User guide

Power Focus 600

Atlas Copco Industrial Technique AB

9836 4954 01
Edition 1.10
2012-06
Copyright Atlas Copco Industrial Technique AB
Note! This manual can be altered without further notice.
For further information log in to Atlas Copco www.atlascopco.com
 Table of content

Contents
Power Focus 600
1 Overview .................................................................................................................7
1.1 Safety and operating instructions ................................................................................7
1.2 Included images and screenshots ...............................................................................7
2 System architecture ...............................................................................................9
2.1 Introduction .................................................................................................................9
2.2 System components ....................................................................................................9
2.2.1 IAM (Intelligent Application Module) ..............................................................................................9
2.2.2 Hardware accessories .................................................................................................................10
2.3 System information ...................................................................................................12
2.3.1 Tool information ............................................................................................................................13
2.3.2 Software information ....................................................................................................................13
2.3.3 Hardware information ...................................................................................................................14
3 Setup ......................................................................................................................15
3.1 Setting up the controller ............................................................................................15
3.1.1 Preferences ..................................................................................................................................16
3.1.2 Network settings ..........................................................................................................................15
3.1.3 Result settings .............................................................................................................................16
3.1.4 PIN settings ..................................................................................................................................17
4 Power Focus user interface ................................................................................19
4.1 Operating and handling .............................................................................................19
4.1.1 Front panel ...................................................................................................................................19
4.1.2 Web interface ...............................................................................................................................21
4.2 Menu overview ..........................................................................................................21
4.2.1 Tightening menu ..........................................................................................................................21
4.2.2 Batch menu ..................................................................................................................................22
4.2.3 Tool menu ....................................................................................................................................22
4.2.4 Controller menu ...........................................................................................................................22
4.2.5 Accessories menu ........................................................................................................................22
4.2.6 Reports menu ..............................................................................................................................23
4.2.7 Settings menu ..............................................................................................................................23
4.2.8 Help menu ....................................................................................................................................23
5 System functionality ............................................................................................25
5.1 Tightening ..................................................................................................................25

9836 4954 01 3
Table of content

5.2 Batch .........................................................................................................................25

5.2.1 Batch sequence settings ..............................................................................................................25
5.2.2 Batch settings ..............................................................................................................................26
5.3 Scanner .....................................................................................................................26
5.3.1 Significant positions .....................................................................................................................26
5.3.2 Connecting the scanner ...............................................................................................................27
5.3.3 Configuring the scanner ...............................................................................................................27
5.3.4 Valid scanners ..............................................................................................................................27
5.4 Export/Import .............................................................................................................28
5.4.1 Exported information ....................................................................................................................28
5.4.2 Export/Import from a PC ..............................................................................................................29
5.4.3 Export/Import from the controller .................................................................................................29
5.5 Motor tuning ..............................................................................................................29
5.6 Calibration .................................................................................................................30
5.7 Software update ........................................................................................................30
5.7.1 Software update – USB ...............................................................................................................30
5.7.2 Software update – Web interface .................................................................................................30
5.8 Software activation ....................................................................................................31
5.9 Reports ......................................................................................................................31
5.9.1 Results .........................................................................................................................................31
5.9.2 Events ..........................................................................................................................................31
6 Tightening setup ...................................................................................................33
6.1 Start stage .................................................................................................................33
6.1.1 Thread direction ...........................................................................................................................34
6.1.2 Soft start .......................................................................................................................................34
6.1.3 Rehit detection .............................................................................................................................35
6.2 Rundown stage .........................................................................................................35
6.2.1 Selftap ..........................................................................................................................................35
6.2.2 Rundown torque limits .................................................................................................................36
6.2.3 Rundown angle limits ...................................................................................................................36
6.2.4 Rundown complete ......................................................................................................................37
6.3 Tightening stage ........................................................................................................37
6.3.1 Tightening strategies ....................................................................................................................38
6.3.2 Final torque limits .........................................................................................................................40
6.3.3 Final angle limits ..........................................................................................................................40
6.3.4 Torque compensation ...................................................................................................................41

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 Table of content

6.4 Stop stage .................................................................................................................41

6.4.1 Soft stop .......................................................................................................................................42
7 Common procedures ...........................................................................................43
7.1 Setting up a Basic Tightening ....................................................................................43
7.1.1 Scenario .......................................................................................................................................43
7.1.2 Configuring the Tightening program ............................................................................................43
7.1.3 Activating the Tightening program (Pset) .....................................................................................44
7.2 Tool calibration ..........................................................................................................44
7.2.1 Scenario .......................................................................................................................................44
7.2.2 Setting up the tool torque transducer ...........................................................................................45
7.2.3 Selecting tightening program .......................................................................................................45
7.2.4 Adjust the tool’s calibration value .................................................................................................45
8 Reference information .........................................................................................47
8.1 Controller connections ..............................................................................................47
8.1.1 Connections – Front .....................................................................................................................47
8.1.2 Connections – Underside .............................................................................................................48
8.2 Digital inputs and outputs ..........................................................................................48
8.2.1 Digital inputs ................................................................................................................................48
8.2.2 Digital outputs ..............................................................................................................................50

9836 4954 01 5
 Overview

1 Overview

1.1 Safety and operating instructions

T WARNING Read all warnings and all instructions.
The safety and operating instructions as described in the Product instructions that is delivered together with
the system must be read and complied. Ensure that you read and understand all instructions. Failure to follow
all the instructions may result in electric shock, fire and/or serious personal injury. All locally legislated
safety regulations with regard to installation, operation and maintenance must be adhered to at all times.
Refer installation and servicing to qualified personnel only.
Save all instructions for future reference.

Contact your Atlas Copco representative if questions regarding the safety and operating instructions arise.

