BUS are used for bus termination Some devices like optical transceivers RS485 to fibre optics may require an external power supply from these pins A Line Negative RxD TxD according to RS485 specification Node address Node address is set with the two rotary switches on the FieldBus module this enables address settings from 1 99 in decimal form Switch 1 x10 Switch 2 x1 See switches on the top drawing Example Address Left Switch Setting x 10 Right Switch Setting x 1 Left switch is set to 5 and right switch is set to 2 This gives a node address of 52 If you want to set the node address from ToolsTalk the switches must be set to 00 G 5 Node address cannot be changed when the power is switched on 208 235 983
25. FieldBus LED 3 Red Module is Off Line and no data exchange is possible Turned Off Module is not Off Line Bus termination The end nodes in a ProfiBus DP network have to be terminated to avoid reflections on the bus line Use cable connectors with built in termination GSD file Each device on a ProfiBus DP network is associated with a GSD file containing all necessary information about the device The network configuration program during configuration of the network uses this file Contact your local Atlas Copco Company for a copy of the GSD file File name pf3profb gsd Icon File Contact you local Atlas Copco representative to get a copy of the Icon file for Pulsor Focus This file can be used to have a Power Focus Icon in PLC configuration SW The file is a bitmap File name pf3profb bmp 9836 4841 21 209 235 FieldBus configuration appendix 30 6 DeviceNet DeviceNet is used for industrial automation normally for the control of valves sensors and I O units and other automation equipment The DeviceNet communication link is based on a broadcast oriented communications protocol Controller Area Network CAN This protocol has I O response and high reliability even for demanding applications e g brake control DeviceNet has a user organization the Open DeviceNet Vendor Association ODVA that assists members in matters concerning DeviceNet Website http www ODVA org The media for the FieldBus 1s a shie
26. Focus RBU 9836 4841 21 173 235 Digital inputs and outputs 24 1 RBU functionality The table below displays the functionality for the RBU available at the time of print Capacity Gold RBU Number of Psets max 100 Number of Jobs max 100 Number of tightening results max Number of events stored max Functionality Pulsor Fixed strategy Batch counting Job Tool drift alarm Configurable memory T O Programming port RS232 I O Expansion up to 124 inputs and 124 outputs Network TCP IP Barcode reader port RS232 Fieldbus with AnyBus HW Networking Cell Multicast ToolsNet Other Traces to ToolsTalk Real time statistics SPC Alarm Barcode reading Open Protocol 174 235 9836 4841 21 Digital inputs and outputs 24 2 Connecting the RBU Connect the RBU to the 15 pin connector on the back panel of the Pulsor Focus see figure below A Make sure that the power is switched off when connecting and disconnecting the RBU 1 E HE a li A gt J a rr 24 3 Start up instructions At start up the Pulsor Focus checks for inconsistencies between the controller and RBU configurations If an inconsistency is detected the user is prompted to select either the controller or RBU configuration This makes it possible to move copy configurations between Pulsor Focus units by using the RBU The user is also given the possibility t
27. ID card inserted in the Euchner system 182 Pulse filter condition detected Pulse filter is tagged during Monitoring setup when the pulse filter is inactivated 183 Tightening data timeout Maximum tightening time exceeded 30 seconds 184 Tightening with a Pset without a Tool A tightening has been performed with a Pset without a Tool Setup TLU Setup 186 Relative torque variation high in Monitoring Setup has relative torque variation outside the interval Monitoring Setup 85 115 189 Monitoring Setup pulse limit exceeded The tightening has more than 300 pulses and will be truncated 192 Tool pressure sensor error Tool pressure sensor reading is not normal The cause of this may be technical problems with the sensor or a bad air sensor tuning 146 235 9836 4841 21 es 00 es 07 Co es ea gt e EN es oo es eS E Digital inputs and outputs E193 Too many tightenings performed in More than the maximum 50 tightenings have been performed in Monitoring Setup Monitoring Setup Further results will be discarded E194 Setup aborted due to exchange of tool The tool was exchanged during Tool Setup or Monitoring Setup E195 Monitoring Setup contains invalid Monitoring Setup contains one or more tightenings with invalid result ACK parameter for one or more parameter E196 Spin error The tool has pulses which are not distinct enough to be measured This is probably due to lack of oi
28. Name IP address port number and controller type If you want to use multiple PF list files you can select which one you want to use settings ra xi Communication Application Printout PulsorF List Pulsor Focus available list ti fat LEER ate suas ae gg 6543 Station 1040165399 6543 Controller 10 40 165 100 6543 Controller 10 40 165 107 6543 Controller Station 104016562 6645 Controller PulsorF Mame Station O le Neth aster Controller IP 10 40 165 se la CellMaster ee 6543 f s Controller Add Modified Remove Select Pulsor Focus list file PulsorF Available List in file C Program Files 4thas Copco Tools 4B4T oolsT alk Pulso PF List tut Jl ie x Cancel 52 235 9836 4841 21 Working with ToolsTalk Pulsor 6 7 Storing programming on file To store the programmed settings on file open the File menu The following options are available Read lt object gt Read PF from File Save lt object gt and Store PF to File lt Object gt could be Pset Job Config Identifier or Diagnostics depending on which corresponding window is currently active Function Description Store Pulsor Focus to When you are connected to a Pulsor Focus and perform Store PF to File all programmed settings in the File Pulsor Focus will be stored to a file You will be asked to name the file Read Pulsor Focus When you are connected to a Pulsor Focus and perform Read PF from File the Pulsor Focus will b
29. Parameter Parameter Name Description Number D130 Total number of tightenings Total number of tightenings performed by the tool during its lifetime D131 Enable disable on off tool service indicator alarm D132 Number of tightenings since service The number of tightenings since latest tool service D133 Service interval Number of tightenings between services Serves as service indicator alarm limit D134 Latest service date Date of latest performed service Service counter reset Button Resets the Number of tightenings since service D132 and Number of pulses since service D137 also sets Latest service date D134 to current date and sets Service indicator D131 to off 9836 4841 21 167 235 Digital inputs and outputs Parameter Parameter Name Description Number D136 Lock tool on alarm Enables disables lock on alarm Tool will be locked while service indicator alarm or while wear indicator alarm is activated D137 Number of pulses since service The number of pulses since latest tool service D138 Service interval in pulses Number of pulses between services Serves as service indicator alarm limit D139 Date for next service Serves as service indicator alarm limit The alarm is triggered when current date exceeds this parameter Automatically increased to 1 year from todays date when Service counter reset is performed D15x Pulsor Tool Info Parameter Number Description D153 Application code version The versi
30. RE AAI a A A R 138 POG OMG acces sonetos 138 POG Barcode readers dudado dala 138 2062 Operator panela a ada 138 Configurable Memory ccccccesseeseeseeeseesseesenseeesenseeesesseeseesseeeeenseeeoenseesoessessons 139 9836 4841 21 Contents 21 1 Configurable memory conditions occccccooconncnnnccnnnnccnnccononnnonnnnonanrrnnnnnnnnnnnnnenonnnos 139 2k22 LOOIS Talk PUSO ODGT ALONG ansia bi 140 atte Memo Se UD ince a ei 140 21 227 Ole PUIsor FOCUS O Tle o e ee DU od 141 21 23 head Pulsor FOCUS TOM Me e a 142 22 EVEN COGS aio cel wenn adii 143 2201 LOO Talk P ls r Operations sisi cas 143 22 2 EVENTO OU Sii Ada 144 223 o ch kde t caret altace an dette tate ae De eed 145 22 04 ADDIEVIGUONS sfesncttte ls nicete 8 chacstte set eet A 145 2202 FAUMOOWM Tales tn antennae ected sal eee at aes ne et eet 145 22 33 WEB and NOSE relaled erorS ali iaa deidad 145 22 3 4 Event related errorS soeces aea enea AEA RERNE 145 22 3 5 User input CVENMS ccccccccssseeccecceeeeeeeceesecececeasseeeceseaueeeessseeeesssaaeeeesssaaaeeseesaas 147 22 3 6 Statistical events suina a inaa NE S e AAA E aa ANA ANA Ea SeS 147 22 3 7 Communication events oocccccccocncncccccnnccnnnnnonnnnnnnononnnnnnononnnnnnnnnnnnnnnnnnnnnnnnnnononnnnnns 148 22 3 8 Hardware events tool oooccccccccnnncnnccoconnonnconnannnnnononncnnonononnnnnononanenononnnancnnnnss 150 22 3 9 Hardware errors DC3000 MC3BOOO ooccccccccccncconcccnnncconononononn
31. SelectPrevPset Select previous Pset Bit 1 bit 0 Not used 1 Select previous Pset SetBatchSize Sets batch size in indicated Pset Bit field 2 8 bits in 00000000 0 SetBatchSizePsetID ID SetBatchSizePsetID These the same 11111111 255 pa ere User LEINE Ul6 2 bytes Binary representation eee Decimal 0 65535 ToolLightsFlashGreen Starts to flash the tool green light Bit 1 bit 0 Not used Resets any existing light pattern 1 Tool light flash on the tool ToolLooseningDisable The function is similar to Tool Bit 1 bit 0 Loosening enable Disable but only for loosening 1 Loosening disable 9836 4841 21 205 235 FieldBus configuration appendix Items To PF Description Data type String Value length ToolTighteningDisable The function is similar to Tool Bit 1 bit 0 TighteningEnable Disable but only for tightening 1 TighteningDisable UnlockTool Unlock tool if tool locked by Bit 1 bit 0 Not used batch ok or lock on reject 1 Unlock tool 206 235 9836 4841 21 FieldBus configuration appendix a a fe fa NN 30 5 ProfiBus DP een Fk ProfiBus DP is a FieldBus normally used in industrial automation to transfer fast data for motor controllers MMI I O units and other industrial equipment ProfiBus has an international user organisation called ProfiBus International PI and other local and national organizations General technical questions regarding the FieldBus should be addressed to your local P
32. Set Pset used e 1 Gear box e 2 mi Set the number of tightenings to be used in calculation of average 500 is default generally the sample size should be an approximation of the average number of tightenings during 24 hours or the maximum 1000 Select Tightenings to be included All or Only approved Tick the checkboxes below Tool Drift alarm limits that is of interrest Normally ticking all boxes provides the best tool drift alarm functionality Each limit value will be updated after lt sample size parameter D902 gt number of tightenings has been performed if the value is 0 0 by that time O Only tightenings where the tool has shut off are included in Tool Drift Alarm supervision Click the Store button to save the settings The tool drift alarm function is now active and you can start using the tool You can also manually set the tool drift alarm limits at any time both before and after the calculation of the first average It is however recommended that you use the automatically calculated limits All limits that is zero by the time that the first average is calculated will automatically be set by the system all other will be left unmodified You can activate or deactivate the limits using their corresponding checkboxes Tool Drift alarm limits These limits are automatically calculated after sample size nr of tightenings if no value is written in advance D911 Average torque deviation Lower limit lv 1 8 0 D913
33. TO 170 A e O A 170 24 RABUINTOMalON cartas nnna 173 2411 RBY TUNCHONAlY ascunsa A A 174 242 GOmecingine RBU ut lo 175 9836 4841 21 Contents 25 26 27 28 29 30 24 3 Star UP INStTUCUON Ss ira 175 Pulsor Focus hardware description ccccsccssseseeseceeeeeeeseeenseeeseeeeseeeeneesenees 177 A e A e 177 21 DIMENSION AFA WIN O racial a a 177 25 1 2 e o 177 252 Ele McCain N E 178 Zoe MAME VOMAGS a tica oia teodia 178 22 2 EOWEer CONSUMPIION rana ten dewtetounelveadelgueteraeemnavds 178 A IN SA A 178 Zoe AL VININGS ac A A T A 178 Tool Control Box hardware description cccccssseesesseseeseeseeseeseeneeseneeeees 179 Digital inputs and OUTPUTS cooonccnnncononccnoncconncenanccnnnnenannnnncrnnanrnnanrnnanrnnanrnnanennanos 181 2k TONGAN MONS E ahah ecieeyiaaisan cece A relict r a a atetiueioauasian heatu eiaon 181 27 2 WIGIAMOUTDUTS VEIAY S rasante ao 183 Connector descriptions ia 185 eo PrN E E ae daa 185 28 2 DENN OC OS li da ose didas 185 AG ee oE ROZS 2 e A daa 186 A TET M IVC rne oats aena tae ciate alan pick eae a ws ada ad fared NS 186 O A TA T iat 186 280 NOOl COMM CCION iii ii 187 O A O tuasdeod eapoiemacd maesimtus neat heed sabia dedaawmpnencetiapureweets 188 20 08 WiGitalOUIDULS elas adi sa 189 COS BUS AT o stas 190 eo OIDO soil Me leidos 190 28 11 Mains power connector menrricai iii 190 PUISOF QUICK GUIS ci 191 edi MMT OGUCTION sti cd 191 FieldBus configuration appendix conmc
34. Work object LED On Off or Tool usage C191 determines how long the Work object LED shall be lit after tool trigger release C195 determines 1f the tool should be locked when a service alarm has triggered 11 2 8 Settings for Tool lock functionality The tool lock wizard provides a quick way of setting conditions for locking the tool All these settings can be done in the respective Psets and Jobs as well the tool lock wizard merely presents an easy way to overview and set lock functionality Select Tool Lock under System gt Config PulsorF Name Not Defined setup from the navigation area Parameter Overview Reset Delete all results Press the button Tool lock wizard a arme ee en Total reset for quick programming of lock arnih Pania wattle conditions Options C160 Printer type Reset C161 Paper size A Printer setup Click on Sto re Configurable memory setup C162 Continuous print Pulsor tool config Configurable memory setup Tooo C170 Configurable memory Default configuration hd 1 0 setup H Communication Pulsor tool config Protocols C190 Work object led function Tool usage s C191 Work object led timeout 300 C195 Lock tool on service alarm Hi Tool lock Tool lock wizard X Close E Read sg Store 9836 4841 21 83 235 Config Using the Tool lock wizard Press the button Tool lock wizard A new window will open olx The following situations will always disable tool Controller power
35. brand provided the previous RBU is re inserted A change between a Gold and a differently branded RBU will clear the result database even if selecting Stop If the Pulsor Focus unit is turned on with no RBU the tightening result database will be cleared without a query to the user 176 235 9836 4841 21 Pulsor Focus hardware description 25 Pulsor Focus hardware description 25 1 Physical data 25 1 1 Dimension drawing 25 1 2 Weight The Pulsor Focus weighs about 12 kg 9836 4841 21 177 235 Pulsor Focus hardware description 25 2 Electrical data 25 2 1 Line voltage Pulsor Focus operates on a single phase 110 VAC 90 120 or 230 VAC 200 240 line voltage Pulsor Focus has a function for sensing the line voltage automatically This means that the Pulsor Focus automatically switches to the voltage you connect to 25 2 2 Power consumption The power consumption of Pulsor Focus is about 20 W 25 2 3 Mains fuse Recommended mains fuses power outlet Mains Voltage V Fuse A 25 2 4 Wiring All connections are located on the rear of the unit If it is necessary to change the plug on the mains cable use the following wiring guide A The power cable is the mains disconnecting device If you open a Pulsor Focus unit first pull out the power cable to make sure that the unit is free from electric power Do not use galvanically insulated line voltage since it disrupts the function of the Ground Fault
36. button again will return to the previous position toggle function It is also possible to make operations in the graph itself With the left mouse button it is possible to zoom into and out of a capture area in the graph This is especially useful when the staples are very small If the capture box is made from top left to bottom right it will zoom in as can be seen in the picture to the right It shows an expanded view of the individual staples each staple ranging from the minimum value to the maximum value within the subgroup size If the capture box is made from bottom right to top left it will zoom back to initial settings With the right mouse button it is possible to move inside the graph Pressing the Reset axis button will return graph to initial appearance 96 235 9836 4841 21 Diagnostics and service 13 4 Air sensor tuning All Pulsor tools have their air pressure sensor tuned when delivered You should only perform a new adjustment of the sensor if you suspect that there is something wrong with the current sensor tuning An incorrectly performed air sensor tuning may cause the tool to malfunction When performing the tuning a valve pin can be obtained from Atlas Copco Tools order no 4080 1340 00 for EPP6 EPP13 4080 1340 01 for EPP15 EPP19 must be fit in according to the first figure in the table below Adjustment is carried out with ToolsTalk Pulsor connected to Pulsor Focus and an external air pressur
37. closer to the mean value than 10 No minimum value shall be less than 50 of the mean value Where the No of Pulses parameter is concerned the limits must not be tighter than 2 pulses If the result is near zero the limits are min 0 max 4 9836 4841 21 71 235 Performing a Monitoring Setup 9 6 Making Monitoring Setup via Pulsor Focus front panel It is possible to make a Monitoring Setup without ToolsTalk Pulsor but there are some limitations It is important to know the following when making a Monitoring Setup via the front panel The tightening angle start is taken from the Pset The rundown pulse filter setting cannot be changed the settings are taken from the Pset Incorrect tightenings can not be deleted Proceed as follows to make a Monitoring Setup via Pulsor Focus front panel Make sure a Tool Setup has been performed before you start Select activate the appropriate parameter set default P1 Press Pset Setup button then or button to select Monitoring Setup menu item rSEt will flash on screen Press Enter to accept Check that the setup light comes on and that rSEt appears on the display together with the Pset number Carry out 1 50 tightenings At least 10 tightenings is recommended The latest Relative torque value and the number of tightenings carried out are shown alternately on the display Press Pset Setup if you wish to abort the setup Press the En
38. deviation alarm the subgroup angle range value has been below the average range value of the average of the last ten subgroups 7 times consecutively E374 2sigma x angle Trend deviation alarm the last subgroup angle average is outside Xang bar bar 2 sigma E375 2sigma r angle Trend deviation alarm the last subgroup angle range average is outside Rang bar bar 2 sigma 22 3 Communication events E401 Duplicate device ID s on IO bus Two IO devices with the same ID are present on the I O Bus E403 IO device not responding The I O device is not properly connected or the ID of the device is not ACK the same as the one configured E404 Selector is not connected or not The selector is not properly connected or the ID of the selector is not ACK responding the same as the one configured E405 IO Expander is not connected or not The I O expander is not properly connected or the ID of the I O ACK responding expander is not the same as the one configured 148 235 9836 4841 21 Digital inputs and outputs RE alarm is not connected or not The Remote alarm is not properly connected or the ID of the Remote responding alarm is not the same as the one configured Too many communication sessions at one There are too many connections at the same time ToolsTalk Pulsor ACK time ToolsNet Open Protocol etc No RBU present No RBU detected at start up or RBU found missing at runtime KR gt E D Gu UW a O Sy AIU
39. easy to use the same tool for tightenings with different target torques as long as the target torque lies within the valid torque range of the tool Just create additional Psets and perform a Tool Setup for each application different target torques and or widely different joint hardness The same tool will tighten the joint as specified in the currently active Pset For the torque range of the different pulsor models please consult www atlascopco com tools 12 235 9836 4841 21 Introduction to Pulsor C The tool measures the torque during pulsing The torque measured is as always the torque in the outgoing shaft from the tool What this torque pulse actually achieves for the installed torque depends on the characteristics of the joint the use of extensions sockets etc For the system to correctly translate the tool torque into installed torque the following procedure needs to be performed once for each Pset during Tool Setup several tightenings are performed on the same type of joint and the resulting torque is manually measured and input to the system via ToolsTalk or PulsorFocus front panel According to these measurements the Torque Tuning Factor will be calculated This factor is one of the parameters that are automatically calculated during Tool Setup Later tightenings will be adjusted with this factor and a result that agrees well with the installed torque is produced The main features of Pulsor C are Functions Description To
40. eek tat dean 67 92 Staring MOMIOMNG SCD eraras e Da 67 9 3 Making Monitoring Setup tiglteningS oocccocnncoccnccncnconcncnonnnonncncnncncnncncnnnnonnncnnnors 68 9 3 1 Making setups during Monitoring Setup ccccccccocccnnccononcnoncnonocnnncnnnancnnnnnnnanennnnnnnns 69 9836 4841 21 Contents 9 4 Completing Monitoring Setup cccococcnnccccnnnccccnnnnncnnonnnnnononcnnnnnnncnnnonnnennnnnanennnnennnnnss 70 9 5 Result values from a Monitoring Setup cccoccncccoccncccncnnononnnononnnconnronononenonnnnnonnncononos 71 9 6 Making Monitoring Setup via Pulsor Focus front panel cocccccccccccnncccnnccnnnononnnos 72 1O OD cid 73 10 1 Creating a standalone JOD msssararsulta ias 74 102 Grealing Multi PUISOF FOCUS JOOS ai a 76 VOS RUNNINO JODS O ad ate 76 10 3 1 Running Jobs using ToolsTalk PulsSor oooocccccccccnncnnccconcnnnonnnancnnnonnnancnnonononons 77 10 32 EUnCIOAS IN JON MON Osetia 77 19 33 EOOS CHING TION a esa 78 10 46 MIO CO TOO aa 78 dia Ie A a aa A a sonar amr mete EEE in scam saen es nea eas esearch 79 Tiek alice Veo to CON suse ete ot osetia carrot uatades atelier 79 MAS O A 80 izda Password and Name ci ee dis 80 A2 Display and tod dle CISD AY rrenan a a 80 11253 Settings Ol ODOM Sri 82 RA AY BER RO O a ne aac den aant eas 82 11 23 Selings Or DMNICN station 83 11 2 6 Settings for configurable MeMory ccccocoonnccnnnccononnnccnnncnnnononnncnnnnnnnonnnannnnnnn
41. even if other barcode string 1s received during the running Job This is applied for all Other Always the latest received VIN number barcode string will be stored together with tightening result in database Yes one null result for batch increment or decrement will be stored inthe No Pulsor Focus database One null result will be stored in the database for each step and remaining Psets in a job in case of bypass Pset or abort job No No null results will be stored in the Pulsor Focus database 161 235 Digital inputs and outputs 23 3 Config 23 3 1 C1xx System setup C10x Password and Name Parameter Parameter name Description Default setup number C100 Use password Prevents parameter updates on the Pulsor Focus keyboard and from No ToolsTalk applications C101 Password entry scope ToolsTalk All All Specify unit allowed to enter the password C105 Ch ID number Identification number of the channel system to which the programming refers Valid values are 0 20 0 1s only used for standalone Pulsor Focus unit PF name Name of the unit You can use up to 20 characters C107 Cell ID number Cell identification number Valid values are 0 1000 0 C108 Cell name Name of the HW group Cell name defines the Cell that comprises the HW group You can use up to 20 characters C109 Set date and time Allows the user to store computer time or user time and to read time and date from Pulsor Focus C11x Display setup 1 Para
42. fault in the tool or a change in line air pressure Network Pulsor Focus includes complete networking capacity as an integrated function Pulsor Focus can be connected to a network for central programming and data collection with the help of ToolsTalk Pulsor and ToolsNet Extensive support for Fieldbus usage is also provided External units The Pulsor system also includes a number of optional accessories such as selector RE alarm I O Expander and barcode reader 9836 4841 21 13 235 Introduction to Pulsor C 1 4 Pulsor components A Pulsor system includes the following main components Pulsor Focus controller unit ToolsTalk Pulsor 14 235 See product catalog for available tools Example Square drive size bit connector EPP ErgoPulse PULSOR C PULSOR Control 10 3 8 square drive i 13 1 2 square drive 20 44 square drive 42 1 4 female hex quick change chuck 43 7 16 female hex quick change chuck EP HS OBR BI 6 81 10 11 55 Max torque is grip In principle all functions are adjusted and set using a PC running ToolsTalk Pulsor connected to a Pulsor Focus unit referred to as Pulsor Focus in the rest of this document locally or via a network Many common functions can be operated directly from the front panel of the Pulsor Focus The TCB Tool Control Box is a combination of a pressure regulator valve and electronics This unit controls the air supplied to the tool Electronic
43. for the latest tightening Job Monitor Displays created Jobs and provide functionality for managing Jobs Operator monitor and Displays detailed information on the tightening results as well as a graphic representation with status Picture monitor indicators Tracking Results continuously displays tightening results see section 16 4 Tracking Results for more information This displays result information from all tightenings stored in the Pulsor Focus memory The information can be exported to a file such as an Microsoft Excel sheet Hs Le as us ME ala zj fobs te hc Cie un nary g PrI F lji Adij E ia E Monitors tal fet Wi fan E A lil Result Monitor E A Job Montar P Result Monitor LJ Operator Monitor Job Monitor O Tracking Results a o ts te er as lua Ol Operator Monitor Ul Tracking Results t ees 107 Dore all eaten a P O 29 9 7 3 Be EE I alli 55 3 Poet Hina Taia Par rl Ba Mia A Mir AE mw his de Dept cri enb cla eee ae PARA ia r a mmn EE eee jaiai ji Ey 4 rines JN OIE ES RE a Il a j EE ES ee _ Cie fave lo Fis Usen les Enga e po 7 gt a paate T Ta E d Er tes 9836 4841 21 111 235 Monitors 16 1 Result monitor The Result Monitor presents the latest tightening results from the Pulsor Focus and the used Pset The tightening result includes those parameters that are monitored in
44. item contains parameters and diagnostic tools for the Tool Control Box Here you can view firmware information set what action to assign to the TCB buttons and check that the buttons work correctly Open the Tool Control Box window by double clicking the Tool Control Box item in the PF map Under the tabs Config and Diagnostic you will find two buttons named Tool Control Box and Diagnose Accessories respectively Tool Control Box PulsorF Name Not Defined SEE Config gt Parameter Overview Setup Tool Accessories P Config Diagnostic Diagnostic Diagnose X Close i sg Store 12 1 Tool Control Box settings Press the Tool Control Box button In the appearing window you define what actions to assign to the two TCB buttons Button 1 is the green button and button 2 is the white button The green button is by default set to Pulsor Tool Enable The default for the white button is Air Hose Test iol xi x Cancel 9836 4841 21 89 235 Tool Control Box 12 2 Diagnose Accessories Pressing this button will open up a list of items that can be diagnosed in your system The common item selectable is the Tool Control Box This item will be selected by default on a system where only the TCB of the accessories can be diagnosed this way After having selected the Tool Control Box press Device Diagnostic to bring up information and diagnostic tools PulsorF Name Not Defined _ aj xj a Device type Status Config
45. menu You can also open the Activate menu If you open the Activate menu you will see a list of available functions Pset Job etc Help You can open the Pulsor Focus help file this manual as a pdf from the Help menu The About ToolsTalk Pulsor item shows registration and version information regarding the current installation of ToolsTalk 9836 4841 21 45 235 Working with ToolsTalk Pulsor 6 3 2 Selection panel Selected Controller The following options are available Serial connection Ethernet connection or Offline mode Running Pset If the selected Pset source Config Parameter C222 is in Ethernet Serial mode you can select Pset from this window Running Job If the selected Job Config Parameter C2217 is in Ethernet Serial mode you can select active from this window PulsorF list button Press this button to open up Settings gt PulsorF list tab directly without using the Settings menu item PulsorF List You can use the PF List dropdown to easy connect to a Pulsor Focus via Ethernet Select an item in the dropdown dropdown list to connect ToolsTalk Pulsor to the corresponding Pulsor Focus The information in this list contains Name IP address and port number The PF list 1s created from Settings in the Options menu PulsorF list tab You can also press the PulsorF list button as mentioned in the item above 6 3 3 Toolbar Tool Setup Clicking this button will start Tool Setup for the active Pset Click the ar
46. new job deleting all existing jobs or selecting job off G 5 It is not possible to unlock the tool by rebooting the Pulsor Focus controller 78 235 9836 4841 21 Config 11 Config 11 1 Introduction to Config The Config contains the configuration parameters that are common to all Psets and is unique for each Pulsor Focus unit This chapter gives an overview of the Config functionality in Pulsor and how to perform some common configuration tasks such as Setting IP address Subnet mask and Default router Setting Pset select source Setting Internal I O Setting Display and toggle display Settings for batch counting Start Config from ToolsTalk Pulsor either by double clicking on Config in the PF Map or by f selecting the function from the toolbar i Config PulsorF Name Not Defined 10 x Parameter Overview C100 Use password No E System setup Password and name Display setup 1 Display setup 2 Options Reset C101 Password entry scope All z Printer setup Configurable memory setup Pulsor tool config Tool lock 1 0 setup C105 Ch ID number C106 PF name C107 Cell ID number C108 Cell name Not Used Not Used Communication Protocols Set date and time X Close Gh Read sg Store System setup System Setup contains basic Pulsor Focus features such as name and display options I O setup Pulsor Focus has extensive I O capabilities
47. oO 1441 A i AA N oO Pulsor Quick Guide Line control start Line control start signal is received alert 2 Service indicator Service level reached On until the service indicator 1s reset one Only valid if the Service indicator D131 is turned on Tool green light Relay follows tool green light Also following function Flash tool green light no flashing Tool yellow light Relay follows tool yellow light no flashing ToolsNet connection lost Open Protocol connection lost Fieldbus Offline When fieldbus goes offline the light on this bit turns off Fieldbus Carried Signals Indicates fieldbus signals disable Disabled Max coherent NOK reached Goes high when max coherent NOK tightening counter is reached Monitoring setup active Monitoring setup is ongoing Pset with Tool Setup The selected Pset has a Monitoring setup performed and is ready for use performed Rundown time low The latest rundown time value below the Pset limits Rundown time high The latest rundown time value above the Pset limits Tightening time low The latest tightening time value below the Pset limits Tightening time high The latest tightening time value above the Pset limits Pulse frequency Tool Drift The latest average pulse frequency value is below the active Tool drift alarm alarm low limit Pulse frequency Tool Drift The latest average pulse frequency value is above the active Tool drift alarm alarm high limit RT Tool Drift alar
48. off Ho tool connected No ABU connected System event code Ho Pset selected Peet without tool setup Digital input locked Click wrench Pset selected In this window information about which situations will shut off the air supply is shown The following parameters can optionally disable tool Batch completed P152 Lock at Batch OF Pet Tightening HOK C130 Lock on reject Contig Job completed 130 Lock at Job done ob Job linecontrol start 130 Lock at Job done Job and J330 Use linecontral ob Tool service needed 0736 Lock tool on alarm The green button on the TCB will by default enable the tool after a lock situation below See configuration of Tool control box under Tool accessones Check the alternatives you BB ctional Conti cere o HEE E Lock tool on HOK tightening O Optional Job 1 La lock with digital input Depending on the Psets and Jobs configured the system will detect the Optional conditions which can lock the tool Select the the desired optional conditions by checking the corresponding checkbox Finally press the OK button 84 235 9836 4841 21 Config Custom I O settings You can use I O devices to trace the Pulsor tool enabled state Relay and set the tool enabled state etc Dig In If desired configure the I O device for lock functionality according to section 20 3 1 Setup of I O Expander The air will always be shut off in these sit
49. order number 8433 061004 Selector 8 order number 8433 0610 08 9836 4841 21 131 235 Accessories 20 2 1 Setup of Selector Hardware Setup Connect the Selector via I O Bus to the Pulsor Focus Make sure that the I O Bus is terminated in both ends For detailed information see chapter 28 Connector descriptions and the Product Instructions document for Selector Software Setup In ToolsTalk Pulsor open the Config dialog and select I O Setup Select Selector under appropriate I O Device This should be the same as the device number set with the rotating switch on the bottom of the selector Device 5 is the default for Selector 4 and device 6 is the default for Selector 8 E Config PulsorF 1 Station 1 loj x E S VO device 07 C200 Internal 1 0 Set System setup C201 Device 1 Of set ee C202 Device 2 Off Set 140 device 0 7 bal 140 device 8 1 5 C203 Device 3 Ot M Set Other 1 0 s 1 C204 Device 4 Selector Pset 4 Pos Set Other 140 3 2 Communication C205 Device 5 Off gt Set l Protocols C206 Device 6 Off Set C207 Device 7 Off z Set Click on Set Drag the Psets that you have created before to the desired positions of the socket tray 1 Selector Setup Dialog I 0 Device 4 x Available Name Jo eF iye Usg Selector postion f1 Gearbox 1 Station 1 Pset Yes dt Loa Al Pset Yes Q Add to Selector Position 3 Station 1 set Yes ER it Remove from Selector Sel
50. r sia 117 Stalis le S aeiae iii 119 17 1 Introduction to Statistics in Pulsor FOCUS cocccccnccncnnccnccnnnncnnnnncnnanononcnnnn cnn nan nnnnnns 119 17 2 Statistical Process Control SP 120 Ao Statistical ictericia 120 1734 Trend deviation alarm siie a ici 121 165 Galcuation or WC ain Olas do 121 176 GaleulatiOn Ol A and R enen a ie arn ani 121 ES G AIC UIATION TO MUS a ies 121 17 8 Constants for calculation of SPC variables coococccnccncnnccncnnconcnnnoncnnconconcnnconannnnns 123 Gelland Netos E A T E AE eee 125 18 1 Network setup via ToolsTalk PulSo0r coooccoccccococococonncocnnonoconnaconnncncnanononoss 126 18 2 Cell and Net configuration via ToolsTalk PulSor c cooccccccncccoccnonoconnnccononcnonnnnos 127 1821 Connection With TOOIS Talkin di as 128 TOO Ne e o 129 ls o s cc5 retest a a no paneneceateactues et E 129 19 2 Enabling the Pulsor system for ToolsNet ooooocoonccccnccncccnccnncnnccconocononnncnnnnncnnnnnconos 130 PROCOSSOMNCS etc oe eae emcee caw ede eset eae sien eect code ned rene cus bvass 131 ZOST aL galo o A nn 131 AA A A A A 131 2020 Selup o0r elec ole eee dead Acne att ois iea dee eens a 132 203 VO EXP Ad datos 133 2031 SetuP O Expand aid det 133 POE E O Ag vanes eon Mata talon eae anette autos ant 135 20 4 1 Setting up a stack light using ToolsTalk ccccceccceeeeeeeeeeeeeeeeeeeaeaeeeeeeeeeeeeeeeeeees 136 ZOO PAE PALA N A getw oeauesueneiaes Sane 138 205 1 Sep
51. ready to go No mechanical adjustment of the tool is normally needed If monitoring of the tightenings is desired limits may be set either manually or automatically by performing a Monitoring setup Follow the instructions in the PulsorC Quickstart Guide to begin working with the system as quickly as possible Tightenings can be prrformed using one of two strategies the Pulsor Fixed or the Angle Shutoff strategies In the first the Pulsor Fixed strategy the optimal pressure for a certain joint and Pset is set once and this pressure is then used throughout all tightenings performed with that Pset The second strategy is used for torquetangle tightenings The system will shut off after the specified angle 1s reached above a torque threshold value This strategy is good at producing consistent clamp force between similar joints Whichever strategy is used the Pulsor Focus collects information about ongoing tightenings and decides when to shut off the tool It is possible to mix Psets with different strategies on the Pulsor C system During Tool Setup 1 e when setting up a Pset the tightening speed can be set in five steps This makes the system usable both for speed critical applications and applications where higher accuracy is needed As usual the rule of faster tightenings higher scatter applies As the target torque and control parameters are set in software there is no need for mechanical adjustments of the tool Therefore it is
52. running tool for safety purpose No tool stop does not stop running tool Tool stop FieldBus start stops running tool if tool start select source is FieldBus F300 Bitmap select This parameter makes it possible to view the bitmap in the same way in Pulsor Focus and the PLC configuration software It defines if byte 0 or byte 1 shall be to the left Default settings are the type that is common for the selected FieldBus type For DeviceNet Intel Endian must be used For ProfiBus Motorola Endian must be used 172 235 9836 4841 21 RBU information 24 RBU information The RBU Rapid Backup Unit is a software key and data storage unit for the Pulsor Focus The RBU unlocks software functions available for each version of the Pulsor Focus It also stores a backup copy of the Pulsor Focus configuration The RBU backup copy makes it possible to move functionality and configurations between different Pulsor Focus units A Pulsor Focus can not be used without a RBU inserted At the time of this manuals print there is one RBU available the Gold RBU The functions available are presented in the table below The RBU serial number is also part of the Pulsor Focus Ethernet MAC address Pulsor Focus Ethernet address 00 50 D6 XX YY ZZ from serial RBU Example RBU with serial number C00015767 C 00015767 003D97 Hexadecimal C00015767 00 50 D6 00 3D 97 MAC address AS Pulsor Focus cannot be used with a Power
53. specifies the network ID number used in the FieldBus system You can set the node address if the selected FieldBus type has this feature Two units in the same FieldBus network cannot have the same node address It 1s possible to set FB node address from 1 to 125 Communication speed on the FieldBus system You can set the baud rate 1f the selected FieldBus types have this feature G The baud rate shall be the same in all Pulsor Focus controllers and in the PLC This parameter manages the way the FieldBus system detects changes of data on the different units Some FieldBus types have the possibility to set different connection modes There are three modes Polled Bit Strobe and Change of State 171 235 Digital inputs and outputs Parameter Parameter Name Description Default value Number gt The settings in the Pulsor Focus controller and the PLC must be the same Set node address from ModBusPlus global data exchanges require a source address which is a node address where you want to get the global data from F120 Software the node address is set from user interface Hardware the node address only can be set from the switches on ProfiBus card F130 PCP length Provides a way to send longer data strings than the standard 20 bytes process data The data package that is sent to or from the Pulsor Focus can be longer than the 20 bytes process data The part exceeding the process data is sent in small packages
54. the serial connector or Ethernet for selecting of Psets and Jobs A filter can also be setup to decide which part of the barcode string must be saved together with the tightening result 53 Barcode strings sent to Pulsor Focus are not allowed to contain the following characters apostrophe comma semicolon point sun amp and pound Start Identifier by either double clicking on Identifier in the PF Map in ToolsTalk Pulsor or by Wi selecting the function from the toolbar 0123488 14 1 Barcode data string The maximum length of the Barcode data string is 25 ASCII signs If the string is longer Pulsor Focus will use the 25 first signs Serial protocol 1 no CI Stop is Y Pay no SSSOSCSC SCS aud rate STX lt data 1 25 characters gt ETX STX 02H ETX 03H 9836 4841 21 103 235 Identifier 14 2 Identifier setup Start by connecting ToolsTalk and the Identifier Barcode reader to the Pulsor Focus G 5 To select Psets via a barcode reader parameter Pset select source C222 should be set to Identifier Start ToolsTalk and click on Identifier in the PF Map Under General setup select wanted Identifier input source 1100 Identifier PF 1 PF1 Parameter O verle E Identifier setup General setup Card reader 1100 Identifier input source Ethernet Seral amp Scanner Y 1101 Significant numbers 12345678 Set Significant no in vit 1104 VIN filter L23
55. they cannot be evaluated Jtis recommended to perform at least 10 tightenings Only one tightening will work but more tightenings will provide better statistics Max 50 tightenings is allowed Itis important for the statistics to be based on representative and correct tightenings Incorrect tightenings can be deleted by clicking on Delete for the tightening See also the following section 68 235 9836 4841 21 Performing a Monitoring Setup 9 3 1 Making setups during Monitoring Setup By pressing the Set reference values button you can change the following parameters while carrying out a Monitoring Setup These parameters affect the measurement values also for tightenings already done during Monitoring Setup Target torque not editable Specified target torque for this PSet Tightening angle start This should be set to the relative torque level from where angle measurement is to start The default start is at 50 of target torque Rundown pulse filter If there are problems with early pulses that are not part of the relevant tightening such as self tap or nyloc such pulses are filtered out The filter is on as default when a Pset is created but can be shut off See more under section 8 8 Strategies for tightening monitoring Keep Pset torque limits if this checkbox is marked torque limits in monitoring limits will not be changed after an accepted Monitoring Setup Click the Set reference values button Set r
56. to a Pulsor Focus unit All programming will be stored to or read from a file This file can be copied to one or more Pulsor Focus units There are three different ways to select the Offline mode Select Focus Offline lt Name gt Connect shown to the ESM CTAC AMAR ut Paid ocean right File Edit Amis Options Window Help Select last alternative in the Selected Controller box a eset t Station 1 Double click on the Offline icon in the PF Map window Ethermet P n Beda Mame Mot Defined The file can be located on the local hard drive or network etc There 1s a number of default files supplied when installing ToolsTalk You can also find these files separately on the ToolsTalk installation CD Depending on the license level Gold RBU or differently branded RBU of the Pulsor Focus the corresponding file shall be selected You can recognize the different license levels by the names of the default files Gold pf3 in the case of a Gold RBU A good idea is to make a backup of these files A file can be created by first connecting Serially or by Ethernet to a Pulsor ToolsTalk Pulsor 3 05 Focus and then selecting Store PF to File from the File menu Name the file and SES Edit Focus Options store it in an appropriate location Read Pulsor Focus From File Select a file with the same license level as the Pulsor Focus unit The selected Store Pulsor Focus to File file is opened and you can change it just as i
57. to check if FieldBus Bit bit 0 Not used works 1 Handshake Identifier Input the VIN number from the Character 24 208 One ASCII sign for each PLC To get this working you string input bit 3 26 character must set identifier input source in bytes First byte is counter PE TO PISSEN Character 16 200 One ASCII sign for each string change bit 2 25 character bytes 2 bytesin U 16 If the value is less the same then 5 digits decimal PF word will fill with zeroes in front 4 bytes in U32 If the value is less then two words 10 digits decimal PF will fill with zeroes in front U32 HNW 4 bytes in Only for Intel format two words Character 16 192 2 One ASCU sign for each string change 24 bytes character string is in Intel Intel format byte order Character One ASCII sign for each string input character Intel format First byte 1s counter String is in Intel byte order 2 8 bits in 0000 0001 Job 1 the same 0001 0000 Job 16 JobSelect Select a Job Job select source Bit Field must be set to FieldBus Job 0 no Job selected JobOff Gets off Job mode and unlocks tool 204 235 9836 4841 21 byte 16 bitsin 00 0001 Job 1 00 1000 Job 8 1 bit 0 Job On U 16 Bit FieldBus configuration appendix Items To PF Description Data type String Value length KeepAlive Send to PF to check if FieldBus Bit Field 2 8 bits in 00000000 0 communi
58. to the tightenings performed during the Monitoring Setup See chapter 6 Working with ToolsTalk Pulsor for more information WO Cancel 70 235 9836 4841 21 Performing a Monitoring Setup 9 5 Result values from a Monitoring Setup When a Monitoring Setup is complete the proposed limit values are stored in the tightening monitoring parameters The result values from the Monitoring Setup are saved for later reference In the window of the active Pset click on View Result under Monitoring Monitoring Setup setup to check the saved values from Monitoring Setup Perform Monitoring Setup P600 Monitoring Setup performed 201 0 03 23 17 18 39 P601 Number of tightenings 10 Result values from a Monitoring Setup are l Monitoring Setup Result 1 Gear box r Tightening basis statistics Proposed limits displayed Tightening parameters i Max Mean Std dev Hin Max Torque Yalue 47 45 2 0 0 Relative torque 104 98 4 83 112 Tightening Angle 10 2 3 15 No of pulses 6 5 1 2 7 Tightening time 0 26 0 19 0 04 0 34 Rundown time 0 20 0 20 0 23 System parameters Pulse frequency Pulse pressure Bar Number of tightenings Tightening Angle Start Rundown Pulse Filter PF name PF serial number 4180006 Main code version 5 4 4 RBU serial number 00289539 Pset 1 Gear box Tool serial number 41420890 User info Proposed limits are calculated on the following basis Limit values are calculated as 4 standard deviations but no
59. used to select Psets or jobs For more information see chapter 14 Identifier When increasing database elements a decreasing of other elements might be necessary For instance if 100 Jobs and 100 Psets are required it is not possible to have more than 3500 results option More Psets Jobs 9836 4841 21 139 235 Configurable memory 21 2 ToolsTalk Pulsor operations This section shows only examples of possible parameter settings 21 2 1 Memory setup In the PF Map select config system setup configurable memory setup gt Config PulsorF Name Not Defined EP 5 ystem setup Password and name Printer setup C160 Printer type C161 Paper size C162 Continuous print O x Delete all results Total reset IBM z Ad r F a 0 a C170 Configurable memory E configuration H Communication H Protocols Tool lock x Close Make a selection for Configurable memory C170 To have more Psets select More psets Click OK to continue A table showing the valid memory setups is displayed Click OK to continue 2193 Line pressure alarm lower limit C194 Line pressure alarm upper limit Pulsor tool config C190 Work object led function C191 Work object led timeout 300 Sec Tool usage k 3 0 Bar 8 0 Bar Tool lock wizard E Read wal Store Configurable memory setup Default configuration Default configuration Hore pets C190 Work object led funct
60. with statistical alarm limits based on the X and R calculations for torque Statistical Process Control SPC functions are used on torque All checks are performed on the Pset that the tool is currently running with If any of the following criteria are true the stat alarm light and a relay if used is activated The tool may still run even if an alarm is issued The alarm is only a warning The alarm signals remain active until the process falls within all limits again or the result memory 1s cleared This means that the alarm does not switch off during tightening 17 3 Statistic alarm x gt UCL x lt LCL R gt UCL R lt LCL Cp lt 2 0 Cpk lt 1 33 SPC x andR compared with LCL UCL alarms cannot function until the LCL and UCL have been programmed 120 235 9836 4841 21 Statistics 17 4 Trend deviation alarm Trend deviation check and alarm are measured and compared against X bar and the range for the currently used Pset 7 points consecutively increasing 7 points consecutively decreasing 7 points consecutively above average X and or R 7 points consecutively below average X and or R point outside Xor R 2 sigma sigma for the whole population Point subgroup The mean is the average of x andr X andR This means that the SPC trend alarms cannot function until the number of tightenings in the memory corresponds with the user specified number of subgroup parameters 17 5 Calculation of UCL and LCL
61. 0 Air sensor tuning 0134 Latest service date U06 01 17 Controller diagnostics l System diagnostics Service counter reset 0136 Lock tool on alarm E D137 Number of pulses since service 1 444339 0738 Service interval in pulses 1 SOD000 0133 Date for nest service 2006 1 1 02 Service indicator alarm configured in the Tool service section provides a mechanism to remind Pulsor Focus users when it is time to service the tool The user specifies how many tightenings is allowed since last service until tool has to be serviced When Number of tightenings since service D132 exceeds Service interval D133 or when Number of pulses since service D137 exceeds Service interval in pulses D138 or when the current date is later than Date for next service D139 date a service indicator alarm will be activated By performing proactive service on a tool failure due to mechanical wear can be avoided during production When Service indicator alarm is activated the following will happen The alarm LED on the front panel of Pulsor Focus will flash continuously Event code Tool service interval expired E502 will be generated This event code will also be automatically generated after each 100 th tightening as long as the service indicator alarm is active It is possible to configure the controller to lock the tool when the service indicator alarm activates see lock tool on service alarm C195 92 235 9836 4841 21 Diagnostics and ser
62. 102 TCE pressure Al al 2 0 Bar EA EA Start 13 6 2 TCB air hose test When the TCB air hose test button is pressed the TCB air hose test window will be shown Here you can choose to start the test stop the test in case something is wrong and close the window When Start is pressed the system will perform an Air Hose Test A series of air puffs will be emitted from the TCB as the air system and hose characteristics are measured After the measurements are done resulting data will be presented in the diagnostic window in the boxes right above the TCB air hose test button Press Close to return to diagnostic window TCB air hose test X 0932 Mas available air pressure b 34 Bar 03933 Air shut off time 0 02 Sec Tightening should not be done during air hose test 9836 4841 21 101 235 Identifier 14 Identifier It is possible to send an Identifier barcode string to the Pulsor Focus This string is normally generated from a barcode reader connected to one of the serial ports on the Pulsor Focus this barcode is usually called VIN or ESN in car plants When entered the Pulsor Focus will use this number and send it together with the results to ToolsNet software etc It is also possible to use the barcode to select Psets and Jobs For parameter descriptions see Parameter List A filter can be setup to decide what part of the barcode string that is of interest The barcode string can be sent to the Pulsor Focus via
63. 16 0 2010 03 16 1 Pzet ref Read Pressing Pset ref button will bring up a window showing the current Psets reference values When tool drift alarm is initiated the Pulsor Focus will continuously after each tightening compare the mean values of the selected parameters with the limits that are set If any mean value parameter exceeds a preset alarm limit for 10 consecutive tightenings the alarm light on Pulsor Focus will flash continuously and an event code will be generated stating which parameter has caused the alarm The event code will be generated after every 100 th tightening as long as the tool drift alarm is active If desired it is possible to configure a digital output to trigger when Tool Drift Alarm activates for any parameter When a new Pset is created it will automatically be included in the Tool Drift Alarm function provided the user does not actively exclude it as described in section 13 3 2 Enabling Tool drift alarm item 3 Tool Setup and Monitoring Setup tightenings are NOT included in the calculations of the mean value for the Tool Drift Alarm parameters Changing tool does not affect Tool Drift Alarm supervision provided the same tool size is used If the new tool has a different target torque and or different application area it is important to note that Tool Drift Alarm supervision might be influenced It is recommended to restart Tool Drift Alarm in such cases 9836 4841 21 95 235 Diagnostics and ser
64. 221 Available options Off default DigIn Ethernet Serial Identifier PF Keyboard C230 Selector lost mode Determines whether the last selected Pset or no Pset is selected Last Pset when communication with a selector is lost C231 Use last Pset at start Use last Pset which was selected before reboot up 23 3 3 C3xx Communication C30x Remote com Parameter Parameter name Description Default number setup C301 IP address The IP address is a number for identification in a network 0 0 0 0 C302 Subnet mask Specifies the number of IP addresses on the subnet and also the number 0 0 0 0 of Pulsor Focus unit that can be placed below a NetMaster if no router is used C303 IP address of the router used on the Subnet 0 0 0 0 C304 NetMaster IP address The NetMaster IP address The address should be written into each 0 0 0 0 included CellMaster The NetMaster monitors and collects information from the CellMasters included in the system C305 CellMaster IP address The CellMaster IP address The address must be written into each 0 0 0 0 included CellMember The CellMaster monitors and collects information from the CellMembers included in the Cell 9836 4841 21 165 235 Digital inputs and outputs C31x Advanced com Parameter Parameter name Description Default setup number C310 Cell keep alive Defines the timeout in seconds for the Cell communication All Pulsor Focus units in the factory should use the sa
65. 35 Accessories 20 5 RE Alarm The RE Alarm gives status information to users using lights and or audible signals It is connected to the Pulsor Focus on the I O Bus The RE Alarm is configured in the Pulsor Focus and it is possible to configure the information you want to see RE Alarm order number 8433 0560 03 20 5 1 Setup of RE Alarm Hardware Setup Connect the RE Alarm via I O Bus to the Pulsor Focus Make sure that the I O Bus is terminated in both ends For detailed information see chapter 28 Connector descriptions and the Product Instructions document for RE alarm Software Setup In ToolsTalk Pulsor open the Config dialog and select I O Setup Select RE Alarm under appropriate I O Device Device 3 1s the default for RE Alarm Select the events and the type action it should trigger Click Store to complete the setup in ToolsTalk Pulsor Remote Alarm Setup Dialog xX Ewent Type Steady light Steady light Steady light Steady light x Co 20 6 Other accessories 20 6 1 Barcode reader The Pulsor Focus is able to identify barcodes via a Barcode reader or a RF tag which enables values to be input from specific car models and tool guides See chapter 14 Identifier how to configure a barcode reader GS There is no standard Atlas Copco barcode reader model 20 6 2 Operator panel Operator panel OP is an external device for Power Focus and Pulsor Focus It is a general purpose lamp
66. 4 56 810171213 set VIN Filter Set Identifier setup send Identifier Card reader setup 200 Card reader type None Y Select positions where the significant information is located in the barcode number 1 to 25 can be selected it is not necessary to set them in a row Click OK when finished Click on Set VIN Filter 104 235 9836 4841 21 Identifier YIH filter x Unmark the characters position you do not want to sawe in the VIN resul 2an S amp B 89 10111213 14 15 1617 18 19 202122232425 Unmark the positions of the barcode string that must not be saved with the tightening result Click on Set Identifier setup Identifier setup In this window you enter the different combinations of the significant numbers that you need 1234567891 23 1 FrontS eat Enter a string same length as in parameter 1234567891 24 3 Cover significant number above in the Add Identifier string field and click Add A matrix where the columns represent existing function ID numbers and the rows represent the added Identifier strings is then formed 123456789125 1 Front 1 FrontPane Once all strings are entered associate them with a Pset or Job by double clicking in the corresponding Cell in the matrix and selecting a function ID number from the pop up list Click OK to exit the window Add Identifier strin Set Card reader type 1200 1234567891 25 Add Click Store to save the settings 2e Remove I
67. 44 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 enligt best mmelser i riktlinjerna 89 336 EEC 73 23 EEC 93 68 EEC Type Type Typ Tipo Tipo Tipo Type Type Type Tyyppi Turtoc Typ Name of and position of issuer No Name und Position des Erstellers Nombre y cargo del expedidor Nome e cargo do emissor Nome e posizione del dichiarante Naam en funktie van de uitgever Udsteder navn og stilling Utsteders navn og stilling Ilmoituksen antajan nimi ja asema Ovopa Kai G on ex0 tn Utfardarens namn och befattning H kan S derstr m General Manager Signature of issuer Signature de l metteur Unterschrift des Erstellers Firma del expedidor Assinatura do emissor Firma del dichiarante Handtekening van de uitgever Udsteder underskrift Utsteders signatur limoituksen antajan allekirjoitus Yrroypapr ek rtn Utf rdarens namnteckning Bl SER bss Edition 1 Page 1 1 9836 4841 21 Atlas Copco Tools No 9834 5221 00 2001 10 EC declaration of conformity 233 235 Atlas Copco 9836 4841 21 Software release 5 5 2010 04 Edition 2 0 www atlascopco com
68. 4841 21 Introduction to Pulsor C 3 3 1 Indicator lights Light Indicator light Description nr 1 OK The OK light indicates that the result of the tightening is within the specified limits The indicator remains active until the next tightening starts 2 NOK The NOK red light indicates that the result of the tightening falls outside the specified limits The light is active until the next tightening starts 3 The ALARM indicates that an alarm message needs to be acknowledged The light is active until the message is cleared The alarm light can also flash indicating active alarm that does not need to be acknowledged e g service indicator alarm or tool drift alarm 4 PSET SETUP The PSET SETUP light indicates when the Tool Setup or Monitoring Setup programming function is graph symbol active The light goes off when the Setup is finished 5 nx OK The n x OK light indicates that the number of approved tightenings corresponds to the number batch size programmed into the Pset The indicator remains active until the next tightening starts JOB OK The JOB OK light indicates that the Job is finished and that the results are OK according to the job parameters The light remains active until the next cycle starts or the system is reset 7 STAT The STAT light indicates when the calculated values fall outside statistical control limits The light remains active until the values are within the control limits or the memory has been reset PR
69. 512 bytes of IO for both Input and Output data The module baud rate is 100Mbit s full duplex The IP address can be configured either via DHCP BootP or DCP Three diagnostic LEDs continuously indicate the actual Profinet status and eventually error messages The module also supports the normal Profinet Alarm functionality In the standard version the module uses a normal RJ45 connector for the bus connection Features Up to 64 slots 1 sub slot Up to 1024 bytes cyclical I O 512 input amp 512 output 2 ms cycle time Indicators Communication Status Online Run Connection with IO Controller established IO Controller is in Run state 2 Green 1 flash Online Stop Connection with IO Controller established IO Controller in Stop state Off Offline No connection with IO Controller f GSD Green 1 flash Diagnostic data available Green 2 flashes Blink Used by an engineering tool to identify the fieldbus module Red 1 flash Configuration Error Too many modules sub modules I O size derived from IO controller configuration is too large Configuration mismatch no module wrong module Red 3 flashes No device name or no IP address assigned No power or not initialized On Profinet the characteristic of a device is stored in an XML data file This file referred to as the GSD file is used by Profibus configuration tool when setting up the network 9836 4841 21 223 235 FieldBus configuration appendix
70. 6 4841 21 FieldBus configuration appendix Baud rate The ProfiBus DP network baud rate is set during configuration of the master and only one baud rate is possible in a ProfiBus DP installation As the Pulsor Focus ProfiBus DP module has an auto baud rate detection function you will not have to configure the baud rate on the module Supported baud rates 9 6 kbit s 19 2 kbit s 93 75 kbit s 187 5 kbit s 500 kbit s 1 5 Mbit s 3 Mbit s 6 Mbit s 12 Mbit s Functionality of the indication LEDs The module is equipped with four color LEDs used for debugging purposes The functions of the LEDs are described in the table and figure below FieldBus Diagnostics Indicates certain faults on the FieldBus side LED 4 Flashing Red 1 Hz Error in configuration IN and or OUT length set during initialization of the module is not equal to the Length set during configuration of the network Flashing Red 2 Hz Error in User Parameter data The Length contents of the User Parameter data set during initialization of the module is not equal to the length contents set during configuration of the network Flashing Red 4 Hz Error in initialization of the ProfiBus communication ASIC Turned Off No diagnostics present On Line Green Indicates that the module is On Line on the FieldBus LED 2 Green Module is On Line and data exchange is possible Turned Off Module is not On Line Red Off Line Indicates that the module is Off Line on the
71. 9 4 2 1 Tooladu tme S cae a ooo dolo 29 4 2 2 OME Vel inthe pulse it e A a 29 5 Performing Tool Setup cia 31 Bek AN 31 5 2 Starting Tool Setup from ToolsTalk Pulsor oonccccoonccncconnccncccnoconnnnnnconcnnnanoncnnnanonoos 31 5 2 1 Starting Tool Setup from ToolsTalk method 7 ooocccccccccccconnccnnnnccnnnnnncnnnnnnnonnnannnnnns 31 52 2 Starting Tool Setup from ToolsTalk method B oooccccccccccoconncconnnccononcncnnnncnnnnnaannnnnns 32 59 TOOSE WNGOW sorosiane etd tn tonite tens Geolene led tett te ecient 32 54 TOO Setup MONTO crs S lee ace ees es ete ee tes roe al ee ean 33 5 4 1 Description of buttons in Tool Setup Monitor cooccccnnccccccconnncnnnnconnnancconnncnonnnanos 33 5 4 2 Making Tool Setup tightenings Tools Talk PulSor oooocccccncccccncoononnnccnnnnnnos 34 5 4 3 Deletion of Tool Setup tighteningsS oooccccnnncccccnoonncnnnonononanncnnnnnonononannnnnnnnnnononans 35 5 5 Finished with the tighteningsS ccccceccccssececceseecceeeeccceucecseeeeseueeeesusessegeeesseeessaes 35 5 6 Manual TOO Sel si a 36 5 7 Tool Setup from Pulsor Focus front panel oonncccnconccncccnnconnnnoncnnnnnnnnnncnnannncnonannnnnos 37 5 7 1 Making Tool Setup Tightenings Pulsor Focus front panel ooocccccccccnnnncccoonnos 37 5 7 2 Performing Tool Setup from Pulsor Focus front panel cccccceeeeeeeseeeeeeeeeeeeees 37 9836 4841 21 5 235 Contents 6 235 5 8 Changing paramet
72. Average torque deviation Upper limit v 18 0 D915 Average frequency deviation Lower Limit v 1 8 0 D917 Average frequency deviation Upper Limit jv 116 0 View Tool Drift results Reset Tool Drift alarm You can view the current status of the Tool drift alarm using the View Tool Drift alarm results button 13 3 3 Restarting Tool Drift alarm Tool Drift alarm can be restarted at any time for example after the tool has been serviced Reset Tool Drift alarm lt 4 _ _ ae Read Wal Store When having pressed Reset Tool Drift alarm and acknowledged that historical data really is to be deleted a message will pop up asking whether the alarm limits should be reset as well After this the historical values and if desired the alarm limits will be reset Tool drift data collection will start again from the 94 235 9836 4841 21 Diagnostics and service beginning If alarm limits are reset these will be updated again the next time lt sample size gt tightenings has been performed 13 3 4 Tool drift alarm supervision After initiation historic results will be displayed in the Tool Drift alarm results panel for each new tightening To see the latest results press the View Tool Drift results button Parameter Value Limit Date verage Torque Deviation min E 3 8 0 2010 03 15 0 18 0 verage Torque Deviation max 2 1 2070 03 15 1 verage frequency deviatian Lomin 0 0 4 0 2010 03 15 0 verage frequency deviatian Lomax 0 0 1
73. Bus DP ProfiBUS InterBus ModBusPlus ModBus TCP and EtherNet IP If there is no FieldBus configuration inside the Pulsor Focus when open FieldBus icon or read from PF None will be shown in the setup window If Offline programming is used None is selected when you start If there is no FieldBus card installed in Pulsor Focus FieldBus programming only works in Offline mode F102 From PF DataLength From PF DataLength F102 is the total length in bytes of the data string sent from the Pulsor Focus controller to the PLC The lengths must be the same as defined in the PLC Because swap bytes are needed for some FieldBus type only even numbers should be programmed 2 4 8 10 etc Data length should be a number higher than zero The maximum length that can be programmed is different for each FieldBus type y If InterBus is used the Pulsor Focus unit has to be restarted when the data length is changed 170 235 9836 4841 21 Parameter Number F103 F104 F105 F110 F111 F112 F113 9836 4841 21 Digital inputs and outputs To PF DataLength From PF Global DataLength To PF Global DataLength Set node address and baudrate from FB node address Baudrate Connection mode To PF DataLength is the total length of the data string send from the PLC to the Pulsor Focus controller The length must be the same as defined in the PLC Because swap bytes are needed for some FieldBus types only
74. C306 can be changed C320 C322 is used to setup the baud rate and protocol for the Pulsor Focus serial ports 9836 4841 21 fio 40 165 96 255 255 252 fo fro ao he py CO C E Sec 9600 y ascii gt 9600 y Gb Read sg Store 87 235 Config 11 5 Protocols Pulsor Focus communicates through a number of protocols This window contains the settings for each communication protocol C400 selects which TCP port to use for ToolsTalk Pulsor Do not change unless you really have a problem using the default port C410 C414 are described in chapter 19 ToolsNet C420 C427 are used with the older software Factory Overview System setup 1 0 setup Communication Protocols ToolsT alk setup ToolsNet setup Multicast setup Open protocol setup C451 The port number for the open protocol server Ethernet communication is 4545 default yc value C452 If checked Pulsor Focus will detect cable loss when running the open protocol on serial port 1 or 2 88 235 Parameter Overview ToolsTalk setup C400 Port ToolsNet setup C410 ToolsNet on C411 IP address C412 Port Multicast setup C420 Multicast on C421 IP address C422 Port C423 Results C42 Event code Open protocol setup C451 Port C452 Serial cable loss detection E Read sa Store 9836 4841 21 Tool Control Box 12 Tool Control Box The Tool Control Box
75. D 3 Flashing every 160 ms This node works normally receiving and passing token Flashing every 1 s This node is in Monitor Offline status 2 Flashing off 2 s This node is in MAC _IDLE never receiving token status 3 Flashing off 1 7 s This node is not hearing any other nodes 4 flashing off 1 4 s This node has heard a valid packet that has a duplicated node address sent from another node on the network using the same Node ID MBP Init Green Indicates that the peer interface is initialized LED 4 Turned Off peer interface is not initialized FieldBus connectors ModBusPlus recommends the use of a 9 pin female D sub connector Depending on the protection class and type of application other connector designs may also be used Connector 9 pin female DSUB Name Node address Node address is set with the first DIP switch on the FieldBus module allowing address settings from 1 64 in binary format If the set node address 1s from SW1 ModBusPlus takes SW node address regardless of hardware switch position osp p Je 8 ens rima AE ON CO CN The Node address cannot be changed during operation 9836 4841 21 219 235 FieldBus configuration appendix Source address Source address is set using the second dip switch the one close to LED on the FieldBus module this enables address settings from 1 64 in binary format If the set source address is from SW2 ModBusPlus takes SW source address reg
76. Edit Focus Options In the file drop down menu select store PF to file A save as dialog box appears State target Read Pulsor Focus from File type name and save the PF3000 text file Store Pulsar Focus to File x pf3 Save all Windows Print Preview Print Exit The PF3000 Text file should be used for the restoring of data when the memory setup is done see section 21 2 3 Read Pulsor Focus from file Now you can reboot the Pulsor Focus This can be HABAS ENT Arba TAE done either with the power switch on the front File Edit Focus isis Window Help panel or via the Reboot PF Action under Options in Selected Controller view Toolbar ToolsTalk Pulsor menu row awe ENTER y O Settings Change language Get Event Log view Com Messages Forced release progcontral A Tightening results event log and tool drift alarm results are not stored in file these will be deleted after reboot 9836 4841 21 141 235 Configurable memory 21 2 3 Read Pulsor Focus from file When memory setup is done and the system is running again after reboot the PF3000 text file including the previous data configuration saved before setup can be restored into the Pulsor Focus controller again A Read Pulsor Focus from file will overwrite current programming and configuration in connected Pulsor Focus controller Open ToolsTalk Pulsor and connect to the Pulsor Focus controller In the file drop down menu select re
77. Focus according to chapter 11 4 Communication 42 235 9836 4841 21 Working with ToolsTalk Pulsor 6 2 Starting ToolsTalk Pulsor Make sure that the PC 1s connected to Pulsor Focus as described in previous chapter and that the Pulsor Focus 1s powered on Start ToolsTalk Pulsor on the PC for example by double Be 1D a clicking on the ToolsTalk Pulsor icon on your desktop Lp A f ToalsT alk ae mites a eee age If running the demo version select Continue evaluation or Pulsor wf ete en Arti cra select Register to register now Connect to Pulsor Focus by either e Double clicking Serial PF below Serial E Name Not Defined or Tool ancessones e Double clicking lt IP number gt below Ethernet or Ml identi selecting a Pulsor Focus from the PulsorF dropdown a E Mendon list The lt IP number gt shown will be the latest Legian connected Pulsor Focus IP number If this computer 3 E iene Dina has not been used to connect via Ethernet before these options may not be available See introduction of chapter 6 6 Settings in ToolsTalk Pulsor and 6 6 1 Settings Communication on how to set up ToolsTalk for communication For serial communication how to select com port For Ethernet communication how to add Pulsor Focus IP addresses to the ToolsTalk PF list After a Pulsor Focus has been added to the PF list you can connect to 1t by selecting 1t from the PulsorF dropdown list If the IP address of the cont
78. Interrupter GFI The test button for the GFI activates the GFI even if the Pulsor Focus is supplied with power from an isolated transformer 178 235 9836 4841 21 Tool Control Box hardware description 26 Tool Control Box hardware description See the TCB instruction manual Product Instructions for information about the Tool Control Box 9836 4841 21 179 235 Digital inputs and outputs 27 _ Digital inputs and outputs 27 1 Digital inputs Off The input is not used Reset batch Reset Batch counter for current Pset Unlock tool This input is present for Power Focus compatibility use Pulsor Tool Enable instead Will unlock any software functionality lock such as Lock on reject or Lock at batch done etc Unlock tool does not unlock digital inputs like tool disable n o n c tool tightening disable etc The tool will not be able to start when this input is active If the tool rotates it will stop when this input is active The input is active when it is X switched on Normally opened Tool disable n o Tool disable n c Same functionality as tool disable n o above but with inverted input Tool tightening disable This input is present for Power Focus compatibility Use tool disable n o instead The function is similar to tool disable n o Tool loosening disable The function is similar to tool disable n o only applicable to loosening Batch
79. J302 Lock at job done Setting Lock at Job done turns of the air supply upon finishing a Job and O thereby prevents use of the tool outside the context of a Job J303 Tool loosening This parameter controls the tool loosening functionality during a running job Enable Enable tool loosening functionality is unlocked during a running job Tool loosening is enabled for all job members Disable tool loosening functionality will be locked during a running job Enable only on NOK tightening The tool loosening is disabled during a job but it will be enabled when a NOK tightening is performed J304 Repeat job After a Job is completed the Job will be automatically restarted To turn off this feature the Job must be aborted deleted or the Job Off mode must be selected J31x Batch Parameter Parameter name Description Default number setup J310 Increase batch at OK Specifies that only accepted tightenings will be considered tightening performed and counted OK NOK Specifies that also not accepted tightenings will be considered performed and counted A This will also have direct effect on the batch status which i will be NOK nxNOK when not accepted tightening is performed and counted in a Job J311 Batch status at OK The batch status will be OK at Batch Increment or Bypass event NOK increment bypass The nxOK led on the Pulsor Focus controller will light NOK The batch status will be NOK nxNOK at Batch Increment or Bypass eve
80. Jobs If a Job is selected using this source it will override the source indicated in C221 C230 Determines whether last selected Pset or no Pset is selected when communication with a selector is lost C231 When this parameter is checked Pulsor Focus starts up using the last Pset selected before reboot 86 235 9836 4841 21 11 3 4 Pset select source Config You can select which Pset source Pulsor Focus shall use By selecting Ethernet Serial for Pset select source C222 you choose to run from ToolsTalk Pulsor Alternatively if you want to control the Pset selection from the Pulsor Focus front panel then select PF keyboard from the List Other choices include Field bus and digin By selecting digin you can choose to select Pset with the buttons on the Tool Control Box Select Other I Os under I O setup from the navigation area If tools talk should be used to select Pset select Ethernet Serial from the list Click on Store to save 11 4 Communication Config PulsorF Station 1 Parameter Overview H System setup 1 0 setup 120 device 0 7 120 device 8 15 Dther140 s 1 Dther1 D s 2 E Communication l Protocols X Close C221 Job select source C222 Pset select source C223 Tool light con source C224 Tool light mode C225 Tool light on timer C226 Selector confirm C22 Job select source override Other 1 0 s 2 C230 Selector lost mode C231 Use
81. LEDs 1 RBDA Remote Bus DisAble Active RED when outgoing remote bus is switched off Transmit Receive Active GREEN when PCP communication is carried out over the InterBus 0 6 s hold time to be visual Cable Check Active GREEN if the cable connection is good and the InterBus Master is not in RESET Active GREEN is monitoring Layer 2 Icon file Contact you local Atlas Copco representative to get a copy of the Icon file for Pulsor Focus This file can be used to have a Power Focus Icon in the PLC configuration SW File name pf3intb ico 216 235 9836 4841 21 FieldBus configuration appendix 30 8 ModBusPlus ModBusPlus is a local area network system designed for industrial control and monitoring applications developed by Modicon Inc The network enables programmable controllers host computers and other devices to communicate throughout plants and substations ModBusPlus transfers fast data for motor controllers MMI I O units and other industrial equipment ModBusPlus has an international user organization called Modicon Inc General technical questions regarding the FieldBus should be addressed to your local ModBusPlus User Group in the first instance A contact address list is available from the ModBusPlus Internet site http www modicon com 30 8 1 ModBusPlus for Pulsor Focus Physical interface Cable Shielded copper cable One Twisted pair Isolation The bus signals are separated from the other electronic
82. M SWEDEN declaramos sob nossa ex clusiva responsabilidade que o produto a que se refere esta declarac o esta em conformidade com as seguintes normas ou documentos normativos EN 50081 1 EN 50144 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 conforme as disposi es das directivas 89 336 EEC 73 23 EEC 93 68 EEC Noi Atlas Copco Tools AB STOCKHOLM SWEDEN dichiariamo sotto nostra unica responsabilita che il prodotto cui questa dichiarazione si riferisce confor me alla seguenti normative e ai relativi documenti EN 50081 1 EN 50144 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 in base alle prescrizione delle direttive 89 336 EEC 73 23 EEC 93 68 EEC Wij Atlas Copco Tools AB STOCKHOLM SWEDEN verklaren onder onze ex clusieve verantwoordelijkheid dat het produkt waarop deze verklaring betrekking heeft in overeenstemming aan volgende normen of normatieve dokumenten EN 50081 1 EN 50144 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 overeenkomstig de bepalingen van de richtlijnen 89 336 EEC 73 23 EEC 93 68 EEC Vi Atlas Copco Tools AB STOCKHOLM SWEDEN erkl rer under eget ansvar at produktet hvortil denne erkl ring relaterer sig er i overensstemmelse med folgende normer eller normative dokumenter EN 50081 1 EN 50144 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 i henhold til bestemmelserne i direktiverne 89 336 EEC 73 23 EEC 93 68 EEC Vi Atlas Copco
83. Name Not Defined necessary parameters for the current Dee ae EE application are stored in the Pset It may Tae o happen that at a later point 1t becomes Ttering Options cee Pe clear that the system is slightly mistuned abraso 3 P123 Target angie he E and although it presents values that are oe eN aR O H Statistic programming Torque Tuning Adjustment within the boundaries the actual installed Torque Tuning Adjustment torque is a bit off To correct this use the A eee eee 000 Nm P682 Torque tuning factor 0 99 Torque Tuning Adjustment function To E Pam Morin Seo P689 Tool setup torque turing factor 039 open the function window press the Torque Tuning Adjustment button in the Pset main window X Close Cie Compare i i s Store 38 235 9836 4841 21 Three read only parameters will be shown the target torque for the current Pset the current torque tuning factor and the torque tuning factor from the Tool Setup The two latter will be identical if no Torque tuning adjustment has been performed for this Pset Write in the mean value of the torque the tool has actually installed in the joints measured by torque wrench or inline transducer in the New measured torque box When OK is pressed new parameters will be calculated to adjust for the difference between the target torque value and the actual installed torque Performing Tool Setup IDI xi Warning Performing this operation will adjust your t
84. OG When the Pulsor Focus is in programming mode the Programming Control light illustrated by an opened CONTROL padlock flashes green Programming Control can be undertaken via the Pulsor Focus unit itself or via padlock ToolsTalk Pulsor A steady green light indicates that the programming buttons on the front panel are symbol unlocked If the Pulsor Focus does not have programming control the padlock flashes and the only buttons on the unit that can be used are Question Mark and Enter If the opened padlock is steady green any key can be accessed provided the soft keys are enabled parameter C 124 9836 4841 21 23 235 Introducing the Pulsor system s user interface 3 3 2 Keys Function Pset Setup Enter wo weno ooo oo Plus Navigates through menus on the display and increase numbers Minus Navigate through menus on the display and decrease numbers Function F Press F Function button to display functions F1 F9 To display function F1 press F one time to display function F2 press F two times etc Press Enter to access and edit a function When finished press F repeatedly to display result mode again or wait 30 seconds for the screen to automatically update F1 Setting minimum limit for torque monitoring Fl rtLL alternates in the display If no Pset is selected F1 is displayed Press Enter to enter edit mode Change the value by pressing the keys Press Ente