1.2 Included images and screenshots

This manual includes screenshots from the product interface. The screenshots can show examples of para-
meter settings or other configurations and are NOT intended to be generally applicable, unless stated otherwise.
Check with your local Atlas Copco representative how to set up your specific system environment.

9836 4954 01 7
 System architecture

2 System architecture

2.1 Introduction
Power Focus 600 is the latest generation of control and monitoring systems for quality critical assembly.
The system is designed to be the successor of air tool solutions and DS/DL systems.

The Power Focus 600 is a control system for Tensor ES tools.

2.2 System components

This section describes the system components such as IAM and hardware accessories in the Power Focus
600 system.

2.2.1 IAM (Intelligent Application Module)

The IAM (Intelligent Application Module) contains the controller software, configurations, results, and events.
It is located on the backside of the front lid and available in two different versions.

9836 4954 01 9
System architecture

PF6-003

Figure 2: IAM - Station control

Functionality Joint control Station control

Pset 1 16

Results 30 1000

Events 1000 1000

Batch — Batch sequence – Configure up to four batch sequences. (1 batch

sequence = 8 batches x 99 tightenings)

Accessories No external hardware accessories can be The following external hardware accesories can be connected and
connected or configured. configured:
• I/O Expander
• Stacklight
• Operator panel
• Socket selector
• Scanner

2.2.2 Hardware accessories

The Power Focus concept features a number of accessories that simplify the guidance and follow-up of per-
formed tightenings. To use accessories with the Power Focus a Station control IAM is required. The accessory
functions can be set up from the Accessories menu on the Power Focus unit.
The benefit of using serial bus-based accessories (I/O bus) is that they can be connected in series, from ac-
cessory to accessory rather than hard wiring each accessory to the Power Focus. This arrangement increases
flexibility and quick installation.
Power Focus uses 24 V DC, 1.5 A to power the bus, which is also used to power external I/Os. If more current
is needed, the bus must be powered externally. Every device has a 24 V DC input for this purpose.
Note! For further information about the accessories, please refer to each accessory’s user guide.

10 9836 4954 01
 System architecture

2.2.2.1 I/O Expander, sealed

I/O Expander enables the connection of several inputs and relays when
more than those built-in are required. There are eight digital inputs, and
four digital and four relay outputs with the same functionality as the four
built-in I/Os. Each input and relay can be configured individually.
The sealed I/O Expander is designed for more demanding environments
than I/O Expander.

PF6-009
2.2.2.2 Socket selector
Socket selector is a socket tray with LED’s that can be used to guide
the user through, for example, a Batch sequence. When using more than
one Pset it is very convenient to use a selector. When a socket is lifted,

PF6-008
the corresponding Pset will be selected.
The Socket Selector is available with four or eight sockets, and
communicates on the I/O bus.

2.2.2.3 Operator panel

Operator panel is an external device for the Power Focus. It is a general
purpose lamp- and switchbox, replacing the customer specials that are
made today. The Operator panel communicates directly with the Power
Focus and the device configuration is made through the controller HMI.
PF6-010

9836 4954 01 11
System architecture

2.2.2.4 Stacklight
Stacklight ESL-04 is a flexible light and switch device designed to
interface with controllers equipped with an I/O Bus.
Stacklight DSL-03 is a simple and customizable light and switch device,
designed to interface with controllers equipped with Internal I/O
connectors instead of I/O-bus.
The stacklight comes with features such as buzzer, rotating light etc..

PF6-011
2.2.2.5 Scanner
Scanners are used to facilitate and automate the process of assembly
and and selection of tightening programs.
Scanners can read a barcode or QR code and, based on that information,
select the appropriate batch sequence to use for that operation.

PF6-025

2.3 System information

System information about controller hardware and software, tool, and tool accessories.

12 9836 4954 01
 System architecture

2.3.1 Tool information

The Tool information view contains information used for giving service personnel accurate information
about the tool connected to the controller so that they give adequate help and support.

Note! To access the Tool menu, a tool must be connected to the controller.

On the Tool menu, go to Tool information.

PF6-014
Figure 8: Tool information view

Information Description

Model Tool model denomination.

Max torque The maximal torque the tool is able to produce. This value is used to calculate the tightening parameter
values depending on Tool max torque.

Max speed The maximal speed the tool is able to produce. This value is used to calculate the tightening parameter
values depending on Tool max speed.

Gear ratio

Serial number The tool’s serial number can be needed when the correct version of the Product instruction is required,
in order to get the correct spare parts or service instructions.

Software version

Product number The tool’s Product or Ordering number.

2.3.2 Software information

The Software view contains information used for giving service personnel accurate information about the
software installed on the controller so that they give adequate help and support, and an option to update and
activate the controller software.

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System architecture

On the Controller menu, go to Software.

PF6-015
Figure 9: Software information

Information Description

Version This is a unique version number of the software currently activated on the controller.

2.3.3 Hardware information

The hardware information window gives details about controller type and serial number as well as the con-
troller’s internal boards.

On the Controller menu, go to Hardware.

PF6-016

Figure 10: Hardware information

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 Setup

3 Setup
For instructions on how to mount and connect the Power Focus 600 controller, please refer to the Product
instructions (9836 5795 00).

3.1 Setting up the controller

The controller can be set up to display the text in the interface in a specific language or to show torque values
in a unit of your choice. You can also set up the controller to be accessed on a LAN.

Controller settings are available in the Settings menu.

Figure: Settings menu

3.1.1 Network settings

The Product name - volume can be set up to be accessed on a LAN (Local Area Network) or accessed directly
from a connected PC. It uses the IPv4 protocol.

Note! Only the Factory Ethernet port can be configured. The Service Ethernet port has a
designated IP address, 169.254.1.1, that cannot be configured.

3.1.1.1 Access controller on LAN

Setting up the controller on a LAN is done by connecting the network cable to the Factory Ethernet port and
then either manually specifying the required information or, if available, using the information provided by
the DHCP server. Required information is IP address, Subnet mask, and Gateway. This information should
be provided by the local system administrator.

9836 4954 01 15
Setup

3.1.1.2 Access controller from a connected PC

To access the controller interface through a PC connected directly to the controller, connect a straight through
ethernet cable (RJ45) to the Service Ethernet port and browse to the port’s designated IP address, 169.254.1.1.

3.1.2 Preferences
3.1.2.1 Language
The controller interface can display the text in the following languages: English, Czech, German, Spanish,
French, Korean, Italian, Japanese, Portuguese, Russian, Swedish and Chinese.

3.1.2.2 Torque units

Different countries use different units of measure for length, weight etc. This can also vary depending on
industry. By specifying the torque unit all displayed torque values will be recalculated and displayed in the
chosen unit.

3.1.2.3 Date and Time

In order to get the correct time stamp on events and results the date and time must be set.

Note! An internal battery will keep date and time set although no external power is connected to
the controller, see section Connections.

3.1.3 Result settings

In Result settings the appearance of the result view can be configured. It can display results in numbers only
or as a graph (or trace).

3.1.3.1 Result view appearance

To better learn how a tightening behaves and to help setting the tightening parameters correctly the trace
functionality can be activated. It is possible to start the trace either from when the tool trigger is pressed or
from when Rundown complete is set. With trace set to off the result will be displayed in numbers.

16 9836 4954 01
 Setup

PF6-013

PF6-012
Figure 12: Trace - Trigger pressed Figure 13: Trace - Rundown complete

3.1.4 PIN settings

Enabling the PIN can prevent unauthorized usage of the controller. The PIN must be a four-digit number in
the range 0000–9999. When enabled the controller will lock after 20 seconds or when the lock button is
pressed.

Note! The controller can always be accessed via a web browser and a connected PC even though
PIN is enabled.

9836 4954 01 17
 Power Focus user interface

4 Power Focus user interface

This section describes how to get started using the controller interface and gives an overview of the controller
functionalities.

4.1 Operating and handling

The Power Focus 600 is set up and configured by using the controller front panel. You can also access the
controller interface through a web-browser by browsing to the controller’s IP-address on a connected PC.

4.1.1 Front panel

The front panel contains a display, a keypad with special keys, navigation keys and an alphanumeric keypad.

Display A color display showing configuration

views and results.

Special keys and Special function keys and arrow keys

Navigation keys for navigation. Display

Special keys and

Alphanumeric The Alphanumeric keypad is used to Navigation keys
keypad enter data into fields and text boxes. Alphanumeric
keypad

PF6-027

Figure 14: Front panel

9836 4954 01 19
Power Focus user interface

4.1.1.1 Display
Header will either show the main menu or the Header
path to the current view. Use the right and left
arrows to navigate when in the menu.

Content displays the options and functions Content

available in a specific view on the controller.

Footer contains help information about the

selected option or function. Footer

Figure 15: Controller display

4.1.1.2 Keypad
Keyboard
Key button Name Description

Lock The Lock button activates the PIN lock. Enter the PIN to unlock the keypad.

Cancel Cancels the current option or deletes a selected value.

HOME Home Brings the user back to the start menu..

Result Go to the result view.

ENTER OK OK is used to execute selected functions, acknowledge events and to enter data into text
OK boxes.

Arrow keys Navigation Use the arrow keys to navigate in the controller interface.
RIGHT arrow: Execute selected function, select current option or view.
LEFT arrow: Leave current option or view

20 9836 4954 01
 Power Focus user interface

4.1.1.3 Navigation
You navigate in the controller interface by using the arrow keys. Options are selected by pressing OK or the
right arrow key. To enter data into a text box press OK.

4.1.2 Web interface

The web interface is identical to the controller display. This enables configuration and programming of the
controller by using a web-browser on a computer connected to the controller, see section Network settings.

Note! Users can program the controller from the controller and the web interface at the same
time.

4.1.2.1 Navigation
You navigate in the web interface by using the arrow keys on your keyboard. To select options press ENTER
or use the right arrow key, and to enter or confirm data in a text box, press ENTER.

4.2 Menu overview

The controller has up to eight menus where you can configure tightenings and hardware accessories, perform
tool maintenance, administer software and view reports.

Note! The Batch menu and the Accessories menu are only available with the Station control
IAM. See section IAM (Intelligent Application Module) for more information about IAM
specifications.

4.2.1 Tightening menu

The Tightening menu lists the tightening configurations (Psets) stored in the controller.
Here you can configure the Psets. Learn more about how to set up and configure a
tightening in section Tightening setup.

9836 4954 01 21
Power Focus user interface

4.2.2 Batch menu

The Batch menu lists the batch programs (Batch sequences) stored in the controller. If
using a scanner with the tool, this is where the scanner is configured. Learn more about
how to set up and configure a batch sequence in section Batch.

Note! The controller must be equipped with a Station control IAM to be able to access batch
funtionalties.

4.2.3 Tool menu

The Tool menu has functions related to the tool connected to the controller. Here the
user can access information about the connected tool, perform tool calibration, motor
tuning, and set up tool maintenance.

4.2.4 Controller menu

On the Controller menu the user can administer and install new controller software,
view information about the hardware devices installed on the controller, and export or
import configurations and reports.

4.2.5 Accessories menu

On the Accessories menu the user can configure the internal I/Os and the hardware
accessories that can be used with the controller such as I/O Expander, Stacklight, Operator
Panel and Socket Selector. The Scanner is configured on the Batch menu.

Note! The controller must be equipped with a Station control IAM to be able to connect to,
and configure accessories.