85. Pulsor C 1 1 Conventions used in this manual The following conventions are used from chapter 1 3 onwards When new concepts are introduced and not yet explained they will be written 1n italic style These will be explained directly or shortly after the first use It may happen that concepts are written in italic style more than once References to chapters will also use the italic style Parts and concepts of the Pulsor system will have their first letter Capitalized This style will also be used for ToolsTalk Controls Table heads and details that are to stand out are written in bold style 1 2 About this document This user manual for the Pulsor C system is divided into three main parts Part I Getting started with Pulsor C This part introduces Pulsor C and is also a step by step instruction on how to get chapter 1 5 to the point of doing real tightenings with your Pulsor C system Part II Describes in detail functions and features of the Pulsor C system 21 Part III Reference information on Pulsor C Gives important reference information on Pulsor C such as event codes and chapter 22 specifications on hardware 1 3 Overview of the Pulsor system A minimal Pulsor C system consists of a Pulsor Focus controlling monitoring unit a Tool Control Box TCB and a Pulsor C tool The system is easy to use Connect the different parts of the system with air hoses and cables perform a Tool setup on the actual joint joints and you are
86. Pulsor Focus since all FieldBus communication is disabled On the FieldBus side from PF all bits will be reset to zero The traffic of keep alive signals continues on the FieldBus In this way no event codes i e no connection on fieldbus will be displayed e All tools are enabled presupposed that the tools were disabled from a source over the fieldbus before then If there is a running job which has been selected via the fieldbus the job will be aborted Open Protocol When activated all commands received by the Pulsor Focus via Open Protocol are X X commands disable rejected Pulsor Tool Enable Will unlock any software functionality lock such as Lock on reject or Lock at batch X X done etc A Pulsor Tool Enable do not unlock digital inputs like tool disable 99 66 n 0 n c tool tightening disable etc External monitored 1 8 These generic digital inputs will activate the relays External controlled relays 1 8 TCB air hose test When activated the TCB will perform an air hose test 182 235 9836 4841 21 Digital inputs and outputs 27 2 Digital outputs relays Name Description Duration Output is not used All results are within the specified limits NOK Some result is above or below any of the programmed max or min limits or on lt P Sh O Q some other not approved result such as re hit The result is below any
87. SWEDEN declare under our sole re sponsibility that the product to which this declaration relates is in conformity with the following standards or standardized documents EN 50081 1 EN 50144 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 in accordance with regulations 89 336 EEC 73 23 EEC 93 68 EEC Nous Atlas Copco Tools AB STOCKHOLM SWEDEN d clarons sous notre re sponsabilit exclusive que ce produit que concerne cette d claration est en con formit avec les normes ou documents normalis s suivant EN 50081 1 EN 50144 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 conforme aux reglementations 89 336 EEC 73 23 EEC 93 68 EEC Wir Atlas Copco Tools AB STOCKHOLM SWEDEN erkl ren hiermit in alleini ger Verantwortung da das Produkt auf das sich diese Erkl rung bezieht mit fol gende Normen oder normativen Dokumentation Ubereinstimmt EN 50081 1 EN 50144 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 gem den Bestimmungen der Richlinien 89 336 EEC 73 23 EEC 93 68 EEC Nosotros Atlas Copco Tools AB STOCKHOLM SWEDEN declaramos bajo nu estra sola responsabilidad que el producto a que se refiere esta declaraci n es conforme con las normas o documentos normalizados siguientes EN 50081 1 EN 50144 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 de acuerdo con las regulaciones 89 336 EEC 73 23 EEC 93 68 EEC N s Atlas Copco Tools AB STOCKHOL
88. The PCP length defines the package length PCP data has lower priority then the process data Available selections are 0 1 2 and 4 These numbers are the lengths in words 0 no PCP y The Pulsor Focus unit has to be restarted when the PCP length is changed The length must be the same in the PLC F131 Process DataLength Process DataLength is the first part of the InterBus message The length has to be same for both input and output data Maximum Process DataLength is 20 bytes minus the PCP length in bytes This means that the highest Process string length is 20 bytes if PCP is zero y The Pulsor Focus unit has to be restarted when the Process DataLength is changed The length must be the same in the PLC Source address Source address is the network ID number used in the FieldBus system Set this source address if you want to get global data from that address F141 F200 FB update interval If the FieldBus system is heavily loaded it might be necessary 0 10s to slow down the update interval in Pulsor Focus FieldBus card If this parameter 1s set to 0 5 seconds the Pulsor Focus updates the bus every 0 5 seconds The average data traffic must be possible to fit within the programmed interval If the traffic has a higher peak load the messages are buffered Valid settings range from 0 05 to 10 seconds F210 Tool stop at offline If the FieldBus system goes down or Pulsor Focus goes offline it might be necessary to stop
89. This item follows the tool red light 0 Not used 1 Red ToolY ellowLight This item follows the tool yellow Bit 1 bit 0 Not used light 1 Yellow I PF Control 3 is selected in Cset yellow led shows the fatal error and reset when error acknowledged ToolReady Indicates that the tool is ready for Bit 1 bit 0 Tool is not ready tightening 1 Tool is ready ToolRunning Indicates that the tool is rotating CW Bit 1 bit 0 Tool is not run ToolTightening Bit 1 bit 0 Tool 1s not tightening TorqueStatus Status torque result Character ASCII Bit field 2 bits 00 Not used 01 OK 10 High 11 Low TorqueStatusHIGH Bit 0 Not used 1 High TorqueStatusLOW Bit 0 Not used 1 Low Bit TorqueStatusOK Torque result is within limits 1 bit 0 Not used 1 OK 202 235 9836 4841 21 VINInput Description Shows the VIN number inputted from FieldBus serial or Ethernet Changes as soon as the number is Data type Character string input FieldBus configuration appendix String length 24 208 bit 3 26 bytes Value One ASCII sign for each character First byte 1s counter given This is not the VIN used in the tightening ru Character 16 200 One ASCII sign for each If the VIN is longer then the VIN string change bit 2 25 character input length the Pulsor Focus will bytes take the first x characters and cut the end If the VIN number is shorter Character 16 192 One ASCII sign fo
90. Tools AB STOCKHOLM SWEDEN erkl rer herved under v rt fulle ansvar at produkten som denne erkleeringen gjelder for er i overensstem melse med f lgende standarder eller standard dokumenter EN 50081 1 EN 50144 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 i samsvar med reguleringer 89 336 EEC 73 23 EEC 93 68 EEC Me Atlas Copco Tools AB STOCKHOLM SWEDEN vakuutamme olevamme yksinomaisessa vastuussa siita etta tama toute on allalueteltujen standardien ja standardoimisasiakirjojen vaatimusten mukainen EN 50081 1 EN 50144 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 seuraavien s nt jen mukaisesti 89 336 EEC 73 23 EEC 93 68 EEC EF OVERENSSTEMMELSESERKL ERING EF ERKLAERING OM OVERENSSTEMMELSE EY N VAATIMUSTENMUKAISUUSILMOITUS AHAQ2H 2YMMOP002H2 2E OAHTIA TH2 EG DEKLARATION OM OVERENSSTAMMELSE Epes n Atlas Copco Tools AB STOCKHOLM SWEDEN dnAwvoupe urte 8uva OTL TO TIPOL V oTo Orto o APOP n TAPO CdA SrAWON BELOKETAl o ri on OULLOPPWON HE TIG ATIALTYGELG TOUS KAWOWIYBOWO N KATAOKEUAOTIKES OUOTAOEIC EN 50081 1 EN 50144 1 EN 50144 2 2 EN 61000 3 2 EN 61000 3 3 EN 61000 6 2 kat Tic IAT XELG TOU KAUOULOUWU TNG Koluns Ayopac 89 336 EEC 73 23 EEC 93 68 EEC Vi Atlas Copco Tools AB STOCKHOLM SWEDEN f rklarar harmed pa v rt ful la ansvar att produkten f r vilken denna deklaration g ller verensst mmer med f ljande normer och dokument EN 50081 1 EN 501
91. Torque Tuning Adjustment P688 New measured torque O MA y ee P682 Torque tuning factor Oo t ee S P689 Tool setup torque tuning factor IS X cose DAD Compare Rea gso 5 3 Tool Setup window The first window shown is the Tool Setup Tool setup programming window In the topmost box of this window the specified max torque for the connected Programming parameters tool will be shown Below this you can D104 Tool max torque Mm select the desired tightening strategy Two P100 Strategy Pulsor fixed H strategies are available the Pulsor Fixed P649 Target torque strategy and the Pulsor Angle Shutoff P120 Start final angle strategy These strategies were described in P123 Target angie chapter 1 3 Overview of the Pulsor system or After having set the desired target P670 Speed lo on parameters press the Start button This will lt Accurate Fast gt bring up the Tool Setup Monitor window Start Cancel 32 235 9836 4841 21 Performing Tool Setup 5 4 Tool Setup Monitor Tool setup monitor System is in learning mode Perform tightenings until the result is satisfactory or use Advanced settings if necessary To modify speed settings press Cancel Target Torque 45 00 Nm Detailed view Tightening Parameters Tool Setup Tightening Result Torque value 42 80 45 70 Tightening angle 22 15 No of Tightenings 4 5 Delete Delete Measured torque 41 00 46 4 Torque Tuning Factor 0 96 Apply Traces AdvancedSetti
92. Tracking Click on button to connect to disconnect from the Pulsor Focus Help Show manual E 46 235 9836 4841 21 Working with ToolsTalk Pulsor 6 3 4 The PF Map The PF Map gives you an overview and shortcuts to all settings in the Pulsor Focus Click on the minus or plus symbols to open or close menus Double click on the function names to open the corresponding function Brief information on the selected item is shown in the right panel of the PF Map Right click on the function name to create a new copy of the function available for some functions Only the left panel of the PF Map is displayed if you click on the Hide details button 6 4 Event codes in ToolsTalk Pulsor There are two kind of event codes you may get when using the Pulsor system Types of event code Display on the front Activity from the user panel in Pulsor Focus Event codes that need The event code flashes This type of event is of such severity that 1t needs to be attended to before acknowledging until acknowledged by work can be continued the user There are three ways to acknowledge an event code l Press the Acknowledge button in the event code window in ToolsTalk Pulsor Press the Enter button on Pulsor Focus front panel Do a Tool Enable from a digin or TCB Green button is configured to Tool Enable by default Other events codes The event code is No activity is required by the user If you so wish the event code window in displayed 5
93. WI Identifier FieldBus H E Monitors LA Trace lila Statistic Offline Name Not Defined 9836 4841 21 97 235 Diagnostics and service Select Air sensor tuning under Tool configuration Sennen A in the navigation area In the Air sensor tuning window you can see the pressure value in the unit selected and date of the last adjustment in the current tool Click on Perform air sensor tuning to make a new adjustment of the air pressure sensor To prevent a user from accidentally making the tool malfunction by performing an improper air sensor tuning a warning will appear Click the Yes button to continue With the trigger released click on the Confirm no pressure button Press and keep the trigger pressed while you read the value on the air pressure gauge and then click on Confirm line pressure The trigger can then be released Enter the measured value from the air pressure gauge with the air pressure unit stated in parameter C128 Air Pressure presentation unit see section 11 2 2 Display and toggle display and click on OK to complete the adjustment Suitable air pressure when performing Air sensor Tuning is between 4 and 7 bar 58 to 102 PSI It is possible to verify the air pressure sensor with air sensor tracking see Air sensor tuning D930 Line pressure 6 34 Bar gt Tool configuration D931 Air sensor tuning performed at 2005 11 07 12 35 18 Tool general information Pulsar
94. Xiro Xii Xiz X13 Xi 14 A subgroup is a group of tightenings Subgroup size is freely programmable and in the example above it is set to 5 which means that all values in the same group range from 1 to 1 4 X bar is the calculated average of the last completed subgroup Subgroup size Group size z Grouprange W max X X 555 X min X X Xa Wit max X A ie 5 99 59 X i422 E min X A 9999 A 49 2 j n 5 6 CAM 1 746 max l min 6 W 122 235 9836 4841 21 Statistics The formula for CAM is calculated using the first 6 subgroups After that a new calculation is made using each completed subgroup in conjunction with the last 5 subgroups RLCL D R A D andD are tabular constants and depend on the Subgroup size 17 8 Constants for calculation of SPC variables Factors for control limits size of standard div a a E a E ps pa a ooo po p pe fos p fs s hes oos fos fon fase ho fow fs o Ppor oe os fos ha fo fon hne w fe fose foi om fro foo fos o a fa foss for o hs foss fos fa 9836 4841 21 123 235 Cell and Net 18 Cell and Net The Pulsor Focus software offers extended networking facilities The Cell and Net concept is part of the Gold RBU software version see chapter 24 RBU information It provides functions to logically arrange your network Ethernet TCP IP networking makes it simple to program and overview all Pulsor Focus units in the networ
95. actual joint type used in production The electronics measure what happens while tightening While the Tool Setup is performed the Pulsor Focus learns how to set the air pressure for a correct tightening Correctly carrying out the Tool Setup is therefore very important Note the differences between performing a Tool Setup mandatory sets up the system for the joint and performing a Monitoring Setup optional helps finding limits for monitoring parameters 9836 4841 21 191 235 FieldBus configuration appendix 30 FieldBus configuration appendix This appendix describes the different possible selections for the FieldBus It also describes the different data types that are used in the FieldBus configuration 30 1 Bit map select Endian Mode 30 1 1 Motorola Endian 30 1 2 Intel Endian Motorola Endian is default setting for ProfiBus DP InterBus ModBusPlus and ModBus TCP Intel Endian is default setting for DeviceNet and EtherNet IP 30 2 FieldBus data types The Pulsor Focus uses position format in all encoding and decoding data types In PF position format the Most Significant Bit MSB is the bit furthest to the left and the Least Significant Bit LSB is the bit furthest to the right If a data type is less than one word the MSB is the bit furthest to the left If data type is longer than one word the MSB is the bit furthest top left If a FieldBus type uses Intel Endian byte numbers are swapped before encoding o
96. ad PF from file F A confirm pop up window appears Confirm Select yes to accept Select no to abort operation Read selection window appears Select functions to restore An unchecked box means no replacement of data in that function area Click OK to confirm The configuration data Psets and jobs will be restored to the system from file A confirm popup window appears Select yes to keep present Pulsor Focus name and Network setup Select no to restore Pulsor Focus name and network setup from file Once more a confirm pop up window appears Select yes to keep present Pulsor Focus password setup Select no to restore Pulsor Focus password setup from file 142 235 ToolsTalk Pulsor 3 05 wie Edit Focus Options Read Pulsor Focus From File Store Pulsor Focus to File Save all windows Print Previews Print Exit Restoring From file will replace everything in the controller Continue 101x W Pset and Multistage Job w Config F F M Sune F Diagnostic e Identifier e Fieldbus e Tool accessories x Cancel Confirm Y Confirm Y Keep PF Mame and network setup Keep current password setup 9836 4841 21 Event codes 22 Event codes Event codes are displayed on the Pulsor Focus display and in ToolsTalk as popup windows to inform users about the status of the Pulsor Focus All events are stored in the statistics event log or the general even
97. al information and Pulsor tool info Tool general information section shows general information about the connected tool Psx Diagnostic PulsorF Station 1 f loj x Parameter Overview D100 Tool type Pulsar E E Tool configuration O e CA Tool general information e Pulsor tool info 0102 Serial number 2501 230 Tool service D104 Tool max torque 32 00 Nm Ne Toal aril aan D105 User tool message Fo i Air sensor tuning E Controller diagnostics D106 Usage Handheld H 5 ystem diagnostics Pulsor tool info D151 Madel type EPP 6032 HR10 D152 Ordering number 8431 037810 0153 Application code version Boes 0154 Boot code version Pos 0950 Tool board revision 0951 Tool board serial number X Close 9836 4841 21 91 235 Diagnostics and service 13 2 Tool service and Service indicator The service parameters are stored in the tool If any active service parameter exceeds a preset alarm limit the alarm light on Pulsor Focus comes on and an event code will state which parameter has caused the alarm The function can be connected to a relay output The service alarm does not reject a tightening it is only a warning A Paame Oveviow Rog SEnce Tool configuration D130 Total number of tightenings 556030 Tool general information 0131 Service indicator Off Pulsor tool Info 0132 Number of tightenings since service 559150 Tool service Tool Drift alarm 10133 Service interval 10000
98. ally it is fit in between the PF and the tool and pneumatically between your air system and the tool RBUs Rapid Backup Units unlock a specified functionality level and at the same time is amemory for backing up the programming and configuration of the Pulsor Focus It is possible to transfer the configuration from one Pulsor Focus to another with the help of the RBU This software offers simple and user friendly system setup and monitoring of the Pulsor Focus units in real time All settings in the Pulsor C system can be set from ToolsTalk Pulsor 9836 4841 21 Introduction to Pulsor C The following is an illustration of a standard configuration of a Pulsor system RBU backside of Pulsor Focus Tool Control Box Z controller _ Tool cable ToolsTalk Pulsor Cable to PC Serial Ethernet See chapter 25 Pulsor Focus hardware description for detailed information about the Pulsor Focus connections 9836 4841 21 15 235 Introduction to Pulsor C 1 5 Pulsor accessories A number of external accessories are available for the Pulsor C system The following are the most important Selector is a socket rack that selects which Pset parameter set the tool shall use I O expander The I O expander makes it possible when necessary to connect more digital inputs outputs in addition to the built in 4 4 The RE alarm Lamp sound box indicates the tightening status to the operator Operator panel The operator pane
99. ancnnonnnrnnonarnncnnanennnnnnens 95 13 3 5 Tool drift alarm graphical VieW ooonncccconnnncconcnnccnonnnnconanoncnnoncnnononcnnnnnanoncnnancnnnnnens 96 134 All SONSON UNN O es ta anar laicos 97 130 Controller diagnos liCS ri 99 13 0 SYSICMMOIAGMOSH Sidi ia 100 326021 TOO WACKING noc dd 101 1362 PGB ANOS e 101 T4 O A dat reant tact T E seveemuud cateausadsseassccuswannecstwasncauues 103 141 Barcode data Sting ess a 103 142 Identifier SOLU Dri i iu 104 9836 4841 21 7 235 Contents 15 16 17 18 19 20 21 8 235 HICIOBUS lt p cias 107 tA General Sets de td ds talent ace 107 15 1 1 Parameters in General Setup oooocnccccnncccccooncnnnnncnonononnnnnnnnononnnannnnnnnnnnonnnannnnnnnnss 108 12 FLOW TO RE SOU DSi add 109 Vee SACO SM sszetco tesacacecanreetessas2eccesarioandaasdacendeautancntan iene taashacamoarvutedaantancemaaveseucancthGeceansas 109 5 2 2 Deleite cidcid ici 110 133 Diner tUACION Scirocco 110 19 31 DIAGNOSTIC MOG rr A NN 110 32 Monitor MOS acicate rodada 110 15 33 Siore toile and Read TOM Meu DAA A 110 MONO S ciociara diidd 111 19031 Result MONO do eae te 112 162 JON MONO A A a A eds 112 16 3 Operator monitor and Picture monitor oonccccccoonnnncccnccnncnnnncnncnnnncnnnonancnnnonancnnnonaness 113 t631 Operator Moni A AA A dd 113 T6 3 2 PICS MOO a cias 114 A ING RESUS uke triste Seca tee ta tateesatantal A AA 116 Oo GET all resulta di 116 10O MACS pst
100. and switchbox replacing the customer specials that are made today The operator panel is configured as 3 I O expanders See Operator Panel Product Information for more information on how to set up the Operator Panel 138 235 9836 4841 21 Configurable memory 21 Configurable memory A All data stored in the Pulsor Focus controller except parameters P address C301 subnet mask C302 and default router C303 will be erased when changing memory setup Therefore use ToolsTalk Pulsor function Store Pulsor Focus to file to save the existing data configuration including Psets and jobs The data can later be retrieved via function Read Pulsor Focus from file see section 6 7 Storing programming on file a When changing the memory setup the Pulsor Focus controller must be rebooted for changes to take effect It is recommended to reboot immediately 21 1 Configurable memory conditions Besides the default memory configuration Pulsor Focus provides the following configurable memory options more Psets more jobs more results more events more identifiers and more Psets Jobs Psets jobs results events identifiers More jobs 8 100 500 100 More results 8 8 5000 500 100 More identifiers 8 8 4000 500 400 More Psets Jobs 100 100 3500 500 100 Morejobs More resas More identifiers More Pstllobs Number of identifiers is the maximum number of significant barcode strings available for identifiers
101. ardless of hardware switch position rows 2 p Je S aso Poco ON l ON EE G 5 The source address cannot be changed during operation Icon file It 1s not necessary for ModBusPlus to install a special file to recognize our product and 1t does not support icon files 220 235 9836 4841 21 FieldBus configuration appendix 30 9 EtherNet Ethernet is one of the most popular network technologies in use today The major reasons for the popularity are a suitable mix of speed cost and ease of installation These benefits the market acceptance and the possibility to support more or less any non real time critical protocol makes the Ethernet an ideal networking technology for most systems More information as well as links can be found at the web site www iaona eu com 30 9 1 EtherNet for Pulsor Focus Hardware The module is based on a high performance CPU operating at 66 MHz It features 8 MB RAM and 2 MB FLASH Supported FieldBus Protocols ModBus TCP The module supports the ModBus TCP protocol and is conform to the ModBus TCP specification 1 0 More information about the ModBus TCP protocol can be found at http www modicon com openmbus index html EtherNet IP The module supports the Ethernet protocol EtherNet IP is based on the control and information protocol CIP which is also the framework for both DeviceNet and ControlNet to carry and exchange data between nodes To be consistent with the other
102. ation is at least ten tightenings 22 3 6 Statistical events E333 Not allowed subscription The requested statistic subscription is not allowed E334 No statistic available for this Pset The Pset strategy is not suitable to calculate statistics no strategy is chosen click wrench E335 Not enough data Not enough data were available to calculate the statistic control limits E336 Mem alloc fail It was not possible to allocate enough memory for the statistic subscription E346 7inc x torque Trend alarm the subgroup relative torque mean value has increased 7 times consecutively E347 7dec x torque Trend deviation alarm the subgroup torque mean value has decreased 7 times consecutively E348 7inc r torque Trend deviation alarm the subgroup torque range value has increased 7 times consecutively 9836 4841 21 147 235 Digital inputs and outputs E349 7dec r torque Trend deviation alarm the subgroup torque mean value has decreased 7 times consecutively E350 7above x torque Trend deviation alarm the subgroup torque mean value has been above the average mean value of the average of the last ten subgroups 7 times consecutively E351 7below x torque Trend deviation alarm the subgroup torque mean value has been below the average mean value of the average of the last ten subgroups 7 times consecutively E352 7above r torque Trend deviation alarm the subgroup torque range value has been above the average range value of t
103. batch will be decremented irrespective of the settings for C133 C132 Reset batch at Pset Yes No change Resets the batch counter when a new Pset is selected C133 Decrement batch at Yes No OK loosening An OK loosening generates a batch decrement for the latest made tightening increment f C134 Batch status at OK NOK NOK increment bypass Defines if an increment or bypass operation is OK or NOK C135 Increase batch at OK tightening OK NOK tightening OK tightening Defines if batch counter shall be increased at OK tightenings or at OK NOK tightenings C136 Reset batch at Pset Yes No store Used 1f batch counter for a Pset is to be stored and a reset of batch counter is wanted C139 Result of non Yes No No tightenings A non tightening 1 e a loosening or a batch increment decrement operation will generate a null tightening result This null result will be saved C15x Reset Parameter Parameter name Description Default setup number C150 Delete all results Tightening database and statistical database for the Pulsor Focus is a deleted C151 Resets all programming tightenings and statistics C16x Printer setup Parameter Parameter name Description Default number setup C160 Printer type With parameter printer type the printer is selected Options are IBM HP and Epson C161 Paper size With parameter paper size the paper format is selected A4 Options are A4 or US Letter C162 Continuous print With parameter continu
104. ber of Pset per socket is 8 C22x Other I O s Parameter Parameter name Description Default setup number Job select source Selection of Job start source Off DigIn Ethernet Serial Identifier PF Keyboard Selector DigIn Ethernet Serial Identifier PF Keyboard Pset select source Available options Off 164 235 9836 4841 21 Digital inputs and outputs Parameter Parameter name Description Default setup number Tool light con source Selection of tool light control source PF controlled 1 Available options PF controlled 1 PF controlled 2 PF controlled 3 Light off Tool light mode On Off Defines whether the tool LEDs should light for a specified period of time On or continuously Off after a tightening Default is Off C225 Tool light on timer Select time for tool light led can be set between 0 and 300 seconds Only valid if Tool light mode C224 is on C226 Selector confirm Define if the selector confirms selection of Psets It is also used Off when selecting Psets in a Job Available options Off On On with Ack This means that the socket must be removed from the selector after Pset is selected If the socket is already removed from the selector put 1t back on the selector again then pick it up and mount it on the tool C227 Job select source This parameter makes it possible to choose a Job from a second Off override source This source will have a higher priority than Job select source C
105. bgroups Pulsor Focus can automatically calculate statistical control limits In 10 order for these limits to be reasonable they must be performed on a greater number of tightenings This parameter 1s used to set the number of subgroups used for these calculations Can be between 1 and 4000 Statistic Process Control for relative torque number P570 Relative torque X bar LCL The lower control limit for mean value no Calculated automatically or entered manually AS P571 Relative torque X bar UCL The upper control limit for mean value Calculated automatically or entered manually e P572 Relative torque range LCL The lower control limit for range Calculated automatically or entered manually MN P573 Relative torque range UCL The upper control limit for range Calculated automatically or entered manually P574 Relative torque X bar bar The desired mean value for calculated mean values for groups of tightenings P573 Relative torque range bar The desired mean value for calculated mean ranges for groups of tightenings P576 SPC alarm relative torque With this parameter it is possible to switch off the current SPC Off alarm function 9836 4841 21 155 235 Digital inputs and outputs P58x SPC line pressure Statistic Process Control for line pressure number P580 Line pressure X bar The lower control limit for mean value PO een Cena or eera mama P581 Line pressure X bar The upper control limit for mean value UCL Ca
106. bus The tool is locked by FieldBus 139 Tool locked by Open protocol The tool is locked by open protocol user 140 Insert user ID card to release tool The tool is locked the user must insert his ID card in the card reader to release the tool 147 Tool locked by click wrench Pset Tool trigger was pressed while a Pset with click wrench strategy was TLU selected 149 Tool locked disable loosening at OK The function Disable loosening at OK C131 has locked the tool E150 Job client does not respond When running a Cell Job this event 1s displayed by the Job master when one of the Job members does not respond The first parameter contains Channel ID number C105 for the Job client that does not respond ou es e 9 07 es The second third and fourth parameters are not used Job in OFF mode Not possible to select a new Job Pulsor Focus is in Job OFF mode PF locked in job mode This event appears when in a forced cell Job an attempt 1s made to tighten with a controller which is not currently active or when a controller has performed all tightenings E153 Not Ok to select new job A Job is currently running it is not possible to select a new Job until the first is finished in some way completed or aborted This message is also displayed if a Job is selected on a Job member Remote job running When running a Cell Job this is displayed by the Job members when a cell Job is selected on the Job mas
107. can also set the status of relays All configured I O devices will appear on the list of available devices This function is useful when you want to test the interaction between Pulsor Focus and different external devices for instance when trouble shooting complex systems with one or several PLC s connected to the controller The Relay Status and DigIn Status windows show the status of the selected I O device S The Read status button has to be pressed in order to update this view to reflect changes The Relay Test function enables to set the relays on a selected I O device The new status of the relays is set when the Set Relay button is pressed Pushing the Restore button will restore the relays to reflect the current status of Pulsor Focus To update this view to reflect changes triggered by other events push the Read Status button 100 235 9836 4841 21 Diagnostics and service 13 6 1 Tool tracking Here you can set a pressure to be delivered from the TCB Press start to start tracking mode Press up or down arrows to set the requested pressure The delivered TCB pressure Tool pressure and Tool speed will be shown By connecting an external air pressure sensor after the TCB the functionality of both the TCB pressure sensor regulation and the tool pressure sensor can be checked Note that the valve pin must be fit in the tool if you are to compare Tool pressure with TCB pressure Tool Tracking 100 Tool pressure 101 Tool speed
108. can later change the parameters to suit the specifications for the joint The user can also choose which monitoring parameters should be active and thereby capture or ignore different faults such as rehits and cross threads as desired Result presentation Basic results are shown on the Pulsor Focus display and lamps on the tool indicate whether the tightening was good or not For a comprehensive result presentation the PC program ToolsTalk Pulsor is used It contains a number of functions that present detailed tightening result information Batch counting of Function for counting tightenings to assure that no bolts are forgotten tightenings Loosening detection It is possible to detect and count loosenings Job Function for making several tightenings on different joint types in a controlled sequence Statistics Functions for calculating statistics on a large number of tightenings Service indicator The parameters for the service indicator are stored in the tool s memory and follow the tool if it is moved to another Pulsor Focus If any active service parameter exceeds a preset alarm limit the alarm light on Pulsor Focus comes on and an event code is displayed stating which parameter caused the alarm Tool Drift Alarm Tool Drift Alarm is a function that helps detect changes in tool performance tool drift before it has an impact on production The cause for this performance change can be lack of oil in the pulse mechanism a technical
109. cation alive the same 11111111 255 byte LineControlAlertl Job not finished alarm 1 Bit 1 bit 0 Not Used 1 Line Control alert 1 LineControlAlert2 Job not finished alarm 2 1 bit 0 Not Used 1 Line Control alert 2 Input signal to start the line 1 bit 0 Not Used control function 1 Line Control PsetSelect Select a Pset Pset select source Bit Field 2 8 bits 0000 0001 Pset 1 must be set to FieldBus Pset0 in the same 0001 0000 Pset 16 no Pset selected byte Ul6 16 bits in 00 0001 Pset 1 one word 00 1000 Pset 8 PsetSelectOIs1 Select a Pset Pset select source Bit Field 2 8 bits 0000 0001 Pset 2 must be set to FieldBus Pset0 in the same 0001 0000 Pset 17 no Pset selected byte LineControlStart Number 0 Pset 1 number 1 Pset 2 etc RelayPos 1 4 Control a relay from FieldBus In 1 bit 0 Relay OFF I O set up the selected relay must 1 Relay ON be programmed to FieldBus relay x There are four different items ResetBatch Reset the batch counter to 0 i 0 Not used i Reset the batch ResetJobStatus Resets Job done status no 1 bit 0 Not used 1 ResetJobStatus ResetResultStatus Reset all result status on relay Bit 1 bit 0 Not Used RE Alarm and FieldBus 1 Reset result RestartJob Stop current Job and restart the Bit 1 bit 0 Not used same Job from 0 1 Restart Job SelectNextPset Selects next Pset Bit 1 bit 0 Not used 1 Select next Pset
110. cell ID ACK must be configured between 1 and 999 E491 Net member registration failed The net member registration failed because one net member is already registered with the same cell ID 22 3 8 Hardware events tool Code Name of event Information Note E510 Tool type not supported by RBU Change tool or change RBU E512 Tool revision not supported by this drive SW The tool is not supported by the controller SW version ACK incompatible E513 Tool EEPROM corrupt service tool Checksum indicates that tool memory is corrupt Tool must be serviced E580 Tool arif alarm relative torque deviation Tow Mean torque deviation below timit E581 Tool drift alarm relative torque deviation high Mean torque deviation above imis E582 Tool drift alarm relative pulse Fequeney low Mean relative pulse frequeney below imit E583 Fool dit alarm relative pulse Fequeney high Mean relative pulse frequency above init checkol 22 3 9 Hardware errors DC3000 MC3000 e tomos E601 System voltage low DC voltage too low 22 3 10 Hardware events E700 PF started This event code is only visible in the event log and used when the Pulsor Focus is started E701 Backup battery low level The backup battery level 1s low 1t may be change soon A E702 Backup battery empty or missing The backup battery level is very low or the battery is missing This must be replaced as soon as possible otherwise data in NVRAM can be corrupt E799
111. ck at job done J302 tool loosening J303 and repeat job J304 Continue with the parameters in Batch Timers Line Control and Result See parameter list section Job for more information Si Job 1 Motor block PulsorF Station 1 Bal x e ahi J102 Name TE block E Programming J301 Job type Forced y cal J302 Lock at Job done no y Bat ah J303 Tool loosening Enbe y Timers J304 Repeat Job No y Line Control Batch J310 Increase batch at tightening OK T J311 Batch status at increment bypass NOK J312 Decrement batch at OK loosening No Timers J320 Maxtime to start Job fo Set J321 Maxtime to complete Job CO Set J322 Display result at autoselect fo _Set Line Control J330 Use line control No Result J340 Vin number in result Other J341 Result of non tightenings no y X Close Change Job gt Read sg Store 9836 4841 21 75 235 Job 10 2 Creating Multi Pulsor Focus Jobs More than one Pulsor Focus can be used to perform a Job If this functionality is desired the Pulsor Focuses used in the Job needs to be members of the same Cell see chapter 18 Cell and Net for details about how to set up Cells When using more than one Pulsor Focus in a job one Pulsor Focus is the Job Reference All other Pulsor Focuses in the job are called Job clients The Job Reference will make sure the correct Job Client is enabled at the correct time and that the correct Psets will be selected To set up a Mul
112. cocccoccconoccnnononononanenannnnnronarenanrnnnrenarenannnnans 193 30 1 Bitmap Select Endian Mode eii o id 193 sti MOTO OA Endanea o 193 SOAs2 IMeErENdA Neal adidas 193 30 2 FelaBis data POS a gl 193 aurea OMC SUING shane teeta cat Pas e E E E ENEE E 195 30 22 FIXed POINT MUMBO sia dius 196 302 MMO id 197 30 stems FON Po a a anne uehecics alee E 199 PP EE PEO 204 205 lr POMS DP sc a a 207 30 50 1 PrOnBUS DIP TOMPUISOF FOCUS a a 207 A cece associa T eaepalvaa te uence cea wile aia ee Saee yaaa 210 30 6 1 DeviceNet for Pulsor FOCUS occcccocccocccncoconococcnnoconnnonnnnonnnnonanononannnonnnnnnonnnecannnonos 210 O 214 30 7 Imenbus TOF PUSO FOCUS perrito oca posa 214 30 8 MOABUS PIU Ss dia 217 50 6 1 ModBusPlus Tor PUlSOMr FOCUS eat ic ta 217 309 BIDEN asa 221 30 91 EtierNel tor PUISOrMFOCUS a ie O nd 221 SOO FROIN A ea ae ee ee 223 10 235 9836 4841 21 Contents 31 IrOUDIESNOO UNO Remeeeereetert se ace esr Miele ert monies ee eel ea ie ae aero eae ees ee 225 lad US AMAS a e e a ee 225 A aeaaeai aa aiaia 227 33 General safety instructions for Pulsor Focus UNIt ccccesseseeseseeseeeeneees 229 Sal WOK dc a A A 229 339 2 Eleciical Sdo yea ais 229 933 9 Personal Sale rreraren E R E 229 IO OON CE pena e a ATT EA a a 230 34 EC declaration of conformity c ooonconnnconncicnncccnnnccnanccnancnnnncnnancnnanrnnnnrenanrrnanrenanenas 233 9836 4841 21 11 235 Introduction to Pulsor C 1 Introduction to
113. completed when a Pset is bypassed The Job Status will be OK NOK depending on parameter Batch status at increment bypass J311 If using Job reference In Job with Free order only the JobClient with the active Pset is able to use Bypass functionality In Job with Forced order the JobClient with the active Pset and the JobReference are able to use Bypass functionality When a Job abort request is received the Job functionality will wait for completion of the ongoing tightening result before aborting the Job Abort can be an external signal as well as an internal order see Max time to start Job J320 and Max time to complete Job J321 If using Job reference Abort Job 1s only allowed via the JobReference This function offers the possibility to turn off the Job functionality and unlock all involved tools Running Job Selecting Job off for a running Job is equal to aborting Job thus the tool tools will always be enabled The JobReference will order JobMembers to select latest Pset that was selected from DigIn or Selector in case one of these is Pset select source C222 Otherwise the latest selected Pset in the Pulsor Focus will remain No running Job The JobReference will unlock all tools of the JobMembers JobReference will also order JobMembers to select latest Pset which was selected from DigIn or Selector in case one of these is Pset select source C222 Otherwise the latest selected Pset in the Pulsor Focus will remain Wh
114. cted values An analysis of the result data can show how the process can be further improved 66 235 9836 4841 21 Performing a Monitoring Setup 9 Performing a Monitoring Setup 9 1 Introduction A Pset may be set to monitor on a lot of tightening parameters To automatically generate suggestions for these limit parameters you can perform a Monitoring Setup This will teach the Pset the difference between good and bad tightenings A prerequisite for being able to carry out a Monitoring Setup 1s that a Tool Setup has been performed for the Pset according to the instructions in chapter 5 Performing Tool Setup It is also possible to carry out a simpler type of Monitoring Setup directly from the Pulsor Focus front panel See section 9 6 Making Monitoring Setup via Pulsor Focus front panel for more information If you want to set up limits for monitoring parameters without performing a Monitoring Setup you can skip this chapter For more information about how to manually set monitoring parameters see chapter 8 4 Tightening monitoring and 8 5 Changing limits and activate monitor parameters 9 2 Starting Monitoring Setup In the window for the active Pset Click on either Perform Monitoring Setup button The Monitoring Setup 1s displayed 9836 4841 21 Monitoring Setup Tightening parameters Tightening time Rundown time System parameters Pulse frequency Pulse pressure Bar Ref setup id Number of tigh