22 9836 4954 01
 Power Focus user interface

4.2.6 Reports menu

On the Reports menu the tightening results, events, and NOK ratio are available.
Depending on IAM type the number of stored tightening results may vary.

4.2.7 Settings menu

The Settings menu contains settings for to set up the controller on a LAN, PIN, language,
date and time, torque unit to be used, as well as how to display the results.

4.2.8 Help menu

The Help menu contains useful help sections about the controller.

9836 4954 01 23
 System functionality

5 System functionality

5.1 Tightening
The tightening settings are divided in four stages; Start, Rundown, Tightening, and Stop. Each one representing
a fundamental part of the tightenings process. Here you can configure target values for torque, angle and
speed for the tightening as well as define limits these values must keep within.
See section Basic Tightening Setup for instructions on how to set up a basic tightening and section Tightening
setup for a more detailed description of the configurable tightening parameters.

5.2 Batch
Batch sequences are used to perform a specified number of tightenings in a specific order.
A batch sequence is activated by selecting the batch sequence in the list of batch sequences and then press
OK. This will immediately activate the batch sequence and show the result view.

5.2.1 Batch sequence settings

A batch sequence can consist of up to eight batches, with a batch size of up to 99 tightenings. The batches
in a batch sequence can be carried out in numerical order, provided they are configured properly, or by using
a Socket selector to decide which batch to run.

Parameters Description

Repeat batch sequence On: The batch sequence is reset and ready to be repeated.
Off: The tool is locked and a Pset or batch sequence must be selected in order to continue
performing tightenings.

Free order No: The configured batches will be executed in the order listed, provided they have been configured
to perform tightenings. If socket has been specified the system will prompt for the socket when
the batch is to be performed.
Yes: The configured batches can be executed in any order. The operator must indicate to the
system which batch to be executed by using a Socket selector.
A batch is regarded as complete when all joints have been completed.

Increment on NOK Makes it possible to increment the batch counter value although the tightening is reported as
NOK.

9836 4954 01 25
System functionality

Parameters Description

Max coherent NOK Max coherent not ok tightenings (NOK) are a defined maximum allowed number of NOK
subsequent tightenings in a batch.

5.2.2 Batch settings

A batch is set up to perform a specified number of consecutive tightenings using the same Pset. Batches must
at least have Pset and Batch size specified in order to run.

Parameter Description

Choose Pset The Pset to use with the batch.

Batch size Number of tightenings the batch will perform.

Socket When using a Socket selector this socket position is used to activate the batch.

5.3 Scanner
Note! The scanner is configured in the Batch menu.

A scanner is used to read a barcode string or a QR code containing information used to have the controller
to choose the appropriate batch sequence.
The controller will read the characters you specify and put them together to a string of text. This text string
is then matched to the pre-defined strings you have specified in the cotroller, and if they match the batch
sequence linked to your pre-defined string will be selected.
Barcode strings of a length of up to 1024 characters can be read and they can contain characters in the positions
32-126 in the ASCII table. If the barcode contains a string longer than 1024 characters the remaining part
of the string, from position 1025 and forward, will be discarded.

5.3.1 Significant positions

Significant positions are used to specify which characters in the barcode string to read when putting together
the string to match with your pre-defined string. The number of significant positions must match the number
of characters in the pre-defined strings.

26 9836 4954 01
 System functionality

Note! When entering the significant positions on the controller the digits will be separated by
a period rather than a comma. However, the period will be changed to a comma when
the OK button is pressed to enter the data.

5.3.1.1 Configuring Significant positions to read in barcode string

The positions in the barcode string are associated with a number between 1–1024. The string’s first position
is 1 and the last is 1024.

String from scanner A B C D E F G H ... X

Number in string 1 2 3 4 5 6 7 8 ... 1024

The significant positions must be specified following the rules described in the table below.

Significant Barcode string to match

Description positions Valid configuration with pre-defined string

Significant positions in order 1,2,3,6,8 Ok ABCFH

Repeating the same position 1,1,3,3,8 Ok AACCH

Significant positions in optional order 7,1,2,3,8 Ok FABCH

Range of numbers 1–3,6,8 Not possible —

5.3.2 Connecting the scanner

The scanner is connected to the controller’s USB port. When connected an icon will appear next to the
scanner item in the accessories menu.

5.3.3 Configuring the scanner

The scanner itself must be set up using a US keyboard, and the scanner shall emit a carriage return character
to terminate the barcode string.

5.3.4 Valid scanners

At the moment the following scanners are available for use with the Power Focus 600 controller:

9836 4954 01 27
System functionality

• Datalogic PD8530
• Honeywell 4800i
• Intermec SR61T
• Symbol DS3508

5.4 Export/Import
The export and import function lets the user export the events and tightening results in the Reports menu
for analysis in external programs, as well as transfer Pset, batch, and controller configurations between
controllers.

Note! When using the import function all settings for Pset, Batch, Accessories and Controller will be
replaced with the settings from the import file. However, settings for Network, PIN, and results
and events will not be imported.

The Export/Import function is located in the Controller menu.

5.4.1 Exported information

The exported file is a zip archive containing a binary file with all the settings, as well as two comma separated
files with results and events.

File Description

PFExport__<Time stamp>_Events.csv A comma separated file containing the following information:

• Severity: Type of event.
• Date and time: A time stamp of when the event occured.
• Code: The event ID.
• Description: A short description of the event.

PFExport__<Time stamp>_Results.csv A comma separated file containing the following information:

• Status: Tightening status OK or NOK.
• Date and time: A time stamp of when the result occured.
• Torque result: The final torque value.
• Description: A short description of the result status.

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 System functionality

File Description

ExportInfo.txt Information about the controller setup and controller software.

settings.bin A binary file containing all Psets and Batch settings, Accessory configurations, and
controller settings such as: Language, Torque units, Date and time, and Result
appearance.