115. d eventual default gateway by using the buttons and Enter button The first 4 numbers set are the IP address the next 4 numbers are the subnet mask and the last 4 are the default gateway From ToolsTalk Pulsor C first connect serially as described above Then go to Communication under Config see chapter 11 1 Introduction to Config and 11 4 Communication for more information on how to do this Set the IP address subnet mask and where applicable the default gateway Store and restart Pulsor Focus 2 Connect the Pulsor Focus to the PC directly using a twisted Ethernet cable or connect both PC and Pulsor Focus to the LAN 3 From Settings under the Options menu set the IP address and Subnet mask to the Pulsor Focus you wish to connect to as described in chapter Settings in ToolsTalk Pulsor 4 Connect with Ethernet to the selected Pulsor Focus with a double click on item Ethernet PF in the PF Map or a click on the connect button 2 5 Exchange of tools Hot swap You can exchange tools while the system is on Hot swap even if the system is connected to ToolsTalk Pulsor 20 235 9836 4841 21 Introducing the Pulsor system s user interface 3 Introducing the Pulsor system s user interface 3 1 Signal lights on the tool The tool has three signal lights green yellow and red Green Tightening approved Flashing red Active monitoring parameter is exceeded Flashing yellow An active monitoring parameter
116. de is on one can set FieldBus data in ToolsTalk and send the data to Pulsor Focus controller by clicking on Set value button If diagnostic mode From PF is used the Pulsor Focus passes data from ToolsTalk to PLC and ignores the data from Pulsor Focus If diagnostic mode To PF 1s used the Pulsor Focus activates functions which is set in ToolsTalk and ignores PLC data 15 3 2 Monitor mode Monitor mode key is used to monitor FieldBus data communication for testing purpose This function works only when ToolsTalk is online connected to the Pulsor Focus controller When Monitor Mode is active the data from Pulsor Focus to PLC are visible in the From PF window bitmap Contrary the data from PLC to Pulsor Focus are visible in the To PF window bitmap It is not possible to change and store FieldBus configuration in monitor mode Data can be displayed in two formats defined data type format and binary format The data in the monitor windows are updated at a rate of 3 messages second 15 3 3 Store to file and Read from file Store and read FieldBus configurations to file Use the Read Save FieldBus functions in the File menu in ToolsTalk To store to or read from a file you must first activate the FieldBus window The FieldBus file extension is pff 110 235 9836 4841 21 Monitors 16 Monitors ToolsTalk Pulsor offers several ways of displaying the tightening result Functions Description Result monitor The tightening result
117. dentifier strin 1234567891 25 Remove 9836 4841 21 105 235 FieldBus 15 FieldBus A FieldBus communication can be used for data communication between the Pulsor Focus unit a and PLC s It is an effective and fast way for data transferring of short data packages It is normally used to send discrete I O data instead of using a large number of discrete cables that have to be hard wired to relays and DigIn For parameter descriptions see Parameter list section 23 6 FieldBus There are many different FieldBus standards on the market and they all have different hardware and software protocols To be able to communicate on FieldBus the Pulsor Focus must be equipped with a specific card for the preferred type of FieldBus ProfiBus DP ProfiNET DeviceNet InterBus ModBusPlus ModBus TCP and Ethernet IP are the possible selections Pulsor Focus acts as a slave in a FieldBus system A PLC or similar will act as the master With help of ToolsTalk the FieldBus functionality in the Pulsor Focus controller can be configured to fit the customer specific bitmap It is a very easy way to configure or modify a customer specific bitmap When the configuration is done you can download to the Pulsor Focus or save it as a file for later use The ToolsTalk interface for FieldBus consists of three parts General setup From PF setup and To PF setup 15 1 General setup Select FieldBus type under General Setup EN FieldBus PF 3 PF1 SEE
118. display Satisfied with the Tool Setup It is Do you want to exit recommended to perform at least 5 Tool Tool Setup without Setup tightenings No saving No Yes Yes Press Enter Tool Setup is finished Press Pset Setup button No Pset changes will be saved 9836 4841 21 37 235 Performing Tool Setup Perform the tightenings After each tightening the torque measured by the system is presented on the display You now have the following options 1 Press buttons to set the actually installed torque Accept with Enter The installed torque can be measured with a torque wrench or an inline torque transducer It is recommended to perform this step after each valid tightening 2 Perform a new tightening By doing this you accept the tightening but do not set installed torque Press Enter to accept the Tool Setup The performed tightenings is accepted and the Pset is saved If no tightening is in memory ie all tightenings have been deleted this option is not available 4 Press Pset Setup to delete the last tightening This is important to do if the tightening was erroneous e g a rehit 5 Press Pset Setup again to cancel Tool Setup Nothing from this Tool Setup will be saved in Pset 5 8 Changing parameters after a Tool Setup The settings mentioned below can be found in the Pset window for the actual Pset 5 8 1 Changing Torque Tuning After a Tool Setup has been performed all Pset 1 Gear box PulsorF
119. display parameter numbers in ToolsTalk Pulsor by activating Show parameter number under the Application tab in Options Settings 23 1 Pset parameters 23 1 1 P1xx Programming P10x Tightening Options Parameter Parameter name Description Default setup number P100 Strategy Pulsor Fixed The air pressure is fixed and depends on the chosen Pulsor Fixed Pset Pulsor angle shutoff Air pressure is fixed for this Pset The tightening will stop when a specified angle is reached from a threshold torque Click wrench A digital input signals the completion of an arbitrary activity No tightening is performed by tool P107 Click wrench no This parameter is only used if Click wrench is chosen as Control Click wrench 1 strategy P100 It is used to connect the Click Wrench strategy to any one of four defined DigIn P112 Monitoring limit minimal accepted torque Connected to P645 P114 Monitoring limit maximal accepted torque Connected to P647 999 9 Nm P14x Tightening Options Parameter Parameter name Description Default setup number P141 End time The time between air shut off until air is turned on again after a 0 5 seconds finished tightening For loosenings the time is fixed changing this parameter has no effect P144 Cycle Abort timer This parameter is used to limit the time a tightening is allowed to progress 9836 4841 21 153 235 Digital inputs and outputs P15x Batch count Parameter Parameter Description De
120. displayed Press Enter to access the Batch Size value range 0 99 Change the Batch Size value by pressing the keys Press Enter to save and exit Press F to exit no save F6 Create Pset F6 CrPsS alternates in the display if the Pset select source C222 is Keyboard Otherwise F6 is displayed Press Enter to access available Pset list The value shown is the first free Pset Press the buttons to change Pset number 24 235 009836 4841 21 9836 4841 21 Pset Setup Question Mark Introduction to Pulsor C Press Enter to create and select the Pset Press F to exit no save F7 Torque Tuning adjustment set new measured torque F7 nEtg alternates on the display Press Enter to access the Torque tuning value The value shown is equal to the target torque for the Pset Press the buttons to change this value to the mean torque achieved during recent tightenings Press Enter to save and exit Press F to exit no save FS Set Pset pressure Fs PSPr alternates on the display Press Enter to access the Pset pressure value The value shown is the current Pset Pressure value Change the value with the buttons Press Enter to save and exit Press F to exit no save The Pset Setup button is used to enter both Tool Setup and Monitoring setup See chapter 5 7 Tool Setup from Pulsor Focus front panel and 9 6 Making Monitoring Setup via Pu
121. done J302 Job line control Job parameters Use line control J330 and Lock at job done J302 Service alarm Diagnostics parameter Lock tool on alarm D136 28 235 9836 4841 21 Tool Control Box and tool introduction 4 2 The tool Consult www atlascopco com tools for the latest list of available tools Recommended air hose diameters for the tools available when this manual is printed are 4 2 1 Tool adjustments By default no mechanical adjustments of the tool can be done all settings are done in software However the tool 1s delivered with a trim valve if the need should arise The trim valve can be exchanged for a silencer supplied with the tool if the trim valve is not needed When the trim valve is fit to the tool it can be used to adjust the air flow out from the tool The trim valve is by default fully open to provide maximum air flow through the tool When using the Pulsor Fixed strategy on particularly hard joints it may be necessary to change this setting to decrease the air flow This will slow the tool down a bit so the first pulse will be weaker The more the air flow is attenuated the weaker the tool will become though the valve setting will affect the first pulse more than the rest of the tightening Because the decrease in pulse effect for the first pulse is greater than the decrease in further pulses in effect this will prevent overshoots in the first pulse while reducing overall performance significantl
122. dustry Food Industry Building Automation Plant Construction Paper Converting Wood Processing and Process Engineering InterBus has a user organisation called the InterBus Club The organisation assists members on a wide variety of matters concerning InterBus For more information contact the InterBus Club http www interbusclub com The media used by InterBus is a shielded copper cable consisting of three twisted pairs Two of these pairs are used for the bus connection and in the last pair only one cable is used This cable is used to earth the bus The baud rate for the bus is 500 kbit s with a total amount of data of 4096 I O points The Pulsor Focus InterBus module is to be used on InterBus Remote Bus networks In applications where it is necessary to exchange large amounts of data and where a parallel application interface is required InterBus is the preferred option InterBus has two ways of exchanging data One is through fast cyclical I O data called process data The other is a somewhat slower protocol called PCP which is mainly used for configuring and setting the parameters of a device The Pulsor Focus InterBus module supports up to 10 words on the bus out of which none one two or four words may be selected to act as the PCP channel necessary if the PCP protocol required The PCP version supported by the module is version 2 0 which is fully backwards compatible a When using InterBus master boards where the PCP cha
123. e from File updated with programmed settings stored on file You will be asked to select file Save lt object gt This function stores a single object to file The data from the active window in ToolsTalk will be stored Config Pset Job etc to file You will be asked to name the file Read lt object gt This function writes a single object file to the Pulsor Focus The data in the active window will be Config Pset Job etc updated with data from the file You will be asked to select file When you store PF to file Tools Talk will ask you to name the file Then ToolsTalk will store the programmed settings on a number of files for example one file for each Pset and Job A Pset will be stored in a file with extension pfp All files will begin with the desired name but will have extensions as below The trace will not be saved to file when storing Pulsor Focus to file To save a trace use Save trace from the File menu when a trace 1s active on screen When you store PF to File you have the option to store files in Excel format Select Excel as file format in the Save As dialogue The overhead file will have the extension pft Extensions for the other stored files will be xls These files can be used in Microsoft Excel 9836 4841 21 53 235 Working with ToolsTalk Pulsor 6 8 Offline mode Offline mode gives the user the opportunity to conduct programming and configuration without being connected
124. e gauge with an accuracy of 0 1 bars or better The operator first confirms without pressing the trigger to ToolsTalk Pulsor that the pressure is zero The tool trigger is then pressed and kept pressed until the operator reads off the pressure on the external sensor and confirms the higher pressure line pressure in ToolsTalk The trigger is released and the pressure from the external sensor is entered in ToolsTalk Do not forget to remove the valve pin when you are finished with the tuning Pq Diagnostic PulsorF 1 PulsorTest Ioj x Parameter Overview 0930 Line pressure 5 36 E er Sonmigurehen 0931 Air sensor tuning performed at 2005 051 9 14 39 48 aa Tool general information Pulsor tool info Perform Aur sensor tuning 3 Air sensor tuning Controller diagnostics E System diagnostics See below for detailed instructions on how to perform an air sensor tuning To be able to perform air sensor tuning you need EII a special valve pin obtainable from Atlas Copco A Tools Make sure the air supply to the tool is disconnected Fit the valve pin like shown to the iyi right Y ou need to unscrew the plug from the back of the tool before you do this Then fasten the y plug and connect the air hose to the tool again BA pe before proceeding with the steps below FEW L Start Diagnostic from the PF Map E a f I Sion 1 0 Pset Rod Job F Config O Y Tool accessories PAVE Diagnostic
125. e Character 64 bit 8 Le 08 15 08 8 ASCII most recent result Format string change character characters 24 hour HH MM SS s The tightening time hour part only 0 24 hour taken from the most recent result The tightening time minutes only 0 60 min taken from the most recent result The tightening time seconds only 0 60 min taken from the most recent result The tightening date taken from the Character 80 bit Le 2000 05 07 10 ASCII most recent result Format string change 10 characters YYYY MM DD character s bytes 201 235 The tightening date day part only Ul6 taken from the most recent result The tightening date month part only U16 taken from the most recent result FieldBus configuration appendix Items From PF Description Data type String Value length TighteningDateY ear The tightening date year part only Year number 4 digits taken from the most recent result TighteningStatus Combined status for all tightening Character 1 byte OK O result parameters that are used ASCII NOK N Bit field 2 bits 00 Not used 01 OK 10 NOK TighteningStatusNOK Tightening result has one or more Bit 1 bit 0 Not used Not OK results 1 NOK TighteningStatusOK All tightening result is OK 0 Not used 1 OK ToolGreenLight This item follows the tool green Bit 1 bit 0 Not used light 1 Green Tool loosening Bit 1 bit 0 Tool is not loosening 1 Tool is loosening ToolRedLight
126. e Control P660 Pset pressure Pulse Control P670 Rundown speed P676 Torque pulse threshold System Control P680 Tool model used P681 Tool setup performed P682 Torque tuning factor P684 Air shutoff time P685 Max available pressure P686 Extrapolation shutoff threshold P68 Tool setup tightening count 44 82 PSI A fo 3 EPP 8C55 HA B10 1 00 bo Sec 94 42 PSI fo a r When a Pset is created default values are provided for all Pset parameters Most of these are not changed automatically during Tool Setup they are kept at their initial values Exceptions are the parameters mentioned below During automatic non manual Tool Setup after you have begun to perform tightenings the parameter P660 Pset Pressure is automatically calculated and updated When this parameter is changed and stored under Advanced Settings as is the case during Manual Tool Setup Tool Setup will not continue to automatically calculate it 36 235 9836 4841 21 Performing Tool Setup 5 7 Tool Setup from Pulsor Focus front panel 5 7 1 Making Tool Setup Tightenings Pulsor Focus front panel Make sure you perform the tightenings with the same equipment as will be used in production For example if an extension will be used in production this should be fit to the tool while Tool Setup 1s performed also The first tightening during Tool Setup will be a standard tightening with parameters set for a careful tightening to simpli
127. e DeviceNet module This means that the DeviceNet cable connected to the Pulsor Focus must not include voltage wires Normally you have a central power supply that feeds all nodes in the network Power consumption Current consumption at 24 VDC V to V is max 70 mA at power up and 25 30 mA continuously Functionality of the indication LEDs The module is equipped with four colors LEDs used for debugging purposes Noimwe O Nowe oO O S Bus termination Termination of the FieldBus requires a terminating resistor at each end of the FieldBus These resistors should have a value of 121 Ohm 212 235 9836 4841 21 FieldBus configuration appendix EDS file Each device on a DeviceNet network is associated with an EDS file containing all necessary information about the device The network configuration program during configuration of the network uses this file Contact your local Atlas Copco representative for a copy of the EDS file File name pf3devn eds Icon file Contact you local Atlas Copco representative to get a copy of the Icon file for Pulsor Focus This file can be used to have a Power Focus Icon in PLC configuration SW File name pf3devn ico 9836 4841 21 213 235 FieldBus configuration appendix 30 7 InterBus A InterBus is normally used for industrial automation applications such as valve sensor and I O unit control InterBus is used in many different types of industry including Automobile In
128. ector ZY 2 Motor block 1 Gearbox 3 Spark plug YW X Cancel SS Click OK to save settings Go back to Other I O s 1 and set the Pset select Source to Selector then press Store to complete the setup B x et Serial z Parameter Overview C221 Job select source Ethern System setup C22 Pset select source Selector E 1 0 setup gt Config PulsorF 1 Station 1 lect i 40 device 0 7 C223 Tool light con source controlled 1 1 0 device 8 15 C224 Tool light mode E Other 1 0 s 1 C225 Tool light on timer o 0 Sec Other 1 O s 2 C226 Selector confirm Off Communication Protocols C227 Job select source override Off baal Other I O s 2 C230 Selector lost mode Last Pset y C231 Use last Pset at startup E 132 235 9836 4841 21 Accessories 20 3 1 0 Expander The I O Expander enables the connection of additional inputs and relays when more than those built in are required There are 8 inputs and 8 relays with the same functionality as the four built in I Os Each input and relay can be configured individually I O Expander order number 8433 0564 38 20 3 1 Setup of I O Expander Hardware Setup Connect the I O Expander via I O Bus to the Pulsor Focus Make sure that the I O Bus is terminated in both ends For detailed information see chapter 28 Connector descriptions and the Product Instructions document for I O expander 9836 4841 21 133 235 Accessories Sof
129. ed during tightening By default the first pulse is not counted when calculating the torque value The pulse filter is used for this function irrespective of whether or not the pulse filter is on Relative torque The achieved torque as a percentage of the target torque It has the same features that apply to torque value as described above Start final angle If the torque of the first pulse is far above the threshold torque where angle should be calculated from then max the angle calculation starts too late This is especially a problem when using the Pulsor Angle Shutoff strategy where the low angle measurement results in bolts being tightened too far When this monitoring limit is activated the tightening will stop 1f the first pulse exceeds this value Final angle Expressed in degrees This is measured from a torque threshold value default 50 of target torque In most cases 50 of target torque is a good choice of threshold value If the threshold value is set at 0 the angle is always measured from the first pulse as is the case if the threshold value lies below the torque value of the first pulse The angle of the first pulse cannot be measured If a Monitoring Setup has been performed the average of the angles is used as basis for the tightening angle monitoring parameters No of Pulses The number of pulses registered during the tightening 10 15 pulses is enough for good accuracy more than 20 pulses will not contribute to the acc
130. eference values If needed change the parameters See explanation in table Target torque above Tightening Angle Start Rundown pulse filter Click on OK Keep Pset limits ma a Changing these parameters results in recalculation of all the tightening results from this monitoring Setup 9836 4841 21 69 235 Performing a Monitoring Setup 9 4 Completing Monitoring Setup Check that the result from the Monitoring Setup tightenings 1s reasonable Review the max min results Identify and delete any deviating tightenings When enough tightenings have been made the Accept button will be marked in yellow or if Tools Talk identifies a XA Cancel problem with the Monitoring Setup see below Setup 1s completed by clicking the Accept button The a UU xl Monitoring Setup window will be closed the results stored A Faos O Monkin ene and no changes or additions to this Monitoring S etup can be Number of tightenings in Monitoring Setup below the recommended made later though it is always possible to perform a new Press OK to Store anyway Press Cancel to return to Monitoring Setup Monitoring Setup If there are any faults in the Monitoring Setup a new window will be shown The problems will be listed and a chance is given to go back and fix the faults or Store anyway The Accept button will be red if there are fewer than ten Monitoring Setup tightenings You have now set the monitoring parameters to values according
131. eger Decimal 0 65 535 Unsigned 32 U32 32 bit unsigned integer Decimal 0 4 294 967 295 U32 HNW 32 bit unsigned integer MSW is the higher number word CharStringChangelntelF Character string Each character uses one byte ASCII code Range 2 25 bytes This type makes Intel Endian character string follows byte order the first character is the lowest byte in the string CharStringInputIntelF Character string with an extra counter byte in front The extra byte is an integer counter and must increase each time when the character string is entered to be able to detect a new input If you want to enter the same value again e g the same Job number just change the counter This type makes Intel Endian character string follows the byte order the integer counter is the lowest byte in the String a Common for all data types is that a change must occur in PLC output area To PF to get l Pulsor Focus to detect a new data entry For example if you want to select JOB number 3 two times in a row you must select 0 in between 194 235 9836 4841 21 FieldBus configuration appendix 30 2 1 Character string Character String 1s in a reading order 1 e from left to right from top to bottom regardless of the byte order The difference between CharStringChange and CharStringInput is a counter byte added before character string in CharStringInput When the counter changes the new input is considered Motorola Endian Type Wo
132. en a Pulsor Focus is in Job off mode it is possible to perform tightening with any existing Pset As long as the JobReference is in Job off mode the user is denied to select a new Job the Job off mode must first be shut off The only occasion when the Job off functionality affects the JobClients is when they have lost communication with their JobReference In this case it is possible to unlock the JobClients locally by using the Job off functionality S Only the JobReference will remember the Job mode after a reboot Job OK Received if all Psets included in the Job have been correctly performed Alternatively if Batch increment bypass has been used if Batch Increment Bypass is configured as an OK event Job NOK Received if any Pset included in the Job have not been correctly performed Alternatively it is considered as NOK Not OK if Batch increment bypass has been used if Batch Increment Bypass is configured as a NOK event Job Aborted The Job was aborted 10 3 3 Loosening in job It is possible to monitor loosenings during a job If monitored you can either count the loosenings Pulsor Focus will decrement batch disallow loosenings after an OK tightening or disallow loosenings altogether see section 10 1 Creating a standalone Job The functionality is the same as for Loosening in Pset see section 7 5 Loosening 10 4 Unlock the tool If the tool is locked by the Tool Control Box after a job unlock the tool by selecting a
133. er ServiceIndicatorAlarm TighteningTime TighteningTimeHour TighteningTimeMin TighteningTimeSec TighteningDate TighteningDateDay TighteningDateMonth 9836 4841 21 Shows running Pset Final target Fixed point 32 bits The value is 2 digits if torque value is less than 100 one digit if 100 lt torque value lt 1000 and 0 if torque value gt 1000 For example if torque value is 25 64 the two byte integer part shows 25 and the two byte decimal part shows 64 if torque value is 345 5 the integer part shows 345 and decimal part shows 5 if torque value is 2431 the integer part shows 2431 and decimal part shows 0 The value is represented in the units determined by the user Shows running Pset Relative Tq Ul6 2 bytes Binary representation Decimal Min in percent multiplied by 100 0 65535 Shows running Pset Relative Tq Ul6 2 bytes Binary representation Decimal Max in percent multiplied by 100 0 65535 Shows running Pset Tightening Ul6 2 bytes Binary representation Decimal Angle Min in degrees 0 65535 Shows running Pset Tightening Ul6 2 bytes Binary representation Decimal Angle Max in degrees 0 65535 Indicates identifier has been received Bit 1 bit 0 not used by PF 1 Received identifier Indicates that the number of Bit 1 bit 0 Alarm Off tightenings in the tool memory has 1 Alarm On reached the service interval limit The tightening time taken from th
134. er v Monitoring Setup Tightening Options Monitoring Batch related settings are also set in this ae E i P144 Cycle abort timer 30 0 Sec Monitoring window l Control Parameters P150 Batch count or y Pset setup P151 Batch size Save changes by clicking Store Statistic programming ON z P153 Max Coherent NOK s o EEE D Undo E ompare X Close De l Compare gt Read sa Store 8 6 Using the tightening monitoring options A change in Tightening angle start and Rundown pulse filter will affect the values of the corresponding tightening results If this is changed the limits for monitoring may need to be adjusted as well Limit values Tightening angle start and Rundown pulse filter can be changed activated or deactivated arbitrarily at any time Rundown pulse filter If early pulses occur that are not part of the tightening such as Rundown pulses of self locking nuts the measurement of various parameters such as tightening time may be incorrect To prevent this there is a Rundown pulse filter that excludes such pulses from the calculations The filter is on by default but can be switched off 64 235 9836 4841 21 Tightening and monitoring 8 7 Changing parameters via Pulsor Focus front panel Some parameters can be changed using the function button F on the front panel The function can be used assuming no other user is accessing the controller Confirm with Enter to go
135. erforming tightenings and how they can be used Advices on what to think of and how different problems can be resolved are given Go directly to sections 8 4 Tightening monitoring and 8 5 Changing limits and activate monitor parameters if you want to get started quickly and adjust the tightening monitoring It is also advisable to read section Viewing results on how the results can be displayed Chapter 9 Performing a Monitoring Setup describes how to automatically calculate monitoring parameters from a number of representative test tightenings 8 1 Performing tightenings To get as accurate measurements as possible from tightenings the following need to be considered Keep the trigger pressed until the tool has shut off Hold the tool steady Keep the tool straight Do not twist the tool while tightening as this will affect the angle measurement When the tightening is completed a correct tightening can be verified by the green OK light on the tool If the tool has not been used for a long time it may spin during the first tightening This 1s sensed by abnormally high pulse frequency and that the tool feels weaker than normal It is normal for this to happen after the tool has rested for about an hour If this happens regularly fill up oil in the pulse unit 8 2 A tightening and its parameters 150 Torque Tightening time Mr EA I Air pressure is measured F Angle increases in at air motor in the tool
136. erial number 0215 RBU tppe D216 ABU serial number M Close Read wig Store If PF Serial number D211 is not set you can write in the serial number from the back of the PF here Press store to save in PF 9836 4841 21 99 235 Diagnostics and service 13 6 System diagnostics System diagnostics functions enable you to test and diagnose your Pulsor Focus system Diagnostic PulsorF Hame Not Defined Parameter Overview Tool Tracking Tool configuration Controller diagnostics System V0 diagnostic System diagnostics D e Tool Tracking Relay status System 70 diagnostic O Digimstatus TCE air hose test Digin status Relay test IO device revision TCE air hose test 0932 Max available air pressure 16 53 Bar 0933 Air shut off time 0 0739 Sec 0934 Air hose test performed at 201 0 03 24 10 02 12 TCE air hose test Ge Read El Store The system air pressure can be diagnosed using the Tool Tracking function The purpose of this function 1s to check that the TCB and tool air pressure sensor 1s working properly and is properly tuned see section Air sensor tuning When in Tool Tracking mode the tool air pressure is shown both in ToolsTalk and on Pulsor Focus display 5 When the Tool Tracking function is active the system will stop monitoring and any tightening performed will be discarded The status of all internal and external I O devices can be viewed in System I O diagnostics You
137. ermine how Tool Setup tightenings should be interpreted During Tool Setup it may happen that tightenings are performed that are not representative or wrong in some way Examples of this are rehits wrong screws etc These measurements can be deleted by pressing the Delete button located in the last row of every tightening column see picture in previous section There is a difference between deleting the most recent tightening and earlier tightenings For earlier tightenings the column and the associated values will be deleted and the Torque Tuning Factor will be recalculated when you press Apply Additionally if you delete the most recent tightening the joint dependent parameters will be restored to their previous values as well In effect this resets the Tool Setup to the state it was in before the faulty tightening pressure is restored etc Tool Setup can then continue as if no faulty tightening was made If the deletion is not done before the next tightening the calculated Pset pressure may be wrong for your application most often leading to slower tightenings than necessary and therefore reduced performance when later used in production The exact result of wrongly calculated joint parameters depends on the chosen tightening strategy G 5 To help the Tool Setup generate optimal tightening parameters it is important that an erroneous tightening is deleted before performing the next tightening 5 5 Finished with the tightenings It i
138. ers after a TOO Setup cccccooonnccncccnnoncconcconnnnccnnccnnnanccnncnnnananinnnnns 38 5 8 1 Changing Torque TUMNO its e an 38 5 8 2 changing Control parameters ends 39 Working with ToolsTalk PulSOr coocconnconocccocconcconoccnanonanonannonorenanenannonarenarenannns 41 6 1 Connecting the computer to Pulsor FOCUS ccooncccccoonccnconnncnnnonnncnnnononcnnnonancnnnnnnos 41 6 1 1 COMMecting via USB Calle stat atada 41 6 1 2 Connecting Via Serial Cal Ocarina als 42 6 1 3 Connecting via crossover Ethernet Cable oooccccccccconononnccnnnccnnnnnncnonnncnnnnnaanncnnnnnnnos 42 6 27 Stalling TOOS Talk PUSO aros E 43 6 3 Tools Talk Pulsor USer INterlace sion dad 45 6 3 1 MEU on Sur ee ee ee rae oS ne eeu Eee 45 6 3 2 o laser ares a a ese reas ie snes ae ele dace 46 6 3 3 A A ee 46 6 3 4 MS PE MA A da 47 64 Event codes in ToolsTalk PUSO ton a o dci casino 47 6 5 Activating Pset and showing Pset Main Window occcoocncccccnnccnccnconncnnonanonononcncnnncnnos 47 6 5 1 Creating anew Ps luca iodo 48 66 Settings TOOS Talk PUSO rai TS 49 6 6 1 Settimds SOmMmMUN ICAO ci RS 50 6 6 2 SENGS PADD ALON Stan rte ba 51 6 6 3 SEMOS PINOUT A eee aed 51 6 6 4 SS Sle LIST arenie a tecgetiaa rocio 52 6 7 StOring Programming ON TNS vvinriniizanai A a E E 53 58 U1 8 21810 811 06 gt RR aa 54 6 9 Miscellaneous ToolsTalk Pulsor tasks oocococcconcoccnncccnconnncconocncnnnanonannonononaninonoos 55 6 9 1 New user for an existing T
139. esence of flammable liquids gases or dust Power tools create sparks which may ignite dust or fumes Keep bystanders children and visitors away while operating a power tool Distractions may cause you to lose control 33 2 Electrical safety Earthed tools must be plugged into an outlet that has been properly installed and earthed in compliance with all relevant codes and ordinances Never remove the earthing prong or modify the plug in any way Do not use any adapter plugs Check with a qualified electrician if you are in any doubt as to whether the outlet is properly earthed Should the tools suffer electronic malfunction or breakdown earthing provides a low resistance path to carry electricity away from the user Applicable only to Class I earthed tools A This apparatus must be earthed A Pulsor Focus unit may not be supplied with a galvanically isolated voltage as this would inhibit the function of the Ground Fault Interrupter GFI The test button on the GFI also activates the GFI in instances where a Pulsor Focus unit is equipped with an isolated transformer Test the earth fault protector by pressing the test button located on the rear panel of the Pulsor Focus unit Test the earth protector every month by pressing the test button Should the earth fault protector disconnect the system be sure to find the primary reason before you resume operation Avoid body contact with grounded surfaces such as pipes radiators ranges and ref
140. et features and functionality 130 235 9836 4841 21 Accessories 20 Accessories 20 1 Introduction This chapter describes available accessories that can be used together with your Pulsor system This chapter focuses on the configuration aspects of ToolsTalk Pulsor for detailed information on the specific accessory see the corresponding Product Instructions document for that accessory Some accessories are connected via relays and digital inputs and some are connected via the I O Bus Up to 15 accessory units can be connected to the I O Bus The I O Bus is a CAN based serial bus The benefit of using serial bus based accessories I O Bus is that they can be connected in series from accessory to accessory rather than hard wiring each accessory to the Pulsor Focus The bus and the accessories are powered with 24V DC 1 A from Pulsor Focus unit If more current is needed the bus must be powered externally Every device has a 24 V DC input for this purpose 20 2 Selector The Selector is a socket tray that can guide the operator through a JOB sequence with LEDs When a socket is lifted the corresponding Pset will be selected When using more than one Pset it is very convenient to use a selector When a socket is lifted the corresponding Pset will be selected There are two different types of Selectors Selector 4 and Selector 8 the only difference being that Selector 4 has four sockets and Selector 8 has eight sockets Selector 4
141. etwork configuration and in particularly the subnet mask and the default router Reboot needed before changes take The configuration changes will not take effect before a system reboot ACK effect IP address already in use The IP address of this Pulsor Focus is already in use by another system 859 IP address collision Another system attempts to use the same IP address as this Pulsor Focus 862 Ethernet overload Error The Ethernet driver of the Pulsor Focus is temporarily switched off due to an overloaded network 863 IP Port already in use An attempt was made to bind a TCP or UDP socket to a port already in use E g a customer protocol is using the same port as ToolsTalk E851 es es Ethernet echo detected An Ethernet packet was discarded since its source MAC address was equal to the Pulsor Focus s own MAC address Notice that this message only occurs once during runtime even if several such packets are detected There is most likely a problem in the network 22 3 12 Events MMI3000 E901 MMI Start up Error Error in MMI detected ACK 22 4 Sub information for event codes Each event code is logged together with four integer parameters For some event codes these parameters are used to store extra information about the event See section 22 1 ToolsTalk Pulsor operations how to display event code integers The follow sections contain event codes and explanations of the related integer parameters 22 4 1 E150 The f
142. even numbers should be programmed 2 4 8 10 etc Data length should be a number higher than zero The maximum length that can be programmed is different for each FieldBus type If InterBus is used the Pulsor Focus unit has to be restarted when the data length is changed From PF Global DataLength is the length of sending broadcast data to the network This is a special function for ModBusPlus not available for other FieldBus type Max length 64 bytes If only point to point data is transferred set this parameter to Zero G From PF Datalength From PF Global Datalength From PF point to point DataLength which only available in ModBusPlus To PF Global DataLength is the length of receiving broadcast data from the network This 1s a special function for ModBusPlus not available for other FieldBus type Max length 64 bytes If only point to point data is received set this parameter to zero a To PF Datalength To PF Global Datalength To PF point to point DataLength which only available in ModBusPlus Some buses can use a SW configured node address and baud rate This parameter has two selections Software Makes it possible to program node address and baud rate from user interface Hardware Node address and baud rate is configured with the switches on the FieldBus card a Normally the switches on the FieldBus card must be set in a specific way to enable these parameters from ToolsTalk This parameter
143. f you were connected to a Pulsor Save all windows Focus If a file with higher license level is selected you can change its contents but the file can not be read to a Pulsor Focus unit with an RBU of a lower license level Print Preview Print Exit 54 235 9836 4841 21 Working with ToolsTalk Pulsor 6 9 Miscellaneous ToolsTalk Pulsor tasks 6 9 1 New user for an existing ToolsTalk Pulsor installation When a new user is added to the computer running ToolsTalk Pulsor the PF List may be inaccessible due to user access rights or due to the list being stored in an unexpected folder or with an unexpected filename This section describes how you point out the PF list you want to use for an existing ToolsTalk Pulsor installation In the settings window click on the PF List tab E un xi Click on the Select Pulsor Focus list file button Pulsor Focus available list PulsorF Name JIP address _ Port PF Ethernet Station 10 40165 98 6543 Controller Station2 10 40 165 99 6543 Controller 10 40 165 100 6543 Controller a 10 40 165 101 6543 Controller Station5 10 40 165 62 6543 Controller hd PulsorF Name Station C Is NetMaster Controller IP fio 40 165 ss C Is CellMaster Premier 6543 Is Controller Add Modified Remove Select Pulsor Focus list file 4 PulsorF Available List in file C Program Files Atlas Copco Tools 4B4T oolsT alk Pulsor PFList txt J OK X Cancel Select file PF3000Li
144. face RS 232 or USB After connecting as described below you can start setting up the Pulsor system for your application The next step is to proceed with performing a Tool Setup described in chapter Error Reference source not found Error Reference source not found 2 4 1 Connecting with USB 1 Driver installation needed for first connection via USB 1s described in chapter 6 1 1 Connecting via USB cable 2 Start ToolsTalk Pulsor C 3 In the PF Map Double click Serial PF item located just below Serial tree item ToolsTalk Pulsor will by default use the first available com port If using any other com port go to Options gt Settings Communication tab to set the correct com port 2 4 2 Connecting serially 1 Connect the Pulsor Focus serial port 2 on the backside of the Pulsor Focus to the PC by using a serial cable 2 Start ToolsTalk Pulsor C 3 In the PF Map Double click Serial PF item located just below Serial tree item ToolsTalk Pulsor will by default use the first available com port If using any other com port go to Options gt Settings Communication tab to set the correct com port 9836 4841 21 19 235 Connecting and installing the Pulsor C system 2 43 Connecting over Ethernet 1 Set the IP address on the Pulsor Focus controller This can be done by either On the Pulsor Focus front panel press the F button until F3 IP shows Press Enter Set the IP address Subnet mask an
145. fault setup number name P150 Batch count A function that signals to the operator when a certain number of tightenings Off have been performed The number of tightenings is set either in the Pset P151 or by other means Select batch size source as follows Off Batch count functionality is not used Pset Use Batch size in Pset P151 Fieldbus An external source determines Batch size via fieldbus Ethernet Serial An external source determines Batch size via Ethernet or serial interface gt If batch count is used in Job this parameter shall be set to Off P151 Batch size The size can be 1 99 l This parameter can be set when the Batch count P150 is in active mode P152 Lock at batch Setting Lock at batch done turns off the air supply upon completing a batch Off done to indicate to the user that all bolts have been tightened P153 Max coherent Defines the number of allowed not ok tightenings in a row 0 Off NOK s Accessible when batch count P150 is set to Pset or off Scope 0 Off 1 10 23 1 2 P4xx Pset setup P40x Pset administration Parameter Parameter name Description Default setup number P400 View existing Psets Button To view existing Psets in the current PF channel Both numbers and logical names will be displayed Create new Pset Button To create and open a new Pset Each Pset has a unique ID number between 1 and 8 or up to 300 with the Configurable Memory functionali
146. from address 40001 and Point to Point Data starts immediately thereafter Global Data To PF data in the module starts from address 41025 and Point to Point Data starts immediately thereafter For example If To PF string length is 8 bytes and To PF Global string length is 4 bytes the Global data are mapped to address 41025 and 41026 the point to point data are mapped to address 41027 and 41028 Baud rate Automatic 1 Mbit s Automatically set from PLC at connection Data to PF total length 0 122 bytes Must be the same in PF and PLC The string length is in Pulsor Focus limited to 122 bytes ModBusPlus standard allows 64 bytes global data and 250 bytes point to point data Data from PF total length 0 122 bytes Must be the same in PF and PLC The string length is in Pulsor Focus limited to 122 bytes ModBusPlus standard allows 64 bytes global data and 250 bytes point to point data Global string length To From PF 0 64 bytes Must be the same in PF and PLC Hardware LED 1 Not used LED 2 Error LED 3 MBP Active LED 4 MBP Init 218 235 9836 4841 21 FieldBus configuration appendix Functionality of the indication LEDs The module is equipped with four color LEDs used for debugging purposes The function of the LEDs is described in the table and figure below Error Indicates that the communication is not OK LED 2 Turned Off communication OK MBP Active Indicates different Node Status LE
147. fy initial calculation of joint characteristics When you perform the tightenings do not release the trigger before the system has shut off the air pressure When the air is shut off release the trigger 5 7 2 Performing Tool Setup from Pulsor Focus front panel Note that the Pulsor Fixed strategy will always be used when performing Tool Setup from the Pulsor Focus front panel Press the Pset Setup button once If no Tool Setup has been done for this Pset previously air hose test will be performed and Tool Setup is started If a Tool Setup has been performed for this Pset already tSEt rSEt will flash on the display Use keys to select tSEt and press Enter to start Tool Setup A suggested target torque value will flash Use the key to change this value Press Enter when done The Tool Setup is now in tightening mode and you can start to perform the tightenings on the joint Here you may cancel Tool Setup by pressing the Pset Setup button Follow the flow chart below for the recommended Tool Setup procedure Below the flow chart the Tool Setup process will be described in text with all alternatives in the different stages presented Perform a tightening OK Tightening NOK tightening for example a rehit Use buttons to enter installed Press Pset Setup button The last torque aS measured by inline tightening will be deleted torque transducer or torque wrench Press Enter Nr of tightenings will flash on
148. g and monitoring 8 5 Changing limits and activate monitor parameters Select Monitoring under Programming in the paan iror bnd PuteorEstomea bet Pots navigation area for the relevant Pset maaan In the Monitoring window you can adjust your ta e reis limit values for monitoring and activate or rici o deactivate them o Arima PE Siwt inal angle mar i Relative torque value is 100 when the Hee tightened torque is equal to the target cirri torque Llerena remamsa f Pestorm Moraira Seba oa ana Only Torque and Trigger lost no machine shut off PE23 Runden ime ma limits are activated by default The absolute and relative torque values are linked if one is changed the other will follow X Chie CAD Compare Best Check the parameter limits that should be activated If Relative torque or Tightening Angle has limits 1 the Monitoring Setup has not been able to determine these parameters They will not be monitored correctly while having these values If the limit values generated during Monitoring setup are asymmetrical it is due to the offset between the target torque and the mean torque achieved during Monitoring setup Save changes by clicking Store You can change the tightening settings in A ee d lO1 x Tightening Options If the angle values have a Petes Hest high variation try changing the Tightening gio P611 Tightening Angle Star fo Angle Start parameter Tool Setup P612 Rundown pulse filt
149. gs are disabled by the function Lock on Reject E103 Tool locked by digital input This event is shown when an attempt to make a tightening 1s made and tightenings are disabled by digital input Rundown prohibited due to Line Control A Job using Line Control is selected The Job does not start until Line Control Start signal is received Tool locked cannot access RBU Pulsor Focus cannot communicate with RBU Pulsor Focus must be TLU restarted to protect data E125 Alarm on timeout alarm on torque lost The torque was not reached in 200 pulses During Tool Setup other limits is active Pulsor Control 100 pulses Pulsor Fixed 70 pulses Trigger lost When the function Trigger lost is activated in the Pset this event indicates that the trigger of the tool was released before final target Tool Disconnected This event code is generated when communication can not be established between tool and PF The tool may be disconnected from TLU the Tool Control Box and or the Tool Control Box is disconnected from the PF The event code is also generated when an attempt to start a disconnected logically or electrically tool is done es es a El28 131 E A damaged cable can result in a disconnected tool E136 Tool locked by batch OK This event code is displayed if the tool is locked by the function Lock at batch done 9836 4841 21 145 235 Digital inputs and outputs E137 Tool locked by field
150. h state B1 Switch state B2 Device 2 9836 4841 21 135 235 Accessories 20 4 1 Setting up a stack light using ToolsTalk This section includes a step by step instruction on how to set up a Stacklight standard ESL 04 with Light 1 indicating tightening result with high torque Light 2 indicating tightening result OK Light 3 indicating tightening result with low torque Light 4 indicating result tightening result NOK not OK The push button used for acknowledging of events The key switch used for batch increment left switch state and to reset batch right switch state The buzzer sound alerting on NOK tightenings and when the tool is locked Serial Y Name Not Defined Ethernet a f 10 46 24 224 Pset Boa Job Contig E Tool cont Bo 40 Diagnostic MI Identifier lt FieldEus Monitors La Trace MA Statistic Offline Hame Not Defined Config PulsorF 1 S Parameter Overvie System setup 1 0 setup 1 0 device 0 7 pi 170 device 8 15 Other 1 0 1 Other 0 s 2 Communication Protocols C215 Device 13 C216 Deve 14 Cal Deva 15 136 235 Connect Stacklight to the Pulsor Focus controller by using the I O bus cable In the PF map double click on Config If using the default stacklight address setting eight then select select I O device 8 15 in the config menu tree Note The address is by default set to start at device eight
151. he average of the last ten subgroups 7 times consecutively E353 7below r torque Trend deviation alarm the subgroup torque range value has been below the average range value of the average of the last ten subgroups 7 times consecutively E354 2sigma x torque Trend deviation alarm the last subgroup torque average is outside Xrt bar bar 2 sigma E355 2sigma r torque Trend deviation alarm the last subgroup torque range average is outside Rrt bar bar 2 sigma E366 7inc x angle Trend deviation alarm the subgroup angle mean value has increased 7 times consecutively E367 7dec x angle Trend deviation alarm the subgroup angle mean value has decreased 7 times consecutively E368 7inc r angle Trend deviation alarm the subgroup angle range value has increased 7 times consecutively E369 7dec r angle Trend deviation alarm the subgroup angle mean value has decreased 7 times consecutively E370 7above x angle Trend deviation alarm the subgroup angle mean value has been above the average mean value of the average of the last ten subgroups 7 times consecutively E371 7below x angle Trend deviation alarm the subgroup angle mean value has been below the average mean value of the average of the last ten subgroups 7 times consecutively E372 7above r angle Trend deviation alarm the subgroup angle range value has been above the average range value of the average of the last ten subgroups 7 times consecutively E373 7below r angle Trend
152. he operator to identify the different Jobs Maximum 25 characters 23 2 2 J3xx Programming J30x Configuration Parameter Parameter name Description Default number setup J300 Job list The job list specifies the Psets that can be included in the job The total number of Psets in one job can not exceed 30 This parameter contains PF channel Pulsor Focus channel ID that the selected Pset belongs to Pset Event identification number of Psets included in the job The Psets specified in the job must be predefined and they can be included in more than one job Same Pset can be used several times in a job Pset name name of the selected Psets Auto select yes auto select no manually select With auto select the job functionality automatically chooses the next Pset With a manually selected Pset the operator must manually choose the next Pset a This function is only available for forced order jobs It is not possible to use the auto select functionality for free order jobs see parameter job order type J301 A job has override privileges in comparison to a single Pset on a selected possible number of NOT OK tightenings Batch size A batch size should be specified for each Pset in a job The batch size specifies the number of tightenings to be performed for each Pset Maximum batch size is 99 It is possible to define free running Psets by setting batch size to 0 In this case the bypass function must be used to be able to co
153. his is just a warning 467 Fieldbus configuration fault Error detected in initialization of FieldBus Fieldbus hardware mismatch The FieldBus module installed in Pulsor Focus is not the same Q gt S B S N AL ALAS E Uy N O OO gt gt Q N A w m D ON Nn es ES Oo ON mM m D ON 00 FieldBus type as configured with ToolsTalk Pulsor Change FieldBus module or configuration to get a match Fieldbus init error Error detected in initialization of FieldBus 0 D ON NO es 470 Fieldbus PCP error InterBus PCP length error 471 Fieldbus claim area failed lost one One packet lost message es es SS J N Fieldbus release area timeout Release area command timed out E473 Fieldbus communication buffer alarm Communication buffer full Decrease FieldBus update timer E474 Fieldbus monitor buffer alarm Fieldbus monitor buffer full Turn off FieldBus monitor mode 9836 4841 21 149 235 Digital inputs and outputs E475 Fieldbus PsetID mismatch selector lifted Fieldbus selected Pset does not file the lifted socket socket E480 Channel ID not valid The channel ID configured is not within the limits permitted The ACK channel ID must be configured between 1 and 20 E481 Cell member registration failed The cell member registration failed because one cell member is already registered with the same channel ID E490 Cell ID not valid The cell ID configured is not within the limits permitted The
154. htenings 4 Rundown time 0 03 0 23 Pulse pressure j 0 01 0 01 Delete Delete Measured torque 141 00 46 50 Torque Tuning Factor 0 96 Apply Traces AdvancedSettings 9836 4841 21 33 235 Performing Tool Setup Pressing the Apply button will update the Torque Tuning Factor parameter This is necessary for the system to evaluate how the tightenings should reach the target with the desired speed It is recommended to write in measured torque and press Apply after each representative tightening The Apply button will be greyed out before the first tightening is performed By pressing the Traces button a torque over time graph will appear on the right hand side of the Tool Setup Monitor window This can be closed again by pressing the Hide button located below the graph The Advanced Settings button is used when you want to manually set parameters This may be desirable for particularly difficult joints where the Tool Setup gives poor results You can also use Advanced settings to view the parameters during Tool Setup After changing a value and pressing the Store button the system will no longer calculate new values for the affected control parameters However more tightenings during Tool Setup still contributes to the Torque Tuning calculation Among the parameters shown in this window are the parameters shown in the Control Parameters tab in the Pset window Pressing the OK button will automatically perform an apply and then clo
155. increment Increase the batch counter one step Batch status is depending on Batch status at increment bypass C134 Batch decrement Only works if you run a Job Job restart Restart the running Job All Batch counters are reset and the Job option timers will be restarted Bypass Pset Skip the next Pset in the running Job Batch status is depending on Batch status at increment bypass C134 Abort Job Abort current Job Job status will be Job aborted If Lock at Job done J302 is activated the tool will be locked Job off Disable the JOB mode All Pset can be used manually When active Pulsor Focus do not care about new Job number entries If a Job is running when this input is activated that Job will be aborted and be given status Job NOK Pset toggle Toggle between Psets connected to one socket in a selector Reset relays Resets all Timer and To next tight relays Tracking event relays are not reset Pset select bit 0 6 Pset select input when selecting Pset from digital input Bit 0 set equals Pset 1 bit 0 and bit 1 set equals Pset 3 etc Select next Pset Select higher number Pset Select previous Pset Select lower number Pset Job select bit 0 6 Job select input when selecting Job from digital input Bit 0 set equals Job 1 bit 0 and X X bit 1 set equals Job 3 etc Line control start Input for a position breaker Needed to start a Job with line control Line control alert 1 Input for a position breaker Gives a
156. incremented manually C135 Determines if only the OK tightenings should increment the Batch Counter or if NOK tightenings should increment the counter as well C136 If checked the Batch counter will be reset when storing an edited Pset C139 Determines if non tightening events e g loosenings or batch increments and decrements shall generate results 11 2 4 Reset Select Config System setup Reset Reset Here it is possible to Delete all results or to Delete all results perform a Total reset A total reset will clear all ey Pulsor Focus settings including network configuration The RBU will also be cleared 82 235 9836 4841 21 Config 11 2 5 Settings for printer Select Config System setup Printer setup Printer setup The connected Printer type C160 and Paper size I mientes sal T C161 are set here Continuous print C162 is n a al 7 C162 Continuous print y turned on or off 11 2 6 Settings for configurable memory Configurable memory is described in detail in chapter 21 Configurable memory 11 2 7 Settings for Pulsor tool config Select Pulsor tool config under System setup Pulsor tool config fr m th n 1 ti n ar C190 Work object led function Tool usage v Daa n ES C191 Work object led timeout 300 Ale Select the appropriate options see below for C195 Lock tool on service alarm m details When finished click on Store to save C190 determines the function of the Tool s
157. ings from the Options menu The Settings window has four tabs Communication Information about communication and En a connection Eset Application Settings for displaying information in ToolsTalk Pulsor Printout Printer settings PF List PF list management 9836 4841 21 Working with ToolsTalk Pulsor ToolsTalk Pulsor 3 05 PulsorF Station 1 File Edit Focus Siesta Window Help Selected Controller view Toolbar Settings Change language Get Event Log View Com Messages Forced release progcontrol 49 235 Working with ToolsTalk Pulsor 6 6 1 Settings Communication The Communication sheet has four Se I x sections View event setup LOG Communication Application Printout PulsorF List Serial setup and Ethernet setup LOG e ON Advanced Log file Low txt The View event setup section contains selections for viewing Pulsor Focus M Show controller warning info in ToolsT alk errors and warnings Under Serial setup it is possible to select which Com port to use Serial setup rate can be set to 2400 4800 or 9600 Ethernet setu vw Make sure all connected Portrumber E543 Pul F R tt th ls NetM aster ulsor Focus is set to use the PUTIN Controller IF fio 40 165 68 same baud rate to prevent Pulsor Focus available list 10 40 165 68 6543 Controller y X Canoa changing ToolsTalk setting f ls Controller unnece
158. ion More jobs C191 Work object led timeout More results Sec More events More identifiers C170 Configurable memory Pulsor tool config 2193 Line pressure alarm lower limit More Psets Jobs C194 Line pressure alarm upper limit Memory Configuration Information Hotel Peet and Job data will be erased when changing Memory setup aN To save existing Psets and Jobs use a PC file via function Store PF to file in ToolsT alk Hotel The identifter list wall be truncated not deleted if number of elements i reduced Motel Restart of the Power Focus is required Selection Default configuration F 4000 4000 4000 More results Sono 4000 4000 3500 x Cancel 500 500 500 500 1000 500 500 Identifiers 100 100 100 100 100 400 100 9836 4841 21 140 235 Configurable memory Click Store to save the settings A The changes made in configurable memory setup will reset the Pulsor Focus memory at the next reboot All data will be lost except parameters P address C301 subnet mask C302 and default router C303 gt Reboot of the Pulsor Focus Warning info controller is needed before changes take effect Erenli MEE PET Press OK to accept Eso Reboot needed before changes take effect Before reboot make a store of the previous settings through function Store PF to file See next section 21 2 2 Store Pulsor Focus to file ToolsTalk Pulsor 3 05 wie
159. irst parameter contains the Ch ID number C105 for the job client not responding The second third and fourth parameters are not in use 22 4 2 E156 The first parameter contains the Ch ID number C105 for the lost job client The second third and fourth parameters are not in use 22 4 3 E403 E404 E405 and E406 The first parameter contains I O device ID of the not responding I O device The second third and fourth parameters are not in use 9836 4841 21 151 235 Digital inputs and outputs 22 4 4 E799 If the first parameter contains a value above 256 there are communication problems between tool and controller which might be due to the cable If the value is below 256 the tightenings are difficult to measure possibly due to lack of oil in tool The second parameter if present will show if there is a sensor signal error and what error it is If this event code is frequent in the event log it is recommended to check the cable and the tool The third and fourth parameters are not used 152 235 9836 4841 21 Parameter list 23 Parameter list This chapter specifies the parameters of the Pulsor Focus functionality To get a visual overview of all the parameters for each parameter type click on the Parameter Overview button top left in the current window Clicking on a specific parameter in the displayed overview window is a shortcut way of going directly to that parameter in the programming window It is possible to
160. is below limits and or the operator has released the trigger before tool shut off Flashing red and Both the conditions for flashing red and yellow lights have been met i e there are multiple faults yellow 3 2 Tool Control Box buttons and lights The Tool Control Box TCB features two signal lights and two configurable buttons for easy access to the most used functions The lights are used to inform the operator of the air status of the system Green System ready to perform a tightening tightening in progress Air shut off by system due to some fault Air turned off by system by other reasons e g a situation where the system waits for input from the user and the tool should not be used What function to perform when a button is pressed is configurable The buttons are used as digital inputs to the Pulsor Focus Use ToolsTalk Pulsor to define what these buttons should do as described in chapter 12 Tool The defaults are Green button Tool enable White button Perform air hose test Read more about the air hose test and when it needs to be started manually in chapter 4 1 2 The Air Hose Test 9836 4841 21 21 235 Introducing the Pulsor system s user interface 3 3 Pulsor Focus front panel The front panel of the Pulsor Focus consists of a display indicator lights buttons and a red and white power switch Pulsor Focus front panel Indicator lights Display Buttons Power switch 22 235 9836
161. is possible to activate monitoring of active the current parameter P631 Tightening time min Defines the lower limit for tightening time P632 Tightening time max Checkbox With this setting it is possible to activate monitoring of N active the current parameter 156 235 9836 4841 21 Digital inputs and outputs Parameter Parameter name Description Default setup number P633 Tightening time max Defines the upper limit for tightening time P634 Tightening angle min Checkbox With this setting it is possible to activate monitoring of No active the current parameter P635 Tightening angle min Defines the lower limit for tightening angle io P636 Tightening angle max Checkbox With this setting it is possible to activate monitoring of No active the current parameter P637 Tightening angle max Defines the upper limit for tightening angle iol P640 No of pulses min active Checkbox With this setting it is possible to activate monitoring of No the current parameter P641 No of pulses min Defines the lower limit for number of pulses P642 No of pulses max Checkbox With this setting it is possible to activate monitoring of No active the current parameter P643 No of pulses max Defines the upper limit for number of pulses il P644 Relative shutoff torque Checkbox With this setting it is possible to activate monitoring of Yes min active the current parameter P645 Relative shutoff torque Defines the lower limit the re
162. is will be recognized as a rapid series of air puffs from the TCB ped ek e O 18 235 9836 4841 21 Introduction to Pulsor C 2 3 Install the ToolsTalk Pulsor C software The requirements for using ToolsTalk Pulsor are Hardware A PC with at least 256 Mb RAM The absolute minimum is 64 Mb RAM but this is not recommended Operating system Microsoft Windows 98 or later Proceed as follows to install ToolsTalk Pulsor Insert the installation CD and the installation will start automatically You can also manually start the installation by double clicking the Setup exe file Follow the instructions on the screen Initially you will be granted a 60 day trial license period To use ToolsTalk Pulsor after that you need to register Registration of ToolsTalk Pulsor is preferably done at the web site http www atlascopco com tools software To register you will need the license number you got when purchasing ToolsTalk Pulsor 2 4 Initial connection of ToolsTalk Pulsor ToolsTalk Pulsor can connect to Pulsor Focus either using serial interface RS 232 or USB or using TCP IP over Ethernet Using Ethernet is the preferred alternative since it allows higher speed than the serial interface To use Ethernet the Pulsor Focus must first be given an IP address The IP address Subnet mask and eventual gateway parameters can be set from Pulsor Focus front panel or from ToolsTalk Pulsor C by first connecting using the serial inter
163. itor with information about the latest tightening to the left and a picture associated with the next tightening Pset in the Job to the left 114 235 9836 4841 21 Monitors Last result Next tightening Job None Pset 2 Motor block Selected Pset 2 Motor block Over all status O Deg O Pulsor 0 Station 1 O nxOK Events a Picture monitor is not adjusted for Pset with batch counter Only one picture per Pset is allowed To edit Picture monitoring choose Picture Setup after selecting Picture Monitor The user has the possibility to associate an image file with a Pset Select a Pset from the list Click on Set picture and select an image file using the file selector window To import saved settings for the Picture monitor click on Read from file To save the settings click on Store to file A Save As window will appear and the user can choose where to store the file containing the settings When finished click OK Pset picture setup ioj x Select Fet Default ard batch picture list 1 C TTFPR DOCST pplockMinijpo Set picture Read fror file Delete picture Store to file Y coe 9836 4841 21 115 235 Monitors 16 4 Tracking Results Tracking Results continuously shows the tightening data as they are performed Select Tracking Results under Monitors in the PF Map E E Serial m Ethernet P 10 46 24 224 Y Pset Ca Job F Config Y Tool Control Box Z Diagnostic
164. k from a PC with ToolsTalk software installed All data traffic from Pulsor Focus could also be collected and compiled by ToolsNet PC software from Atlas Copco Via the Cell concept it is possible to arrange all Pulsor Focus units at an assembly station in a Cell The Net concept enables functionality to group all Cells on the assembly line in one Net A Cell consists of one CellMaster and a maximum of 19 CellMembers a total of 20 units Cells can then be grouped into Nets the maximum number of Cells in a Net is 1000 Each Net has a NetMaster One Pulsor Focus unit can function both as CellMaster and NetMaster Every Cell has a Cell identification number Cell ID unique on the network Within a Cell every Pulsor Focus unit has its own unique channel identification number Channel ID CellMaster and CellMembers can be configured through the ToolsTalk Pulsor interface i All Pulsor Focus units in a Cell must have the same software version installed AN When configuring a remote Pulsor Focus make sure it is not in use by anyone else Otherwise it might lead to damages on the tool or a joint It might also lead to personnel injuries 9836 4841 21 125 235 Cell and Net 18 1 Network setup via ToolsTalk Pulsor Open Settings via Options from the menu bar In the Serial setup section select the Com port connected to the Pulsor Focus Settings Communication Application Printout PulsorF List View event setup 7 lob
165. l A warning message will be shown upon leaving Monitoring Setup if this recommendation is not followed See also section 8 2 A tightening and its parameters New limit values for monitoring are calculated for each new Monitoring Setup tightening as are certain statistics on the tightening result Check that the Monitoring Setup tightenings have been done correctly Monitoring Setup Tightening basis statistics Proposed limits Tightening values Tightening parameters i Max Mean Std dev Hin Max Torque Value 47 30 4454 169 430 451 Relative torque 3 amp 83 112 100 Tightening Angle 2 15 9 No of pulses 5 1 Fy 5 Tightening time E O19 004 0 34 f sats Rundown time O20 001 0 23 O18 System parameters Pulse frequency Pulse pressure Bar Ref setup id 7 9 Number of tightenings Delete Delete Delete Delete Target torque Tightening Angle Start _Set reference values Rundown pulse filter KeepPsetLimitsParameter User info ES Y Accept Tightenings where the torque lies outside 15 of the mean value are shown in orange Tightenings with invalid parameter values are shown with for example tightenings with a negative angle or pulse frequency value when less than 3 pulses Min and max values are presented with and proposed limits are set to 1 for that parameter since
166. l in the pulse unit Check oil level according to tool instruction manual product information E198 Start final angle exceeded The first pulses exceeded the start final angle value with more than 20 during tool setup There is a risk that the angle measurement will not be correct 22 3 5 User input events ACK E206 Pset number invalid An attempt was made to do a tightening with the wrong Pset E207 Wrong Pset Select Source Attempt to select Pset from a source not specified in the Cset E208 Not Ok to select new Pset It is not allowed to select new Pset when the already selected Pset is auto selected by Job E211 Wrong Identifier input source Wrong input source for a barcode string WN E237 Strategy Configuration error An attempt has been made to tighten with the wrong tool model for this Pset Use the same tool model that was used during Tool Setup E240 Password incorrect input source The password 1s entered from an invalid source according to the configuration E250 Max time for first tightening run out job This message is displayed and the Job is terminated if the first tightening 1s not performed within the specified time E251 Max time to complete Job run out This message 1s displayed and the Job aborted 1f 1t 1s not completed within the specified time E260 Number of tightenings in Monitoring Setup A Monitoring Setup with fewer tightenings than recommended has ACK below the recommended been performed The recommend
167. l is a general purpose lamp and switchbox replacing the customer specials that are made today Stacklight Stacklight is a flexible light and switch device ToolsNet ToolsNet is a standard software package for server usage This facilitates collection storage and presentation of data from the tightenings that are done by Pulsor Focus along the production line See chapter 19 ToolsNet and chapter 20 Accessories for more information 16 235 9836 4841 21 Connecting and installing the Pulsor C system 2 Connecting and installing the Pulsor C system This chapter will take you through connecting and installing the Pulsor C system The major steps are Make sure that all required hardware and software is included Connect the physical parts of the system Learn about the Pulsor system user interface chapter 3 Introducing the Pulsor system s user interface Install the ToolsTalk Pulsor software on a PC running Microsoft Windows Connect computer to Pulsor Focus by using ToolsTalk Pulsor This step can be skipped if Tool setup will be started from the Pulsor Focus front panel After completing the steps above you can start using the Pulsor system and proceed with the Tool setup It is recommended though to skim through chapters 3 and 4 before starting to use the tool 2 1 Required hardware and software Installation checklist Pulsor Focus unit Power cable TCB Tool Control Box RBU 1 Pulsor cab
168. larm if a Job with line control is not finished Input for a position breaker Gives alarm if a Job with line control is not finished po ranee Line control alert 2 9836 4841 21 181 235 Pulsor Quick Guide Acknowledge an event error message X Fieldbus digin 1 4 These inputs give a direct link to FieldBus Fieldbus digital input numbers must be configured in Pulsor Focus I O expander and in FieldBus Fieldbus mimics the status of a digital input X Flash tool green light Activate the tool green light flashing ca 1 33 Hz Light is on until tightening starts After tightening the tool light indicates status according to result Activating this input at this time will close the status information and start the flashing again During rundown this input shall be ignored Click wrench 1 4 Click wrench number connected to Pulsor Focus ID Card Signal to the Pulsor Focus that an ID Card has been inserted in the Euchner system Reset NOK counter This digital input unlocks if locked and resets the max coherent not ok tightening counter Disable fieldbus carried When this digital input goes high following events occur X X signals Fieldbus communication is disabled Relay fieldbus carried signals disabled goes high In ToolsTalk Pulsor monitoring mode on fieldbus To PF side it is possible to display changes in signals sent to the PF over the FieldBus Note that the signals have no effect on the
169. last Pset at startup 15 x Off PF controlled 1 y m 0 0 Sec Off fon y Last Pset NN Gh Read sg Store Pulsor Focus communicates by both Ethernet and Serial communication links and can work together with ToolsTalk Pulsor and database applications such as ToolsNet etc Parameters such as IP addresses and baud rate are set up 1n this window Select Remote com under Communication in the navigation area Enter appropriate values ask the network administrator at your site if unsure what values to use Click on Store to save Restart Pulsor Focus using the power switch on the front panel it must be switched off for at least 10 seconds 2 Config PulsorF Station 1 Parameter Overview System setup 140 setup Communication Advanced A Serial ports setup Protocols C301 IP address C302 Subnet mask C303 Default router A NI ps 04 Netmaster TP address C305 Cellmaster IP address C306 Jobreference IP address Advanced com C310 Cell keep alive Serial ports setup C320 Serial 1 baudrate C321 Serial 1 protocol C322 Serial 2 baudrate X Close C301 C303 are required when communicating using Ethernet C304 C305 and C310 are explained in chapter 18 Cell and Net C306 is the IP address of the Job reference This can only be set if the Pulsor Focus is part of a cell 1 e C304 must have been set before
170. lation threshold Mostly used with prevailing torque joints e g Nyloc nuts Expressed in of target torque P682 Torque tuning factor The current torque tuning factor May be modified through the Torque Tuning Yes Adjustment function P684 Air shutoff time The air shutoff time from the Air Hose Test performed just before Tool Setup P685 Max available The max available pressure from the Air Hose Test performed just before Tool No pressure Setup P686 Extrapolation When a pulse reaches this torque level the system starts to determine when to Yes shutoff threshold shut off the air pressure Expressed in of target torque 9836 4841 21 157 235 Digital inputs and outputs P687 Tool setup The number of tightenings performed during Tool Setup not including deleted No tightening count tightenings Yes P688 New measured The measured torque value written in when performing a Torque Tuning torque Adjustment The parameter is set in the Torque Tuning Adjustment window P689 Tool Setup torque The Torque Tuning Factor generated during Tool Setup No tuning factor P78x Control Parameters Parameter Parameter name Description Editable number P785 The mean value of the manually measured torques during Tool Setup 158 235 9836 4841 21 Digital inputs and outputs 23 2 Job 23 2 1 J1xx Setup J10x Admin Parameter Parameter name Description Default setup number J102 Name job The name of the Job helps t
171. lative shutoff torque Connected to Lo min P112 P646 Relative shutoff torque Checkbox With this setting it is possible to activate monitoring of Yes max active the current parameter P647 Relative shutoff torque Defines the upper limit the relative shutoff torque Connected to MI max P114 P648 Trigger lost Determines 1f monitoring of machine shutoff shall be active If the Yes tool trigger 1s released before the machine shuts off when this parameter 1s active the tightening will not be approved and an event code will be displayed P649 Target torque value Target torque in user units to be used in the tightening application This value corresponds to 100 Relative torque P650 Keep Pset torque limits Checkbox With this setting the Pset torque monitoring limits will be No kept even if a new Monitoring setup is performed P66x P68x Control Parameters Parameter Parameter name Description Editable number P660 Pset pressure For the Control strategy this is the air pressure supplied to the tool before tightening For the Pulsor Fixed strategy this pressure is used throughout the whole tightening Yes P664 The air pressure when performing a loosening Yes Yes O O O P680 Tool model used The tool model used when performing Tool Setup P681 Tool Setup The date and time when the Tool Setup was started performed N N P676 Torque pulse Below this threshold a pulse is not counted as strong enough to start regu
172. lculated automatically or entered manually P582 Line pressure range The lower control limit for range LCL Calculated automatically or entered manually P583 Line pressure range The upper control limit for range UCL Calculated automatically or entered manually P584 Line pressure X bar The desired value for calculated mean values for groups of bar tightenings P585 ine pressure range bar The desired value for calculated mean ranges for groups of tightenings P586 SPC alarm Line With this parameter it is possible to switch off the current SPC alarm Off pressure function 23 1 4 P6xx Programming P60x Monitoring setup P61x Tightening options Parameter Parameter name Description Default setup number P611 Tightening angle start Angle is measured from this threshold torque 50 of target P612 Rundown pulse filter Defines if pulses during rundown phase shall be filtered away when Yes active calculating tightening results P62x P64x Monitoring parameters Parameter Parameter name Description Default setup number P620 Rundown time min Checkbox With this setting it is possible to activate monitoring of active the current parameter P621 Defines the lower limit for rundown time P622 Rundown time max Checkbox With this setting it is possible to activate monitoring of No active the current parameter O P623 Defines the upper limit for rundown time P630 Tightening time min Checkbox With this setting it
173. lded copper cable composed of one twisted pair and two cables for the external power supply The baud rate can be changed between 125k 250k and 500kbit s This can be done in two different ways The first is simply by using the DIP switch second is via SW configuration There are several different DeviceNet Scanners available on the market both for PLC systems and for PCs 30 6 1 DeviceNet for Pulsor Focus DeviceNet module Connection modes supported Polled I O Use same as in PLC Bit strobe I O Change of status cyclic I O Baud rate 125kbit sec Default 250kbit sec 500kbit sec Data to PF length 0 122 bytes Must be the same in PF and PLC The data string is in PF limited to 122 bytes DeviceNet standard allows 255 bytes Data from PF length 0 122 bytes Must be the same in PF and PLC The data string is in PF limited to 122 bytes DeviceNet standard allows 255 bytes Configuration In a DeviceNet network each node has a Mac ID the address in the network The Mac ID is a number between 0 and 63 Each node s Mac ID has to be unique since it is used to identify the node In a DeviceNet network you can also set baud rate with the following baud rates being available 125 250 and 500 kbit sec All nodes in the network have to communicate at the same baud rate On the Pulsor Focus DeviceNet module it is possible to set the Mac ID and baud rate using DIP switches mounted on the module or from SW using ToolsTalk Dip 1 and