5.4.2 Export/Import from a PC

When using this function from a PC the user will bli prompted to select where to save or get the exported
file.

5.4.3 Export/Import from the controller

When using this function from the controller a USB-device must be connected to be able to export and import
data.

5.5 Motor tuning

A motor tuning adjusts the tool’s motor control unit to optimize the performance and minimize loss. A motor
tuning should be performed on each specific combination of controller and tool together.
Before performing the motor tuning make sure tool and controller are set up to perform tightenings.
To start the motor tuning:

1. On the Tool menu, go to Motor tuning, and then

select Perform.
2. Press OK to start the Motor tuning.
3. The motor tuning will take approximately 2 minutes
and will rotate the spindle in both clockwise and
counterclockwise direction before it is finished.
4. If the motor tuning was successfull an OK event
will be displayed.
5. If the motor tuning was not successful, or the tool Figure 30: Motor tuning
trigger was released before the motor tuning was
finished, a NOK event will be displayed.

9836 4954 01 29
System functionality

5.6 Calibration
Tool calibration is used to control how well a tool, a controller-tool combination or equivalent corresponds
to a transducer.
The calibration value stored in the tool memory is used to adjust the torque value given by the tool’s torque
transducer so that the correct torque value is displayed on the controller. The controller displays the date
when the tool was last calibrated.
See section Tool calibration for a tutorial on how to calibrate the tool.

5.7 Software update

Installing a second version of the controller software can be useful when performing upgrades on multiple
controllers. When production is ready for switching to the upgraded software, activation of the new software
version can be made locally on the controller or from a remote computer.
A new software distribution can be installed either by connecting a USB flash drive containing the software
to the controller’s USB port, by using the web interface.
After the installation the user is prompted to activate the software.

Note! The Software update option is only visible when browsing to the controller interface from a PC,
but the user will be prompted to update the software when inserting a mass storage device with
a valid software version in the USB port

5.7.1 Software update – USB

The installation wizard will start automatically when connecting the USB flash drive to the controller. Follow
the instructions to finish installation.

5.7.2 Software update – Web interface

To install the software from the web interface:
1. On the Controller menu, go to Software, and then select Software update and click Choose File.
2. Browse and choose the software upgrade file and follow the instructions to finish installation.

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 System functionality

5.8 Software activation

The controller can store two installed software versions. By using the Software activation it is possible to
choose which software version to use. Software activation can be performed either locally from the controller
or remotely from a web-browser.

Note! The activation process requires a restart of the controller.

To activate the installed software:

1. On the Controller menu, go to Software, and then select Software activation.
2. Press OK to start activation, and follow the instructions.

5.9 Reports
The Power Focus 600 can store up to 1000 individual tightening results and events, depending on IAM type,
on the IAM device. The reports and events can also be exported as comma separated files to a PC or USB-
device. For more information on the Export/Import function, please refer to the section Export/Import.

5.9.1 Results
The information stored is the tightening status (OK/NOK), date and time of the performed tightening, and
the resulting torque value.When the list is full the oldest result value will be overwritten when a new tightening
is performed.

5.9.2 Events
The information stored is date and time when the event occured, the event id or event code to identify the
specific event, event description and severity of the event. When the list is full the oldest event value will be
overwritten when a new event occurs.

9836 4954 01 31
 Tightening setup

6 Tightening setup
The Power Focus 600 tightening program need some parameters to be set in order to perform a tightening,
such as the Target torque. Other settings are optional such as Soft start, Selftap, and Torque compensation
or which tightening strategy to use. It is also possible to monitor the tightening as it progresses by adding
limits in which the torque, or angle the nut turns, should keep within.
The tightening procedure is divided into four stages; Start, Rundown, Tightening and Stop.
Torque/Time Angle/Time Speed/Time

Angle Max

Tq Max Angle Max

Angle Angle Angle Angle
Offset Interval Angle Min

Tq Compl. An Angle Min Target Tq

Tq Max Speed
Tq Min

Angle Limit
Tq Max From Tq
Tq Min

Tq Max Rundown
Compl.
Angle Limit
From Tq Tq Compl.
Tq Min Point
Time
Speed Speed Length

Soft start Selftap Rundown Tightening Soft stop

Figure 35: Power Focus 600 tightening steps

6.1 Start stage

The Start stage initiates the tightening and enables socket and thread finding. Here you also specify whether
to use clockwise or counterclockwise torque by defining the tightening direction.

9836 4954 01 33
Tightening setup
Torque

Time

Figure 36: Start stage

6.1.1 Thread direction

This defines the tightening direction of the spindle to clockwise or counterclockwise. The rotation of the
spindle will always be in this direction except during the loosening step used in the Three step behavior or
if it has been redefined by the Rotate strategy.

Parameter Description Default value

Thread direction Defines the tightening direction of the spindle. Clockwise

6.1.2 Soft start

The Soft start behavior enables setting of the speed, angle and torque to help the bolt to enter the thread, and
to prevent the tool being jerked out of position when pressing the tool trigger.

Parameter name Description Default value

Soft start Enables setting the tool’s speed, turn and torque to facilitate for the bolt to enter the On
thread.
Off: Soft start is turned off.
On: Soft start is turned on.

Speed Defines the speed during the Soft start.

Angle Defines the angle to turn the spindle for the bolt to enter the thread. 90°

Torque max Defines the torque applied during the Soft start.

34 9836 4954 01
 Tightening setup

6.1.3 Rehit detection

When activated it detects during tightening if the bolt to be tightened is already tightened or not.

Parameter Description Default value

Rehit detection Detects attempts to tighten an already tightened bolt. Early

Early: Terminates the tightening immediately when a rehit is detected to end the
tightening in an ergonomic behavior. The tightening will be considered as NOK.
Requires that Soft start is activated.
Complete: The tightening is not terminated until all tightening stages have been
executed. The tightening will be considered as NOK.
Off: No rehit detection will be performed.