174. le Pulsor Focus to Tool Control Box Pulsor cable Tool Control Box to tool Pulsor C Tool ToolsTalk Pulsor Software Recommended Air hose for connection TCB tool Use air nipple supplied with TCB for the TCB side of the hose 9836 4841 21 17 235 Connecting and installing the Pulsor C system 2 2 Connect the physical parts of the system Wall Lock L e SN Pulsor Focus Before performing step 9 below make sure the Tool Control Box is fit with the correct air sockets A socket that is locked when no air hose is connected i e a female socket must be used for the Tool Control Box air outlet to the tool If possible use the ErgoQic fitting already mounted on delivery For more information concerning air quality air lubrication etc please refer to the Product Instructions for the Tool Control Box Open the lock mechanism and open the Pulsor Focus by pulling the upper part towards you Connect the TCB cable power cable Ethernet Serial cable etc Connect the RBU Check the ground fault cirquit interrupter 1s switched on Close the Pulsor Focus and lock it Connect the power cable to a power supply Connect the TCB cable to the TCB Connect the TCB to the tool using the tool cable ee ot ee ee Se Connect air hose from your air system to the TCB Connect the tool and TCB with air hose Turn on the power on the TCB After approximately 30s an air hose test will be performed automatically Th
175. lsor CD is inserted in the CD DVD drive On 7 a looking on your computer on the hardware installation CD or on Windows XP click No not this time in the first popup window he Windows Update Web ste vih your permission P ead our privacy policy and then click Next Can Windows connect to Windows Update to search for software O Yes this time only Click Next to continue Click Install from a list or specific location Advanced and then HH click Next This wizard helps you install software for EV4L232 Board USB lt gt Serial If your hardware came with an installation CD lt 6 or floppy disk insert it now What do you want the wizard to do O Install the software automatically Recommended tall from a list or specific location Advanced Click Next to continue 9836 4841 21 41 235 Working with ToolsTalk Pulsor Click Search for the best drivers in these locations Click Browse to find the driver location on the ToolsTalk Pulsor CD When the driver folder has been selected click Next If a warning window about unsigned software appears click Continue anyway and then click Finish The above procedure has to be finished twice before the USB port can be used The new serial interface will be given the name ComN where N is the first available com port on your computer The next time a Pulsor Focus is connected to this computer it will automatically be detected If uncertain of which com po
176. lsor Focus display C120 will select the language used for printouts from the printer port See also section 11 2 5 Settings for print C121 will select presentation unit for torque measurements C124 if checked the keys on the Pulsor Focus front panel will be enabled otherwise disabled C128 the air pressure units displayed in the system for pressure parameters Valid units bar PSI kpond cm and kPa 9836 4841 21 81 235 Config 11 2 3 Settings for Options The batch count settings can be found under Options Select Options under System setup from the a Options navigation area C130 Lock on reject pf Select the appropriate options see below for C131 Disable loosening at OK E details C132 Reset batch at Pset change iw When finished click Store to save C133 Dec batch at OF loosening E C134 Batch status at increment bypass MORE hd C135 Increase batch at tightening OK bal C136 Reset batch at Pzet store y C139 Result of non tightenings wt C130 Used to shut off the air supply to the tool after a NOK tightening C131 Used to shut off the air supply to the tool when a loosening 1s started after an OK tightening C132 If active Batch Counter will be reset when changing Pset C133 For all Psets with Batch Counting activated performing a loosening will decrement the Batch Count C134 This parameter determines whether the batch 1s to be considered OK or NOK when a tightening 1s bypassed or Batch Counter is
177. lsor Focus front panel for information on how to use the Pulsor Focus display to make a Tool Setup and Monitoring Setup respectively Pressing the Question Mark button will display the following information press repeatedly to step through list RBU License level rbu toggle with RBU type PuAu for Gold RBU Software version rEL with version number roll on the display from right to left Tool model name The tool model name rolls on the display from right to left Current Pset Pset alternates with the current Pset ID e g P2 Current Job Job alternates with the current Job ID e g J3 The Enter button is used to execute selected functions and for event acknowledgement 3 4 ToolsTalk Pulsor ToolsTalk Pulsor is a Microsoft Windows application that lets you configure your system in detail and simplifies setup of the system Many parameters are not available from the Pulsor Focus front panel but only from ToolsTalk Pulsor An introduction can be found in chapter 6 2 to 6 5 If you have used ToolsTalk Pulsor before you can skip reading these chapters 9836 4841 21 25 235 Tool Control Box and tool introduction 4 Tool Control Box and tool introduction The Pulsor C pulse tool comes in a number of different sizes and models The Pulsor Focus and Tool Control Box used are the same for all tool sizes 4 1 The Tool Control Box The Tool Control Box TCB is responsible for suppl
178. m low The latest average relative torque deviation value is below the active Tool drift alarm limit RT Tool Drift alarm high The latest average relative torque deviation value is above the active Tool drift alarm limit Line pressure out of limits Active if the latest measured line pressure was outside stipulated limits Pulsor Tool Enabled This relay is active as long as the Pulsor Focus wants the air supply to the tool enabled Open protocol commands Set when the Open Protocol commands disable is activated In this case all disabled commands that Pulsor will receive from Open Protocol are disabled External controlled relays Set when External monitored inputs 1 8 are enabled 1 8 184 235 Duration it 9836 4841 21 Connector descriptions 28 Connector descriptions 28 1 Printer Connector 25 pin DSUB female Function Parallel printer Electrical data Normal TTL levels High level signal 1 Outputs High gt 2 4 V Low lt 0 4 V Inputs High gt 2 0 V Low lt 0 8 V Function Function Pin Function 6 Danona 1s er 24 Groma fx Danone 17 seam o paonr is Goma O OO 28 2 Serial RS232 1 Connector 9 pin DSUB female Function RS232 serial Fin ren Digln Not used i p 9 Die out Nor usea 9836 4841 21 185 235 Connector descriptions 28 3 Serial RS232 2 Connector 9 pin DSUB female Function RS232 serial connection Use crossover cable to connect to PC Fin unci
179. me time C32x Serial ports setup C320 Serial 1 baud rate Options 9600 A a a C321 Serial 1 protocol T ASCII C322 Serial 2 baud rate Options 9600 bit s ORME aon seno 19 20 57 520 23 3 4 C4xx Protocols C40x ToolsTalk setup Parameter Parameter name Description Default setup number C400 Port Port number for ToolsTalk Ethernet communication ee Do not use port number 6543 default value when the y same IP address is shared between several Pulsor Focus units C41x ToolsNet setup A ToolsNet database registers and stores the results from tightenings traces data and history Each Pulsor Focus unit can store information from approximately 4000 tightenings But the capacity in the ToolsNet database is in principle unlimited The information can be mapped against the Pulsor Focus object or VIN number as desired Parameter Parameter name Description Default number setup C410 ToolsNet on On Off Result after each tightening is recorded in ToolsNet C411 IP address IP address for ToolsNet Only valid if ToolsNet on C410 is activated C412 Port number for ToolsNet communication GD Port 6570 is not to ToolsNet but to the PIM server which connects Pulsor Focus unit to ToolsNet C42x Multicast setup Parameter Parameter Description Default number name or C420 Multicast on On Off Multicast function Only valid if Multicast on C420 is activated C421 Multicast IP It is possible to set this IP addres
180. meter Parameter name Description Default setup number Display Selects result parameter to be displayed Final torque Available options Off Relative torque Tightening angle Number of pulses Tightening time Rundown time Remaining in batch Completed in batch Selected Pset Final torque Target torque C115 Toggle display Selects result parameter to be toggled on display with chosen parameter Off above see the options in C114 You can also choose to have toggling inactive C12x Display setup 2 Parameter Parameter name Description Default setup number C120 Select language for printout English C121 PF Tq presentation Select which unit to use for torque presentation both on PF display and Ibf ft unit in ToolsTalk C124 Soft keys enabled Here you connect and disconnect the menu selection buttons On the Yes Pulsor Focus the functions Monitoring Setup plus and minus button will be affected C128 Air Pressure Select unit for showing air pressure Available options PSI Presentation Unit bar PSI kPond cm kPa 162 235 9836 4841 21 Digital inputs and outputs C13x Options Parameter Parameter name Description Default setup number C130 Allows the air to be shut off whenever a non approved tightening has been done C131 Disable loosening Yes No No at OK When activated the Tool Control Box box will shut off the air if trying to loosen after an OK tightening If batch count is used the
181. meter description see Parameter list section 23 1 Pset Show Pset window either by double clicking the Pset in the PF Map in ToolsTalk Pulsor or by O selecting the function from the toolbar 7 1 Activating Pset To be able to use a Pset 1t must be activated Select the required Pset in the Selection panel in t ToolsTalk Pulsor 305 FEA File Edit Focus Options Window Help ToolsTalk Pulsor a prerequisite is that Pset select ssected Cortroler H Staion z Running 21 P 1 Gear box source 1s set at Ethernet Serial see section 11 3 3 i Le ON UMM 2 Other I O s settings ae s oh a Y 0 CERATI rem hl 10 x 9 P 1 Gear box nonet 7 2 Programming 7 2 1 Strategies Here you can view edit the tightening strategy used The strategy is normally selected during Tool Setup An exception from this is the Click Wrench strategy which does not use a Tool Setup Note that if you change from one strategy to another it is important to perform a new Tool Setup before using the Pset Parameters calculated for one strategy is not reusable for the other 7 2 2 Batch count of tightenings Pulsor has a function for batch counting of tightenings Batch size indicates the number of tightenings that shall be done in a batch Batch counting is either taken from the Pset or can be set from Ethernet Serial or Fieldbus In the example below the count is taken from the Pset 9836 4841 21 57 235 P
182. munication Specify an IP address that is similar to but not identical to the one allocated to the PC such as 192 168 1 10 With the subnet mask above the three first numbers should be equal Specify a Subnet mask as above 1 e 255 255 255 0 DO NOT specify a default router gateway If there is one already delete it You should see 0 0 0 0 Click on Store to save ToolsTalk Pulsor displays a message that Pulsor Focus should be rebooted Connecting Close the ToolsTalk Pulsor connection and reboot the PC if necessary Switch off Pulsor Focus wait at least 10 seconds and then switch it on again Connect ToolsTalk Pulsor to Pulsor Focus via the Ethernet it may be necessary to enter your new connection to the PF list this is done in Settings under the Options menu 56 235 9836 4841 21 Pset and batch count 7 Pset and batch count All Pulsor tightenings are performed in the context of a Pset Parameter set The Pset contains the set of parameters that controls and monitors the tightening process including the result of Tool and Monitoring Setup This chapter introduces basic tasks of creating and activating a Pset and also describes how to enable batch counting of tightenings For a description on Pset programming Tool Setup Monitoring Setup Tightening options and Monitoring see chapter 5 Performing Tool Setup 9 Performing a Monitoring Setup and 8 Tightening and monitoring respectively For para
183. n all cables are connected place a termination in the empty connectors I O Bus connectors 1 and 2 are fully parallel and can be used in any combination If nothing is connected to the I O Bus there is no need for terminations CIT CTN 9 8 V iso for I O Bus only Selector Tanmination a Cibi VO bus termination in empty ports 28 10 I O Bus 2 Connector 9 pin DSUB male Function To connect Atlas Copco I O Bus accessories Parallel with I O Bus connector 1 28 11 Mains power connector Connector EC320 Electrical data Input voltage 90 120 VAC 200 240 VAC 50 60 Hz Auto select of voltage input span 190 235 9836 4841 21 Pulsor Quick Guide 29 Pulsor Quick Guide 29 1 Introduction The Quick guide is provided as a separate document The purpose of the guide is to clarify the minimum that needs to be done in order to get started with the system and give some additional information regarding common tasks Basic information not shown in the Quick guide can be found below The tool will automatically be shut off by the system when a given target criteria has been reached By performing a Tool Setup for a given Pset you can set the target torque and preferred speed of the tightening for that Pset The higher the tightening speed the higher the torque scatter A Tool Setup must be performed before the tool can be used to perform any tightenings The tool setup should be done on the
184. n the tool drift alarm P1 or ol created evaluation Psets D902 Sample size Determines the number of tightenings that shall be used when calculating the running mean value in the tool drift alarm evaluation D903 Tightenings to be included Determines if all tightenings shall be included or only All approved tightenings D904 Tool Drift alarm updated Time stamp for latest update of tool drift alarm general parameters D91x Tool drift alarm limits Parameter Parameter Name Description Default setup Number ae torque deviation Lower Checkbox With this parameter it is possible to switch off e active tool drift alarm indication for this parameter D911 Average torque deviation Lower The lower limit for average torque deviation limit Calculated automatically or entered manually Average torque deviation Upper Checkbox With this parameter it is possible to switch off limit active tool drift alarm indication for this parameter D913 Average torque deviation Upper The upper limit for average torque deviation limit Calculated automatically or entered manually Pulse oe Lower limit Checkbox With this parameter it is possible to switch off oe tool drift alarm indication for this parameter ee a Calculated automatically or leed manually Checkbox With this parameter it is possible to switch off active tool drift alarm indication for this parameter Calculated automatically or entered manually D93x Air sensor tuning
185. n will also be enabled C105 is the channel number for this unit when it is a part of a cell C106 is the name of this Pulsor Focus unit C107 C108 When this Pulsor Focus unit is a Cell Master the Cell name and Cell number should be entered here The date and time of the unit can be set using the Set date and time It is important that the unit has correct date and time settings otherwise the results is stamped with wrong time data 11 2 2 Display and toggle display Display and Toggle display determine what is shown on the Pulsor Focus front panel after each tightening Select Display setup 1 or 2 under System setup from the navigation area C114 Display Final torque A Select the appropriate options see below for details E llS Toggle display El Display setup 2 C120 Language English Click Store to save C121 FF Tq presentation unit Hm al C124 Soft keys enabled rj C128 Ar Pressure Presentation Unit bar g C114 is used to select what result parameter is to be shown on the display of the Pulsor Focus unit Parameter Display Relative torque 123 P Number of pulses n12 Tightening time s t6 47 Rundown time s r0 59 80 235 9836 4841 21 Config Completed in batch 01 05 Remaining in batch 04 05 Selected Pset Pl Final torque 92 1 Final angle 123 Target torque 25 00 C115 is used to optionally display a second result parameter The first and second parameters will then toggle on the Pu
186. nabled ToolsNet gives the user access to reports on shifts production lines individual vehicles or controller units for process improvement aan AA The stand alone version of ToolsNet includes the following Collection of tightening data and storage in a standard database ORACLE or MS SQL Server Each Pulsor Focus can store information from a limited number of tightenings around 4000 depending on memory configuration but the capacity in the ToolsNet database is in principle unlimited The information can be mapped against Pulsor Focus object or VIN number as required Web based report interface with standard reports and statistical information Process improvement through extensive statistical functions for process control Itis possible to save each individual tightening made with a connected Pulsor Focus unit Overall status torque status and angle status can be seen for all Pulsor Focus tightenings GS Torque values will only be reported to ToolsNet if a valid torque tuning has been made during Tool Setup This means that manually measured torque values must have been written in Note that the torque presented is dependent on this torque tuning and results are therefore not measurement traceable However they are process traceable 9836 4841 21 129 235 ToolsNet 19 2 Enabling the Pulsor system for ToolsNet This section gives a step by step instruction on how to enable reporting from the Pulsor system to
187. ned 10 x Parameter Overview FEED Peet pressure 44 02 PSI E Programming E Control Parameters BES Pressure Control PE76 Torque pulse threshold Pulse Control at 3 Pulse Control System Control 3 System Control FESE Extrapolation shutoff threshold so H Pet setup Statistic programming at Ds Perform Tool Setup Perform Monitoring Setup ose ampare ndo Lompare ea tore Cl E Urda E Read 5 P660 will affect rundown and tightening speed and should be set so that the torque installed by the first pulse is sensible P676 Torque Pulse Threshold expressed as a percentage of the target torque At time of print this parameter do not affect the tightening or tightetning results P686 Extrapolation Shutoff Threshold expressed as a percentage of the target torque The system waits until the torque has reached this level until torque extrapolation is activated When extrapolation is active the system will estimate the following pulse torques and shut off the air when the estimated values of the coming pulses exceeds the target torque This parameter should normally be around 90 but may be lowered if using hard joints combined with long air hoses Values lower than 70 is not recommended 58 235 9836 4841 21 Pset and batch count 7 4 Pset administration In Pset administration you will be presented with five options Name Pset View existing Pset Create new Pset Copy Pset and Delete Pset When creating a ne
188. ngs Store Cancel In the Tool Setup Monitor all tightenings performed during Tool Setup will be shown The tightenings you perform and the measured torque values you enter in this window will help the system determine how to reach the target at the desired speed During Tool Setup the End Time the time between air shutoff to air on after a tightening is set to a fixed value of one second The high time delay is used to help the operator to perform correct Tool Setup tightenings The parameter is reset to previous value after the Tool Setup If using Pulsor Angle Shutoff strategy StartFinalAngle and TargetAngle will be shown in the topmost left corner instead of Target Torque 5 4 1 Description of buttons in Tool Setup Monitor See picture in table below for button positions When you enter Tool Setup Monitor it is shown in Standard view mode Pressing the Detailed view button toggles between Standard view and Detailed view The button text changes accordingly The view mode determines how many tightening parameters are shown Tool setup monitor System is in learning mode Perform tightenings until the result is satisfactory or use Advanced settings if necessary To modify speed settings press Cancel Target Torque 45 00 Nm Standard view Tightening Parameters Tool Setup Tightening Result Torque value 42 80 45 70 Tightening angle 22 15 No of Pulses 8 6 Tool Torque Value 42 80 45 70 Torque Tuning Factor 1 00 0 96 No of Tig
189. nnel is not supported the maximum input and output is 20 Bytes in and 20 Bytes out 30 7 1 InterBus for Pulsor Focus Physical interface Shielded copper cable Three Twisted pair Isolation The bus is galvanically separated from the other electronics with two DC DC Converters Bus signals are isolated via opto couplers ASICs and circuits Module is based on SUPI 3 and SRE1 chip from Phoenix Contact 214 235 9836 4841 21 FieldBus configuration appendix InterBus module Number of nodes in an InterBus network Process string length lt 20 bytes Parameter string length send with PCP 122 byte Process string length The string length in the Pulsor Focus is limited to 122 bytes InterBus standard allows 512 bytes PCP length 0 1 2 4 Words Parameter data index 0x6000 R W I 1 0 1 0x6040 RO I 1 0 1 ID code in PLC side PCP 0 3 PCP 1 0xF3 PCP 2 OxF0 PCP 4 OxF1 Hardware LED 1 RBDA LED 2 TR LED 3 CC LED 4 BA BUS IN 9 pin Dsub male Fn Name e mo e iosa 9 iosa 9836 4841 21 215 235 FieldBus configuration appendix BUS OUT 9 pin Dsub female COIN DO2 DR Housing GND GND e o C Noted oo es G 5 Always connect RBST to GND if it is not the last module on the bus If the RBST is not l connected to GND on the output connector the Pulsor Focus InterBus module will terminate the outgoing bus Functionality of the indicator
190. nonenanennnos 83 11 2 7 Settings for Pulsor tool CON IO ccoooccccnncccccoconnnccnnnncnonnonnncnnnnnononnnnnnnnnnonononanenonos 83 11 2 8 Settings for Tool lock functionality cccccccococcnnnconnncccconononccnnnnonnnnnnnnnnnnnnnononans 83 ANP o 85 Mee A as ebedee yee te hieateatosnas alee cactusuteeee ee 85 32 ElemaN Odev Ce S eco dolia 86 io Other VO S SEUS a e a e ee ea 86 ISA PSCUSECIECT SOURCE an ee eee tee Mee te ete eee 87 A124 COMMUNI Call Ol eiainttietatusd restates ateeauapt a 87 Ms iaeetia tai ohae sean ed eration aes ae keaton teed data aad aa 88 12 Tool Control BOX iio 89 121 TOOLlCONOKBOX SENIN Suecia 89 12 2 DIAGNOSE AGCESSOMNES iaa a cada 90 12 2 1 Diagnose Accessories Tool Control BOX cccccccccoonnccnnncccconononccnnnnconnnancnnnnnnnnonnnans 90 13 DIAGNOSUCS and SCEVICC sioscisstecseccsncostdescenteacs aca AAA anaidia 91 13 1 Tool general information and Pulsor tool info occccooccccnnnncncnncnnnnonannnnnnnnonanonos 91 13 2 Tool Service a d SEriCe INGICAIOl daria 92 33 TOMTOM E tna Ae aa nian 93 13 31 A A r A Ea AaS 93 13 3 2 Enabling Tool drift alarM ooonncccnonnnnnccnnnncoconnnnnnonnononnannnnononcnnnnnnnnonnancnnnnnnrannnnas 93 13 3 3 Restarting Tool Drift alarM ooonncccnnnnnnncconnnncconnnnonnnnnncnnannnnononcnnononnncnnancnnonancnnnnnos 94 13 3 4 Tool drift alarm SUPervisSiON occoooncnccconnncononnncononennnnnncnnoonanoncon
191. nononnnnnnnnonnnonononnncnnnnonons 150 22 39 00 A i vee E E E EES a 150 22 011 SSOMWALS GVCIAIS ad dada 150 220 12 EVES MMS OOO iio limda debater eatede 151 22 4 Sub information for event codes occccoccccccncccoccnccncnconcnononnnonncnonnnnnoncnononnnnnnnnnnncnnnnons 151 224A EIO ctsiesehctei seis Suisctees a a a 151 2242 Eo cil poniadielsiatoisoib eiii 151 22 4 3 E408 E404 E405 and E4Ob occccccccccconnnonconccnnononnnnnnnnnnnononnnnnnnnnnnnnncnnnnnnnnnnnnnnnnnnns 151 224A E799 A 152 23 ParaAMElEr IS pie 153 23 PSeLpa amete S ad E A abi ient ate 153 ZS Nell POCO ANIA iea a a E 153 Za Wee PAXP SCL SUD loas 154 2 PSOCSTAUSHC oO AMM ui det 155 231 4 POX Programing tara clic G 156 76 SPER O 159 ac ASD SS UID AAA Penn savant a a ates inne hamtieea ae samenene 159 2922 IRONMAN ee doit 159 2 ONO tio 162 233 1 GIS SYSICM Sel a a diia 162 2332 C2 IA dictate r ees bateraiee uaneaeeatet oeseaitee 164 23 30 GSN COMMUNICA UCI a AAA acca 165 233A CAPOC esse stirs eect ato cs cet See ee eee 166 23 A DIANO SUCS aiii iia 167 23 41 DIX WOOL conig rati r a 167 23 42 DeaocGontroller diagnostics sean iio dd lata dale ace aides 168 23 4 3 D3xx System diagnostics ccccccccoonnnnccnnnccnononannccnnnnnnnonnnccnnnnononnnnancrnnnnnnnnnnnanrrnnnnns 168 23 4 4 D9xx Tool Drift alarM occcoonnccccnnncncoconcnnconnnnconanonnnnoncnnonnncnnnonancnnnnnnrnnonnnrnnnnanennss 169 230 ION IM a dolina 170 23 91 TIX sE erea o
192. nt J312 Decrement batch at OK Decrement batch at OK loosening makes it possible to redo the latest loosening made tightening increment in a job The batch counter of the Pset or multistage is decreased with one step It is not possible to go back one step after the job has been completed If batch counter type is set to OK and last tightening was a NOK tightening an OK loosening will not decrease the batch counter J32x Timers Parameter Parameter name Description Default number setup J320 Max time to start job This parameter defines time limit from the Job is running to the first tightening is started or Batch increment bypass is performed If the time limit is exceeded the Job will be aborted The timer restarts if a Job is reselected Allowed values are between 1 9999 seconds Value 0 seconds 160 235 9836 4841 21 Digital inputs and outputs Parameter Parameter name Description Default number setup J321 Max time to complete This parameter defines time limit from Job is up running to the last job J322 Display result at auto select J33x Line control tightening in the Job is started If the time limit is exceeded the Job will be aborted Allowed values are between 1 9999 seconds Value 0 seconds deactivates this function This parameter is a timer for Jobs with auto selected Psets It defines the time for tightening result to be displayed on a Pulsor Focus controller The result disap
193. ntinue the selected job Max coherent Not OK tightenings NOK s Max coherent Not OK tightenings NOK s are a selectable possible number of Not OK tightenings for each Pset in a job This function 1s also available for each single Pset see parameter max coherent NOK s P153 The tool will be locked for both tightening and loosening when number of possible not OK tightenings is reached for each batch When the tool 1s locked due to possible not OK tightenings the only ways to unlock the tool are Reset counter for performed not OK tightening via a digital input Select abort job in case the selected job shall not lock the tool Select job off 9836 4841 21 159 235 Digital inputs and outputs Parameter Parameter name Description Default number setup J301 Job order type A Job must be defined as Forced order Job Free order Job or Free and Forced Forced order Job Free order Offers the operator to perform Psets in any order The JobMembers work independently from each other In a CellJob with free order all JobMembers are able to perform tightenings at the same time Forced order Psets must be performed in the order specified in the Job list One JobMember at a time performs a tightening while the other JobMembers are locked Free and forced order Offers the operator to perform Psets in the same Pulsor Focus channel as the order defined Job but the operator is free to perform tightening from any channel in the Job N
194. o calculate 16 5 Getall results This displays result information from all tightenings stored in the Pulsor Focus memory Start the function by selecting Get All Results from the Selection panel in ToolsTalk Pulsor The information can be exported to a file such as a Microsoft Excel sheet The result information in Excel can easily be sorted with the help of Excel filters for example the auto filter To give an example all rejected tightenings can be filtered You can then see easily what happens when something has gone wrong and thereby understand what measures can further refine the process 116 235 9836 4841 21 Monitors Pulsor Focus can store up to 4000 tightening results Each tightening result consists of 30 result parameters Retrieve and view these with the Get all results option The user also has the choice of saving results to a text file or an Excel file When the Get All Results option is chosen the window below appears Select Pset E xj Select one or more Pset s Gear box Station 1 Station 1 Station 1 x Cancel Simply choose a specific Pset and click OK The results from that Pset is then shown in the following window PF DataBase Results Pset 8 Gear box Total Nr OF Results Hr OF Results With Machine Shutoff g7 g4 i Results ji Display only results with machine shutoff r OK le2 19 3 OK is OK T 18 2 OK OK 57 18 4 OK OK T 182 OK Save To File Open In Excel
195. o clear both configurations S When changing RBU type it is possible to load the configuration from the RBU but not from the PF Press the plus or minus button on the Pulsor Focus unit to toggle between the selections Confirm selection with the Enter button 9836 4841 21 175 235 Digital inputs and outputs The table describes the selections available and how to choose configuration If the Pulsor Focus and RBU are incompatible for other reasons than a configuration mismatch e g they have an older software version either the Pulsor Focus unit or the RBU is considered as NOK Pulsor Focus and RBU No message No action Normal start up matches Pulsor Focus and RBU Clear RBU PF Select PF for Pulsor Focus configuration RBU for RBU configuration or don t match Clear All to clear Pulsor Focus and RBU memories Pulsor Focus OK PF Clear Stop Select PF for Pulsor Focus configuration Clear All to clear Pulsor RBU NOK Focus and RBU memories Otherwise select Stop Pulsor Focus NOK RBU Clear Stop Select RBU for RBU configuration Clear All to clear Pulsor Focus and RBU OK RBU memories Otherwise select Stop Pulsor Focus NOK Clear Stop Select Clear All to clear Pulsor Focus and RBU memories Otherwise RBU NOK select Stop Changing RBU will clear the tightening result database G Selecting Stop will only prevent the result database from being erased if the RBU has been changed within the same
196. ob select source C221 and Job select source override C227 To be able to select a Job at least one of the two parameters has to be set Job select source override C227 has a higher priority than Job select source C221 76 235 9836 4841 21 Job Ifa Job is chosen from Job select source C221 then it is possible to select a new Job from the same source or from Job select source override C227 Ifa Job is chosen from Job select source override C227 then it is only possible to select a new Job from the same source a The system will remember the most recently selected source until the Job either is completed or aborted 10 3 1 Running Jobs using ToolsTalk Pulsor In ToolsTalk Pulsor select Job to run from the combo box in the selection row Running Job ee none To run the Job from ToolsTalk Pulsor set parameter C221 Job select source to Ethernet Serial in Config window Other I O s 1 tab In ToolsTalk Pulsor click on the arrow to the right of the Monitor icon Monitors and select Job Monitor Alternatively double click Job Monitor from rif the PF Map as shown to the right EE Job Monitor displays the selected Job and provides functionality for Job management l ojx Job1 Motor block OrderForced status running A PF 1 PF 1 PF 1 P21 Auto P Auto P Auto 1 Batch 01 x Close Job off Restart Job Decrement Increment Bypass Peet d For description
197. of Job off Restart Job Decrement Increment Bypass Pset and Abort Job see next section Functions in Job monitor 10 3 2 Functions in Job monitor Restart Job This function allows the user to restart the running Job without needing to reselect the Job All batch counters in the running Job resets and Job timers restarts Decrement Batch Decrement makes it possible to redo the latest tightening increment in a Job The batch counter of the Pset is decreased with one step It is not possible to go back one step after Job has been completed If using Job reference Job Batch Decrement functionality is only reachable from the JobReference In Job with Free Order only the JobClient with the active Pset is able to use Batch Increment In Job with Forced Order the JobClient with the active Pset and the JobReference are able to use Batch Increment Increment Batch Increment allows skipping the batch counter value of a Pset without performing a tightening It is allowed to complete a Job by using the Batch Increment function The Job Status will be NOK Not OK in case of Batch status at increment bypass J311 is selected as NOK Otherwise the Job Status will be OK If using Job Reference 9836 4841 21 77 235 Job Abort Job Job off Job status information Bypass skips a specific Pset in a running Job independently of batch size The batch counter will be set equal to the batch size value and the Pset will be considered as
198. of the programmed min limits High The result is above any of the programmed max limits o o oe Job NOK Job is done but the status of the Job is not OK because of not OK tightening batch increment or bypass Pset Job running A Job is selected In case a Job with line control is selected even the line pf control start signal is not received this relay will be on Job Off Active when in Job off mode Pf XK PF ready Pulsor Focus controller is healthy No errors that needs to be X acknowledged AAA PEEP AA pe PET EE EET frane Pulsor Focus is ready to do tightenings A Valid Job and or Pset is selected The tool will start when the trigger is pressed Tool start switch Relay that follows the tool start input Follow the configured Tool start select source C220 Tool tightening Tool tightening in progress Tool loosening Tool loosening in progress Tool running The tool is running Stat alarm Follows the stat indicator on the Pulsor Focus front Active when some of the selected statistic limits or trend is outside of the approved limits Tool ready Tool locked lt gt This relay is present for Power Focus compatibility use Pulsor Tool Enabled instead Is active whenever the Pulsor Focus wants to disable the tool Tool locked is the inverse of Pulsor Tool Enabled Running Pset bit 0 6 Shows selected Pset Running Job bit 0 6 Shows selected Job 9836 4841 21 Ao 00
199. ol setup Pulsor C features an easy to use Tool Setup to help you get ready to use the system as quickly as possible By performing a couple of tightenings and telling the system what torque is actually achieved the system parameters are automatically set to appropriate values There is no need for any mechanical adjustments of the tool Pulsor Fixed strategy Using this strategy the optimal pressure to use for the actual joint is calculated during Tool Setup This pressure is then used throughout the whole tightening Some parameters among these the air pressure can be set manually if necessary The speed is set in five steps and affects the pressure that is used for tightening Pulsor Angle Shutoff After a user defined torque threshold is reached the system will continue to tighten the joint It will strategy continue until 1t reaches a programmable angle Angle measurement starts at the threshold torque angle at threshold is zero Pressure will be fixed during tightenings with this strategy Tightening Monitoring parameters can be used to suit your specific monitoring needs Monitoring max limits for monitoring torque angle and number of pulses are also shutoff limits meaning that if a tightening is going to be rejected the system will automatically shut off The monitoring limits may be set manually or by performing a Monitoring Setup the system can suggest values for these parameters Even if a Monitoring Setup is performed the user
200. on of the tool software D154 Boot code version The version of the boot code in the tool 23 4 2 D2xx Controller diagnostics D20x Software information D21x Hardware information D210 PF Type Shows what kind of hardware that hosts the Pulsor application D211 PF serial number Shows the serial number of the Pulsor Focus controller This parameter is possible to change D215 RBU type The type of RBU Available type Gold D216 RBU serial number Shows the serial number of the RBU Shows half of the unique MAC address 23 4 3 D3xx System diagnostics D31x System I O Diagnostic D310 Button Shows the usage and status of the relay devices D311 Button Shows the usage and status of the digital input devices D312 Relay test Button Performs a test of the relays used Note that it is not possible to have Pulsor Focus in normal operation during the test D313 I O device revision Button Presents a matrix of all devices currently on the I O Bus All hardware connected to the I O Bus are shown with serial number software and hardware revisions and if the device is alive 168 235 9836 4841 21 Digital inputs and outputs 23 4 4 D9xx Tool Drift alarm D90x Tool drift alarm general Parameter Parameter Name Description Default setup Number Drift alarm activated With this setting it is possible to activate tool drift alarm for the tool that is being used le Pset used Determines which Psets are included i
201. ong Pret Select Source 16 16 43 0006 05 11 0 0 0 0 E128 Trigger lost 16 15 53 2006 05 11 0 0 0 0 Clear Save to file Open in Excel l Automatic Update Ge Read M Close 9836 4841 21 143 235 Digital inputs and outputs 22 2 Event groups EN Rundown tues Ea00 F99 6 Hardware events DC3000MC300 ER00 F899 s Sofware events e900 6999 fo Evens MMI3000 144 235 9836 4841 21 Digital inputs and outputs 22 3 Event code list 22 3 1 Abbreviations ACK Acknowledgement TLU Tool locked unconditionally 22 3 2 Rundown failures E050 Tool calculation error Calculation error in the tool The results are not reliable E051 Communication error between tool and controller E052 Sensor wheel mechanical error Replace tool E053 Angular sensor signal fault If frequent contact service fo 22 3 3 TCB and hose related errors E067 Air hose not connected TCB gt tool or TCB unable to shut off air Tool control box wrong model The TCB model connected is not supported by this software configuration E069 Tool Control Box pressure error Check that the TCB is receiving the correct pressure input and check all the hose connections to the TCB and the tool If all seems OK and the problem prevails after a restart the TCB must be checked for service 22 3 4 Event related errors E102 Rundown prohibited due to Lock on This event code is displayed when an attempt to make a tightening is Reject made and tightenin
202. ool torque setting to compensate for the measured torque value written below F649 Target torque FESZ Torque tuning factor f M0 F689 Tool setup torque tuning factor f 0 PERE New measured torque E Ibr Ft Ibr Ft OR Cancel 5 8 2 Changing Control parameters In the Control Parameters tab the parameters used to control the tightening for this Pset are presented All parameters are automatically calculated during Tool Setup but some can be edited later 1f needed The most usable parameters are described in chapter 7 3 Control Parameters A description of all parameters can be found in chapter 23 Parameter list 9836 4841 21 39 235 Working with ToolsTalk Pulsor 6 Working with ToolsTalk Pulsor This chapter describes how to use ToolsTalk Pulsor 6 1 Connecting the computer to Pulsor Focus The computer can be connected to the Pulsor Focus by using any of the following options 1 USB cable 2 Serial cable 3 Crossover Ethernet cable 6 1 1 Connecting via USB cable The USB connection is found just below the front panel of the PF4000 under the small rubber cover Connect the PC to the Pulsor Focus with the USB cable The computer will detect a USB device a USB to RS232 converter If this is the first time the Pulsor Focus is connected to this PC gua de the Hardware wizard window will pop up Make sure the steed ala ardware Wizard Windows will search for current and updated software by ToolsTalk Pu
203. ools Talk Pulsor installation ooccccoccncccnnnconcnnnos 55 6 9 2 Connecting Tools Talk Pulsor to Pulsor Focus using crossover Ethernet cable 55 Pset and Dalen CO UN dius iaa 57 Tali ACI IN Si tito EN 57 Pie A wha Graven Waine Bee E a 57 7 2 1 o A 57 7 2 2 Bailen COUNT OF TIGMLCNINGS dad ai 57 aa SCOMMOWIP ara mete Sita dde aa 58 LA JP SCCAGMIMIS Tal O Misses deta 59 E SI A tency esanentaieianattan cavanaigietantesstansutenaunane ametetannetantenne luton cum nen emanns 59 Tightening and monitoring censcccccseccscancedcanathnaaanostscessccsascesstiadecnatwsdacsasenaswenteeaswnse 61 Sul Pernorming TOMLGMING Srita ains 61 8 2 A tightening and its PAraMeElS cccceecccssccceeeeccesecceneecsueeccueeceeeeeseeecsusecsusessaess 61 SS WICWINGMCSUING casinos 63 84 TIGHTS AINGHMONMO MIN Gis tild 63 8 5 Changing limits and activate monitor parameters oooccncccccnnccncnnconnnononannnonnnnnnnnanonos 64 8 6 Using the tightening monitoring OPTIONS oooncccconcnconccnnonnnnnnnnnnnnonncnnonananonnnnnnnnncnnos 64 8 7 Changing parameters via Pulsor Focus front panel occccccccccccnccccnnncnnnoconnncnanonnns 65 8 8 Strategies for tightening MONITOFINQ cccoocccnccccoccnnccnononononnnnncnnonnnncnnonnnncnnanenenonanens 65 o9 AMAlVSISOF IMMFOVEM GINS a a 66 Performing a Monitoring SetUp cconncconncconccconoccnnncconoconancnnnnnonannnnanrnnanrnanrnnanenzas 67 Oli o attache hh haart te et teh tet ites cet
204. or by double clicking on the item in the PF Map It is recommended to use a mouse however it 1s also possible to operate ToolsTalk Pulsor using only a keyboard 6 3 1 Menu row This section provides an overview of the different functions that are available via the menu row Additional menus are displayed in the menu row when you open a function window If for example you open a Pset window you will see a new menu in the menu row called Pset You can open save and close files print and close ToolsTalk Pulsor from the File menu Y ou can create a new Pset or a new Job from the Edit menu Active window This menu option is dependent on which window is active For example if the Pset window is active Pset will be visible with menu items for creating deleting and copying a Pset Focus You can choose how to make connections to Pulsor Focus from the Focus menu You can choose between an Ethernet connection and a serial connection In the Offline mode you can use ToolsTalk Pulsor without being connected to a Pulsor Focus Settings made in Offline mode can later be loaded to a Pulsor Focus Options The following functions are available from the Options menu View Hide Toolbar Settings Change language Get Event Log View Com Messages NOTE only available if LOG is set to ON in Options gt Settings communication tab Forced Release Program Control Reboot PF Action Window You can make settings for windows and icons in the Window
205. or monitor Toggle MouseCursor Set Label Color Toggle Window Toggle Mouse Cursor Set Label Color Possibility to set the label color for the Operator monitor When choosing Activate Presentation the window to the right is Operator Monitor Sel O X shown W Relative Torque By checking the boxes the user can customize the information shown 4 Final Torque in the Operator monitor see table below for parameter description Iv Final Angle p OK W Batch Result Tess UR T Job Result jw Plot Chart J Statistic Chart OF Cancel Uperator Monitor i a all xi Pulsor Staliom 1 PE Peet Atlas Copco fc Relalea Torque Wine wibi 107 Over all status O Final Torque O 29 92 A 5 O Events Final Angle O 90 gt Deg O 9836 4841 21 113 235 Monitors Indicator for the overall status of the tightening Batch order The Over all status for the respective operation in the batch 16 3 2 Picture monitor The Picture monitor is a feature that gives the user visual guidance throughout the Job sequence The next tightening Pset in the job can be presented graphically with an image e g a picture of the area where a bolt is placed When selecting Operator Monitor the window to the left 1s Xl shown To open the Picture monitor select Picture Monitor and click Operator Monitor OK Picture Setup X Cancel Select Picture monitor and click OK The window shown 1s similar to the Operator mon
206. ost list is the list of available Psets The list in the middle is the list of Psets currently in the job Between the two lists are three buttons Manual select Auto select and Remove The first two are used to add Psets from the available list to the Job list list of Psets in the Job Select the first Pset you would like to add to the Job Pressing Manual Select will add the Pset to the Job list and set the Auto Select parameter to Yes Similarly pressing Auto Select will add the Pset to the Job list and set the Auto Select parameter to No Marking a Pset in the Job list and pressing Remove will remove the entry from the Job list In the bottom of the window you can view existing Jobs and their included Psets The list in the bottom of the window shows the Psets of the currently viewed already existing Job You can select a Job with the Previous Job and Next Job buttons and then press Copy Job to transfer the Psets of that Job to the one you are currently setting up It is possible to change between Manual and Auto select afterwards by clicking in the Job list table in the Auto Select column for the actual Pset entry Auto select is not allowed for Free order Jobs with two or more Psets selected from the same Pulsor Focus To change Batch size for a Pset click in the column in the Job list table and enter value In the Configuration tab you can set Name J102 job type J301 lo
207. ous print set to Yes the results after each No tightening are automatically sent to the printer port C19x Pulsor Tool config Parameter Parameter name Description Default setup number C190 Work object LED Selects it Work object LED should be always on always off or Tool Usage function turned on when the tool is used C191 Work object LED Specifies the time the LED should be on when controlled by tool 9836 4841 21 163 235 Digital inputs and outputs meat ld MU C195 Lock tool on service If on the tool will be locked unconditionally if a service alarm has Off alarm triggered 23 3 2 C2xx I O setup C20x I O device 0 7 Parameter Parameter name Description Default setup number C200 Internal I O Pulsor Focus features four built in DigIn and relays These parameters are used to configure the DigIn and relays For more information see chapter 27 Digital inputs and outputs C201 Selection and configuration of connecting devices Selector 4 and 8 C202 position RE Alarm and I O Expander C203 In the Selector Setup dialog box the user can select Pset for each socket be The largest number of Pset per socket is 8 C21 x I O device 8 15 Parameter Parameter name Description Default setup number Selection and configuration of connecting devices Selector 4 and 8 Off position RE Alarm and I O Expander In the Selector Setup dialog box the user can select Pset for each socket The largest num
208. own at a certain level This time delay 1s called the Air Shutoff Time To measure Air Shutoff Time and Maximum Available Pressure the system uses the Air Hose Test The Air Hose Test is run whenever the user orders it on system startup when a tool is connected or when a Tool Setup 1s started The TCB will emit a series of air puffs while performing the test If you change the air hose length between the TCB and tool it may be necessary to manually initiate an air hose test This is done to update the system with new information on when to shut off the air The Air Hose Test can be started in a number of ways from ToolsTalk Pulsor by disconnecting and reconnecting the tool with the white button on the TCB if not reconfigured to perform another action or by restarting the system Make sure the air hose is correctly connected to the tool before you start the test to get correct tightenings Do not press the trigger during the Air Hose Test Ca To prevent loss of tightening accuracy make sure an Air Hose Test is run if you change the hose between TCB and tool 9836 4841 21 27 235 Tool Control Box and tool introduction 4 13 Starting Air Hose Test from Tool Control Box The white TCB button is by default set to start an Air Hose Test The functions associated with the TCB buttons can be changed from ToolsTalk Pulsor 4 1 4 Lights The TCB features two signal lights one green and one red What the lights mean is described in chapte
209. pears and led OK NOK and nxOK shots off when the tool trigger is pushed or if the time limit is exceeded The timer also works for Restart Job when a Job is completed before another Pset is selected or when a Pset is deselected Allowed values are between 1 60 seconds Value 0 seconds deactivates this function Parameter Parameter name Description Default number setup O J330 Use line control J34x Result The Job will be ready to start when a Job with activated Line control has N been selected and Line control start signal has been received Otherwise if Line control start signal has not been received the Job will not be ready to start and the tool will be locked until the Line control start signal is received A Line control start signal is an external signal defined to be received by the Pulsor Focus unit from a digital input This signal can be received before or after a Job selection Line control start signal status will be cleared when the running Job has been completed or aborted Line Control related inputs outputs have only effect on a JobReference Parameter Parameter name Description Default number setup J340 VIN number in result J341 Result of non tightenings 9836 4841 21 JobMembers in a CellJob This function is only applicable if a Job is selected via a scanner Other Job VIN number All tightening results events during a Job will be saved in database together with the Job VIN numbers
210. play one or two tightening parameters on the display ToolsTalk Pulsor is used to select which parameter s to display If two parameters are selected these will be shown alternately on the display As default only Torque value is displayed See section 11 2 2 Display and toggle display for instructions on how to use ToolsTalk Pulsor to set the display When using ToolsTalk Pulsor the Tracking result monitor show all results from the tightenings See chapter 16 Monitors for more information 8 4 Tightening monitoring Monitoring is used to determine if a tightening is OK or not OK If after a tightening a parameter that is monitored lies outside of its accepted interval that tightening will be rejected How the system should react on a rejected tightening is configurable The signal lights on the tool will show if a tightening was rejected or not as described in 3 1 Signal lights on the tool The limit values can be set in the monitoring tabs in the Pset window as described below Which monitor limits to activate can also be set here If Monitoring Setup has been performed for the Pset limit values will automatically be provided for all the parameters you can monitor on Most tightenings will lie within these limits Changes made in the monitoring tabs will not affect the result of a Monitoring Setup The Monitoring Setup results are saved and shown under View Result in the Pset window Monitoring Setup tab 9836 4841 21 63 235 Tightenin
211. r 3 2 Tool Control Box 4 1 5 Silencing A silencer is delivered with the system to attenuate the noise produced by outrushing air during air shutoffs This silencer will keep the noise emitted from the TCB at a reasonable level The system can be further silenced by leading the outrushing air away from the working position To do this remove the silencer connect an air hose instead and lead the hose to the desired place You can optionally fit the silencer at the end of this hose to further reduce the noise Make sure that the air hose used for leading the air away has at least the same diameter as the hose from TCB to tool to admit quick air evacuations from the tool hose 4 1 6 Lock functionality The TCB will automatically shut off air to the tool under certain circumstances The system can additionally be configured to shut off the air in a number of other situations The air will always be shut off in these situations When the Pulsor Focus is powered off No tool connected or tool connection problem No RBU connected System event 1 e an event that need acknowledgement No Pset selected Locked through digital input Pset with Click wrench strategy selected The Pulsor Focus can also optionally disable the air supply in these situations Batch completed Pset parameter Lock at batch done P152 Non approved tightening Config parameter Lock on reject C130 Job completed Job parameter Lock at job
212. r decoding to a specific data type The data field in the FieldBus is from the beginning a blank data field without structure In order to map Pulsor Focus item data types into FieldBus we defined FieldBus Data Type which holds the information about placement and structure of a certain application data type mapped into the FieldBus data field The table below shows the different data types used in FieldBus data The section Items From To PF shows the data type available for different items pao One bit Normally used for discrete I O data Bit Field Length is 2 8 bits All bits must be in the same byte The left bit is the most significant bit and the right bit is the less significant bit i e 0001 1 1000 8 Character One byte ASCII code Character String Change Character string Each character uses one byte ASCII code Range 2 25 bytes 9836 4841 21 193 235 FieldBus configuration appendix Character String Input Character string with an extra counter byte in front The extra byte is an integer counter and must increase each time when the character string is entered to be able to detect a new input If you want to enter the same value again e g the same Job number just change the counter Fixed Point Number Two byte integer part and two byte decimal part The first two bytes hold the integer part and the last two bytes hold the decimal part Used to represent torque value Unsigned 16 Ul6 16 bit unsigned int
213. r each String bit 2 24 character then this parameter length the Pulsor Change Intel bytes Focus will not fill with zero Format Character String Input Intel Format 32 208 bit 4 26 One ASCII sign for each character bytes First byte is counter Shows the VIN number used in a Character 16 200 One ASCII sign for each tightening This is the VIN used in string change bit 2 25 character the tightening result bytes If the VIN is longer then the VIN input length the Pulsor Focus will take the first x characters and cut the end If the VIN number is shorter then this parameter length the Pulsor Focus will not fill with zero VINUsedInTightening 9836 4841 21 203 235 FieldBus configuration appendix 30 4 Items To PF This section contains a description of the items that can be selected when data to the Pulsor Focus is configured Items To PF Description Data type String Value length Bit AbortJob Aborts the running Job 1 bit 0 Not used 1 Abort Character 8 bit 1 A Abort byte AckErrorMessage Acknowledge error message Bit 1 bit 0 Not Used 1 Ack Error BatchDecrement Decrement the batch counter with Bit 1 bit 0 Not used one 1 Decrement BatchIncrement Increment the batch counter with Bit 1 bit 0 Not used one 1 Increment BypassPsetInJob Stop current Pset and jump to Bit 1 bit 0 Not used next Pset in the Job Bypass Pset in Job FieldBusHandShake Send to PF
214. r to save and exit Press F to exit without saving F2 Setting maximum limit for torque monitoring F2 rtUL alternates in the display If no Pset is selected F2 is displayed Press Enter to enter edit mode Change the value by pressing the keys Press Enter to save and exit Press F to exit without saving F3 Setting IP address F3 IP alternates in the display Press Enter to enter edit mode The IP settings are divided into 12 numbers The first four are the IP address the next four are the Subnet mask and the last four are the IP address to the default gateway Increase decrease each number by pressing the plus minus keys Press Enter to confirm each number and edit the next number in IP settings Repeat this for all remaining address parts Event code Reboot needed before changes take effect E857 will be blinking on the display when finished Press Enter to acknowledge the event code Restart the Pulsor Focus controller F4 Selecting Pset F4 Pset alternates in the display if the Pset select source C222 is Keyboard Otherwise F4 is displayed Press Enter to access the available Psets Browse existing Psets by pressing the keys Press Enter to select a Pset and exit Press F to exit no selection F5 Setting Batch count ES batS alternates in the display indicating that a Pset is selected Otherwise F5 is
215. rNet connector RJ45 The module uses twisted pair cables and no external termination is required RJ45 Standard Pin Sigal C 5 Terminaron Status indicators The module has four status LEDs Led 1 Link Steady Off Module is not connected to EtherNet Steady Red A major internal error has been detected Led 3 Network Status Steady Off No power or no IP Module has no power or no IP address address Steady Green Module has at least one EtherNet IP connection Flashing Green There are no EtherNet IP connections established Flashing Red Connection timeout One or more of the connections in which this module is the target has timed out This state 1s only left if all timed out connections are re established or if the module is reset Steady Red Duplicate IP Module has detected that its IP address is already in use Flashing Green Red Module performing a power on self test LED 4 Activity Flashing Green Flashes each time a packet is received or transmitted 222 235 9836 4841 21 FieldBus configuration appendix 30 10 Profinet The embedded Profinet interface is a complete Profinet solution for a Profinet IO device All analogue and digital components that are needed for a complete Profinet IO interface with soft real time RT are mounted on the module The module is based on the Siemens Profinet I O software technology The Profinet module works as an I O Device on the Profinet network The module supports up to
216. rd Byte Bit Lend CharstinglharO OF 0 40 Charstinginputs 0 0 48 CS PS CO ES CI IES o h m Le CharStringInput 3 1 counter P o BP s E Oo B TT P Pen 9836 4841 21 195 235 FieldBus configuration appendix Intel Endian Type Y Bou Bit Le Charstingbhange OU 1 0 40 Chars ting nput 3 1 46 CharstlhangelntelF 1 0 45 Charstinputintele 3 1 0 45 Data Type Word Byte 1 Byte 0 Convert to PF data Caso o JP ee ee ANN o p p sd EY PO S a ESA CA a S e oe CharStringInput CharStringChangelntelF A E IO 2 7 E iP CharStringInputIntelF FE 1 counter O A A AA 30 2 2 Fixed point number S T S Fixed Point Number integer part is in low number word and decimal part is in high number word The table below shows the conditions valid for the integer and decimal parts 1 e 1f integer part is 1 digit or 2 digits decimal part is 2 digits Integer part in digits Decimal part in digits A 196 235 9836 4841 21 FieldBus configuration appendix Motorola Endian Type Word Byte Bit_ Lend FiredPomth uml 0 j O Je EA EE AAA o Jo 000000 1 0000000 Data type Byte 0 Byte 1 Convert to PF data word 7 e 5 4 Ja 12 1 fo 7 le 000 0 0 4 0 Intel Endian Type Word Byte Bit_ Lenc Byte 1 Byte 0 FixedPointNumid 1 0 32 word 7 le fs a 3 l2 1 fo 7 6 AAA o Ce oo 0 oo 00 1 o Jjooooooo00 Data type Byte 1
217. rigerators There is an increased risk of electric shock if your body is grounded Don t expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock This instruction does not apply to tools classified as watertight or splash proof For minimum electrical interference place the instrument far away from possible sources of electrical noise e g arc welding equipment etc Do not abuse the cord Never use the cord to carry the tools or pull the plug from an outlet Keep cord away from heat oil sharp edges or moving parts Replace damaged cords immediately Damaged cords increase the risk of electric shock 33 3 Personal safety Stay alert watch what you are doing and use common sense when operating a power tool Do not use tool while tired or under the influence of drugs alcohol or medication A momentary lapse in concentration whilst operating power tools may result in serious personal injury Dress properly Do not wear loose clothing or jewellery Tie long hair back Keep your hair clothing and gloves away from moving parts Loose clothes jewellery or long hair can be caught in moving parts 9836 4841 21 229 235 General safety instructions for Pulsor Focus unit Avoid accidental starting Be sure switches are in the off position before plugging in Carrying tools with your finger on the switch or plugging in tools that have the switch set to on invite accidents Remove adj
218. rofiBus User Group in the first instance A contact address list is available on the ProfiBus Internet site http www ProfiBus com For general help on ProfiBus contact ProfiBus International on ProfiBus_international compuserve com 30 5 1 ProfiBus DP for Pulsor Focus Physical interface Interface Description Description S FieldBus connectors 9 pin female DSUB standard Isolation The bus is galvanically separated from the other electronics with an on board DC DC converter Bus signals A line and B line are isolated via optics couplers ProfiBus DP communication ASIC SPC3 chip from Siemens ProfiBus DP module Node Address 1 124 Set Switches to 00 if you want to set the 1 99 with HW setting node address from SW TT Pulsor Number of nodes in a ProfiBus DP Max 126 network Baud rate Automatic 9 6 kbaud 12 Mbaud Automatically set from PLC at connection Data to PF length 0 122 bytes Must be the same in PF and PLC The string length in PF is limited to 122 bytes ProfiBus DP standard allows 244 bytes Data from PF length 0 122 bytes Must be the same in PF and PLC The string length in PF is limited to 122 bytes ProfiBus DP standard allows 244 bytes The module only supports cyclic I O data transmission 9836 4841 21 207 235 FieldBus configuration appendix Hardware FieldBus connectors The ProfiBus DP standard EN 50170 DIN 19245 recommends the use of a 9 pin female D sub connector
219. roller 1s invalid e g the first time the PF 1s used you need to connect serially then you can set up the PF for Ethernet communication according to 11 4 Communication 9836 4841 21 43 235 Working with ToolsTalk Pulsor Check that Pset select source in Config is set to Ps Se Ethernet Serial This setting is permanent and need not Eypio normally be changed This is done so that Psets can be selected from ToolsTalk Use another Pset select source if you want to select Pset by other means 44 235 C271 Job select poca Cae Poet select iure CE Tool ight con source CEH Tod ight mode CZS Tool light on times C226 Selector conim Other Oca 2 C230 Selectos los mode CEN Use lol Pest al lat 9836 4841 21 Working with ToolsTalk Pulsor 6 3 ToolsTalk Pulsor user interface The figure below shows the principal areas in ToolsTalk Pulsor s user interface 2 ToolsTalk Pulsor 3 05 PulsorF Station 1 Menu row gt HE Edi fos Options won He Selection panel gt Running Job Toolbar gt E 1 PF Map E e Se al 2 Ena 0 9 Job PF Map o Config Y Tool accessories Diagnostic MI Identifier FieldBus 22 Monitors LZ Trace ES Statistic oA wl zi lt lt Hide details y There are several ways to start a function in ToolsTalk Pulsor Generally all functions can be reached by a menu item in the menu row by clicking on a tool button in the toolbar
220. rotocols C206 Device 6 Off Set C207 Device 7 Off Set X Close Ge Read sg Store 9836 4841 21 85 235 Config Set the wanted Relay functions and choose its MATAR behavior Digital Input Set the Digital input functions Click Store to save when configuration is done 11 3 2 External I O devices Setting up external I O devices is explained in chapter 20 Accessories 11 3 3 Other l O s settings Select Other I Os under I O setup from the Other 1 0 5 1 navigation area C221 Job select source Digi hal Select the appropriate options see below for C222 Pset select source Ethemet Serial C223 Tool light con source PF contralled 1 details C224 Tool light mode E Click on Store to save S225 Ta fg nmn liner Sen C226 Selector confirm Ott CAF Job select source override Ot Other LO 2 C230 Selector lost mode Last Pzet C231 Use last Peet at startup ra C221 is used to configure what source to use to select Jobs C222 determines which source the Pulsor Focus shall use to select Psets See section 11 3 4 Pset select source for more information C223 C225 is used to configure the behavior of the tool status LEDs See chapter 23 Parameter list for further information C226 When using a selector the operator can be forced to use the right socket even when the selector is not used to select Psets C227 A secondary source can be used to select
221. row to the right of this q button button to show a drop down list of available Psets and an option to create a new Pset After a Pset 1s activated or created the Pset will be selected and Tool Setup for that Pset will automatically be started Note that Pset select source in Config must be set to Ethernet Serial for ToolsTalk to be able to select a new Pset You will get an option to set this automatically when the Tool Setup button is pressed if not set already See chapter 11 3 4 Pset select source for instructions on how to set this manually 8 Pset This icon opens the Pset programming window Click on the arrow to the right to show the i programmed Psets with numbers and names gee This icon opens the Job programming window E Configuration This icon opens the configuration window This icon opens the diagnostics window i Identifier This icon opens the identifier window barcodes FieldBus This icon opens the FieldBus configuration window Results monitor mi Trace Click the Trace icon to bring up a graphical display of a tightening Up to 5 tightenings can be 5 A superimposed on the graph ME Statistics Click on this icon to display statistical results and graphs oc PF Map This icon opens the PF Map if it is closed Monitors Press this button to open the Tracking results monitor Click on the arrow to the right of this icon to select between the following monitors Result monitor Job monitor Operator monitor or
222. rt is used by the connected Pulsor Focus open up the Device Manager Control Panel gt System gt Hardware tab and click the sign to the left of Ports to expand that option The device appears as a USB Serial Port with the Com number in parentheses Found New Hardware Wizard Please choose your search and installation options SS Y Search for the best driver in these locations Use the check boxes below to limit or expand the default search which includes local paths and removable media The best driver found will be installed C Search removable media floppy CD ROM Include this location in the search E CDM 2 00 00 Don t search will choose the driver to install Choose this option to select the device driver from a list Windows does not guarantee that the driver you choose will be the best match for your hardware Hardware Installation A The software you are installing for this hardware USB Serial Converter has not passed Windows Logo testing to verify its compatibility with Windows lt P Tell me why this testing is important Continuing your installation of this software may impair or destabilize the correct operation of your system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the hardware vendor for software that has passed Windows Logo testing E Device Manager Fir in Ye He mFS Cmar
223. running Bit 1 bit 0 Job done and no Job selected 1 Job is running KeepAliveAck Indicate FieldBus communication Bit field 00000000 0 alive which send back the save value 11111111 255 received from PLC LineControlAlerted 1 Indicates Line Control Alert Bit 1 bit 0 Not used received by Pulsor Focus 1 LineControlAlerted1 LineControlAlerted 2 Indicates Line Control Alert2 Bit 1 bit 0 Not used received by Pulsor Focus 1 LineControlA lerted2 Bit LineControlDone Indicates Job with line control 1 bit 0 Not used finished before line control alert2 1 LineControlDone inputted LineControlStarted Indicates Line Control Start set in Bit 1 bit 0 Not used LineControlStartAck Indicates that Pulsor Focus received Bit 1 bit 0 LineControlStartreseted Line control start 1 LineControlStart NewPsetSelected Running Pset number Bit field 0000 0001 Pset 1 0001 0000 Pset 16 Ul6 16 bits in 00 0001 Pset 1 one word 00 1000 Pset 8 NewPsetSelectedOIs1 Running Pset number Number 0 Bit field 0000 0001 Pset 2 Pset 1 number 1 Pset 2 etc 0001 0000 Pset 17 PFChannelID Gives the channel ID number on the Bit field 0000 0001 CH 1 FieldBus Pulsor Focus 0001 0000 CH 16 200 235 9836 4841 21 FieldBus configuration appendix length U16 16 bits in 00 0001 CH 1 one word 00 1000 CH 8 PFReady No severe errors in PF Bit 1 bit 0 Errors in PF PsetFinalTarget ReceivedIdentifi
224. s between 224 0 0 1 all devices on this sub net a 6 7 8 address and 239 255 255 255 Multicast standard 166 235 9836 4841 21 Digital inputs and outputs Parameter Parameter Description Default number name setup C422 Port Port number for Multicast communication for Multicast communication 8086 C423 Results None All Not OK ca The results that are reported to the Multicast address C427 Event code On Off Off r C45x Open protocol setup Parameter Parameter name Description Default number setup C451 Port number for open AA T server Ethernet communication C452 Serial cable loss O enabled Pulsor Focus detects cable loss when running open protocol detection serial on serial port or 2 23 4 Diagnostics 23 4 1 D1xx Tool configuration D10x Tool general information Parameter Parameter Name Description Number Motor size Shows information about size of the tool Ss Type formats are 6 8 10 and 11 Tool max torque Shows the maximum tightening torque for the tool in chosen unit The value is possible to change if correct password privileges are met Tool max torque must only be changed by users with tool knowledge User tool message User tool message shows a user specified message string of maximum 35 characters The message is stored in the tool memory The value is possible to change if correct password privileges are met D106 Type of tool fixed or handheld D13x Tools service
225. s recommended to continue performing Tool Setup tightenings until the system torque value is close to the manually measured torque Most often around five tightenings is enough to accomplish this After the desired number of tightenings has been performed you have two choices 1 Ifyou are satisfied with the Tool Setup results press Store to store the settings in Pulsor Focus 2 Ifyou are not satisfied press Cancel Cancel discards the performed tightenings and the Tool Setup Window will be shown again where settings can be changed If Cancel was pressed the Tool Setup window gives the option to either cancel Tool Setup completely by pressing Cancel or start over by entering new settings and pressing Perform tightenings 9836 4841 21 35 235 Performing Tool Setup 5 6 Manual Tool Setup If the joint is particularly difficult the Tool Setup may fail to find the correct parameters In this case you can perform a manual Tool Setup Start Tool Setup as usual Set Tightening Strategy Target Torque and Speed Press the Perform Tightenings button Then in the Tool Setup Monitor press the Advanced Settings button Here you can set a number of parameters that control the tightening The different parameters are described in chapter 23 1 Pset parameters These parameters are the same as the ones shown in the Control Parameters tab in the Pset window The Pset window is described later Tool setup monitor advanced settings Pressur
226. s should be created The Job is performed by one Pulsor Focus and automatic Pset selection is desired The following Job would solve the task above provided that the Psets previously have been set up rar vs A Yes BP Yes Yes es 9836 4841 21 73 235 Job 10 1 Creating a standalone Job The Job creation section is accessible from ToolsTalk Pulsor Every Job has a unique ID number 1 100 Create a Job by combining Psets as shown below Right click on Job in the PF Map and select Create New Job lea serial Ethernet a p Station 1 E D Pset ai 1 Gearbox 0 Diagnostic MI Identifier 22 FieldBus E E Monitors be Trace E l h Statistic 2 3 Offline Select New Job ID and give the Job a name Station 1 Create new Job eS xi optional Click OK to continue New JoblD i E New Job Name Motor block The Job window appears Si Job 1 Motor block PulsorF Station 1 J loj x Parameter Overview eS Sees Ep Precisa Job List I 1 Gearbox a Configuration 2 Motor block E Batch 0 3 3 Spark plug a Timers Be Line Control Bn Result Add to Job w Manual Select w Auto Select ai Remove Job List Pzet Pset Name Auto Select Batch size Max Coherent NOK View Job 1 Motor block Previous Job a Copy Job f Nest Job Pset Name Auto Select Batch size Max Coherent NOK x Close Change Job wal Store 74 235 9836 4841 21 Job The topm
227. s with a transformer according to ModBusPlus interface description ASICs and circuits Module is based on chip set and software from Modicon Inc Mechanical overview ModBusPlus module is a host device This host device can be read and written to from another ModBusPlus host device or controller ModBusPlus module will not initiate any Point to point communication to other nodes it will only respond to incoming commands It can although broadcast Global data to all nodes on the network Protocol and supported functions ModBusPlus has two ways of exchanging data One through fast cyclic I O data called Global data and one through a somewhat slower ModBusPlus protocol for point to point parameter data transfer The Maximum Global Data is 32 words on the bus The point to point data transfer is handled by using one of the following ModBus functions Read holding Registers PreSet Single Register and PreSet Multiple Registers all 40000 registers 9836 4841 21 217 235 FieldBus configuration appendix ModBusPlus module information Node Address 1 64 The node address cannot be changed during operation Source Address 1 64 The node address cannot be changed during operation Number of nodes in a ModBusPlus network Max 32 with repeaters 64 A Bus length Max 2000 m with repeaters Data address 40001 I 1 0 1 From PF This address is based on words 41025 I1 1 0 1 To PF Global Data From PF Data in the module starts
228. se the Tool Setup Monitor window After each tightening is performed a new column with data from that tightening will be shown in a table In the bottom of each data column is a Delete button Pressing this button will remove the tightening from the set of Tool Setup tightenings Depending on whether this is done for the most recent tightening or not there is an important difference in how the system handles the removal More on this in chapter 5 4 3 below 5 4 2 Making Tool Setup tightenings ToolsTalk Pulsor Make sure you perform the tightenings with the same equipment as will be used in production For example if an extension will be used in production this should be fit to the tool while Tool Setup is performed also The first tightening during Tool Setup will be a standard tightening with parameters set for a careful tightening to simplify initial calculation of joint characteristics When you perform the tightenings do not release the trigger before the system has shut off the air pressure When the air is shut off release the trigger Tool setup monitor Start by performing one tightening on System is in learning mode the correct joint The performed sila ea rie AO tightening will show up in a new ee m ame column in the Tool Setup Monitor A ae window It is recommended that for Teva 4670 s0 No of Tightenings 2 1 3 Delete Delete 45 90 44 8 each good tightening the measured installed
229. seconds ToolsTalk Pulsor can be switched off by clicking on the OK button Events will be shown in ToolsTalk Pulsor as a popup window with a single button A text describing the event is shown in the window If the event needs acknowledging the window contains a button Acknowledge which when pressed will acknowledge the event If 1t is a non acknowledge event the window contains a button Ok which when pressed will close the window Chapter 22 Event codes provides more information on the different event codes The event code will end up in an Event log that can be analyzed at a later time 6 5 Activating Pset and showing Pset main window This section describes how to activate a Pset parameter set and show the main window for a Pset In the Pset main window you can start a Tool Setup Monitoring Setup or change view other Pset parameters Activate the desired Pset in the Selection panel in File Edit Focus Options Window Help ToolsTalk Pulsor a prerequisite 1s that Pset select Selected Contole E Station Running source is set to Ethernet Serial see section 11 3 4 P Y m l Ds Y amp MI Pset select source for more information io 2 Terma 2 P 1 Gear box 9836 4841 21 47 235 Working with ToolsTalk Pulsor Open the Pset main window for example by double clicking on the required Pset En Serial Mame Mot Defined under Pset in the PF Map E a ll 10 46 24 224 Peet
230. set and batch count Open the relevant Pset from the PF Map psa sL Gearbox AS 10 xi Parameter Overview Tightening Options Select Tightening options under programming ica P611 Tightening Angle Start 50 from the navigation area Strategies ool Setup We eee Sati P612 Rundown pulse filter Iv Activate Batch count by selecting Pset from pc as Oe the list in Batch count and then enter the gee P144 Cycle abort timer P150 Batch count number in the Batch size field od r llo ins P151 Batch size Not Use y gt dd ii P152 Lock at batch done The parameter Max coherent NOK s will P153 Max Coherent NOK s fo count how many NOK tightenings that may be performed consecutively until air will be shut off Save by clicking Store There are also settings in Config that affect X cose DAD Compare batch counting See section 11 2 3 Settings for Options for more information g Perform Tool Setup Perform Monitoring Setup gt Read sa Store 8 Undo Compare See also section 23 1 1 P xx Programming 7 3 Control Parameters In the Control Parameters tab the parameters used to control the tightening for the Pset are presented All parameters are automatically calculated during Tool Setup Some can be edited later if needed A description of all parameters 1s given in chapter 23 Parameter list 2 Pset 3 PulsorF Name Not Defi
231. ssarily often Under Ethernet setup select the type of connected Pulsor Focus NetMaster CellMaster or Controller set Port number and Controller IP address Default port number value is 6543 If using an item from PF List PF available list all three parameters type port IP will be set simultaneously S To be able to edit Ethernet setup parameters ToolsTalk Pulsor must not be connected to a PF In the LOG section you can select if you want to log communication between Pulsor Focus and ToolsTalk If you set Log to On then messages will be stored in a file The file name is stated in the Log file field Via the Advanced button you can make special setup x for logging Y Split Log Logfile size 1 MByte If Split Log is activated the size of log txt file cannot exceed the value set in Logfile size When the file is full the file will be renamed to log txt and the contents of log txt will be erased Then data will M Logpollmessages Hex continue to be stored in log txt M Log the message Log all messages Log Hex e Log messages size 50 235 9836 4841 21 Working with ToolsTalk Pulsor 6 6 2 Settings Application The Application tab sheet has three sections itt The first section is about ToolsTalk Presentation Automatic functionality Presentation Use this if you want to view Show hints M Auto collaps treeviews hints and parameter numbers v i ete ee No auto connection
232. st txt or if the file is located elsewhere A browse to find the correct directory E AE Click Open a a Choose OK to exit Deir My Documents ys Hp Cancun My Hek Fibs reir Fis of hpa 6 9 2 Connecting ToolsTalk Pulsor to Pulsor Focus using crossover Ethernet cable When Pulsor Focus is not connected to a network it is recommended to use a crossover Ethernet cable to connect the computer running ToolsTalk Pulsor to the Pulsor Focus Follow the instructions below to configure the PC and the Pulsor Focus 9836 4841 21 55 235 Working with ToolsTalk Pulsor Hardware required A Pulsor Focus unit A crossover Ethernet cable RX TX crossed A PC with an Ethernet connection the PC shall not be connected to the network Configuring the PC Go into Windows network settings e g Start Settings Network connections Local area connection on Windows XP Select Properties and make sure that TCP IP is marked Double click on it or mark it and select Properties Select the PC s hard IP address often if you are connected to a network the choice Select an IP address automatically is selected such as 192 168 1 1 and specify a subnet mask e g 255 255 255 0 DO NOT specify a default gateway Save the settings by clicking OK Configuring Pulsor Focus Make a serial connection via RS232 with Pulsor Focus required first time Go into the Config menu and select Com
233. steps for each pulse Measured torque Angular measurement starts when torque 50 of target torque Measured angle 0 8 0 9 Time 8 1 The above graph shows the torque black angle dashed and the air pressure at the air motor in the tool dotted for a typical tightening The tightening starts t 0 when the tool trigger 1s pressed During the 9836 4841 21 61 235 Tightening and monitoring first 0 2 seconds the thread 1s run down and then the first pulse occurs and the actual tightening is started The torque and the tightening angle increases in stages for each pulse When the pulse torque is sufficiently high the air to the tool will be shut off and the tightening is completed a The tool air pressure decreases to zero when the operator releases the trigger and or the l system has shut off the air supply Parameter Description Pulse filter Sometimes a pulse occurs during rundown that has nothing to do with the tightening Examples of this are when locknuts are used or the thread is damaged The pulse filter identifies such pulses and removes them from the calculations of torque relative angle number of pulses tightening time rundown time pulse frequency and pulse pressure Even if the Pulse filter is turned off it is used when calculating the torque and pulse frequency Trigger lost This indicates that the operator has released the trigger before the tightening is ready Torque value The highest torque measur