6.2 Rundown stage

The part of the tightening from when the bolt enters the thread until just before the bolt head touches the
underlying surface and snug is reached. The torque required during rundown does not contribute to any
clamping force.
Torque

Time

Figure 37: Rundown stage

6.2.1 Selftap
Selftap enables tightening where the rundown torque required is greater than the target torque. For example
when tightening thin layers of metal using self-drilling bolts.

9836 4954 01 35
Tightening setup

Parameter Description Default value

Selftap Activates the Selftap behavior. Off

Angle Defines the angle to turn the socket during Selftap. Measured from the end of Start 360°
stage.

Speed Defines the speed during selftap.

Torque min Torque value for lower Selftap limit. 0 N·m

Torque max Torque value for upper Selftap limit. Tool max torque

6.2.2 Rundown torque limits

The friction and resistance between the nut and joint members can vary, causing the torque required to run
a nut down a thread before engagement with the joint surface to vary as well. These effects could be, for
example, hole interference, prevailing torque or lubrication.
Monitoring the rundown torque can be useful when running down a lock nut which has a plastic insert in the
threads to help the fastener resist vibration. This will require a higher torque, known as prevailing torque, to
overcome the interference.

Parameter Description Default value

Rundown torque limits Off: Off

On:

Angle offset Angle offset before the Angle interval begins. 0°

Angle interval Angle defining the Rundown torque limit section. 360°

Torque min Torque value for lower Rundown torque limit.

Torque max Torque value for upper Rundown torque limit.

6.2.3 Rundown angle limits

By monitoring the angle of rotation during rundown, errors such as missing washers or too short or too long
threads can be detected. For example would a missing washer or too long threads require a greater turning
angle for the bolt to reach snug.

Parameter Description Default value

Rundown angle limits Activates Rundown angle limits. The angle limits are set relative to when the tool Off
trigger is pressed or when a specified torque value is reached. Angle limits will
not be checked during Selftap if Selftap is activated.
Off: No limits are set.

36 9836 4954 01
 Tightening setup

Parameter Description Default value

From trigger: Limit values are set relative to when the tool trigger is pressed.
From torque: Limit values are set relative to when this torque value is reached.

<From torque> Torque value from where Rundown angle limits are set.

Angle min Angle value for lower angle limit from starting point. 100°

Angle max Angle value for upper angle limit from starting point. 1000°

6.2.3.1 From trigger

The system starts to monitor the tightening angle as soon as the tool trigger is pressed and reports if angle
limits are violated.

6.2.3.2 From torque

The system starts to monitor the tightening angle from the defined torque value and reports if angle limits
are violated.

6.2.4 Rundown complete

To detect if the bolt has reached snug and the tightening stage can be entered.

Parameter Description Default value

Rundown complete Specifies how to control when snug is reached. At torque

At torque: Specifies the torque value for when the rundown stage is completed.

<At torque> Defines the torque value for when the rundown stage is completed

6.3 Tightening stage

The tightening stage applies clamping force to the joint by one or more tightening steps depending on selected
behavior.

9836 4954 01 37
Tightening setup
Torque

Time

Figure 38: Tightening stage

6.3.1 Tightening strategies

By selecting tightening strategy you can choose the method for applying clamping force (or preload) to the
joint. Different joints require different strategies for how to apply the desired clamping force and to minimize
unwanted in-service effects.
All tightening strategies require that you at least set the Target torque value.

Parameter Description Default value

Strategy Available tightening behaviors. TurboTight

TurboTight: No additional tightening behavior will be used as default. Only target
values will be used.
Quick step: Adds an initial tightening step to counteract short-term relaxation
effects.
Two step: Adds a pause between the first and last tightening step to further
counteract short-term relaxation effects.
Three step: Tightens to a defined First torque value, then loosens the bolt and
immediately retightens it to Target torque.

Target torque Defines the target torque of the tightening or final step.

Target speed Activates setting the tool speed manually or using the default max speed. Auto
Auto:
Manual:

<Manual> Tool speed during tightening. If a first step is added this corresponds to the speed
of the final step.

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 Tightening setup

6.3.1.1 TurboTight
TurboTight is the default tightening strategy and it is designed to perform a very fast and ergonomic tightening
based on the tool’s maximum speed (Tool max speed). This strategy requires only the Target torque to be
set to perform the tightening. Depending on the joint properties, that is, if the joint is very stiff or very soft,
a different tightening strategy might be required. Also the tool used can affect what tightening strategy to
use.

6.3.1.2 Quick step

Quick step is a tightening strategy used to counteract short-term relaxation effects in the joint. By adding an
initial step with a given torque and speed, and then reducing the target speed in the final step, it gives the
joint time to relax and reduces preload scatter. Nevertheless it is a very fast tightening.

Parameter Description Default value

First torque Torque during first step.

First speed Tool speed during first step.

6.3.1.3 Two step

The Two step strategy is very similar to the Quick step strategy besides that it adds a small time delay between
the first step and the final step to further counteract short-term relaxation effects in the joint.

Parameter Description Default value

First torque Torque during first step.

First speed Tool speed during first step.

Pause time Time between first and second step. 50 ms

6.3.1.4 Three step

The Three step strategy adds a loosening step between the first step and the final step to overcome creep and
relaxation, and reduce preload scatter. This is sometimes called to condition the joint. This can be useful in,
for example, joints containing gaskets to overcome gasket creep or in joints with many adjoining surfaces.
This will have greater effect on new parts than on reused ones due to the smoothening of surfaces which will
reduce embedment.
Conditioning the joint is done by tightening the first step to a given torque, First torque, and then releasing
the load by turning the nut a specified Conditioning angle and then retighten the nut to its Target torque.

Parameter Description Default value

First torque Torque during first step.

First speed Tool speed during first step.

9836 4954 01 39
Tightening setup

Parameter Description Default value

Conditioning speed Tool speed during the conditioning step.

Conditioning angle Angle to turn the socket during the conditioning step. 180°

6.3.1.5 Rotate
The Rotate strategy is in the Power Focus 600 primarily a strategy for testing and demo purposes. When
letting the tool rotate in free air, it will turn the socket the specified angle using such a low torque as possible.

Parameter Description Default value

Target speed Tool speed during the Rotate strategy. Auto

<Target speed> Manual tool speed during the Rotate strategy.

Target angle Angle to turn the spindle. 360°

Rotational direction Defines the tightening direction of the spindle. Clockwise

6.3.2 Final torque limits

By setting the Final torque limits is it possible to discard a tightening, should its final torque not fall within
the specified torque limits. A too high torque could cause the bolt to deform as a result of passing the yield
point. and even break, or to the stripping of threads. Not enough torque could end up with the clamping force
not being enough to withstand the forces for which the joint is designed.

Parameter Description Default value

Final torque limits The tightening is considered as NOK if its final torque is outside the legal area Auto
defined by Torque min and Torque max.
Auto: Torque limits are automatically set to the default values specified for Torque
min and Torque max.
Manual: Enables setting the Final torque limit values manually.

Torque min Torque value for lower torque limit. 95% of Target torque

Torque max Torque value for upper torque limit. 120% of Target torque

6.3.3 Final angle limits

With Final angle limits set it is possible to monitor if the nut is turned the desired degree during the tightening.

Parameter Description Default value

Final angle limits Select the region, in degrees, where to monitor the Calculated angle. Off
Off:

40 9836 4954 01
 Tightening setup

Parameter Description Default value

From rundown complete:

From torque: The monitoring begins when the specified torque value is reached.
Torque must be greater than First torque
From First target: The monitoring begins when First target is reached. This option
is not available if TurboTight is chosen.

<From torque> Torque value from where angle limits are set.

Angle min Angle value for lower angle limit 90°

Angle max Angle value for upper angle limit 720°

6.3.4 Torque compensation

By defining when the rundown stage is completed and the tightening starts to build up clamping force in the
joint, a torque compensation point can be set. The torque compensation point is located inside the rundown
stage and enables taking into account the torque used to perform the rundown of the bolt and compensate
for this when creating the preload in the bolt. By using torque compensation, the actual clamping force applied
to the joint can be better determined.

Parameter Description Default value

Torque compensation Enables adjusting Target torque for torque used in the rundown stage. Auto
Auto: Automatically determines the Torque compensation point.
Off: No compensation is made.
Manual: Manually sets the Torque compensation point.

Torque compensation point 45°

6.4 Stop stage

Terminates the tightening so that the socket can be released.

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Tightening setup
Torque

Time

Figure 39: Stop stage

6.4.1 Soft stop

Soft stop makes the tightening stop in a more ergonomic fashion. Either dynamically based on joint hardness,
or by defining the stop time parameter.

Parameter Description Default value

Soft stop Type of soft stop behavior. Off

Off: No soft stop behavior is used.
On: Manually specify the time for the tool to stop.

<Manual> Length of time to perform the soft stop. 200 ms

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 Common procedures

7 Common procedures
This chapter describes commonly used procedures and functions in the Power Focus 600 controller. Each
tutorial gives a step by step instruction on how to solve the problem described or the task to be performed.

7.1 Setting up a basic tightening

This tutorial describes how to set up a basic tightening using the TurboTight strategy. You will learn how
to activate your tightening program (Pset) and how to set the target torque with which the tool will tighten
the bolt.

7.1.1 Scenario
The task is to set up the controller to perform a tightening that clamps together two joint members with a
bolt and nut to the specified torque 30 Nm using the default tightening strategy TurboTight.

Required hardware Power Focus 600, Power tool

7.1.2 Configuring the Pset

1. On the Main menu, choose Tightening and press OK.
2. Use the DOWN ARROW key and go to the Pset that you
wish to use. Make sure the Pset is not in use by other users
and that you are allowed to configure it. In this example
we will use Pset 1.
3. Use the RIGHT ARROW key to to enter the Pset
configuration area. Configuration mode should be set to
Quick prog (Quick programming). If Configuration mode
is set to Manual, press OK and then select Quick prog
and follow the instructions on the screen. Figure 40: Tightening menu - Configuring Pset
4. In the Target torque text box, press OK to edit the target
torque value and enter the value 30 using the alphanumeric
keypad. Press OK to store the value.

9836 4954 01 43
Common procedures

7.1.3 Activating the Pset

1. Return to the list of Psets and go to the Pset you just
configured.
2. Press OK to activate the selected Pset. This will enable
the Pset and make it the default tightening program. The
option button for the selected Pset will turn yellow when
activated.

Figure 41: Tightening menu - Activating Pset

The controller is now set up to tighten the bolt to the specified target torque 30 Nm, using the default tight-
ening strategy TurboTight.

7.2 Tool calibration

This tutorial describes how to adjust the tool by using the calibration settings on the controller. You will
learn how to set up your tool with the reference torque transducer, what tightening program to use for your
calibration, and how to use the controller’s calibration function to adjust your tool.

7.2.1 Scenario
The tool calibration is scheduled to be performed once a year. During this operation when the operator checks
the tool’s torque accuracy using an ACTA with an IRTT it is discovered that the difference between the
torque value given by the tool differs from the torque value given by the ACTA. The operator realizes that
the difference in the torque readings exceeds the tool’s torque tolerance values and that it needs an adjustment.
The tool is used to perform tightenings in the torque range 50–70 Nm.
The operator performs the calibration and adjusts the tool by entering the new calibration value.