234. t log depending on the event code type Number of events that can be stored in the log depends on RBU see section 24 1 RBU functionality Once the log is full the oldest events will be overwritten by the most recent ones 22 1 ToolsTalk Pulsor operations This section shows only examples of possible parameter settings To open the event log click get event log in the File Edit Focus MARES Window Help options list Selected Controller view Toolbar Running fl Click clear to delete all events in the log Settings Click save to file to store the event log as a text M ro y fil Change language ile AAA a Click open in Excel to export the log to Microsoft Get Event Log View Com Messages Excel ea E Sen al F ame 1 Stat Forced release progcontra Click read to update status of the event code E e Ethernet AER oe sea Reboot PF Action window El RL type Ether When option automatic update is checked the 3 Y Fret IP addr 10 40 155 events in the log are shown directly when they appear gt Description ime Dae Contra E FOO PF Started 16 18 54 2006 05 11 0 0 0 0 E131 Tool Disconnected Acknowledged 16 18 15 2006 05 11 0 0 0 0 E131 Tool Disconnected 16 17 58 2006 05 11 0 0 0 0 E405 10 expander is not connected or not responding Acknowledged 16 17 41 2006 05 11 4 0 0 0 E405 10 espander is not connected or not responding 16 17 33 006 05 11 40 0 0 E207 Wr
235. t IP address Subnet mask and Default router Set NetMaster IP address to the IP address of the NetMaster Set CellMaster IP address to the IP address of the CellMaster To define current PF as a CellMaster or NetMaster set CellMaster IP address NetMaster IP address to same IP address as current PF If the PF in the case below should be Cellmaster C305 Cellmaster IP address should be set to 10 40 165 96 Config PulsorF 1 Station 1 0 x Parameter Overview Remote com C301 IP address ho fso fes 96 pra C302 Subnet mask 255 255 252 fo Communication C303 Default router fio ao fies fi Remote com C304 Netmaster IP address fo fo fo fo Eee C305 Cellmaster IP address fio fo fes 93 Protocols C306 Jobreference IP address fo fo fo fo C310 Cell keep alive 6 Sec Serial ports setup C320 Serial 1 baudrate 9600 y C321 Serial 1 protocol as Cll y C322 Serial 2 baudrate o y X Close G Read sg Store Open the Password and name window Config System setup Password and name Set Channel ID to a number unique within the Cell 1 20 PF name is optional Set Cell ID to a number unique within the network 1 1000 Cell name is optional Click Store to save the settings Restart the Pulsor Focus unit a Config PulsorF Name Not Defined Parameter Overview El System setup C100 Use password No C101 Password entry scope All hd Display se
236. tal impu 2 13 l 15 16 l Digital input 3 Digital input 3 Digital input 4 Digital input 4 24 VDC isolated GND 24VDC isolated 188 235 9836 4841 21 Connector descriptions 28 8 Digital outputs relays Connector 12 pin detachable screw terminal Mating connector Phoenix MCVR 1 5 12 ST 3 81 or compatible Function Two way dry contact relays Isolated outputs Logical function is set in the configuration of the Pulsor Focus Electrical data Max 50 V DC AC Switching load min 1 mA max 500 mA resistive load Function OV 24 Relay 1 Normally open gt Relay 1 common Relay 1 Normally closed Mc E Relay 2 Normally open e E e 1 NO 40 Relay 2 common Relay 2 Normally closed yc e o Relay 3 Normally opened REJ a E Relay 3 common NO 7 Relay 3 Normally closed Relay 4 Normally opened NC Relay 4 REZ mE elay 4 common NO a A ES Relay 4 Normally closed HG Y 7 REIS 2 0 e B 9836 4841 21 189 235 Connector descriptions 28 9 I O Bus 1 Connector 9 pin DSUB male Function To connect Atlas Copco I O Bus accessories Parallel with I O Bus connector 2 There is a range of Pulsor Focus accessories that connect over the proprietary Pulsor Focus I O Bus for example Selector socket tray RE Alarm I O Expander To have a well functioning I O Bus always use bus terminations All accessories and Pulsor Focus units are equipped with two parallel connectors Whe
237. ten in advance 03911 Average torque deviation Lower limit 0913 Average torque deviation Upper limit 0915 Average frequency deviation Lower Limit 0917 Average frequency deviation Upper Limit Mew Tool Drift results Reset Tool Drift alarm Ge Read sa Store The Tool Drift data activated is always on This means that the system collects data for tool drift calculation in the background Normally all Psets are used as basis for the tool drift calculation The torque statistics is based on the achieved percentage of target torque Before tightenings from a new Pset are included in tool drift alarm tightenings the system will collect lt Sample size gt tightenings with this Pset Based on these tightenings a mean frequency will be calculated When further tightenings are made with the Pset the pulse frequency is compared to the mean frequency calculated from the first tightenings generating a relative frequency value A value of 100 means the pulse frequency has not changed since the mean was calculated Because tool drift alarm values are based on relative torque and pulse frequency it is possible to use Psets with different target torques and pulse frequencies as basis for tool drift calculation If you feel uncertain 9836 4841 21 93 235 Diagnostics and service of which Psets to use select all Psets default To deselect a Pset click on the Set Pset used button and deselect one or more Psets and confirm with OK
238. tenings Target torque Tightening Angle Start Rundown pulse filter KeepPsetLimitsParameter User info Pset 1 Gear box Pulsort Mame Not Detined Puente Overview Monitoring Setup fom Monitoring Setup Progr A omic SA vd Setup Torque Tuning Aduiment Tiger Options PEDO Monitoring Setup perfomed PG01 Number of tightensnge 0 Pi Perom Tool Setup a al Perdon Mordoro Seip X Cove DSC Compare Mes GJ Store Tightening basis statistics Proposed limits Tightening values Max Mean Std dev Hin Max 45 00 Nm Set reference values 50 r r S 67 235 Performing a Monitoring Setup 9 3 Making Monitoring setup tightenings Important information regarding tightenings Use the tool on the actual target joint Perform the tightenings Do not release the tool trigger prematurely The tool must shut off after each tightening tightenings where the tool has not shut off are not included in Monitoring Setup Ifa performed tightening has spin error it is not included in Monitoring setup The tool oil level must be checked before Monitoring Setup can be continued No lights will light up on the tool the Pulsor Focus front panel or other accessories that are connected when you carry out Monitoring Setup tightenings since the system does not monitor these tightenings Itis strongly recommended to have at least 5 pulses and at the most 30 pulses to have optimal use of the too
239. ter 155 Remote job aborted When running a Cell Job This is displayed by the Job members when a cell Job is aborted E156 Job members lost When running a Cell Job this is displayed by the master when it has lost contact with one of its Job member E157 Job reference lost When running a Cell Job this is displayed by the Job members when they have lost contact with their Job Master E158 Invalid Job ID When the selected Job does not exist E159 No Pset In Selected Job When the selected Job does not contain any Pset E160 Job select source not valid Attempt to select a Job with the wrong input source Line Control Alert 1 The line control has been activated and the first control alert limit has been reached Line Control Alert 2 The line control has been activated and the second control alert limit has been reached 6 Job aborted Job has been aborted Max coherent Not OK tightenings reached When the number of NOT OK tightenings in a row is reached then the tool will be locked and can be unlocked only via a digital input es mi m jd gt 0 NAJ MN Eh NO es ON ON ON NO oN A uE E reset NOK counter The protocol settings for the serial COM port 1 is not set to 3964R it E180 Euchner Ident System only supports Siemens 3964R protocol is not possible to use the Euchner Ident System with this configuration Not possible to read ID card It was not possible to read the
240. ter button The upper relative torque limit and lower relative torque limit is toggled on the display Monitoring Setup is complete and the result is stored in the relevant Pset parameter set When the Monitoring Setup is complete the display shows the proposed min max limit values for Relative torque alternately e g 90 110 These limit values can be changed directly after Monitoring Setup or at a later time See section 8 6 Using the tightening monitoring options for more information 72 235 9836 4841 21 Job 10 Job The Job function is useful when an object requires tightenings in a controlled sequence often with more than one Pset used for the application Instead of manually selecting the Pset you can create a Job and let Pulsor Focus keep track of the parameters that are needed to perform the task For parameter descriptions see Parameter list Start Job from ToolsTalk Pulsor by either double clicking on the Job in the PF Map in ToolsTalk Pulsor or by selecting the function from the toolbar A Job is created by combining a set of Psets The Job list may contain 30 entries Psets It is possible to use a Pset more than once in a Job Up to 100 Jobs can be stored in Pulsor Focus The figure on the right shows an example of an object with bolts that require different torque values 1 Four bolts hard joint 2 Three bolts soft joint 3 One bolt medium joint For this example three different Pset
241. the currently used Pset Final torque will be shown if torque monitoring is on and at least one manually measured torque value was written in during Tool Setup You can watch several windows with different views with a max limit of four EA Result Monitor PF Running P 1 Values 2007 03 23 16 49 21 Over all status Relative Torque Machine stop Final torque Batch x Close Clear Remove Add iw Automatic Update 16 2 Job monitor Job Monitor displays running Jobs and provides functionality for managing Jobs 1 Job status Al ES Job 1 Motor black OrderForced status running PF 1 PF 1 rel PF 1 PF 1 P 1 Auto P 2 Auto F afuta P 1 Auto F 1 Auto Batch 111 Batch 0 1 Batch 0 1 Batch O 1 Batch 0 1 M Close Job off Restart Job Decrement Increment Bypass Pset a For a function description Restart Job Decrement Increment Bypass Abort Job and Job off see chapter 10 Job 112 235 9836 4841 21 Monitors 16 3 Operator monitor and Picture monitor 16 3 1 Operator monitor Select Operator monitor xi Press OK Operator monitor window appears Right click anywhere in the window to open options menu 7 Picture Monitor Picture Setup A _ x toos Activate Presentation User preferences for the content of the Operator Activate Presentation monitor Set Background Color Set Background Color Possibility to set the background color for the Toggle Window Operat
242. ti Pulsor Focus Job set up the Job on the Job Reference only See chapter 11 4 Communication for information regarding how to set the Job Reference IP address The Job Reference IP address needs to be set on all Pulsor Focuses that are to be used in the Job both for the Job Reference and the Job Clients After this is done set up the job as described in chapter 10 1 Creating a standalone Job on the Job Reference The list of available Psets now contains all the Psets from the Job Reference and Job Clients S Job 1 PulsorF 1 Station 1 E joj xi Parameter Overview Avaiatia Pants Programming Pr Pset PsetName Job List 1 1 1 Gearbox Configuration 1 2 2 Motor block Batch u 3 Spark plug 4 Timers Line Control AE MENA Add to Job w Manual Select i 4 Remove Job List View Job 1 Previous Job Auto Select Batch size Max Coherent NOK X Close Change Job gt Read swe 10 3 Running Jobs When a Job has been selected it is possible to select a new Job only until the first tightening 1s started or a batch increment is performed After that the only way to select a new Job is either to complete the running Job or to abort the running Job Sources that Jobs can be selected aborted from Digin Digital input Ethernet Serial Identifier no abortion selection only Fieldbus Pulsor Focus allows two different possibilities for Job selection J
243. to edit mode for the currently selected function shown on the display Confirm with Enter when you have made an adjustment to exit edit mode Press F to select parameter F1 the minimum limit for torque monitoring The parameter value e g 92 will flash After entering edit mode this value can be increased decreased using the buttons Press F again to select parameter F2 the maximum limit for torque monitoring Press F F3 Pulsor Focus IP address Press F F4 Active Pset Note that Pset select source must be set to PF Keyboard for this to work For more information see section 11 3 4 Pset select source Press F F5 The number of batch tightenings Press F F6 Select this to create a new Pset Note that Pset select source must be set to PF Keyboard for this to work For more information see section 11 3 4 Pset select source Press F F7 Select this to perform a Torque tuning adjustment Press F F8 Pset pressure Press F again to exit to working mode G 5 Press the F button repeatedly to exit edit mode or wait 30 seconds 8 8 Strategies for tightening monitoring Torque limit values The number of rejected tightenings will vary accordingly to the limits set If a Monitoring Setup has been performed and the limits are set unnecessarily tight or too wide set the limits to better values preferably according to specification Rehit There is no automatic function for detecting a rehit However
244. to use you need to create one Pset Parameter set For example if you want to tighten one joint to 45 Nm and another to 55 Nm you need to create two Psets although in this case you can use the same tool All Pulsor tightenings are carried out in the context of their respective Pset During Tool Setup correct parameter values will be determined for the Pset Before a Tool Setup has been performed for a Pset the Pset can not be used When the Tool Setup is ready the Pset is initialized with Torque Tuning Factor pressure values and other parameter values suitable for the application The Torque Tuning Factor translates the torque recognized by the tool into the actual torque installed in the joint To perform a Tool Setup you will need a Pulsor C system test joints the actual application joints and your preferred torque measuring tool e g torque wrench or inline torque transducer 5 2 Starting Tool Setup from ToolsTalk Pulsor There are three different ways to start a Tool Setup In two of the methods you use ToolsTalk Pulsor these methods are described here 5 2 1 Starting Tool Setup from ToolsTalk method 1 The generally quickest way to start Tool Setup is by using the Tool Setup dropdown menu symbolized as boxes with the letters ABC This dropdown is located in the toolbar Select a Pset from the list and the system will automatically select the Pset and start the Tool Setup If you choose the bottom alternative in the list Create ne
245. tool info Perform Air sensor tuning Tool service ss Tool Drift alarm Air sensor tuning Controller diagnostics a System diagnostics Confirm xi Warning Performing air sensor tuning will modify the pre set values on the tool Improper air sensor tuning may cause SA the tool to malfunction Are you sure you want to continue Air tuning Confirm no pressure Confirm line pressure Line pressure Confirm line pressure Cancel aleje Line pressure as t Air sensor tuning section 13 6 System diagnostics Also here the valve pin must be inserted into the tool After having finished this procedure do not forget to remove the valve pin again The tool will not work with the pin inserted 98 235 9836 4841 21 Diagnostics and service 13 5 Controller diagnostics The Controller diagnostics window shows the software versions and hardware configuration installed on the Pulsor Focus unit E Diagnostic PulsorF Station 1 l Oj xj Parameter Overview D200 Main code version 3 2 0 E Tool configuration E Controller diagnostics ae oftware information Hardware information H System diagnostics D201 Application code version D202 Parameter tree version D203 MC code version D204 RBU code version 0205 Boot code version fam 7 F2B iso fia a 0206 0SP code version 1 0 180 Pulsar Focus Pulsor_6 old Pau 00289535 Hardware information 0210 PF tpe D211 PF s
246. torque is entered in the Measured Torque row of the new column followed by pressing Apply The installed torque can be measured with a torque wrench or an inline Measured torque 45 35 transducer You can do the tightenings Torque Turing Factor 038 without soins through the Process of Traces AdvancedSettings Store Cancel writing in the installed torque value and pressing Apply after each tightening However it is recommended to write them in often especially for the first tightenings 34 235 9836 4841 21 Performing Tool Setup After having pressed Apply proceed with tightening the next joint if any If only one joint is used it is recommended to perform a number of tightenings on that type of joint and write in measured torque until you are satisfied with the Tool Setup results A Tool Setup can be performed without writing in any measured torque value at all although this is not recommended In such cases the Torque Tuning factor 1s set to 1 1 e the basic calculated torque value will be used a If no measured values are written in during Tool Setup the torque actually installed in the l joints during production tightenings may deviate a lot from the torque result presented Torque and angle values will not be reported to ToolsNet if no torque tuning has been done 5 4 3 Deletion of Tool Setup tightenings During Tool Setup certain parameters are calculated to identify joint properties which in turn det
247. tup To PF Setup Bit Character AckErrormMeszage Bit BatchDlecrement Bit Bit Bit Bit Bit CharstiEhangelntelF Unsigned 6 132 HN Uneigneds2 CharStlaputlntelF CharStringlnput CharStinglhange BitPield Unzigned 6 Bit BitPield Bit Bit Bit E Diagnostic mode Monitor mode Add item In the list you can see start word start byte and start bit for the selected item The start word byte and bit give the start position of an item in the bitmap The length 1s also possible to see and sometimes change If this does not match the wanted bitmap it is easy to change the length and position in the bitmap by changing the start positions in the item list Change one line at the time and then press Enter key on the PC after each line is changed It is also possible to drag and drop directly in the bitmap In this case the start positions in the Item list are updated automatically If the bitmapping is changed and a conflict occurs this part is marked with red color in the bitmap The max number of selected items is 60 in From PF setup and 60 in to PF setup For detailed information about all possible selections see chapter 30 FieldBus configuration appendix 9836 4841 21 109 235 FieldBus 15 2 2 Delete item To delete an item highlight it in the Item list and click the Delete item key 15 3 Other functions 15 3 1 Diagnostic mode When Diagnostic mo
248. tup 1 Display setup 2 Options Reset Printer setup C105 Ch ID number Configurable memory setup C106 PF name Pulsor tool config Tool lock C107 Cell ID number Not Used 10 setup C108 Cell name Not Used Set date and time Communication Protocols E EE X Close E Read sg Store 9836 4841 21 127 235 Cell and Net 18 21 Connection with ToolsTalk When connecting to a Controller CellMaster or NetMaster make sure that the following settings are correct Open Settings via Options from the menu bar Set Controller IP address of the Pulsor Focus to connect Under Ethernet setup check whether the connected Pulsor Focus is a Controller CellMaster or a NetMaster To connect the Pulsor Focus CellMaster or NetMaster click on the connect button When a CellMaster or NetMaster is connected clicking on the corresponding line in the PF Map will expand the Cell tree Net tree 128 235 9836 4841 21 ToolsNet 19 ToolsNet This chapter describes how to configure your Pulsor system together with ToolsNet 19 1 Introduction ToolsNet is part of the ATS system Assembly Tools Software that consists of Factory Overview Event Monitor and ToolsNet E ToolsNet collects saves and displays historical tightening data from Pulsor Focus Power Focus and PowerMacs units It is also possible to include other units or applications that support ToolsNet Open Protocol Once reporting is e
249. tware Setup In ToolsTalk Pulsor open the Config dialog and select I O Setup Choose appropriate I O device tab Select I O Expander under appropriate I O Device Device 2 is the default for I O Expander Select your alternatives The procedure is the same as for Internal I O See section 11 3 1 Internal I O Click Store to complete the setup in ToolsTalk Pulsor 1 Relay and digital input setup dialog Jf OK X Cancel 134 235 9836 4841 21 Accessories 20 4 Stacklight The Stacklight features four lights piled on each other it is possible to use up to five lights The user is free to change the order of the lights and also replace lights with different colors The Stacklight is configured as 2 I O expanders A light lamp uses one output a switch uses two inputs If a two way switch is used then A1 B1 represents the left switch state and A2 B2 the right switch state When a push button or one way switch is used it is enough to configure A1 B1 but it is possible to use both outputs for different functions Stacklight has two external outputs C and two external inputs D which is useful for various functions such as position switches and external warning lights Via an I O bus connector G is Stacklight connected to the tightening controller A termination plug should be applied to the second I O bus connector if Stacklight 1s at the end of the I O bus line Device 1 Ligh Light 4 Switch state A2 Switc
250. ty P402 Used when a selected Pset is to be named with a logical name Up to 25 Empty string characters P403 Copy Pset Button Used when a source Pset is to be copied to a destination Pset Cd P404 Delete Pset Button Used when a Pset is to be removed lt r If a Pset is a part of a Job it can not be deleted a P406 Pset updated Timestamp date and time for latest Pset modification Not editable 4 P41x Reset Parameter number Parameter name Description P410 Delete Pset results Button Used when all results that belongs to the current Pset is to be deleted P411 Delete all results Button Used when all Pset results 1s to be deleted 154 235 9836 4841 21 Digital inputs and outputs 23 1 3 P5xx Statistic programming P50x Statistic common parameters Parameter Parameter name Description Default setup number P502 Subgroup size Defines the subgroup size for statistical diagrams and control limits If this parameter is changed the results will be recalculated Group size can be set between 1 and 500 O For statistic process control maximum subgroup size is 20 between 1 and 4000 P505 Latest n values The latest number of values 1 100 that is used in the statistical calculations P57x SPC relative torque P504 Subgroup Defines which subgroups that will be used in the statistical calculations frequency If the frequency is 4 then only every fifth subgroup will be used Can be P503 No of su
251. uations When the Pulsor Focus is powered off No tool connected or tool connection problem No RBU connected System event 1 e an event that need acknowledgement No Pset selected Pset without Tool Setup is active Locked through digital input Pset with Click wrench strategy selected The Pulsor Focus can also optionally disable the air supply in these situations Batch completed Pset parameter Lock at batch done P152 Non approved tightening Config parameter Lock on reject C130 Job completed Job parameter Lock at job done J302 Job line control Job parameters Use line control J330 and Lock at job done J302 Service alarm Diagnostics parameter Lock tool on alarm D136 11 3 1 0 setup Pulsor Focus has extensive I O capabilities configured in branch I O Setup Apart from the internal I O ports it is also possible to connect up to 15 external I O devices to the Pulsor Focus I O Bus 11 3 1 Internal I O Pulsor Focus has four connections to internal digital inputs and relays Parameters in Config are used to configure the digital inputs and relays Select I O device 0 7 under I O setup from the Tl Config PulsorF Station 1 navigation area Parameter veriew MS A Click on Set on Internal I O line to open the 0 ae LE configuration window va damscts Wer C205 Devico 3 T Set Other 1 0 s 1 3 C204 Device 4 Dif Set Other 1 0 s 2 PNE sa 5 C205 Device 5 Off Set_ P
252. uracy Too many pulses has the drawback that oil must be filled more often in the pulse unit If you consistently have more than 30 pulses per tightening a larger tool size is recommended for the application Conversely 3 pulses or less has the drawback that the accuracy becomes poor and the pulse frequency which is used when using the tool drift alarm function cannot be calculated In this case a smaller tool model can be better for the application Tightening time The time between the first pulse and the last pulse The time between the tool trigger is activated and the first pulse Pulse frequency The number of pulses per second The time between the first and second pulse is not used in the calculation since this time is not representative Consequently the tightening must comprise at least 3 pulses for the pulse frequency to be calculated Since the calculation of the pulse frequency for 3 pulses uses only a single time interval between two pulses the result in this case should be interpreted with caution The more pulses the tightening includes the more reliable the result of the pulse frequency calculation The maximum requested pressure from the Pulsor Focus during a tightening The maximum air pressure in tool between pulses during the tightening TCB pressure The maximum pressure reached at the outlet of the TCB during tightening 62 235 9836 4841 21 Tightening and monitoring 8 3 Viewing results The Pulsor Focus can dis
253. uration name gt Tool control box Ok x Close Device diagnostic 12 2 1 Diagnose Accessories Tool Control Box In this window common information about the TCB will be shown The information contains Serial number Production date Model Ordering number Software version Boot version Boot hardware version and status of TCB buttons When Read is pressed the window including button status button pressed or not will be updated 1 SN control box Seral number A 30004 Production date 2009 10 05 Model TCB 1E Ordering number 2433 0606 20 Software version 118 Boot version 1 1 2 Board hardware version 1 Green button Up White Button Up 90 235 9836 4841 21 Diagnostics and service 13 Diagnostics and service This chapter describes how to use Diagnostic in ToolsTalk Pulsor The Diagnostics functionality can be used for retrieving information from Pulsor Focus containing general tool information service status hardware and software configuration and also includes important Pulsor features such as settings for service indicator tool drift alarm and performing an air sensor tuning and Air Hose Test For parameter descriptions see Parameter List section 23 4 Diagnostic Start Diagnostic by either double clicking on Diagnostic in the PF Map in ToolsTalk Pulsor or ED by selecting the function from the toolbar e A When storing diagnostics settings it is necessary to have a tool connected 13 1 Tool gener
254. usting keys or switches before turning the tool on A wrench or a key that is left attached to a rotating part of the tool may result in personal injury Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control of the tool in unexpected situations Use clamps or other practical means to secure and support the work piece to a stable platform Holding the work by hand or against your body is unstable and may lead to loss of control Do not force the tool Use the correct Atlas Copco tool for your application The correct tool will do the Job better and safer at the rate for which it is designed Do not use tool if switch does not work Any tool that cannot be controlled by the switch is dangerous and must be repaired Disconnect the plug from the power source before making any adjustments changing accessories or storing the tool The mains plug is considered to be a disconnecting device Disconnect the tool from the mains by pulling the plug from the socket in order to cut the power Store tools out of reach of children and other untrained persons when not in use Tools are dangerous in the hands of untrained users Check for misalignment or binding of moving parts damage and any other condition that may affect tool operation If damaged have the tool serviced before using Poorly maintained tools cause many accidents Only use accessories that are recommended by the manufacturer for
255. vice 13 3 5 Tool drift alarm graphical view After the number of tightenings passes the sample size it is possible to see a graphical view of the tool drift Press View Tool Drift alarm results button to view the information t Tool Drift alarm result Result and information Graphs Latest activation date J Nr of tightenings since activation 4704 Fit Y scale Reset Axis Latest average torque deviation Latest average frequency deviation Latest tightening date stamp Historic Results Latest history value reset date Nr of tightenings since latest history reset Value Limit Date Average Torque Deviation min i a 8 0 201 0 03 15 0 Average Torque Deviation max 21 8 0 2010 03 15 1 Average frequency deviation Lomin 0 0 8 0 2010 03 15 0 Average frequency deviation Lomax 0 0 16 0 2010 03 16 1 Pset ref Read 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 Read from file Save to file The graph will show a staple diagram containing maximum 80 values depicting the maximum and minimum values of the subgroup for each parameter The subgroup size is 2 in the beginning When all staples have been drawn the subgroup size will be doubled and the staple diagram will proceed from the 41 st position in the graph This is continuously repeated as the tool performs tightenings There are two buttons to facilitate the graphical view Fit Y scale will adapt the curve so that it optimally fits the Y axis Pressing the
256. vice 13 3 Tool drift alarm 13 3 1 Introduction Tool drift alarm is a function that detect changes in tool performance tool drift before it has an impact on production The cause of this performance change can be lack of oil in the pulse mechanism a technical fault in the tool or a change in line air pressure Tool drift alarm calculates a moving average of the relative torque and pulse frequency after each tightening If the average is above or below an activated limit the Alarm lamp on Pulsor Focus will start flashing and an event code will be generated The Tool drift alarm does not reject a tightening 1t only generates a warning 13 3 2 Enabling Tool drift alarm Follow this step by step instruction to enable Tool drift alarm Start Diagnostic either by double clicking on Diagnostic in the PF Map or by selecting the function from the toolbar and then select Tool drift alarm under Tool configuration in the navigation area a Diagnostic PulsorF Name Not Defined Parameter Overview Tool Drift alarm Tool Drift alarm general tada O D900 Tool Drift data activated Tool general information D901 Peet used Pulsar tool info i Tool service a Tool Dritt alarm Alr sensor tuning D902 Sample size FOO Controller diagnostics D903 Tightenings to be included Al ii id D904 Tool drift alarm updated os 23 Wes Tool Drift alarm limits These limits are automatically calculated after sample size nr of tightenings if no value is writ
257. w a new Pset is created and you will be given the option to name the Pset Thereafter it is automatically selected and Tool Setup is started ToolsTalk Pulsor ACTA F File Edit Focus Options selected Controller I Na l Create mew ER Ethernet ToolsTalk Pulsor can select a new Pset only if Pset Select Source is set to Ethernet Serial If it is not ToolsTalk Pulsor will ask if it should set the Pset select source for you Answering yes in this dialog will set Pset select source and store automatically To set Pset select source manually see chapter 11 3 4 Pset select source 9836 4841 21 31 235 Performing Tool Setup 5 2 2 Starting Tool Setup from ToolsTalk method 2 Make sure the correct Pset is activated and that the Pset window for that Pset is open Start Tool Setup by clicking the Perform Tool Setup button located in the Pset window Programming gt Tool Setup If the correct Pset is active the Tool Setup window will be shown The Perform Tool Setup button will be greyed out if the correct Pset is not active 94 Pset 1 Gear box PulsorF Name Not Defined Parameter Overview Tool Setup Perform Tool Setup Programming Torque Tuning Adjustment Tightening Options P100 Strategy Pulsor fixed v vee count P649 Target torque 0 00 Nm onitoring i Monitoring Setup P123 Target angle Deg Control Parameters P680 Tool model used Pset setup P681 Tool setup performed ir Staic programming
258. w Pset choose a number in the list and name the Pset ie Pset 1 Gearbox PulsorF Station 1 ioj x Parameter Overview P402 Name Pset Gearbox E Programming E Control Parameters View existing Pets Er Pse t setup E Peet administration Create new Piet Statistic programming Copy Fset Delete Peet P406 Pret updated 2008 04 09 11 03 23 Reset ls Perom Tool Setup Delete Pset results Perform Monitoring Setup Delete all results M Close Pa Compare A i Undo Compare Ge Read el Store 7 5 Loosening Loosening should be performed by keeping the trigger button pressed until the joint is entirely loosened Avoid pressing the trigger button repeatedly during the loosening It is possible to take loosenings in account if batch count is used This is done by setting parameter C133 Decrement batch at OK loosening See section 11 2 3 Settings for Options It is also possible to disallow loosenings after a correctly performed tightening This is done by setting parameter C131 Disable loosening at OK see section 11 2 3 Settings for Options Note that an attempt to loosen a correctly tightened joint will also be counted as a batch decrement if batch count is used since the joint s clamp force may have been altered before the air was shut off 9836 4841 21 59 235 Tightening and monitoring 8 Tightening and monitoring This chapter describes the parameters that are measured when p
259. with the Cursor function It is possible to zoom inside the diagram by creating a zoom box with the mouse button pressed 118 235 9836 4841 21 Statistics 17 Statistics 17 1 Introduction to Statistics in Pulsor Focus The Pulsor Focus statistics are measured after each tightening and can be sent to a PC via serial or Ethernet connection It is also possible to send statistical reports to a printer There is a stat alarm LED on the front panel of the Pulsor Focus unit Statistics are calculated based on the eee result parameters Torque As selected in EE system Final angle deg Final angle in degrees Number of pulses Number of pulses in the tightening Line pressure is displayed in the unit stated in parameter C128 Air Pressure presentation unit see section 11 2 2 Display and toggle display The following statistical results are calculated and displayed for torque and angle parameters CO Highest result in ees Pset eooo o i e Tow AE C Xo The mean value for the selected Pset E Sigma Shows the calculated standard deviation Mean 3 sigma e CAT 9836 4841 21 119 235 Statistics Mas Average value for the latest completed subgroup Sigma for the latest completed subgroup R Average of subgroup range number of subgroups Average of subgroup average number of subgroups 17 2 Statistical Process Control SPC In order to rapidly detect changes in the process Pulsor Focus is equipped
260. y less 4 2 2 Oil level in the pulse unit With continuous use the oil level in the pulse unit will gradually decrease This will increase the tool s pulse frequency The pulse frequency can be monitored in Tool Drift Alarm see section 13 3 Tool drift alarm When the oil level in the pulse unit gets too low the pulses become weaker and the pulse frequency will get noticeably higher If the tool has previously worked well but now displays the above described symptoms you should fill the pulse unit with ca 0 05 0 5 ml oil the exact amount is dependent on the tool size If the tool still does not function satisfactorily please see the tool s Product Instructions document for the exact method for filling oil in the pulse unit G 5 If the oil level is too high the tool will run slower and may have problems reaching high torques 9836 4841 21 29 235 Performing Tool Setup 5 Performing Tool Setup The Tool Setup can be started from ToolsTalk Pulsor or directly from the Pulsor Focus using the buttons on the front panel If you want to perform Tool Setup from ToolsTalk Pulsor but are new to the program please consult chapter 6 1 Connecting the computer to Pulsor Focus to 6 5 Activating Pset and showing Pset main window before continuing with this chapter 5 1 Introduction The same Pulsor Focus unit can be used to tighten different joints with different target torques and with different Pulsor C tools For each combination you want
261. y reducing the air pressure If the Pulsor Fixed strategy is used this will also lower the performance of the tool In this case the method can not be used if the resulting final torque 1s too low See tools PI for detailed instructions Change these parameters in the Control Parameters tab in the Pset window if Tool Setup is already finished or press Advanced Settings if performing Tool Setup from ToolsTalk Pulsor 9836 4841 21 225 235 32 intel zx The centre line xo me o o Xo The mean of the average o Sigma andada a Alpha lohen a symbol forane o omais C CL Clear button Config Configuration me Hen anio YO input mD Trienio OK ___ Approved tightnings P Pulsor Focus 9836 4841 21 Abbreviations 227 235 Abbreviations Rapid Backup memory 228 235 9836 4841 21 General safety instructions for Pulsor Focus unit 33 General safety instructions for Pulsor Focus unit Read and understand all instructions Failure to follow all the instructions listed below may result in electric shock fire and or serious personal injury All locally legislated safety rules with regard to installation operation and maintenance must be respected at all times Refer installation and servicing to qualified personnel only 33 1 Work area Keep your work area clean and well lit Cluttered benches and dark areas invite accidents Do not operate power tools in explosive atmospheres such as in the pr
262. ying the air pressure to the tool At any given time the TCB feeds the air pressure as determined by the system It is important that the air supply to the tool is sufficient To secure that the tool works under optimal conditions make sure that the coupling between the air system and the TCB allows air to flow freely into the TCB For the connection between TCB and tool hose a coupling of type ErgoQic will be provided with the TCB It is strongly recommended to use this coupling or another high throughput coupling here as the scatter characteristics of the tightenings will be heavily dependent on the capacity of this coupling For recommended tool hose diameters for the different tool models see chapter The tool 4 1 1 Buttons Located on the TCB front are a green and a white button The buttons have default functions assigned to them as described in chapter 3 2 Tool Control Box To change the assigned functions refer to chapter 12 1 Tool Control Box settings 4 1 2 The Air Hose Test The Pulsor C system supports air hose lengths of up to 10 meters between TCB and tool It may work with a longer hose but the quality of the tightenings will decrease when using a long hose A shorter air hose between TCB and tool improves tightening accuracy and decreases tightening scatter To be able to determine when to shut off the air to the tool the system needs to estimate how much time will pass after air shutoff until the air pressure is d
263. your model Accessories that may be suitable for one tool may become hazardous when used on another tool 33 4 Service Tools should only be serviced by qualified repair personnel Service or maintenance performed by unqualified personnel could expose users to serious personal injury When servicing a tool only use original replacement parts Use of unauthorized parts or failure to follow Maintenance Instructions may create a result in electric shock or personal injury A There is a danger of explosion if batteries are incorrectly replaced Replace only with the same or equivalent type recommended by the equipment manufacturer Discard used batteries in accordance with manufacturer s instructions 230 235 9836 4841 21 General safety instructions for Pulsor Focus unit es XAXXX wit sed A Atlas ds Tools AB STOCKHOLM SHEDEN Made in Sweden 0000 Type rt no Ser 4222 0367 01 90 120 180 240 VAC 300 W 50 60 Hz DUTY CYCLE 1 10 Max amb temperature 40 C 104 F ETL LISTED CONFORMS TO UL STD ANSI UL 5086 2000 NP us CERTIFIED TO dls CAN CSA STD 022 2 NO 14 95 9836 4841 21 231 235 34 EC declaration of conformity EC DECLARATION OF CONFORMITY DECLARATION DE CONFORMITE CE EG KONFORMITATSERKLARUNG DECLARACION DE CONFORMIDAD CE DECLARAGAO DE CONFORMIDADE CE DICHIARAZIONE DI CONFORMITA CE EG KONFORMITEITSVERKLARING EYPQNAIKH2 KOINOTHTA2 CE We Atlas Copco Tools AB STOCKHOLM

Pulsor C - Edlo Sales & Engineering

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Pulsor C - Edlo Sales &amp; Engineering

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Pulsor C - Edlo Sales & Engineering