Required hardware Power Focus 600, Power tool, IRTT and ACTA.

44 9836 4954 01
 Common procedures

7.2.2 Setting up the tool torque transducer

Make sure the tool and the controller are set up to perform tightenings. Set up the tool with a torque reference
transducer such as an ACTA or BLM Bench. Please refer to the torque reference transducer’s user guide for
setup instructions.

7.2.3 Selecting tightening program

Choose a Pset with a target torque corresponding to a tightening normally used with the tool.
See Setting up a basic tightening for a tutorial on setting up and activating a suitable Pset.

7.2.4 Adjust the tool’s calibration value

To set the tool’s calibration value it must first be calculated from the torque readings from the controller and
the torque reference transducer by using the equation below.

PF6-026

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Common procedures

1. On the Tool menu, go to Calibration, and then

Configuration.
2. Press OK to enter the Configuration dialog.
3. Calculate the new calibration value using the
equation above.
• Make at least three tightenings and use the torque
values read from the controller and the reference
transducer (ACTA or similar) for calculating the
new calibration value.
Figure: Tightening menu - Configuring Pset
• The old calibration value is shown in the
Calibration value box.
4. To store the new calibration value in tool memory,
enter the value in the Calibration value text box by
using the keypad and then press OK.
5. To activate the alarm for when the next calibration
is to be performed, go to Show alarm and select
On.
6. To set the alarm interval, go to Next calibration date
and then press OK.
• To keep the calibration interval to once a year
just press OK, as the default value is set to be
the same date a year from today provided you
have set the time and date correctly in Settings-
>Preferences. For more information, see section
Date and time.
• To set another date enter it on the format
yyyymmdd and then press OK.
7. To store the settings go to Apply and press OK.

46 9836 4954 01
 Reference information

8 Reference information

8.1 Controller connections

This section describes the connections on the Power Focus 600 controller’s front and underside. Please refer
to the Product instruction for more specific technical data about the controller.

8.1.1 Connections – Front

Connections and switches on the Power Focus 600 controller.

1. Battery
2. Cable
3. USB port 6

4. IAM 7
1
5. Residual-current device (RCBO) 2 8
6. Aux. power out (24V, 1.5A) 3 9
7. Digital input
4 10
8. Digital output
5
9. Factory Ethernet port
10. I/O Bus 11
11. Power connector PF6-001

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Reference information

8.1.2 Connections – Underside

1. USB port 1
2
2. Service Ethernet port
3. Main switch
4. Tool socket 3

PF6-002
8.2 Digital inputs and outputs
The Power Focus 600 uses the same hardware accessories (Stacklight, Operator panel etc.) as the Power
Focus 4000 system. However, the digital input and output connectors are configured differently and uses a
different plug. In order to rewire the plug from Power Focus 4000 to Power Focus 600 correctly use the
connector descriptions in the following sections.

8.2.1 Digital inputs

The Power Focus has four configurable internal digital inputs (DIG IN) that are located behind the front lid.

48 9836 4954 01
 Reference information

8.2.1.1 Digital inputs Power Focus 600

Pin Function

13 24V 24V 13

14
14 24V 24V

0V 15
15 0V
0V 16
16 0V 17
0V
2.7k
17 0V COM
18 -
DI 1 19
18 Digital input - +

DI 2 20
19 Digital input 1 +
+ 2.7k
+
DI 3 + 21
20 Digital input 2 +

PF6-004
DI 4 + 22

21 Digital input 3 +

22 Digital input 4 + Figure 47: Digital inputs Power Focus 600

9836 4954 01 49
Reference information

8.2.1.2 Digital inputs Power Focus 4000

Pin Function

22 GND (+24VDC isolated)

22
0
21
21 +24VDC isolated +24VD

20
20 Digital input 4 - -
DI 4 19
+
19 Digital input 4 +
- 18
18 Digital input 3 - DI 3
+ 17 2.7k
-
17 Digital input 3 + 16
-
DI 2
+ 15
16 Digital input 2 - 2.7k
+
14
15 Digital input 2 + DI 1
-

PF6-005
+ 13

14 Digital input 1 -

13 Digital input 1 + Figure 48: Digital input Power Focus 4000

8.2.2 Digital outputs

The Power Focus has four configurable internal digital outputs (DIG OUT) that are located behind the front
lid.

50 9836 4954 01
 Reference information

8.2.2.1 Digital outputs Power Focus 600

Pin Relay Function

1 Normally closed 0V +24V

2 Relay 1 Common
NC 1
3 Normally open 2
RE 1 C
NO 3
4 Normally closed
NC 4
5 Relay 2 Common 5
RE 2 C
NO 6
6 Normally open

7 Normally closed NC 7
RE 3 C 8
8 Relay 3 Common NO 9

9 Normally open NC 10
RE 4 C 11
10 Normally closed NO 12 PF6-006

11 Relay 4 Common

12 Normally open Figure 49: Digital output Power Focus 600

9836 4954 01 51
Reference information

8.2.2.2 Digital outputs Power Focus 4000

Pin Relay Function

12 Normally closed 0V +24V

11 Relay 4 Common
NC 12
10 Normally open
RE 4 C 11
NO 10
9 Normally closed
NC 9
8 Relay 3 Common
RE 3 C 8
7 Normally open NO 7

6 Normally closed NC 6
RE 2 C 5
4
5 Relay 2 Common NO

4 Normally open NC 3
RE 1 C 2
3 Normally closed NO 1
PF6-007

2 Relay 1 Common

1 Normally open Figure 50: Digital output Power Focus 4000

52 9836 4954 01
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Edition 1.10
2012-11

www.atlascopco.com